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BCDC

®

Dual Input Multi-Stage

In-Vehicle Battery Charger

MODELS:

BCDC1225D

25 A

BCDC1240D

40 A

BCDC1250D

50 A

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2
3
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Summary of Contents for BCDC Series

Page 1: ...BCDC Dual Input Multi Stage In Vehicle Battery Charger MODELS BCDC1225D 25 A BCDC1240D 40 A BCDC1250D 50 A ...

Page 2: ...heir type or size The Dual Input In vehicle Battery Chargers also feature a Maximum Power Point Tracking MPPT solar regulator The unit will always take as much power from the unregulated Solar input as it can before supplementing that power up to the maximum rated output from Vehicle power input The Dual Input In vehicle Battery Chargers are suitable for all common types of automotive lead acid ba...

Page 3: ... 9 1 5 Soft Start Charging Process 10 1 6 Error Codes 11 1 7 Battery Test Mode 11 2 INSTALLATION 12 2 1 Install Location 12 2 2 Charge Profile Selection Orange Wire 13 2 3 Input Trigger Settings Blue Wire 14 2 4 Cable sizing 14 2 5 Wiring 15 2 6 Fusing 16 2 7 Typical Setup 16 2 8 Connecting Solar Panels Yellow Wire 18 3 TROUBLESHOOTING 19 4 FREQUENTLY ASKED QUESTIONS 21 5 WARRANTY 23 ...

Page 4: ... normal operation For this reason it is of utmost importance that you follow the instructions when installing and using the charger SAFETY MESSAGE CONVENTIONS Safety messages in this manual include a signal word to indicate the level of the hazard as follows WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury to the operator or to bystan...

Page 5: ...ded maximum charging current 6 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 7 The Battery Charger is not intended to supply power to a low voltage electrical system other than to charge a battery 8 Cable and fuse sizes are...

Page 6: ... Battery Type Standard Lead Acid Calcium content Gel AGM or LiFePO4 type only Charging Profile A B C Li Maximum Voltage 14 6 V 15 0 V 15 3 V 14 5 V Float Voltage 13 3 V 13 6 V No Load Current 100 mA Standby Current 8 mA Charging Temperature Charging Profile A B C Ouput battery 10 5 V 15 C to 80 C 5 F to 176 F Charging Profile A B C Output Battery 10 5V 0 C to 80 C 32 F to 176 F Charging Profile Li...

Page 7: ...CDC1225D BCDC1240D BCDC1250D is also designed to isolate the main battery from the auxiliary battery to avoid over discharging the main battery 1 1 Display Panel The front panel features 7 LEDs that display the Charge Profile and Charge Status 1 2 Charge Profile LEDs The Dual Input In vehicle Battery Charger features 4 different charging profiles designed to suit your battery s charging requiremen...

Page 8: ...Float Stages The BCDC1250D charger will output a 4 Stage type charging profile with Soft Start Boost Absorption and Float Stages Table 1 3 2 1 Charge Stage LED Sequences outlines the LED sequences which indicate these stages Figure 1 4 3 1 Charging Process for BCDC1225D and BCDC1240D on page 9 explains the Charging Process and Figure 1 5 3 1 Soft Start Charging Process for BCDC1250D on page 10 exp...

Page 9: ...he Charger will enter Float stage FLOAT Float stage maintains 13 3 V 13 6 V for LiFePO4 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 Figure 1 4 3 1 Charging Process for BCDC1225D and BCDC1240D Voltage Float Absorption Boost Current The...

Page 10: ...Voltage Standard Low Voltage N A Input Open Circuit Low voltage conditions 1 Turn ON ABOVE 12 9 V 12 0 V 25 8 V 24 0 V 9 0 V Turn OFF BELOW 12 7 V 11 9 V 25 4 V 23 8 V 9 0 V Input Loaded Low voltage conditions 2 Stop Charging BELOW 12 2 V 11 3 V 24 4 V 22 6 V N A Turn OFF instantly BELOW 8 0 V 8 0 V 9 0 V Turn OFF after 20 s BELOW 9 0 V 9 0 V N A Input Overvoltage shutdown Turn ON BELOW 15 5 V 32 ...

Page 11: ...rom the vehicle and solar simultaneously and ONE of those sources is undervoltage that specific source LED will flash 5 times If the unit is being supplied power from the vehicle and solar with BOTH sources under voltage OR if the unit is being supplied power from one input only and that input is undervoltage ALL LED s will flash 5 times 1 8 Battery Test Mode The unit features a battery test mode ...

Page 12: ...he cabin of the vehicle along a chassis rail or in the engine bay ensure the unit does not become covered by a build up of mud or other If mounting in an engine bay locate the unit away from high temperature areas for maximum performance Choose locations such as on the inner guard behind a headlight or behind the grille to one side of the radiator REDARC recommend keeping the cable length between ...

Page 13: ...exceed the manufacturer s recommended maximum charging voltage If the Maximum voltage is too high for your battery type select another Charging Profile When using the Battery Charger to charge a Lithium Iron Phosphate LiFePO4 battery only batteries with an inbuilt battery management system with under and over voltage protection and cell balancing are suitable Figure 2 2 2 Setting the Maximum Volta...

Page 14: ...Settings 1 Input Mode Blue Wire Connection 12 V Mode 24 V Mode ON above OFF below ON above OFF below Standard Not Connected or Connected to Ground 12 9 V 12 7 V 25 8 V 25 4 V Low Voltage D for Idle Stop Ignition for others 12 0 V 11 9 V 24 0 V 23 8 V 1 Tested every 100 seconds 2 4 Cable sizing Refer to Table 2 4 1 Cable Sizing for the Vehicle Input Solar Input Ground and Battery Output cable thick...

Page 15: ...reakdown of the wire insulation and cause a short circuit or worst case a fire We recommend that this activity be undertaken by an appropriately trained person REDARC recommends using a soldered butt splice crimp connection see Figure 2 5 1 Ensuring a good wiring connection that is covered with heatshrink REDARC does not recommend using standard red blue yellow blade connections as they are not ra...

Page 16: ... Input Ground and Battery Output cable thickness and length requirements 2 7 1 LEAD ACID BATTERY SETUP Figure 2 7 1 1 Typical Lead Acid Battery Setup 12 V or 24 V and Solar 12 V 12 V or 24 V Start Battery Bank Fuse Optional LED Charging Profile Select YELLOW RED BLUE Connect all ground points to chassis earth Auxiliary Battery Fuse B L A C K B R O W N Low Voltage Trigger Settings to D or Vehicle I...

Page 17: ...se B L A C K B R O W N Load Fuse Loads Low Voltage Disconnect 12 V Solar Panel Array Unregulated Low Voltage Trigger Settings to D or Vehicle Ignition YELLOW RED BLUE GREEN ORANGE Fuse Ratings to be as per the table in Specifications on page 6 To connect the Blue wire to the vehicle s ignition connect the Blue wire to an ignition switched fuse in one of the vehicles fuse boxes located in either th...

Page 18: ...ng to the unit if the panels supply more than the maximum needed 375W for BCDC1225D 600W for BCDC1240D 750W for BCDC1250D Power generated by solar panels is affected by light level cloud cover and time of day so having additional solar panels can still be beneficial for charging in sub optimal conditions NOTE Most house panels have an open circuit voltage with a 32 V limit the BCDC is not suitable...

Page 19: ...ted to the output of the charger however there is currently no valid charging source 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 The Vehicle RED wire should connect directly to the Vehicle battery positive terminal via an adeq...

Page 20: ...nise the input if the problem persists contact your local Auto Electrician 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 12 9 V for a 12 ...

Page 21: ...t This allows the unit to charge specific to the battery type even if the input voltage is low due to voltage drop Where should I mount the BCDC Dual Input Unit The BCDC Dual Input should be mounted as close as possible to the battery being charged generally called the Auxiliary or House battery If the Auxiliary battery is located under the bonnet pick a location for the BCDC Dual Input that is cl...

Page 22: ...tup is fine what s the problem The most likely cause of this issue is that the BCDC Dual Input is somehow stuck in 24 V mode Try removing the Vehicle wire RED and reconnecting it If the problem persists contact REDARC Alternatively the input voltage may be too low check that the input voltage is above the input thresholds outlined in 1 6 Turn On Off Thresholds on page 10 Can the BCDC Dual Input ch...

Page 23: ... Inc 308 Component Dr Smithfield NC 27577 USA Australia 61 8 8322 4848 New Zealand 64 9 222 1024 UK Europe 44 0 20 3930 8109 USA 1 704 247 5150 Canada 1 604 260 5512 Mexico 52 558 526 2898 CHECKING THE PRODUCT SERIAL NUMBER The Product Serial Number is located on the Main Unit and on the product packaging Design and specifications are subject to change without notice Copyright REDARC Electronics P...

Page 24: ... CONTACT Tech Support 1300 REDARC Head Office 61 8 8322 4848 New Zealand 64 9 222 1024 UK Europe 44 0 20 3930 8109 redarc com au USA 1 704 247 5150 Canada 1 604 260 5512 Mexico 52 558 526 2898 redarcelectronics com ...

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