DS LT AGE THRES 40A In-vehicle 3-Stage 12V Battery Charger BCDC1240-LV OL V LV H V LOW LOW O LDS HO E THRE TAG S OL
THE BCDC1240-LV The BCDC1240-LV 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 BCDC1240-LV 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. Alternator Input 2. Solar Input 3. Charging Algorithm 4. Turn On/Off Thresholds 5. External LED Indication 6. Display Panel 7. Error Codes 2 Installation 1.
1 PRODUCT FUNCTION The BCDC1240-LV is a multi stage, 12V, 40A, DC-DC battery charger that operates from an input of either 12V nominal or a 12V nominal solar panel input. The input voltage of the BCDC1240-LV can be above, below or equal to the output voltage making it ideal for charging an auxiliary 12V battery where the distance from the main battery may cause a significant voltage drop.
1 PRODUCT FUNCTION 1.4 Turn On/Off Thresholds 12V Solar Low voltage conditions (open circuit, tested every 100s) Turn ON above 12V Turn ON above 17.5V Turn OFF below 11.9V Turn OFF below 17.2V Low voltage conditions (loaded, constantly tested) Turn OFF instantly below Turn OFF instantly below 8V 8V Over voltage shutdown Turn OFF after 20 secs below 9V N/A Turn ON below 15.5V Turn ON below 28V Turn OFF instantly above Turn OFF instantly above 16V 29V Turn OFF after 20 secs above 15.
1 PRODUCT FUNCTION 1.6 Display Panel The BCDC1240-LV has three Battery Type Settings available. These settings enable optimal charging profiles for the auxiliary battery. The battery type selected is displayed via the LEDs on the front panel in the section ‘Battery Type’. In addition to the battery type, the status of the charger is indicated via three LEDs. The ‘Charging Status’ shows when the unit is in BOOST, ABSORPTION or FLOAT.
2 INSTALLATION 1 Mount the unit to a flat surface close to the auxiliary battery and away from any heat sources. NOTE: The unit will operate optimally below 55°C with good airflow. At higher temperatures the unit will de-rate output current. 2 Wire into vehicle as per the applicable diagram on the next pages, and following the steps below.
2 INSTALLATION 4. Wire the ‘Source Select’ wire according to your installation requirements. For a setup charging from a 12V alternator, connect this wire to the ‘Vehicle Ignition’. For a Solar only charging setup, connect this wire to GROUND or just leave it disconnected. This wire is monitored at all times. 5. Wire the ‘Battery Type’ wire according to the type of Auxiliary battery you have installed. This wire is monitored when the charger is not charging.
2 INSTALLATION 2.1 Wiring The heavy gauge wires on the BCDC1240-LV unit carry peak currents of up to 50 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. We recommend that this activity be undertaken by an appropriately trained person.
2 INSTALLATION Crimp here. Slip heatshrink over wire and insert wires into butt splice. Keep heatshrink away from joint until after soldering is complete and has cooled. Crimp both wires to the butt splice using indent type crimpers. Solder here. Wait for the butt splice to cool, slip heatshrink over the joint and heat. Solder the wires to the butt splice. Ensure that a good connection is made. Figure 2.
2 INSTALLATION 12V INPUT 50A Fuse To vehicle ignition Note: Power wires must be at least 6mm² and must be crimped using an appropriate crimp tool. Start Battery Battery config wire 50A Fuse Load Fuse All ground points must be connected to chassis earth. Loads Auxiliary Battery Figure 2.3 - Standard setup for a 12V Start Battery SOLAR INPUT 12 Solar Panel Array Battery config wire Note: Power wires must be at least 6mm² and must be crimped using an appropriate crimp tool.
3 TROUBLESHOOTING Start and run engine for 30 seconds - leave engine running whilst troubleshooting. Is the correct ‘Battery Type’ LED on solid or flashing? Shutdown the vehicle and rectify the problem. Check the ORANGE wire. Is it installed as per the instructions and correct for your battery type? No Yes Is the ‘Charge Status’ light flashing in one of the three stages? Yes Check the RED wire.
4 FREQUENTLY ASKED QUESTIONS Q A The BCDC turns ON at 12.0V and OFF at 11.9V, but you say it operates down to 9V, explain? The BCDC will turn OFF for a split second every 100 seconds to measure the unloaded voltage at the battery. When the BCDC 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 BCDC to measure the actual battery voltage, or the voltage at the battery. If this actual battery voltage is below 12.
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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 © 2012 Redarc Electronics Pty Ltd. All rights reserved. WARBCDC1240-LV - REV2 www.redarc.com.
