I would suspect that you might be reading open circuit voltage from your PV array that is possibly wired for 12 volts nominal. But you know better than to make that mistake. Right?
There is not much that is more difficult to do than troubleshooting a problem sight unseen and all by word of mouth. There are of course some exceptions to this. One of my duties as an electrician is troubleshooting industrial motor controls and machinery and without actually being there its difficult if not impossible to pinpoint the problem. But I'll try by going over what should be first.
Its a lot like being a detective looking for clues to catch a criminal.
http://www.mysterynet.com/holmes/Process of elimination. If you can eliminate what it isn't then what is left must be what it is. Of course there are exceptions. Its not always Mrs. Mustard in the kitchen with a candle holder.
Please don't take anything I write as an attack on you personally. It might "sound" that way but it is not intended that way. I don't know you personally so I can't know what your experiences are or what they are not, in the matter of electrical wiring practices. Do you have hand held multimeter?
http://www.nextag.com/400A-and-AC-DC-71818353/prices-htmlOk, first of all 5-210 watt and 1-130 watt PV modules all 12 volts nominal cannot be wired together readily for a successful 24 volt nominal PV array.
4 of the identical 210's can however simply by wiring them in series/parallel.
4 - 210 watt modules, I'll call them A,B,C and,D.
2 sets of 2 in series -
A neg. to B pos.
C neg. to D pos.
Then those 2 sets in parallel -
B neg. to D neg.
A pos. to C pos.
This will give you a 24 volt nominal array and there should be an open circuit voltage that is twice the rated amount for one 12 volt nominal PV module.
What you described about the charge controller sounds accurate. The blinking green LED can be misleading. It will blink 1, or 2, or 3, or 4, or 5, times in a row (depending on stage) then a very short pause and, it starts again. That pause can be hard to pick up on sometimes. Try counting out load.
With a multimeter check;
open circuit voltage of the PV array,
that any and all fuses and or breakers have continuity.
Be absolutely positive that polarity's are correct all the way thru and that all wire terminations are clean and tight and the wire insulation has been striped back sufficiently for all wire terminations.
Double check that wire sizes and types is sufficient for the circuits they are conducting.
If doing all of these things does not reveal the "culprit,"
I might dosconnect the monitor and rely on the multimeter to for a time.
Based on what I am reading in your posts about PV array circuit voltages and the number and type of PV modules, there are strong clues that point toward PV array series/parallel wiring being suspect.