Redarc BCDC1225, Owner'S Manual

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THE BCDC1225-XXX & BCDC1240-XXX
The BCDC1225-XXX / BCDC1240-XXX In-vehicle Battery Chargers feature technology
designed to charge your auxiliary batteries to 100%, regardless of their type or size.
Units that feature a Yellow wire include a Maximum Power Point Tracking (MPPT) solar
regulator. These units always take as much power from the unregulated Solar input as possible
before supplementing from Vehicle power input, up to the maximum rated power.
All In-vehicle Battery Chargers are suitable for all common types of automotive lead acid
batteries and LiFePO
4
lithium type batteries.
WARNING & SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS - THIS MANUAL CONTAINS IMPORTANT SAFETY INSTRUCTIONS FOR THE BCDC1225-
XXX/BCDC1240-XXX BATTERY CHARGER RANGE.
DO NOT OPERATE THE BATTERY CHARGER UNLESS YOU HAVE READ AND UNDERSTOOD THIS MANUAL AND
THE CHARGER IS INSTALLED AS PER THESE INSTALLATION INSTRUCTIONS. REDARC RECOMMENDS THAT THE
CHARGER BE INSTALLED BY A SUITABLY QUALIFIED PERSON.
1. If you need to replace your auxiliary battery, check the manufacturer’s data for your battery and ensure that the
‘Maximum’ voltage of the profile you select does not exceed the manufacturer’s recommended maximum charging
voltage. If the ‘Maximum’ voltage is too high for your battery type, please select another charging profile.
2. When using the Battery Charger to charge a Lithium Iron Phosphate battery, only batteries that feature an inbuilt
battery management system featuring inbuilt under and over voltage protection and cell balancing are suitable.
SPECIFICATIONS
Part Number BCDC1225-XXX BCDC1240-XXX
Continuous Current Rating 25A 40A
Vehicle Input Fuse Rating
40A (Not Supplied)
REDARC FK40 recommended
60A (Not supplied)
REDARC FK60 recommended
Output Fuse Rating
Output Power
375W 600W
Vehicle Input Voltage Range *1 9-32V
Solar Input Voltage Range *1 9-32V (unregulated only)
Output Battery Type Standard Lead Acid, Calcium content, Gel, AGM or LiFePO
4
type only
Charging Profile A B C Li
- Maximum Voltage *1 14.6V 15.0V 15.3V 14.5V
- Float Voltage *1 13.3V 13.6V
No Load Current <100mA
Standby Current
<8mA
Operating Temperature -15°C to 80°C / 5°F to 175°F
Minimum O/P Battery Volts 0.1V
Weight 0.9kg / 2lbs
Dimensions
165x120x37mm
Warranty 2 years
Standards ECE Reg. 10
*1
Voltages Specified are ±100mV
PRODUCT FUNCTION
The BCDC1225-XXX / BCDC1240-XXX is a three-stage, 12V DC-DC battery charger
that operates from an alternator input of 12V or 24V and, if your unit features a
YELLOW wire, an unregulated 12V nominal solar panel input. The input voltage of the
BCDC1225-XXX / BCDC1240-XXX can be above, below or equal to the output voltage
making it ideal for charging an auxiliary 12V battery where the distance from the main
battery may cause a significant voltage drop. The BCDC1225-XXX / BCDC1240-XXX
is also designed to isolate the main battery from the auxiliary battery, to avoid over-
discharging the main battery.
Display Panel
The front panel features 7 LEDs to display the charge profile and charge status.
Figure 1 - The BCDC1225-XXX and BCDC1240-XXX Variant Front Panels
Charge Profile LEDs
In-vehicle Battery Chargers feature 4 different charging profiles designed to suit
your battery’s charging requirements. It is recommended to refer to the charging
specifications stated by the battery manufacturer and the installation temperature
chart below (Figure 2) before selecting the profile for your installation.
The selected Profile LED will be on solid when the unit is ON and charging. A flashing
profile LED indicates that the unit is in standby mode and NOT charging.
Auxiliary Battery Location
Maximum Battery
Voltage Specification
Cabin
Install
Engine Bay
Install
14.6
A A
15.0
B A
15.3
C B
14.5 (LiFePO
4
)
Li Not Recommended
Figure 2 - Charge Profile Selection
Check the manufacturer’s data for your battery and ensure that the ‘Maximum’ voltage of
the profile you select does not exceed the manufacturer’s recommended maximum charging
voltage. If the ‘Maximum’ voltage is too high for your battery type, please select another
charging profile.
PRODUCT FUNCTION
Charge Status LEDs
The Charge Status LEDs indicate to the user which inputs are available and what stage
of the charge process is currently in.
Solar & Vehicle LEDs
Units with a YELLOW wire feature an In-built MPPT solar regulator.
The Solar and Vehicle LEDs will be ON when the input is available and in use and OFF
when the input is not available or not in use.
If both LEDs are ON, both input sources are available and in use.
Units with the MPPT Regulator use Green Power Priority technology. This means
the unit will always supply as much power as possible from the Solar input before
supplementing this with power from the Vehicle input, to the maximum output of the
unit or required by the battery at the time.
Stage LED
The Stage LED indicates the charge profile stage. With any profile selected the
charger will output a 3-Stage type charging profile with
Boost, Absorption and Float
Stages.
Figure 3 outlines the LED sequences which indicate these stages and Figure 4
explains the Charging Process.
LED Sequence Profile Stage (Lithium)
Continuous
OFF / No Output
Continuous
Boost (Constant Current)
2 Seconds
Absorption (Constant Voltage)
2 Seconds
Float
Figure 3 - Charge Stage LED Sequences
PRODUCT FUNCTION
Charging Process
Voltage
Float Absorption Boost
Current
Charging Process
Figure 4 - Charging Process
When the Charger is turned on, it will move into the Boost stage. The Boost stage
maintains a constant current until the battery voltage reaches its Absorption Voltage.
The current in
Boost stage may vary during operation in order to maintain safe
operating temperature, or to limit the difference between input and output voltages.
The Charger will then move to
Absorption stage which maintains a constant voltage
level for a predetermined period of time or until the current being drawn by the output
battery drops to less than 4A for 30 seconds; after which the Charger will enter
Float
stage.
Float stage maintains 13.3V (13.6V for LiFePO
4
) on the output battery, keeping the
battery topped up. This counteracts the battery’s self discharging or loads applied
to the battery. When the battery loses charge, the Charger will move back into the
Boost stage.
The unit features a battery test mode which occurs every 100 seconds. The test
mode is designed to both test that the input conditions are still met and check for the
presence of a battery on the output of the unit. This feature is designed to protect the
vehicle battery from over discharge and protect the vehicle and wiring in the event of
damage to the output connection. During low output current situations (when in Float
mode for example) this battery test may take up to 60 seconds to complete.
PRODUCT FUNCTION
Turn ON/OFF Thresholds
Input 12V Vehicle Input 24V Vehicle Input Solar
Input Trigger
Settings
Standard
Low
Voltage
Standard
Low
Voltage
N/A
Input
Open Circuit
Low voltage
conditions *
1
Turn ON
ABOVE
13.2V 12.0V 26.4V 24.0V 9.0V
Turn OFF
BELOW
12.7V 11.9V 25.4V 23.8V 9.0V
Input
Loaded Low
voltage
conditions*
2
Turn OFF instantly
BELOW
8.0V 16.0V 9.0V
Turn OFF after 20s
BELOW
9.0V 18.0V N/A
Input
Over voltage
shutdown
Turn ON
BELOW
15.5V 32.0V
Turn OFF instantly
ABOVE
16.0V 32.5V 33.0V
Turn OFF after 20s
ABOVE
15.6V 32.1V N/A
Output
Under voltage
shutdown * 1
Shutdown if Output Battery < 0.1V
*
1
Tested every 100 Seconds.
* 2 Constantly tested.
There is a maximum 20 second delay before the charger will produce an output any
time a source is introduced into the system, this allows the unit to provide optimum
input sharing and effective battery isolation.
Error Codes
In the event of a fault with the unit installation, either battery or solar panel, ALL
the LEDs on the unit will flash to indicate the fault type. Flashing sequences are
described in the table below.
LED State Description
1 flash (1 flash followed by 3.5 second off) Internal Hardware Fault
2 flash (2 flash followed by 3.5 second off) Unit under temp fault
3 flash (3 flash followed by 3.5 second off) Unit over temp fault
4 flash (4 flash followed by 3.5 second off) Output Battery Fault (Volts too high)
5 flash (5 flash followed by 3.5 second off) Input under voltage (Battery)
6 flash (6 flash followed by 3.5 second off) Input over voltage (Battery or Solar panel)
TROUBLESHOOTING
There are no LEDs ON at all…
This indicates that there is no battery connected to the output (BROWN wire) or that battery is not at a
suitable voltage level to be charged
AND the input (YELLOW/RED wire) of the charger is not connected.
1. Check all wiring to the charger and battery, particularly the Ground (BLACK wire).
2. Check fuses are intact and properly connected.
If the problem is still evident please contact your local Auto-Electrician.
The ‘Charge Profile’ LED is flashing…
This indicates that either Output or Input is not valid.
Specifically, an Auxiliary battery, at a suitable voltage level to be charged, is connected to the output of
the charger however there is currently no valid charging source
OR a valid charging source is available
but the Auxiliary battery is not at a suitable voltage level to be charged or is not connected.
1. Check that the Vehicle (RED wire) and/or Solar (YELLOW wire) are electrically connected
a. The Vehicle (RED wire) should connect directly to the Vehicle battery positive terminal via an
adequately rated fuse
b. The Solar (YELLOW wire) should connect directly to the Solar Panel positive terminal/wire.
2. Check that the Ground (BLACK wire) is connected to the Auxiliary battery and Chassis Earth and/
or the Solar Panel negative terminal/wire.
3. Check the Auxiliary battery is above 0.1V
4. Check all wiring to the Auxiliary battery, particularly the Ground (BLACK wire).
5. Check fuses are intact and properly connected.
If the problem is still evident please see the relevant points below.
I have Solar connected but the ‘Solar’ LED is OFF…
This indicates that the required turn ON conditions for this source have not been met. Either the Open
Circuit Voltage at the YELLOW wire on the charger is below 9V or there is not sufficient power available
from the Solar Panel (due to poor light conditions or a faulty panel).
1. Is the sun out? No or low sunlight levels mean low power to your solar panels.
2. Check that the solar panel is not being shaded (by a tree etc.)
3. Check the voltage at the YELLOW wire, as close as possible to the charger, is above 9V.
4. Check all wiring to the Solar Panel, particularly the Ground (BLACK wire).
5. Ensure you have an unregulated solar panel.
Allow up to 2 minutes after any change for the unit to recognise the input.
The BCDC is connected to the ‘Vehicle’ but the Vehicle LED is OFF…
This indicates that the required turn ON conditions for this source have not been met
OR
the Solar input
is supplying the full input power requirements of the charger. With the BLUE wire left unconnected, the
voltage at the RED wire must be above 13.2V for a 12V installation or above 26.4V for a 24V installation.
With the BLUE wire connected to Ignition, Ignition must be on and the voltage at the RED wire must be
above 12.0V for a 12V installation or above 24.0V for a 24V installation.
1. Check that the vehicle is running.
2. Check the voltage on the RED wire is above the required turn ON threshold for your installation.
3. Check all wiring to the Vehicle battery, particularly the Ground (BLACK wire).