Dual Input Multi-stage 12V In-vehicle Battery Charger BCDC1250D
THE BCDC1250D The BCDC1250D Dual Input In-vehicle Battery Chargers feature technology designed to charge your auxiliary batteries to 100%, regardless of their type or size. The Dual Input In-vehicle Battery Chargers also feature a Maximum Power Point Tracking (MPPT) solar regulator. The unit will always take as much power from the Solar input as it can before supplementing that power, up to the maximum rated output, from Vehicle power input.
CONTENTS Warnings and Safety Instructions Contents Specifications 1 Product Function 1. Display Panel 2. Charge Profile LEDs 3. Charge Status LEDs 1. Solar & Vehicle LEDs 2. Stage LED 3. Charging Process 4. Turn ON/OFF Thresholds 5. Error Codes 6. Battery Test Mode 2 Installation 1. Install Location 2. Charge Profile Selection (ORANGE Wire) 3. Input Trigger Settings (BLUE Wire) 4. Cable Sizing 5. Wiring 6. Fusing 7.
1 PRODUCT FUNCTION The BCDC1250D is a four-stage, 12V DC-DC battery charger that operates from an alternator input of 12V or 24V and a 12V nominal solar panel input. The input voltage of the BCDC1250D 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 1.3 Charge Status LEDs The Charge Status LEDs indicate to the user which inputs are available and what stage of the charge process is currently in. 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. If both LEDs are ON, both input sources are available and in use. The Dual Input In-vehicle Battery Charger uses Green Power Priority technology.
1 PRODUCT FUNCTION 1.3.3 Charging Process Charging Process Soft-Start Boost Absorption Float Voltage Current Figure 1.3.3.1 - Charging Process When the Charger is turned on, it will start ramping current from 0A up to the full rated current, this is called Soft-Start and usually takes around 30 seconds. Once the full rated current is reached the charger will move into Boost stage. The Boost stage maintains a constant current until the battery voltage reaches its Absorption Voltage.
1 PRODUCT FUNCTION 1.4 Turn On/Off Thresholds Input Input Trigger Settings Input Open Circuit Low voltage conditions *1 Input Loaded Low voltage conditions*2 Input Over voltage shutdown Turn ON ABOVE Turn OFF BELOW Turn OFF instantly BELOW Turn OFF after 20s BELOW Turn ON BELOW Turn OFF instantly ABOVE Turn OFF after 20s ABOVE Output Under voltage shutdown *1 12V Vehicle Input 24V Vehicle Input Solar Standard Low Voltage Standard Low Voltage N/A 13.2V 12.0V 26.4V 24.0V 9.0V 12.7V 11.
1 PRODUCT FUNCTION 1.6 Battery Test Mode The unit features a battery test mode which occurs every 100 seconds. The test mode is designed to both test that the input conditions are still met and check for the presence of a battery on the output of the unit. This feature is designed to protect the vehicle battery from over discharge and protect the vehicle and wiring in the event of damage to the output connection.
2 INSTALLATION 2.2 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.
2 INSTALLATION 2.3 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 alternators) Standard Low Voltage Not Connected Vehicle Ignition Blue Wire Blue Wire Figure 2.3.1 - Setting the Input Trigger Settings 12V Mode 2.4 24V Mode Input Mode Blue Wire Connection Standard Not Connected 13.2V 12.7V 26.4V 25.
2 INSTALLATION 2.5 Wiring The heavy gauge wires on the BCDC1250D unit carry peak currents of up to 55A 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.
INSTALLATION 2.7 Typical Setup 12V OR 24V AND INPUT INPUT SOLAR Optional LED INPUT Green Charging Profile Select Refer to section 2.2 Yellow Red Blue Black Orange 12V Solar Panel Array (Unregulated) Fuse* Leave unconnected Standard Trigger Settings to Vehicle Ignition 12V or 24V Start Battery Bank Brown 2 Fuse* Loads Load Fuse Low Voltage Trigger Settings All ground points must be connected to chassis earth. Auxiliary Battery *Fuse Ratings as per table on Page 2 Figure 2.7.
3 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 4.2V 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.
4 Q A Q A Q A Q A Q A Q A Q A Q A FREQUENTLY ASKED QUESTIONS The BCDC Dual Input turns ON at 13.2V(12V) and OFF at 12.7V(11.9V), but you say it operates down to 9V, explain? The BCDC Dual Input will turn OFF for a split second every 100 seconds to measure the unloaded voltage at the battery. When the BCDC Dual Input 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.
