User Manual BCDC1225-LV
Contents
1. Warranty Period enforceable and valid it must be read in the latter way If any clause or part of Such claims must include the following a clause in this Warranty is illegal unenforceable or invalid that clause or part is 7 1 details of the alleged defect or fault and the circumstances surrounding the to be treated as removed from this Warranty but the rest of this Warranty is not defect or fault affected 7 2 evidence of the claim including photographs of the Product where the subject Redarc s contact details of the claim is capable of being photographed 21 Redarc s contact details for the sending of Warranty claims under this Warranty are 7 3 i serial number of the Product specified on the label affixed to the Product Redarc Electronics Pty Ltd 7 4 proof of purchase documentation for the Product from an authorised distributor w te Road Morin Lonsdale SA 5160 or reseller of Redarc which clearly shows the date and place of purchase mail power redarc com au The return of any Products without the prior written instructions of Redarc will not Telephone 61 8 8322 4848 be accepted by Redarc 14 THE POWER OF REDARC 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 WARBCDC1225 LV REV32. 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 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 protect both the battery and the BCDC unit If I use the BCDC to charge my auxiliary battery do 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 similarly it will turn OFF when the vehicle is turned OFF I ve heard that you shouldn t charge 2 batteries of different chemistries from the same source will have any problems charging my AGM or Gel auxiliary
3. and finally heat the heatshrink Do not solder the wire before crimping Redarc does not recommend using standard red blue yellow blade connections as they are not rated for either the current or gauge of wire supplied on the unit The appropriate sized butt splice should be selected for example if 8AWG wires are used to connect the unit then an 8AWG butt splice should be used If the wire gauge brought up to the unit is larger than the 8AWG then it is recommended to use a butt splice that has two different size entrys each matching the respective wire size Various butt splices are available from auto electrical suppliers Crimping provides good mechanical connection soldering provides a long lasting electrical connection and forming of the heatshrink will prevent any shorting contact with your vehicle chassis The term crimping refers to a method of firmly attaching a terminal or contact to the end of an electrical conductor by pressure forming or reshaping a metal barrel onto the connector The forming of a satisfactory crimp is dependent upon the correct combination of conductor crimp barrel and crimping tool When the correct combination of equipment is employed a crimp that has both good electrical and mechanical characteristics will be formed Butt splices are used to dress and terminate multiple conductors of the same or different gauges in an end to end or series configuration 2 INSTALLATION Slip heatshrink over wire an
4. in one of the three stages Yes If an External LED is fitted is it working as described on page 5 of this manual Check the connection to the BCDC and the orientation of the LED as per the install diagrams If the problem is still evident contact a qualified Auto Electrician or Redarc Electronics Yes The BCDC is operating correctly If a low auxiliary battery voltage occurs check BROWN wire is making a good connection to the auxiliary battery If the problem is still evident get a qualified Auto Electrician to inspect the system 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 Check the RED wire Is it installed with appropriate gauge wire and connected to the source you require No Yes Check the BLUE wire BATTERY BLUE to IGNITION SOLAR BLUE to GROUND or NO CONNECT is the BLUE wire setup like this No Yes Are all battery negative wires solar negative wire and BLACK BCDC wire connected to a common ground point chassis No Yes Check that the alternator Is the input voltage above 13 2V for a 12V system or 17 5V for a solar setup No Yes The BCDC is not operating correctly Have a qualified Auto Electrician check the wiring fu
5. lt pGE THRE O A o S 2 9 D T Y z S A r S AGE THe THE POWER OF REDARC 20A In vehicle 3 Stage 12V Battery Charger BCDC1225 LV THE BCDC1225 LV The BCDC1225 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 BCDC1225 LV In Vehicle Battery Charger is able to achieve and maintain an optimal charge in your auxiliary battery at all times It is designed to operate with variable voltage alternators The BCDC1225 LV In vehicle Battery Charger also features a Maximum Power Point Tracking MPPT solar regulator allowing you to deliver the maximum amount of power from your solar panels to your auxiliary battery WARNING amp SAFETY INSTRUCTIONS This appliance is not intended for use 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 appliance Do NOT disassemble the BCDC1225 LV the internal circuitry contains hazardous voltages Attempting to service the unit yourself may result in electric shock or fire and will void the unit warranty Do NOT use the BCDC1225 LV to charge non rechargeable batteries Doing
6. on 08 8322 4848 or power redarc com au for prompt and efficient diagnosis and product support Our goods come with guarantees that cannot be excluded under the Australian Consumer Law You are entitled to a replacement or refund for a major failure and compensation for any other reasonably foreseeable loss or damage You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure The benefits of this Warranty are in addition to other rights and remedies available at law in respect of the Products and shall not derogate from any applicable mandatory statutory provisions or rights under the Australian Consumer Law Redarc Electronics Pty Ltd atf the Redarc Trust trading as Redarc Electronics Redarc offers a warranty in respect of its Products where the Products are purchased from an authorised distributor or reseller of Redarc by a person Purchaser on the terms and conditions and for the duration outlined below in this document Warranty 1 In this Warranty the term Products means 8 Without limiting any other clause in this Warranty Redarc has the right to reject any 1 1 all products manufactured or supplied by Redarc excluding its solar products Warranty claim made by a Purchaser pursuant to this Warranty where which are covered by Redarc s Solar Product Warranty and 8
7. supplied Current rating is for 24V input voltage 1 Wire the Common Ground wire to a ground point that is common to both the Start battery or the Solar Input Ground wire and the Auxiliary battery to be charged This point MUST be on the chassis of the vehicle on the chassis of the trailer camper caravan NOT directly wired to the main battery 2 Wire the Output Battery Positive to the Auxiliary battery positive terminal Ideally the BCDC unit should be a maximum of 1 metre in cable length from the battery positive terminal and should be wired with a minimum of 7 71mm or 8 B amp S cable 3 Wire the Input Battery Positive wire to the Start battery positive terminal via a 60A N O ignition controlled relay or the Solar Input Positive wire depending on your install 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 Cable Install Length Minimum Wire Size Recommended Wire Closest BAE B amp S a Size mm AWG 13 56 6 a a 20 28 A 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 accordi
8. 1 the Purchaser does not notify Redarc in writing of a Warranty claim within the 1 2 any component of or accessory for any product in clause 1 1 manufactured or Warranty Period supplied by Redarc 8 2 the Purchaser does not notify Redarc in writing of a Warranty claim within 1 otter and duration of product warranties month of becoming aware of the relevant circumstances giving rise to the Redarc warrants that its Products will be free under normal application installation claim so that any further problems with the Product are minimised use and service conditions from defects in materials and workmanship affecting 8 3 the serial number of the Product has been altered removed or made illegible normal use for 2 years from the date of purchase Warranty Period without the written authority of Redarc gt 3 Where a Product malfunctions or becomes inoperative during the Warranty Period 8 4 the Purchaser is unable to provide proof of purchase documentation in due to a defect in materials or workmanship as determined by Redarc then subject accordance with clause 7 4 or evidence that the Product was properly installed to further rights conferred by the Australian Consumer Law on the Purchaser and removed if relevant and that proper maintenance has been performed Redarc will in exercise of its sole discretion either on the Product by or under the supervision of a qualified auto electrician or 3 1 repa ir the defective Product echnic
9. Australia LWWWMIELALG GOM AU Figure 1 6 1 BCDC1225 LV Front Panel Standby mode is entered when the unit is not charging In this mode the Battery Type LED will blink approx once per second the charging status LEDs will be off In this mode if the battery type wire is moved then the selected battery type will update Error Godes In the event of a fault with the unit installation either battery or solar panel both the External LED and ALL the LEDs on the unit will flash to indicate the fault type Flashing sequences are described in the table below 3 flash 3 flash followed by 3 5 second off 5 flash 5 flash followed by 3 5 second off Input under voltage Battery 6 flash 6 flash followed by 3 5 second off Input over voltage Battery or Solar panel 7 flash 7 flash followed by 3 5 second off Reverse polarity INSTALLATION 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 Wire into vehicle as per the applicable diagram on the next pages and following the steps below The BCDC1225 LV is connected using 6 wires listed below e Source Select Blue e Battery Type Orange e Remote Indicator Green e Input Battery Positive Red 40A 30A Fuse not supplied e Common Ground Black e Output Battery Positive Brown 40A Fuse not
10. 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 My BCDC is setup for 12V Alternator input but will not start when the vehicle is turned On I ve followed the trouble shooting guide and the setup is fine what s the problem The most likely cause of this issue is that the BCDC is somehow stuck in 24V mode Try removing the Source Select Blue wire and reconnecting it If the problem still exists please contact Redarc Electronics 12 13 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 We believe in total customer satisfaction and practice this by offering our customers e Technical advice free of jargon and free of charge e Prompt turnaround of orders throughout Australia and globally e Friendly personalised professional service and product support In the unlikely event that a technical issue arises with a Redarc product customers are encouraged to initially contact the Redarc Technical Support Team
11. d insert wires into Crimp both wires to the butt splice using indent butt splice Keep heatshrink away from joint until type crimpers after soldering is complete and has cooled Solder here Solder the wires to the butt splice Ensure that a Wait for the butt splice to cool slip heatshrink good connection is made over the joint and heat Figure 2 1 Ensuring a good wiring connection 12V Changeover Relay 60A to vehicle ignition Note Power wires must be All ground points must at least 6mm and must be be connected to chassis Battery crimped using an earth appropriate crimp tool Auxiliary Battery Figure 2 2 Standard setup for a 12V Start Battery amp 12V Solar Array 9 2 INSTALLATION To vehicle ignition Note Power wires must be All ground points must at least 6mm and must be be connected to chassis crimped using an earth appropriate crimp tool Figure 2 3 Standard setup for a 12V Start Battery Note Power wires must be All ground points must at least 6mm and must be be connected to chassis crimped using an earth appropriate crimp tool Figure 2 4 Standard setup for a 12V Solar array 10 Auxiliary Battery Auxiliary Battery 3 TROUBLESHOOTING Start and run engine for 30 seconds leave engine running whilst troubleshooting Is the correct Battery Type LED on solid or flashing Is the Charge Status light flashing
12. hall only be entitled to the benefit of this Warranty after all amounts 6 2 accident misuse abuse negligence vandalism alteration or modification ___ owing in respect of the Product have been paid 6 3 non observance of any of he instructions supplied by Redarc including 5 While Redarc warrants that the Products will be free from defects in materials and instructions concerning installation configuri ng connecting commissioning workmanship n the circumstances set out in this Warranty to the maximum extent use or application of the Product including without limitation choice of location permitted by law Redarc does not warrant that the operation of the Products will be 6 4 failure to ensure proper maintenance of the Product strictly in accordance with Uninterrupted or error free nale i Redarc s instructions or failure to ensure proper maintenance of any associated To the maximum extent permitted by law Redarc s determination of the existence of 6 equipment or machinery any defect and the cause of any defect will be conclusive 6 5 repairs to the Product that are not strictly in accordance with Redarc s 7 Spare parts or materials for the Products are guaranteed to be available for a period instructions of at least 2 years after purchase of the Products 8 9 6 6 installation repairs or maintenance of the Product by or under the supervision 18 The agents officers and empl
13. he unit will accept an input directly from the solar panels and act as a MPPT Solar Regulator To select the Solar charging mode the BLUE Source Select wire can either be left disconnected or connected to GROUND Charging Algorithm When the BCDC1225 LV is turned on it will move into the bulk charging stage called Boost stage Boost stage maintains a constant current until the battery voltage reaches its set point 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 voltage The charger will then move to Absorption stage This stage maintains a constant voltage level until the battery is full after which the charger will enter float stage Float stage maintains 13 3V on the output battery keeping the battery topped up This counteracts the battery s self discharging When a load applied to the battery causes it to lose charge the charger will move back into Boost 3 1 4 1 5 PRODUCT FUNCTION Turn On Off Thresholds ee Low voltage conditions Turn ON above 12V Turn ON above 17 5V a circuit tested every Turn OFF below 11 9V Turn OFF below 17 2V Low voltage conditions Turn OFF instantly below Turn OFF instantly below loaded constantly tested 8V 6V Turn OFF after 20 secs N A below 9V Over voltage shutdown Turn ON below 15 5V Turn ON below 28V Turn OFF instantly above Turn OFF instantly above 16V 29V Tu
14. ian in accordance with the instructions of Redarc 3 2 replace the defective Product or 9 If the Product is found to be working satisfactorily on return to Redarc or upon 3 3 provide a refund to the Purchaser for the purchase price paid for the defective investigation by Redarc the Purchaser must pay Redarc s reasonable costs of Product testing and investigating the Product in addition to shipping and transportation without charge to the Purchaser charges Where Redarc is in possession of the Product the Product will be 4 The warranty given by Redarc in clause 3 covers the reasonable costs of delivery returned to the Purchaser on receipt of the amount charged and installation of any repaired or replaced Products or components of Products 10 Any replaced Products or components of Products shall become the property of to the Purchaser s usual residential address notified to Redarc together with the Redarc ee reasonable costs of removal and return of any Products determined by Redarc tobe _ 11 Redarc may in exercise of its sole discretion deliver another type of Product or defective component of a Product different in size colour shape weight brand and or 5 Ifthe Purchaser incurs expenses of the nature referred to in clause 4 in the other specifications in fulfilling its obligations under this Warranty in the event context of making a claim pursuant to this Warranty that is accepted by Redarc that Redarc has discontinued man
15. ithm 04 4 Turn On Off Thresholds 04 5 External LED Indication 05 6 Display Panel 05 7 Error Codes 06 2 Installation 06 1 Wiring 08 3 Troubleshooting 11 4 Frequently Asked Questions 12 5 Two Year Warranty 14 Specifications _ BGDOY225 W po Gel AGM Std Lead Acid Calcium Content Weight BOQ Dimensions fJ 8 OXI20K37MmM Warranty 2 years po years Standards CE C Tick AS NZS CISPR11 2004 1 PRODUCT FUNCTION The BCDC1225 LV is a multi stage 12V 25A DC DC battery charger that operates from an input of 12V nominal or a 12V nominal solar panel input The input voltage of the BCDC1225 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 The BCDC1225 LV is also designed to isolate the main battery from the auxiliary battery to avoid over discharging the main battery and operate with variable voltage alternators 1 1 1 2 1 3 Alternator Input To select the Alternator charging mode the BLUE Source Select wire must be connected to Input Positive The output battery will only be charged when the alternator is running and the vehicle ignition is ON guaranteeing that the charger will not drain the input battery Solar Input The BCDC1225 LV is also capable of charging the auxiliary 12V battery from a Solar source Solar charging mode is selected at time of installation T
16. ng to the type of Auxiliary battery you have installed This wire is monitored when the charger is not charging Battery type Orange source select Blue 12V input positive Calcium Gan Alternator charge a Standard Lead Acid Solar charge Ni Not connected AGM or Gel Solar charge NOTE The unit will operate optimally below 55 C with good airflow At higher temperatures the unit will de rate output current IMPORTANT NOTE Battery type selection refers to a typical installation where the battery and unit are mounted in a low to mid temperature situation For situations of higher temperature such as under the bonnet or in a caravan battery box a softer profile eg Std Lead Acid instead of Calcium may need to be selected to avoid damage to the battery 2 1 INSTALLATION Wiring The heavy gauge wires on the BCDC1225 LV unit carry peak currents of up to 35 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 Redarc recommends using a soldered butt splice crimp connection that is covered with heatshrink The process should be to feed the heatshrink over the wires crimp the wires into the butt splice then solder the wires on the butt splice
17. oyees of any distributor or reseller of the Products and of a person who is not a qualified auto electrician or technician or if non of Redarc are not authorised to vary or extend the terms of this Warranty genuine or non approved parts have been fitted 19 Redarc shall not be responsible or liable to the Customer or any third party in 6 7 faulty power supply power failure electrical spikes or surges lightning flood connection with any non performance or delay in performance of any terms and storm hail extreme heat fire or other occurrence outside the control of conditions of this Warranty due to acts of God war riots strikes warlike conditions Redarc plague or other epidemic fire flood blizzard hurricane changes of public policies 6 8 use other than for any reasonable purpose for which the Product was terrorism and other events which are beyond the control of Redarc In such manufactured circumstances Redarc may suspend performance of this Warranty without liability 6 9 any indirect or incidental damage of whatever nature outside the control of for the period of the delay reasonably attributable to such causes Redarc 20 If a clause or part of a clause in this Warranty can be read in a way that makes it 7 Warranty claims in respect of a Product must be made in writing to Redarc at the illegal unenforceable or invalid but can also be read in a way that makes it legal postal address or email address specified in clause 21 within the
18. rn OFF after 20 secs Turn OFF after 20 secs above 15 6V above 28 2V Under voltage shutdown Shutdown if Output Battery lt 4V External LED Indication A flying lead output GREEN wire is provided to connect an external indicator LED which can be mounted away from the unit for example in the vehicle cabin The positive lead of the LED will be connected to the indicator output wire flying lead provided and the negative lead of the LED will be connected to the vehicle s ground No external resistors are required The remote indicator LED will indicate charging state as described below LED State Off constant Not charging Charging or maintaining charge 1 6 1 7 PRODUCT FUNCTION Display Panel The BCDC1225 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 In order to give more information the applicable LED will flash to indicate the output by the unit The longer the flash the more current the charger is putting out If the LED is ON solid then the unit is supplying a full 25A to the auxiliary battery BATTERY TYPE Pe o o o o o o Paka e battery charger Designed and made In
19. ses batteries and charging system or contact Redarc Electronics for more information Is the auxiliary battery voltage above 4V Yes No Figure 3 1 Standard BCDC1225 LV Troubleshooting Guide 11 overnight using a multi stage charger is charging properly If the problem is still evident contact a qualified Auto Electrician or Redarc Electronics Remove all loads from the auxiliary battery and charge it and then recheck the battery If the battery voltage is still low replace battery FREQUENTLY ASKED QUESTIONS 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 11 9V the BCDC will turn OFF At any other time during the charging process if the voltage at the BCDC drops below 9V the BCDC will turn OFF How does the BCDC charge an Auxiliary battery at 14V when it only gets 9V 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
20. so may result in harm to the user and or damage to the BCDC1225 LV Only use the BCDC1225 LV for charging Standard Lead Acid Calcium content Gel amp AGM type 12V batteries All lead acid batteries produce harmful explosive gases The Battery should be mounted in a well ventilated area as far as possible from any ignition sources Do NOT smoke when in the vicinity of the battery under charge Battery acid is a harmful substance Care should be taken when working with lead acid batteries if the acid comes into contact with your eyes or skin immediately wash the affected area with cold running water and seek medical assistance Eye protection and gloves should be worn when handling lead acid batteries The BCDC1225 LV will achieve best results when proper battery maintenance is regularly performed This includes but is not limited to checking water and specific gravity levels of the battery Warning Check the manufacturers data for your battery and ensure that the Absorption voltage of the profile you select does not exceed the manufacturers recommended maximum charging voltage If the Absorption voltage for your battery type is too high please select another charging profile SAL FOR Instruction Manual BCDC1225 LV D0C482 Version 3 4 CONTENTS Table of Contents Page Warnings and Safety Instructions 01 Contents 02 Specifications 02 1 Product Function 03 1 Alternator Input 03 2 Solar Input 03 3 Charging Algor
21. ufacturing or supplying the relevant Product or the Purchaser will be entitled to claim for reimbursement of those expenses which component at the time of the Warranty claim or where such Product or component Redarc determines in exercise of its sole discretion to be reasonably incurred is superior to that originally purchased by the Purchaser provided that the claim is notified to Redarc in writing at the postal address or email Other conditions of Warranty address specified in clause 21 and includes 12 If the Purchaser acquired a Product for the purpose of resupply then this Warranty 5 1 details of the relevant expenses incurred by the Purchaser and shall not apply to that Product 5 2 proof of the relevant expenses having been incurred by the Purchaser 13 In particular the sale of a Product via an online auction online store or other Exclusions and limitations internet website by a party that is not an authorised distributor or reseller of the 6 This Warranty will not apply to or include any defect damage fault failure Product will be deemed to be a resupply within the meaning of the Australian or malfunction of a Product which Redarc determines in exercise of its sole Consumer Law and will render this Warranty void as Redarc has no control over the discretion to be due to storage handling quality or safety of Products sold by such persons 6 1 normal wear and tear or exposure to weather conditions over time 14 A Purchaser s
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