In-vehicle 3-Stage 12V Battery Charger BCDC1220 & BCDC1220-IGN
THE BCDC1220 & BCDC1220-IGN 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.
CONTENTS Table of Contents Page Warnings and Safety Instructions Contents Specifications 1 Product Function 1. Display Panel 2. Charging Algorithm 3. Turn On/Off Thresholds 4. Error Codes 2 Installation 1. RED wire - Input Positive 2. BLUE wire - Input Trigger 3. ORANGE wire - Charging Profile Select 4. BROWN wire - Auxiliary Battery Positive 5. BLACK wire - Common Ground 6. Cable Sizing 7. Wiring 8.
1 PRODUCT FUNCTION The BCDC1220(-IGN) is a multi stage, 12V, 20A, DC-DC battery charger that operates from an input of either 12V or 24V nominal. The input voltage of the BCDC1220 can be above, below or equal to the output voltage making it ideal for charging from a 24V vehicle or charging an auxiliary 12V battery where the distance from the main battery may cause a significant voltage drop.
1 PRODUCT FUNCTION 1.2 Charging Algorithm When the BCDC1220(-IGN) is turned on, it will move into the Boost stage. The Boost stage maintains a constant current until the battery voltage reaches the Absorption Voltage. The current during Boost stage may vary throughout operation in order to maintain a safe operating temperature, or to limit the difference between input and output voltages.
2 INSTALLATION Mount the unit to a flat surface close to the auxiliary battery and away from any heat sources. The BCDC1220(-IGN) has 5 wires and should be installed as described over the following pages. NOTE: The unit will operate optimally below 55°C 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 20A for the BCDC1220(-IGN).
2 INSTALLATION 2.2 BLUE wire - Input Trigger The BLUE wire is provided to select the units input trigger behaviour. This wire is monitored at all times. 2.1.1 BCDC1220 To charge from a 12V 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 24V alternator the BLUE ‘Input Trigger’ wire must be connected to the vehicle ignition.
2 INSTALLATION 2.3 ORANGE wire - Battery Type Select The ORANGE wire is used to select the Maximum output voltage. This is achieved by connecting in the following way: Not Connected To select Profile A leave the ORANGE wire disconnected. This will set the Maximum voltage to 14.6V*1. To select Profile B connect the ORANGE wire to Common Ground. This will set the Maximum voltage to 15.0V*1. To select Profile C connect the ORANGE wire to the RED wire (Input source positive).
INSTALLATION 2.4 BROWN wire - Auxiliary Battery Positive The BROWN wire should be connected to the auxiliary battery’s positive terminal. The unit should be a maximum of 1 metre in cable length from the battery. Appropriate size fuses should be used as per the specifications table on page 2. 2.5 Brown Wire Midi Fuse 2 Auxiliary Battery BLACK wire - Common Ground 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.
2 INSTALLATION 2.6 Cable sizing Below is a table outlining the required cable size for a given cable install length. Always choose a wire diameter equal to or greater than what is specified below. 2.7 Cable Install Length (m) Recommended Wire Size (mm²) Closest (BAE, B&S, AWG) 1-3 3-5 5-9 3.5 5.7 10.
2 INSTALLATION BCDC1220 12V INPUT 30A Fuse Battery config wire 30A Fuse Load Fuse All ground points must be connected to chassis earth. Start Battery Loads Auxiliary Battery Figure 2.7a - BCDC1220 12V Starter battery installation BCDC1220-IGN 12V INPUT 30A Fuse To vehicle ignition Battery config wire 30A Fuse All ground points must be connected to chassis earth. Start Battery Figure 2.
2 INSTALLATION BCDC1220 & BCDC1220-IGN 24V INPUT 20A Fuse To vehicle ignition Battery config wire 30A Fuse Load Fuse All ground points must be connected to chassis earth. Start Battery Loads Auxiliary Battery Figure 2.7c - BCDC1220 & BCDC1220-IGN 24V installation BCDC1220 & BCDC1220-IGN 12V OR 24V INPUT INPUT 30A N/O Relay To vehicle ignition 20A Fuse Battery config wire 30A Fuse All ground points must be connected to chassis earth. Start Battery Figure 2.
2 INSTALLATION 2.9 Fusing REDARC recommend using MIDI style bolt down fuses as they ensure a low resistance connection. The REDARC FK40 fuse kit is 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. Selfresetting circuit breakers are not recommended as they may trip prematurely due to the heat generated by the current flowing through the wires.
4 Q A FREQUENTLY ASKED QUESTIONS The BCDC1220(-IGN) turns ON at 13.2V(12V) and OFF at 12.7V(11.9V), but you say it operates down to 9V, 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.
5 TWO YEAR PRODUCT WARRANTY Over the last three decades our company has established a reputation as the power conversion specialist. A 100% Australian-owned company, we have met the needs of customers in transport and other industries through exciting, innovative thinking.
Free technical assistance! please contact REDARC Electronics 23 Brodie Road North, Lonsdale SA (08) 8322 4848 power@redarc.com.au www.redarc.com.au Copyright © 2016 REDARC Electronics Pty Ltd. All rights reserved. www.redarc.com.
