2
INSTALLATION
Mounting the Unit
The charger is suitable for mounting in the cabin of the vehicle only and should not
be mounted in a location exposed to water or dust ingress e.g. under bonnet or
vehicle exterior. The unit will operate optimally below 55°C/130°F with good airflow.
At higher temperatures the unit will de-rate output current up to 80°C/ 175°F at
which point the unit will turn OFF.
It is important to ensure the charger is mounted as close as possible to the battery
being charged (auxiliary battery). Lithium type (LiFePO
4
) batteries are not suitable for
engine bay installations.
The charger should be mounted in any orientation (so that the front decal is visible)
using the 4 mounting tabs provided on the heatsink using Zinc plated, G4.6 M5
Screws.
A single fuse and holder
setup from the Fuse Kits
available from REDARC.
Part number FK40 (40A)
or FK60 (60A).
Fusing
REDARC recommend using MIDI style bolt down fuses as they ensure a low resistance
connection. The REDARC FK40 and FK60 fuse kits are recommended.
Blade type fuses are not recommended as they can result in a high resistance
connection which causes excess heat and may damage the fuse holder and/or the
wiring.
Self-resetting circuit breakers are not recommended as they may trip prematurely due
to the heat generated by the current flowing through the wires.
Charge Profile Selection (ORANGE Wire)
The ORANGE wire is used to select the Maximum output voltage. This is achieved by
connecting in the following way:
To select Profile A leave the ORANGE wire disconnected. This will set the Maximum
voltage to 14.6V.
To select Profile B connect the ORANGE wire to Common Ground. This will set the
Maximum voltage to 15.0V.
To select Profile C connect the ORANGE wire to the RED wire (Input source positive).
This will set the Maximum voltage to 15.3V.
To select the Li Profile connect the ORANGE wire to the GREEN wire (LED output).
This will set the charger to Lithium mode.
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.
Not
Connected
Orange Wire
Orange Wire
Orange Wire
Red Wire
Input
Source
Positive
Midi
Fuse
Green Wire
Optional
LED
Orange Wire
INSTALLATION
Input Trigger Settings (BLUE Wire)
The BLUE wire is used to switch the vehicle input turn ON trigger mode between:
• Standard trigger (for fixed voltage or temperature compensating alternators)
• Low Voltage trigger (for variable voltage or Smart Alternators)
Standard Low Voltage
Vehicle
Ignition
Blue Wire
Not
Connected
Blue Wire
Input Mode Blue Wire Connection
12V Mode 24V Mode
ON above OFF below ON above OFF below
Standard Not Connected 13.2V 12.7V 26.4V 25.4V
Low Voltage Vehicle Ignition 12.0V 11.9V 24.0V 23.8V
Cable sizing
Below is a table outlining the required cable size for a given cable install length.
Please refer to this table for Vehicle Input, Solar Input, Ground and Battery Output cable
thickness requirements. Always choose a wire cross sectional area equal to or greater
than what is specified below.
Part Number Cable Install Length
(m) (ft)
Recommended Wire
Cross Section (mm²)
Closest
(BAE, B&S, AWG)
BCDC1225-XXX
Variants
1 - 5 3 - 16 7.71 8
5 - 9 16 - 30 13.56 6
BCDC1240-XXX
Variants
1 - 5 3 - 16 13.56 6
5 - 9 16 - 30 20.28 4
Cable and fuse sizes are specified by various codes and standards which depend on the type
of vehicle the Battery Charger is installed into. Selecting the wrong cable or fuse size could
result in harm to the installer or user and/or damage to the Battery Charger or other equipment
installed in the system. The installer is responsible for ensuring that the correct cable and fuse
sizes are used when installing this Battery Charger.
Typical Setup
12V or 24V
Start Battery
Bank
Fuse*
12V Solar Panel
Array
(Unregulated)
24V
INPUT
Fuse*
Optional LED
All ground points must
be connected to chassis
earth.
Auxiliary
Battery
Charging Profile Select
Red
Blue
Orange
Black
Brown
Green
12V
INPUT
OR
Yellow
AND
SOLAR
INPUT
Standard
Trigger Settings
Low Voltage
Trigger Settings
Load
Fuse
Loads
to Vehicle
Ignition
Leave
unconnected
Figure 1 - Typical Lead Acid type Setup
NOTE: BCDC1225-002/BCDC1240-002 will only accept input from an unregulated solar panel.
24V
INPUT
Fuse*
Optional LED
All ground points must
be connected to chassis
earth.
Auxiliary
Battery
Fuse*
Join GREEN and ORANGE
for LiFePO
4
Charging
Red
Blue
Orange
Black
Brown
Green
12V
INPUT
OR
Yellow
AND
SOLAR
INPUT
Low Voltage
Trigger Settings
to Vehicle
Ignition
Load
Fuse
Loads
Low Voltage
Disconnect
Standard
Trigger Settings
Leave
unconnected
12V or 24V
Start Battery
Bank
12V Solar Panel
Array
(Unregulated)
Figure 2 - Typical LiFePO
4
Setup
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 the Auxiliary battery is above 0.1V
2. Check all wiring to the charger and battery, particularly the Ground (BLACK wire).
3. 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).
EN
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