UNDERSTANDING YOUR PCU, PT.2
Section 4 is comprised of two screens. The ‘Volts’ screen will display the average voltage being produced by the
charger, as felt on the output terminals. The ‘Amps’ screen will display the total current being produced by the
charger.
This is the grounding terminal and connects to the rear grounding panel of the PCU. This should be connected to
your vehicles chassis to maximise safety.
Section 6 covers the ‘Multi Speed Fan’ and the ‘Charger Output’ LEDs.
ŸMulti Speed Fan LEDs will display to communicate the fan speed control. This will vary depending on
temperature and has three speeds.
ŸCharger Output LEDs will display the percentage power output of the PCU. If it is displaying at 50%, the unit
is only outputting 50% of its rating. At 100% it is outputting 100% of its rating.
Section 7 covers the Auto Conservation Modes and Charge Modes.
ŸThe Stand-By LED will be illuminated when the unit has AC power input, but is not needed to charge any
batteries. This may happen due to no batteries being connected for a long period of time or all of the batteries
attached are sufficiently full and have been on float for long periods of time.
ŸThe Battery Health Program LED will illuminate if the charger is in Open Lead Acid maintenance, and will
cause it to run a desulphation cycle once every 21 days.
ŸThe Fast Charge, Absorption, Float and De-sulphation LEDs will illuminate to display which stage of the
charging cycle the PCU is presently in. These tell you what your charger is presently attempting to do.
Section 8 covers the Fault LED section. These LEDs will illuminate to display when a fault is ongoing with your
unit, and what the likely culprit will be. Please consult the troubleshooting section of this handbook, or consider
contacting Sterling support.
Section 9 covers the Setup/Enter, Up arrow and Down arrow buttons. This is the main user interface and these
buttons are how you will control and customise your PCU.
Section 10 highlights the available battery types, and the battery type presently selected. This is useful for
choosing battery types and to know what charge profile you are presently using. The battery types translate to
the following voltages.
Section 11 indicates the PCU endcap, typically red in colour, or grey for older units. It has been ‘removed’ in this
demonstration to help with clarity and to show you what is underneath.
This area is for the 3 core AC connection. Left to right is for Live, Neutral and Ground/Earth. Accessible by
removing the white cover. Only connect AC wires when the AC connection is isolated. When cables are
connected, replace the white cover.
The black port is for the Pro Charge Ultra Remote, product code : PCUR.
The grey port is for the TEMP1 temperature sensor. This allows the PCU to give you your battery temperature
readings. It also causes the PCU output voltage to vary by 0.018V per degree Celsius either side of 20C. If your
batteries are warmer, we decrease the charge voltage. If they are colder, we increase the voltage. This connects
to the negative battery stud. This will also cause the PCU to trip to OFF if the battery terminal reaches 50degC.
This area is for the positive line DC connections.
This is the negative line DC connection.
These fuses are for the negative line of the PCU. Inspect these if the PCU is unresponsive.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
1) Ammeter, shows the total current being
produced by the charger.
2) Voltmeter, showing the average voltage being
produced by the charger.
3) Power meter, shows the % power being produced
by the unit and the remaining power available.
4) AC power, shows the AC power is connected and
the product is live. LED flashes if power is available
but the unit is switched off (see on/off later) push
buttons. Setup and up arrow for 5 secs to activate.
5) Auto temp control, shows the battery temp sensor
is connected and operational. If sensor not
connected then the unit will default to a 20 deg C / 69
F charge curve.
6) Shows that the active PFC (Power Factor
Correction is on).
7) Fan speed control, varies depending on temp, 3
speeds.
8) Standby, charger power system power
requirement very low, unit on low float voltage to
prolong battery life.
9) Fast charge unit on constant current mode.
10) OK, unit operating within normal parameters
11) Fault, fatal fault, needs to be returned for repair.
12) Battery type selector, shows which battery
charger curve in operation (adjustable).
13) Buttons to select charge options (see later in
instructions) also used to switch unit off or on in
conjunction with the setup button (see 14).
Off select button press down button for 5 seconds.
On select button press up button for 5 seconds.
14) Button to enter selections. Also, use to switch
unit on/off in conjunction with the up or down button.
15) Battery health program, unit doing a 21 day de-
sulphation cycle.
16) , charger on initial charge cycle.Absorption
17) De-sulphation cycle operational. For safety
reasons only available when on open lead acid
battery type.
18) Float, unit on float charge or power pack mode,
main charge complete.
19) DC output service, output working correctly.
20) DC output low voltage warning, either batteries
are very low / more power is being taken than the
charger can supply / or the charger is defective.
21) High voltage trip, the unit is defective and
tripped itself, or a high back DC voltage has been
detected, like a wind generator reg gone defective.
22) High charger temp, if the unit is positioned in too
hot an environment and over heated, or the fans
have failed.
23) Check fans, if LED on, fans are defective.
24) Case screws to access the wiring of the product.
Battery type High Charge V Float Charge V Maintenance V High Charge V Float Charge V Maintenance V
Flooded/Open Lead acid 14.8 13.6 12.8 14.7 13.4 12.8
Sealed Lead acid 14.4 13.6 12.8 14.6 13.4 12.8
AGM Lead acid 14.3 13.3 13.0 14.6 13.6 13.0
GEL Lead acid 14.0 13.7 13.2 14.4 13.8 13.2
LiFePO4-Lithium 14.2 13.8 13.2 14.4 13.8 13.2
Calcium / Custom 15.1 13.6 13.2 Your choice see custom setup in instructions
Equalization / Desulph 15.5 15.5 15.5 15.5
Preset 1 Profiles Preset 2 Profilesx 2 all voltages for 24V unit x 2.66 for 32 V x 3 for 36V x 4 for 48V
GLOBAL AC Input & Active Power Factor Correction
OK
CHARGER MODE
AC Power
Auto Temp Control
Active PFC
Multi Speed Fan
Volts Amps
AUTO CONSERVATION MODES
Fault
Absorption
Stand-by Battery Health Program
Fast Charge Float
DC Output Fault
DC Low Voltage
DC High Voltage Trip
High Charger temp trip
Check Fan
De-sulphation
1 2 3
SETUP
ENTER
CHARGE INFORMATION
Open lead acid
Sealed lead acid
A.G.M
GEL
Calcium / Custom
Lithium (LiFePO4)*
System self test Battery Type
Charger Output
0% 100%
Progressive DIGITAL software control Charger / Powerpack
High Voltage AC Low Voltage DCWARNING
www.sterling-power-usa.com
Preset 1
Preset 2
www.sterling-power.com
*Lithium must be used in conjunction
with a lithium balancing system.
Safety Certified by: TUV
Built and tested to
UL 1236 SB
CSA C22.2-107.2
RoHS
compliant
CEC
approved
Pro Charge ULTRA
Sterling Power
Warm air
out
Cooling
Air flow
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Quick LED feature guide
Lithium battery Use
this charger must not be used to
charge lithium battery cells by itself
( ie lithium cells only with no BMS ) .
You cannot charge lithium cells on
their own. You must have a
B M Sattery anagement ystem
attached to built into the or
batteries for safety.
No Battery charger can act as a BMS,
that is an independent operation
for Lithium batteries .
PRODUCT INFORMATION
PRODUCT INFORMATION
STERLING
POWER
02
07
Battery type High Charge V Float Charge V Maintenance V High Charge V Float Charge V Maintenance V
Flooded/Open Lead acid 14.8 13.6 12.8 14.7 13.4 12.8
Sealed Lead acid 14.4 13.6 12.8 14.6 13.4 12.8
AGM Lead acid 14.3 13.3 13.0 14.6 13.6 13.0
GEL Lead acid 14.0 13.7 13.2 14.4 13.8 13.2
LiFePO4-Lithium 13.8 13.8 13.8 14.6 14.6 14.6
Calcium / Custom 15.1 13.6 13.2 CUSTOM
Equalization / Desulph 15.5 15.5 15.5 15.5
Preset 1 Profiles Preset 2 Profilesx 2 all voltages for 24V unit x 2.66 for 32 V x 3 for 36V x 4 for 48V
