Related Manuals for Redarc BCDCN1225
Summary of Contents for Redarc BCDCN1225
- Page 1 BCDC Core ® Dual Input Multi-Stage In-Cabin Battery Charger MODELS: BCDCN1225 ƒ 25 A CHARGER BCDCN1240 ƒ 40 A CHARGER...
- Page 2 BCDCN1225 & BCDCN1240 Dual Input Multi-Stage In-Cabin Battery Charger The BCDC Core Battery Chargers are designed to keep your vehicles auxiliary battery system fully charged and can source power from 12 V or 24 V vehicle alternators and 12 V solar panels.
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Page 3: Table Of Contents
CONTENTS WARNINGS AND SAFETY INSTRUCTIONS ��������������������������������������������������������������������������� 1 PRODUCT OVERVIEW ��������������������������������������������������������������������������������������������������������� 1.1 Cables and Wires ��������������������������������������������������������������������������������������������������������� 1.2 Charge Profile LEDs ���������������������������������������������������������������������������������������������������� 1.3 Charge Status LEDs ���������������������������������������������������������������������������������������������������� 2 PRODUCT FUNCTION ��������������������������������������������������������������������������������������������������������� 2.1 Charging Stages ���������������������������������������������������������������������������������������������������������� 2.2 Battery Test Mode ����������������������������������������������������������������������������������������������������� 2.3 Green Power Priority �������������������������������������������������������������������������������������������������... - Page 4 BCDCN1225 / BCDCN1240 Battery Charger. Do not operate the BCDC Core 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.
- Page 5 2. Do NOT alter or disassemble the BCDC Core 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.
- Page 6 1 PRODUCT OVERVIEW The BCDC Core 25 and BCDC Core 40 are three-stage, DC-DC 12 V auxiliary battery chargers that source power from both the vehicles alternator and solar panel input. The BCDC Core's vehicle input is suitable for 12 V or 24 V start battery and alternator systems while the solar input is designed for connection to unregulated 12 V nominal solar panels.
- Page 7 1.1 Cables and Wires The BCDC Core Battery Chargers are equipped with a fly lead wiring harness that must be correctly connected to ensure effective charging of the auxiliary battery. See "Table 1.1.1: Wire Description" for more information. Refer to "3.2.1 Battery Setup"...
- Page 8 1.3 Charge Status LEDs The Charge Status LEDs indicate to the Status LED user which inputs are available and what Solar stage of the charge process the unit is Vehicle currently in. Stage 1.3.1 SOLAR & VEHICLE LEDS 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.
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Page 9: Product Function
2 PRODUCT FUNCTION 2.1 Charging Stages BOOST When the Battery Charger is correctly installed and has a valid power input source it will begin charging the auxiliary battery in 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. -
Page 10: Battery Test Mode
2.2 Battery Test Mode The Battery Charger enters a battery test mode every 100 seconds to check that the input being received from either solar or vehicle battery is still valid and that the auxiliary battery is still correctly connected to the output. This feature protects the vehicle start battery from over discharge as well as protecting the vehicle and its wiring in the event of damage to the output connection. -
Page 11: Installation
1 m of cable length from the unit to the auxiliary battery. Assess a suitable mounting position for the auxiliary battery and Battery Charger before planning out cables and connections. REDARC recommend ensuring the LED indicators on the Battery Charger can be accessed and are visible for troubleshooting (see "4.2 Turn On/Off Thresholds"... -
Page 12: Installation Overview
Refer to "Figure 3.2.1.1: Typical Battery Setup" to plan the required cabling, fusing and connections needed for your installation. REDARC recommends that the Battery Charger be installed by a suitably qualified person. 3.2.1 BATTERY SETUP Figure 3.2.1.1: Typical Battery Setup... - Page 13 3.2.2 CONSIDERATIONS PRIOR TO INSTALLATION 1. Auxiliary Battery Profile Selection — Determine the chemistry of your auxiliary battery prior to install as this will influence the connection of the ORANGE wire that is used to set the charge profile of the BCDC Core (see "3.7.3 Profile Selection —...
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Page 14: Cable Sizing
Sectional Area B&S, BAE, AWG Size 1 – 5 m 3' – 16' ≥ 7.7 mm² 8 B&S / 10 mm² BCDCN1225 5 – 9 m 16' – 30' ≥ 13.6 mm² 6 B&S / 16 mm² 1 – 5 m 3' – 16' ≥ 13.6 mm²... -
Page 15: Cable Connections
CAUTION Failure to make a good reliable connection may result in breakdown of the wire insulation and cause a short circuit, or worst case a fire. REDARC recommend this activity be undertaken by an appropriately trained person. For extending the cables provided on the BCDC Core, REDARC recommends using a soldered butt-splice crimp connection that is covered with heat shrink (see "Figure 3.4.1: Crimping using... - Page 16 BCDC Core’s 8 B&S cables as they are not rated to carry the required current. REDARC fuse kits FK40 and FK60 include 4 × 10mm² (8 B&S) crimp lugs that allow connection of the Vehicle Input and Output cables to the MIDI fuse holders in the kit.
- Page 17 Figure 3.4.2: Typical Cable Connectors — Portable Auxiliary Battery System 12 V BROWN Output Fuse Vehicle Earth YELLOW Connection Point BLACK Anderson SB50 VEHICLE Connectors BATTERY Vehicle Input Fuse Load Fuse Both batteries, BCDC and solar panels are grounded to the vehicle chassis BATTERY ≤100 mm / 3.9"...
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Page 18: Fusing
"Figure 3.2.1.1: Typical Battery Setup" (page 12) fuses are required to protect the RED Vehicle Input cable and the BROWN Output cable. REDARC recommends the RED cable fuse to be mounted within 100 mm cable length from the vehicle start battery positive terminal. -
Page 19: Mounting
NOTE: Damage to cabling can cause failure of the BCDC and vehicle electrical systems. Ensure cabling is clear of sharp edges or moving parts, and have enough slack to allow for flexing. REDARC recommend using cable ties and conduit or split tubing to manage cabling. 3.7.1 OUTPUT AUXILIARY BATTERY —... - Page 20 3.7.2 COMMON GROUND — BLACK CABLE The BLACK wire must be connected to a ground point that forms a common ground with both the start battery and the auxiliary battery. Most commonly the vehicle electrical systems ground/earth reference is the metal of the bodywork. See "Figure 3.4.2: Typical Cable Connectors —...
- Page 21 Figure 3.7.3.2: Setting the Maximum Voltage (ORANGE wire) PROFILE A PROFILE B Leave the ORANGE Wire disconnected to Connect the ORANGE Wire to Common set the Maximum voltage to 14.6 V. Ground to set the Maximum voltage to 15.0 V. PROFILE C PROFILE Li Connect the ORANGE Wire to the RED...
- Page 22 3.7.5 VEHICLE IGNITION INPUT — BLUE WIRE The BLUE wire is required for the BCDC Core to operate in Low Voltage mode when installed in vehicles with variable-voltage alternators. If required to leave the BLUE wire disconnected, apply electrical tape over the end of the wire. Figure 3.7.5.1: Connecting the BLUE wire LOW VOLTAGE MODE STANDARD VOLTAGE MODE...
- Page 23 "Figure 3.7.5.3: Installation Using a Relay"). For 12 V applications, REDARC recommends the RK1260 Relay Kit that includes all components required including heat shrink, relay holder and butt-splice connectors. Alternatively the installer can source any high quality relay that meets or exceeds the current rating of the Vehicle Input Fuse.
- Page 24 3.7.6 SOLAR PANEL(S) — YELLOW CABLE The YELLOW wire connects solar input to the BCDC. If solar is not installed, tape over the end of the wire. IMPORTANT: DO NOT connect solar panels that have inbuilt regulators. The BCDC Core has an inbuilt regulator that may not function correctly if regulated solar panels are connected.
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Page 25: Maintenance
Table 3.7.1: Maximum Output Power rating Model BCDCN1225 BCDCN1240 Maximum Output Power rating 375 W 600 W While output power may be limited in peak solar conditions, having this additional solar panel wattage is beneficial for solar power availability when conditions are sub-optimal. -
Page 26: Troubleshooting
4 TROUBLESHOOTING There are no LEDs ON at all. This indicates that there is no battery connected to the output (BROWN wire) 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. - Page 27 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 9 V or there is not sufficient power available from the Solar Panel (due to poor light conditions or a faulty panel).
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Page 28: Error Codes
4.1 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. Table 4.1.1: Flashing Sequences LED State Description 1 flash (followed by 3.5 second off) Internal Hardware Fault 2 flash (followed by 3.5 second off) Unit under temp fault... -
Page 29: Turn On/Off Thresholds
4.2 Turn On/Off Thresholds Table 4.2.1: Turn On/Off Thresholds Input 12 V Vehicle Input 24 V Vehicle Input Solar Input Trigger Settings Standard Standard Voltage Voltage Input Open Turn ON ABOVE 12.9 V 12.0 V 25.8 V 24.0 V 9.0 V Circuit Low voltage Turn OFF BELOW... -
Page 30: Frequently Asked Questions
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. - Page 31 The most likely cause of this issue is that the BCDC Core Input is somehow stuck in 24 V mode. Try disconnecting the Vehicle wire (RED) and the Output wire (BROWN) and then reconnecting it. If the problem persists, contact REDARC. Can the BCDC Core Input charge from Solar and Vehicle power at the same time? Yes.
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Page 32: Specifications
35 A 55 A Vehicle Input Fuse Rating 40 A (Not Supplied) 60 A (Not Supplied) and Output Fuse Rating REDARC FK40 recommended REDARC FK60 recommended Maximum Output Power 375 W 600 W Vehicle Input Voltage Range 9 to 32 V... - Page 33 23 Brodie Road (North), Lonsdale South Australia 5160, Australia Design and specifications are subject to change without notice | Copyright © 2022 REDARC Electronics Pty Ltd� All rights reserved REDARC®, THE POWER OF REDARC®, and BCDC® are trademarks of REDARC Electronics Pty Ltd�...
- Page 34 NOTES...
- Page 36 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 +1 (704) 247 5150 Canada +1 (604) 260 5512 Mexico +52 (558) 526-2898 redarcelectronics.com INST148-1 EN...
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