Redarc Bcdc1220 User manual

BCDC®

Dual Input Multi-Stage

In-Vehicle Battery Charger

MODEL:

 BCDC1220

 BCDC1220-IGN

2 | Contents

CONTENTS

1 PRODUCT OVERVIEW��3

2 WARNINGS AND SAFETY INSTRUCTIONS ��3

3 SPECIFICATIONS ��5

4 PRODUCT FUNCTION ��6

4.1 Display Panel�� 6

4.2 Charging Process �� 7

4.3 Turn On/Off Thresholds�� 8

5 INSTALLATION ��9

5.1 Install Location �� 9

5.2 Cable sizing �� 9

5.3 Fusing ��10

5.4 Cable Connections �� 10

5.5 Auxiliary Battery Positive — Brown Wire �� 11

5.6 Common Ground — Black wire ��11

5.7 Charge Proﬁle Selection — Orange Wire��12

5.8 Input Positive — Red Wire�� 13

5.9 Input Trigger Settings — Blue Wire�� 13

5.10 Typical Setups �� 14

6 FREQUENTLY ASKED QUESTIONS �� 16

7 WARRANTY�� 17

Contents | 3

1 PRODUCT OVERVIEW

The BCDC1220(-IGN) In-Vehicle Battery Charger

features technology designed to charge your

batteries to 100%, regardless of their type or size. By

providing a unique charging proﬁle to each speciﬁc

battery type, the BCDC1220(-IGN) In-Vehicle Battery

Charger is able to achieve and maintain an optimal

charge in your auxiliary battery, at all times. The

BCDC1220 is designed to work with either ﬁxed

voltage or temperature compensating alternators

while the BCDC1220-IGN is designed to operate

with variable voltage alternators.

2 WARNINGS AND SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS — This manual contains important safety instructions for the

BCDC1220 and BCDC1220-IGN Battery Charger.

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.

Disclaimer: REDARC accepts no liability for any injury, loss or property damage which may occur

from the improper or unsafe installation or use of its products.

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 could result in death or

serious injury to the operator or to bystanders.

CAUTION Indicates a potentially hazardous situation which may result in moderate or

minor injury to the operator or to bystanders.

NOTICE Indicates a situation that may cause equipment damage.

WARNING

Risk of explosive gases: Working in vicinity of a Lead-Acid battery is dangerous. Batteries

generate explosive gases during normal operation. For this reason, it is of utmost

importance that you follow the instructions when installing and using the Charger.

4 | Contents

CAUTION

1. The Battery Charger should not be used by persons (including children) with reduced physical,

sensory or mental capabilities, or lack of experience and knowledge, unless they are supervised

or have been instructed on how to use the appliance by a person responsible for their safety.

Children should be supervised to ensure that they do not play with the Battery Charger.

2. Do NOT alter or disassemble the Battery Charger under any circumstances. All faulty units

must be returned to REDARC for repair. Incorrect handling or reassembly may result in a risk of

electric shock or ﬁre and may void the unit warranty.

3. Only use the Battery Charger for charging Standard Automotive Lead Acid, Calcium Content,

Gel, AGM, SLI or Deep Cycle type 12 V batteries.

4. 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.

5. Check the manufacturer’s data for your battery and ensure that the ‘Continuous Current Rating’

of the Charger does not exceed the manufacturer’s recommended maximum charging current.

6. The Battery Charger is not intended to supply power to a low voltage electrical system other

than to charge a battery.

7. 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.

8. NEVER smoke or allow a spark or ﬂame in vicinity of battery or engine. This may cause the

battery to explode.

PERSONAL SAFETY PRECAUTIONS

9. To assist with the safe operation and use of the Battery Charger when connected to the battery:

a. Wear complete eye protection and clothing protection. Avoid touching eyes while working near a

battery.

b. If battery acid contacts your skin or clothing, remove the affected clothing and wash the affected

area of your skin immediately with soap and water. If battery acid enters your eye, immediately

ﬂood the eye with running cold water for at least 10 minutes and seek medical assistance

immediately.

Contents | 5

3 SPECIFICATIONS

Part Number BCDC1220 and BCDC220-IGN

Continuous Current Rating 20 A

Vehicle Input Fuse Rating 40 A (Not Supplied)

REDARC FK40 recommended

Output Fuse Rating

Output Power 300 W

DC Input Voltage Range*1 9 to 32 VDC ⎓

Output Battery Type Standard Lead Acid, Calcium content, Gel or AGM type only

Charging Proﬁle A B C

Maximum Voltage*1

(refer to Table 2.2.1 on page 6)14.6 V 15.0 V 15.4 V

Float Voltage*1 13.3 V

No Load Current <100 mA

Standby Current <5 mA

Ambient Temperature −20°C to +80°C (−4°F to +176°F)

Minimum O/P Battery Volts*1 4 V

Weight 450 g (15.9 oz)

Dimensions 100×120×37 mm (3.9"× 4.75"× 1.5")

Warranty 2 years

Standards CE,C-Tick, AS/NZS CISPR11:2004

*1 Voltages Speciﬁed are ±100mV

6 | Product Function

4 PRODUCT FUNCTION

The BCDC1220(-IGN) is a three-stage, 12 V, 20 A DC-DC Battery Charger that operates from an

input of either 12 V or 24 V nominal. The input voltage of the BCDC1220 can be above, below or

equal to the output voltage, making it ideal for charging from a 24 V vehicle or charging an auxiliary

12 V battery where the distance from the main battery may cause a signiﬁcant voltage drop. The

BCDC1220-IGN is also designed to isolate the main battery from the auxiliary battery, to avoid

over-discharging the main battery. The BCDC1220-IGN operates almost identically to the

BCDC1220 but is designed to operate from an ignition trigger to allow operation in vehicles with

Variable Voltage or Smart Alternators.

4.1 DISPLAY PANEL

The front panel features 6 LEDs that display the Charge Proﬁle and Charge Status.

BCDC1220 Front Panel

When blinking, the ﬂash duty-cycle of the 'Charge Status' LED will increase to reﬂect the amount of

current being supplied. If the LED is ON solid, the Unit is applying full power (e.g. 20 A).

Table 1: Charge Proﬁle and Status

LED State Charge Proﬁle LED Charge Status LED

Off Unit has no power Output is off

Blinking Unit is in Standby

Unit is supplying power

On Unit is on and can supply power

Product Function | 7

4.2 CHARGING PROCESS

BOOST

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.

ABSORPTION

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 4 A for 30 seconds; after which the Charger will enter Float stage.

FLOAT

Float stage maintains 13.3 V* 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 automatically move back into the Boost stage.

Figure 1: Charging Process

Voltage

FloatAbsorptionBoost

Soft-Start

Current

The BCDC has automatic Timeouts to protect the battery from being damaged by overcharging. The BCDC will

automatically move from Boost to Absorption or Float according to these timeouts. If a Timeout occurs before

the battery is fully charged, the charge process will begin again from the Boost stage after a brief 'rest-period'.

*Voltages Speciﬁed are ±100 mV.

8 | Product Function

4.3 TURN ON/OFF THRESHOLDS

12 V BCDC1220 BCDC1220-IGN 24 V BCDC1220 &

BCDC1220-IGN

Input Open

Circuit Low

voltage

conditions*2

Turn ON above 12.9 V 12.0 V With Ignition

Turn OFF above 12.7 V 11.9 V With Ignition

Input Loaded

Low voltage

conditions*3

Turn OFF

instantly below 8 V

Turn OFF after

20 secs below 9 V

Input Over

voltage

shutdown

Turn ON below 32 V

Turn OFF

instantly above 32.5 V

Turn OFF after

20 secs above 32.1 V

Output Under

voltage

shutdown

Shutdown if Output Battery < 4 V

Voltages Speciﬁed are ±100 mV.

*2 Tested every 100 seconds.

*3 Constantly tested.

Installation | 9

5 INSTALLATION

5.1 INSTALL LOCATION

Mount the Battery Charger to a ﬂat surface in close

proximity to the auxiliary battery and away from any

heat sources. The BCDC1220(-IGN) has ﬁve wires and

should be installed as described over the following

pages.

The Charger operates in any orientation (but it is

recommended that the front of the decal be visible).

Mount using the 4 mounting tabs provided on the

heatsink with suitable M6 fasteners.

NOTE: The Unit will operate optimally below 55°C

(130°F) with good airﬂow. At higher temperatures the

Unit will de-rate output current.

NOTE: Appropriate connections must be made to the

wires with a continuous current rating of at least 20 A

for the BCDC1220(-IGN). Failure to do so may cause

damage to the Unit and vehicle.

Figure 2: Mounting the Charger

5.2 CABLE SIZING

Below is a table outlinging the required cable size for a given cable install length. Always choose a

wire cross sectional area equal to or greater than what is speciﬁed below.

Table 2: Cable Sizing

Part Number Cable Install Length Wire Cross

Sectional Area

Nearest Equivalent

BAE, B&S, AWG

BCDC1220 and

BCDC1220-IGN

1 – 3 m 3' – 10' ≥3.5 mm² 6 mm auto

3 – 5 m 10' – 16' ≥5.7 mm² 8B&S

5 – 9 m 16' – 30' ≥10.2 mm² 8

10 | Installation

5.3 FUSING

REDARC recommends using MIDI style bolt down fuses as they ensure a low resistance

connection. The REDARC FK40 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.

Figure 3: MIDI Style Bolt-Down Fuse Figure 4: MIDI Fuse Assembly

5.4 CABLE CONNECTIONS

CAUTION: 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. Cabling is recommended to

be away from heat sources and in protected areas, especially when installing or routing in the

engine bay.

The wires on the BCDC1220 and BCDC1220-IGN Unit carry peak currents of up to 30Amps and

it is important to make a good, low resistance, electrical connection that will not degrade over time.

Failure to make a good, reliable contact may result in breakdown of the wire insulation and cause

a short circuit, or worst case a ﬁre. REDARC recommend that this activity be undertaken by an

appropriately trained person.

REDARC recommends using a soldered butt slice crimp connection that is covered with heat-shirnk

(see "Figure 5: Ensuring a good wiring connection"). REDARC does not recommend using standard

red/blue/yellow blade connections, as they are not rated for either the current required or gauge of

wire supplied on the Unit.

Crimping provides good mechanical connection, soldering provides a long lasting electrical

connection and forming of the heat-shirnk ill prevent any shorting/contact with your vehicle chassis.

Installation | 11

Figure 5: Ensuring a good wiring connection

Crimp both wires to the butt splice using

single-indent type crimpers. Fold the cable over

before inserting into the butt-splice as required.

Single-indent crimpers should also be used on

any lugs used.

Solder the wires to the butt splice. Ensure that

a good connection is made.

Keep heatshrink away until after soldering is

complete and has cooled.

5.5 AUXILIARY BATTERY POSITIVE — BROWN WIRE

The BROWN wire should be connected to the

auxiliary battery positive terminal of the auxiliary

battery.

Ensure the cable length is at maximum 1 m

(3.9') from the Unit and the MIDI fuse is

mounted in within 100 mm (3.9") of cable length

from the auxiliary battery. See "Speciﬁcations"

on page 5for appropriate size fuses.

Figure 6: Connecting the BROWN wire

5.6 COMMON GROUND — BLACK WIRE

The BLACK wire should be connected to a

ground point that is common to both the start

battery and the auxiliary battery to be charged.

This point may be on the chassis of the vehicle,

on the chassis of the trailer/camper/caravan

or directly wired to both batteries, depending on

your installation requirements.

Figure 7: Connecting the BLACK wire

12 | Installation

5.7 CHARGE PROFILE SELECTION — ORANGE WIRE

Connect the ORANGE wire to set the Maximum output voltage to suit your selected Charge Proﬁle.

Figure 8: Setting the Maximum Voltage (ORANGE wire)

PROFILE A

Leave the ORANGE wire disconnected to set

the Maximum voltage to 14.6 V*.

PROFILE B

Connect the ORANGE wire to Common

Ground to set the Maximum voltage to

15.0 V*.

PROFILE C

Connect the ORANGE wire to the RED wire

(Input source positive) to set the Maximum

voltage to 15.4 V*.

CAUTION: Check the manufacturer’s data for your battery and ensure that the Maximum

voltage of the Charging Proﬁle you select does not exceed the manufacturer’s recommended

maximum charging voltage. If the Maximum voltage is too high for your battery type, select

another Charging Proﬁle.

Table 3: Charge Proﬁle Selection

Auxiliary Battery Location

Maximum Battery Voltage

Speciﬁcation

Cabin Install

(25°C / 75°F)

Engine Bay Install

(50°C / 120°F)

14.6 V A A

15.0 V B A

15.4 V C B

*Voltages Speciﬁed are ±100 mV.

Installation | 13

5.8 INPUT POSITIVE — RED WIRE

The RED wire should be connected to the

positive input from the vehicles start battery,

see "Speciﬁcations" on page 5 for

appropriate fuse sizes.

Figure 9: Connecting the RED wire

5.9 INPUT TRIGGER SETTINGS — BLUE WIRE

The BLUE wire is provided to select the Units input trigger behaviour, this wire must

be monitored at all times.

BCDC1220 BLUE WIRE CONNECTION

To charge from a 12 V alternator simply connect the BLUE 'input trigger' wire to the RED 'input

positive' wire. Alternatively, the BLUE 'input trigger' wire can be connected to the vehicle ignition.

NOTE: To charge from a 24 V alternator, the BLUE input trigger wire must be connected to the

vehicle ignition.

Figure 10: BCDC1220 BLUE wire with the

12 V Starter Battery

Connect the BLUE wire to the RED wire

12 V or 24 V Starter Battery

Connect the BLUE wire to vehicle ignition.

Vehicle

Ignition

BCDC1220-IGN BLUE WIRE CONNECTION

To charge from either a 12 V or 24 V Variable

Voltage or Smart Alternator system, the BLUE

'input trigger' wire must always be connected to

the vehicle ignition.

Figure 11: BCDC1220-IGN BLUE wire

12 V or 24 V Starter Battery

Connect the BLUE wire to vehicle ignition.

Vehicle

Ignition

14 | Installation

5.10 TYPICAL SETUPS

REDARC recommends that the Charger be installed by a suitably qualiﬁed person.

Figure 12: BCDC1220 12V Starter Battery Installation

Start

Battery

All ground

points must be

connected to

chassis earth

Auxiliury

Battery

Load

Fuse

Loads

30 A

Fuse

30 A

Fuse

RED

BLUE

ORANGE

BROWN

BLACK

12V

INPUT BCDC1220

Charging Prole Select

(refer to page 12)

Figure 13: BCDC1220-IGN 12V Starter Battery Installation

To vehicle

ignition

BCDC1220-IGN

All ground points

must be connected

to chassis earth

Auxiliury

Battery

Load

Fuse

Loads

30 A

Fuse

30 A

Fuse

RED

BLUE

ORANGE

BROWN

BLACK

12V

INPUT

Start

Battery

Charging Prole Select

(refer to page 12)

Installation | 15

Figure 14: BCDC1220 and BCDC1220-IGN 24V Installation

To vehicle

ignition

All ground

points must be

connected to

chassis earth

Auxiliury

Battery

Load

Fuse

Loads

30 A

Fuse

20 A

Fuse

Start

Battery

Start

Battery

RED

BLUE

ORANGE

BROWN

BLACK

24V

INPUT

BCDC1220 &

BCDC1220-IGN

Charging

Prole Select

(refer to

page 12)

Figure 15: Standard Setup for a 24V Starter Battery using Relay for Ignition Switch

All ground

points must be

connected to

chassis earth

Auxiliury

Battery

Load

Fuse

Loads

30 A

Fuse

30 A

N/O Relay

20 A

Fuse

Vehicle

Ignition

RED

BLUE

ORANGE

BROWN

BLACK

12V

INPUT

24V

INPUT

BCDC1220 &

BCDC1220-IGN

OR

Charging Prole Select

(refer to page 12)

Start

Battery

Start

Battery

16 | Frequently Asked Questions

6 FREQUENTLY ASKED QUESTIONS

The BCDC1220(-IGN) turns on at 12.9V (12V) and OFF at 12.7V (11.9V), but it can also

operate down to 9V, explain?

The BCDC1220(-IGN) will turn OFF for a split second every 100 seconds to measure the

unloaded voltage at the battery. When the BCDC1220(-IGN) turns off it is not drawing any load

from the start battery, no load means that there is no voltage drop over the cable run. This allows

the BCDC1220(-IGN) to measure the actual battery voltage, or the voltage at the battery. If this

actual battery voltage is below 12.7V (11.9V) the BCDC1220(-IGN) will turn OFF. At any other

time during the charging process, if the voltage at the BCDC1220(-IGN) drops below 9V the

BCDC1220(-IGN) will turn OFF.

How does the BCDC charge an Auxiliary battery at 14V when it only gets 9V in?

The BCDC can act as both a reducer and a booster, so it can operate from a voltage of above,

equal to or below the desired output voltage. The Unit is also microprocessor controlled allowing it

to output a REDARC proprietary charging algorithm independent of the input. 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 Unit?

The BCDC 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 that is close to the battery and away from any direct engine heat. If the BCDC is to

be mounted into a caravan or camper, near or in the battery compartment is generally the best

position. It is also a good idea to mount the BCDC to a metal surface if possible to ensure optimal

heat dissipation, though this is not crucial.

What does the Charger do if the temperature around it rises above its operating

temperature?

As the temperature of the BCDC rises above a certain level the current capacity of the

output is decreased gradually in order to protect both the battery and the BCDC Unit.

If I use the BCDC to charge my auxiliary battery do I still need to install a battery isolator?

The BCDC incorporates the functionality of a battery isolator, it will turn ON and start charging when

it senses that the vehicle has started and simiarly it will turn OFF when the vehicle is turned OFF.

Can I charge two batteries of different chemistries from the same source? Will I have any

problems charging my AGM or Gel auxiliary battery from my Lead Acid start battery?

The BCDC does not 'link' the batteries together like a battery isolator does, it is a DC-DC Battery

Charger. The output from the Unit is tailored speciﬁcally to the selected output battery type and

therefore allows the optimal charging of the auxiliary battery, no matter what chemistry your start

battery is.

17

7 WARRANTY

LIMITED WARRANTY

For full warranty terms and conditions, visit the Warranty page of the REDARC website.

www.redarcelectronics.com/warranty

Australia, New Zealand & Europe

REDARC Electronics Pty Ltd

23 Brodie Road (North),

Lonsdale SA 5160

Australia

North America

REDARC Corporation

c/o Shallco, 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.

REDARC®, THE POWER OF REDARC®, and BCDC® are trademarks of REDARC Electronics Pty Ltd�

REDARC Electronics Pty Ltd

23 Brodie Road (North), Lonsdale South Australia 5160, Australia

IMPORTER CONTACT INFORMATION

UK

Ozparts UK Ltd

1 Prospect Place

Pride Park

DE24 8HG, Derby

UK

Europe

Ozparts Sp. z o. o. Sp. kom.

Slowackiego 32/5

87−100 Torun

Poland

For written request please email power@redarcelectronics.eu

18

NOTES

19

WARBCDC1220-8 EN

Tech Support

1300 REDARC (1300-733-272)

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

redarcelectronics.com

Redarc BCDC1220 User manual

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