Redarc BCDC1220, BCDC1220-IGN Instruction Manual

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. The BCDC1220 is designed to
work with either fixed voltage or temperature compensating alternators while the BCDC1220-IGN
is designed to operate with variable voltage alternators.

WARNING & SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS - This manual contains IMPORTANT SAFETY INSTRUCTIONS for the
BCDC1220 & BCDC1220-IGN battery chargers.

DO NOT OPERATE THE BATTERY CHARGER 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.

RISK OF EXPLOSIVE GASES:

WORKING IN VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. BATTERIES GENERATE EXPLOSIVE

GASES DURING NORMAL OPERATION. FOR THIS REASON, IT IS OF UTMOST IMPORTANCE THAT YOU
FOLLOW THE INSTRUCTIONS WHEN INSTALLING AND USING THE CHARGER.

1. The Battery Charger should not be used 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 Battery Charger.

2. Do NOT alter or disassemble the Battery Charger 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.

3. Only use the Battery Charger for charging Standard Automotive Lead Acid, Calcium Content, Gel, AGM or Deep
Cycle type 12V batteries. Check the manufacturers data for your battery and ensure that the ‘Maximum’ voltage
of the profile you select does not exceed the manufacturers recommended maximum charging voltage. If the
‘Maximum’ voltage for your battery type is too high, please select another charging profile. The Battery Charger
is not intended to supply power to a low voltage electrical system other than to charge a battery.

4. NEVER smoke or allow a spark or flame in vicinity of battery or engine. This may cause the battery to explode.

5. PERSONAL SAFETY PRECAUTIONS

To assist with the safe operation and use of the Battery Charger:
a) Wear complete eye protection and clothing protection. Avoid touching eyes while working near a battery.
b) If battery acid contacts your skin or clothing, remove the affected clothing and wash the affected area of your

skin immediately with soap and water. If battery acid enters your eye, immediately flood the eye with running
cold water for at least 10 minutes and seek medical assistance immediately.

SAL.FOR.Instruction Manual.BCDC1220 - DOC480 – Version 6

1

CONTENTS

Table of Contents Page

Warnings and Safety Instructions 01
Contents 02
Specifications 02
1 Product Function 03

1. Display Panel 03

2. Charging Algorithm 04

3. Turn On/Off Thresholds 04

4. Error Codes 05

2 Installation 05

1. RED wire - Input Positive 05

2. BLUE wire - Input Trigger 06

3. ORANGE wire - Charging Profile Select 07

4. BROWN wire - Auxiliary Battery Positive 08

5. BLACK wire - Common Ground 08

6. Cable Sizing 09

7. Wiring 09

8. Fusing 12

4 Frequently Asked Questions 13
5 Two Year Warranty 14

Specifications

Part Number BCDC1220 BCDC1220-IGN

Continuous Current Rating 20A

Input Fuse Rating

Output Fuse Rating

Output Power 300W

DC Input Voltage Range

Output Battery Type Standard Lead Acid, Calcium content, Gel & AGM type only

Charging Profile

- Maximum Voltage*1 (refer to section 2.3)

- Float Voltage

No Load Current <100mA

Standby Current <5mA

Ambient Temperature -20°C to +80°C

Minimum O/P Battery Volts

Weight 450g

Dimensions 100x120x37mm

Warranty 2 years

Standards CE, C-Tick, AS/NZS CISPR11:2004

*1

9-32V 9-32V

A B C

14.6 15.0 15.4

*1

*1

40A (Not Supplied)

REDARC FK40 recommended

13.3V

4.0V

*1

Voltages Specified are ±100mV

2

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. The BCDC1220(-IGN) is also designed to isolate the main battery
from the auxiliary battery, to avoid over-discharging the main battery.
The BCDC1220-IGN operates almost identically to the BCDC1220 but is designed to
operate from an ignition trigger to allow operation in vehicles with Variable Voltage or
Smart Alternators.

1.1 Display Panel

The front panel features 6 LEDs to display the charge profile and charge status.

LED State ‘Charge Profile’ LED ‘Charge Status’ LED

Off Unit has no Power Output is off

Blinking Unit is in Standby

On Unit is on and can supply power

Unit is supplying power

When blinking, the flash duty-cycle of the ‘Charge Status’ LED will increase to
reflect the amount of current being supplied - If the LED is ON solid, the unit is
supplying full power (e.g. 20A).

Figure 1.6.1 - The BCDC1220(-IGN) Front Panel

3

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.
The charger will then move to Absorption stage which maintains a constant
voltage level for a predetermined period of time or until the current being drawn
by the output battery drops to less than 4A for 30 seconds; after which the charger
will enter Float stage.
Float stage maintains 13.3V*1 on the output battery, keeping the battery topped
up. This counteracts the battery’s self discharging or loads applied to the battery.
When the battery loses charge, the charger will move back into the Boost stage.

1.3 Turn On/Off Thresholds

Input

Open Circuit Low

voltage conditions *

Input

Loaded Low voltage

conditions*

Input

Over voltage shutdown

Output

Under voltage

shutdown

*1

Voltages Specified are ±100mV

*2

Tested every 100 Seconds.

*3

Constantly tested.

2

3

*1

12V

BCDC1220

12V

BCDC1220-IGN

Turn ON above 13.2V 12.0V

Turn OFF below 12.7V 11.9V

Turn OFF

instantly below

Turn OFF after

20 secs below

8V

9V

Turn ON below 32V

Turn OFF

instantly above

Turn OFF after

20 secs above

32.5V

32.1V

Shutdown if Output Battery < 4V

4

24V

BCDC1220 &

BCDC1220-IGN

with Ignition

with Ignition