Redarc BCDC1220 - User Manual

BCDC
®
Dual Input Multi-Stage
In-Vehicle Battery Charger
MODEL:
 BCDC1220
 BCDC1220-IGN

Summary

Product Overview

Warnings and Safety Instructions

Specifications

Product Function

Display Panel

Details the 6 LEDs on the front panel used to display charge profile and status.

Charging Process

Explains the three-stage charging process: Boost, Absorption, and Float, including automatic timeouts.

Turn On;Off Thresholds

Specifies the voltage thresholds for the charger to turn ON and OFF under various conditions.

Installation

Install Location

Guidance on mounting the charger in close proximity to the auxiliary battery, away from heat sources.

Cable Sizing

Provides a table for selecting appropriate wire cross-sectional area based on cable length for safe operation.

Fusing

Recommends MIDI style bolt-down fuses and advises against blade fuses and self-resetting circuit breakers.

Cable Connections

Emphasizes good, low-resistance electrical connections, recommending soldered butt splice crimps with heat-shrink.

Auxiliary Battery Positive - Brown Wire

Instructions for connecting the brown wire to the auxiliary battery positive terminal, including fuse placement.

Common Ground - Black Wire

Details connecting the black wire to a common ground point for both start and auxiliary batteries.

Charge Profile Selection - Orange Wire

Explains how to connect the orange wire to set the maximum output voltage for different battery profiles.

Input Positive - Red Wire

Instructions for connecting the red wire to the positive input from the vehicle's start battery.

Input Trigger Settings - Blue Wire

Details how to connect the blue wire for input trigger behaviour, depending on alternator type and vehicle ignition.

Typical Setups

Illustrates common wiring configurations for 12V and 24V starter battery installations.

Frequently Asked Questions

Warranty

Overview

1. Function Description
2. Usage Features
3. Maintenance Features

The REDARC BCDC® Dual Input Multi-Stage In-Vehicle Battery Charger is a sophisticated device designed to optimize the charging of auxiliary batteries in vehicles. It is available in two models: BCDC1220 and BCDC1220-IGN. The BCDC1220 is engineered to work with fixed voltage or temperature compensating alternators, while the BCDC1220-IGN is specifically designed for vehicles equipped with variable voltage alternators. Both models aim to ensure that your auxiliary batteries are charged to 100% capacity, regardless of their type or size, by providing a unique and appropriate charging profile for each specific battery chemistry.

Function Description

The BCDC® charger operates as a three-stage, 12V, 20A DC-DC battery charger. It can accept input from either 12V or 24V nominal systems. A key feature is its ability to handle input voltages that are above, below, or equal to the output voltage, making it particularly useful for charging a 12V auxiliary battery from a 24V vehicle, or in scenarios where significant voltage drop occurs over long cable runs from the main battery. The BCDC1220-IGN model further enhances functionality by isolating the main battery from the auxiliary battery, preventing over-discharge of the main battery. This model also incorporates an ignition trigger to facilitate operation in vehicles with variable voltage or smart alternators, ensuring the charger only operates when the vehicle is running.

The charging process is divided into three distinct stages: Boost, Absorption, and Float.

1. Boost Stage: In this initial stage, the charger maintains a constant current until the auxiliary battery voltage reaches its Absorption Voltage. The current may be adjusted during operation to maintain a safe operating temperature or to limit the voltage difference between the input and output.
2. Absorption Stage: Following the Boost stage, the charger transitions to the Absorption stage. Here, it maintains a constant voltage level for a predetermined period or until the current drawn by the output battery drops below 4A for 30 seconds.
3. Float Stage: Once the Absorption stage is complete, the charger enters the Float stage. In this stage, it maintains a constant voltage of 13.3V on the output battery, effectively keeping the battery topped up. This counteracts self-discharge and any minor loads applied to the battery. If the battery loses charge during this stage, the charger will automatically revert to the Boost stage to recommence a full charging cycle.

The BCDC® charger includes automatic timeouts to prevent overcharging and potential damage to the battery. If a timeout occurs before the battery is fully charged, the charging process will restart from the Boost stage after a brief rest period. The device can act as both a reducer and a booster, allowing it to output a REDARC proprietary charging algorithm that is independent of the input voltage. This ensures optimal charging specific to the battery type, even if the input voltage is low due to voltage drop. The charger also incorporates the functionality of a battery isolator, turning on and initiating charging when it detects that the vehicle has started, and turning off when the vehicle is turned off. This eliminates the need for a separate battery isolator.

Usage Features

The charger features a user-friendly display panel with six LEDs that indicate the current charge profile and charge status.

• Charge Profile LEDs: These LEDs (A, B, C) indicate the selected charging profile, which corresponds to different maximum output voltages (14.6V, 15.0V, 15.4V) suitable for various battery types and installation environments (e.g., cabin or engine bay).
• Charge Status LEDs: These LEDs provide real-time feedback on the charging process.
  • Off: Indicates no power to the unit and output is off.
  • Blinking: Signifies that the unit is in Standby mode. The flash duty-cycle increases to reflect the amount of current being supplied.
  • On (Solid): Indicates that the unit is on, can supply power, and is applying full power (e.g., 20A).

The selection of the charge profile is managed by connecting the ORANGE wire. Leaving it disconnected sets the maximum voltage to 14.6V (Profile A). Connecting it to Common Ground sets it to 15.0V (Profile B). Connecting it to the RED wire (input source positive) sets it to 15.4V (Profile C). It is crucial to select a profile that does not exceed the battery manufacturer's recommended maximum charging voltage to prevent damage.

The input trigger settings are controlled by the BLUE wire. For a 12V alternator, the BLUE wire can be connected to the RED 'input positive' wire or directly to the vehicle ignition. For a 24V alternator, the BLUE wire must be connected to the vehicle ignition. For the BCDC1220-IGN model, designed for variable voltage or smart alternator systems, the BLUE 'input trigger' wire must always be connected to the vehicle ignition.

Maintenance Features

While the manual does not detail specific user-level maintenance tasks, it emphasizes proper installation as a key factor in the device's longevity and performance.

• Installation Location: The charger should be mounted on a flat surface close to the auxiliary battery and away from direct heat sources. Good airflow is recommended to ensure optimal operation, as the unit may de-rate its output current at higher temperatures (above 55°C / 130°F). Mounting to a metal surface can aid in heat dissipation.
• Cable Sizing and Connections: Correct cable sizing and robust, low-resistance electrical connections are critical. The manual provides a table for appropriate cable sizes based on installation length. REDARC recommends MIDI style bolt-down fuses (specifically FK40 fuse kits) for their low resistance, warning against blade type fuses or self-resetting circuit breakers due to potential heat generation and premature tripping. Connections should be made using soldered butt splice crimp connections covered with heat-shrink, to ensure a long-lasting electrical connection and prevent shorting or contact with the vehicle chassis. This activity should ideally be undertaken by an appropriately trained person.
• Safety Precautions: The manual outlines several safety instructions, including wearing eye and clothing protection when working near a battery, and immediately addressing battery acid contact with skin or eyes. It also warns against smoking or allowing sparks/flames near the battery or engine due to the risk of explosion. The device should not be altered or disassembled, and faulty units must be returned to REDARC for repair to avoid electric shock, fire, and voiding the warranty.

The BCDC® charger is designed to be a reliable and efficient solution for managing auxiliary battery charging in various vehicle setups, ensuring optimal battery health and performance through its intelligent multi-stage charging process and robust design.

Redarc BCDC1220 Specifications