Redarc BCDC2420, BCDC2420-LV Instruction Manual

In-vehicle 3-Stage

24V Battery Charger

BCDC2420 &

BCDC2420-LV

THE BCDC2420(-LV)

The BCDC2420(-LV) In-vehicle Battery Chargers feature technology designed to charge your
lead-acid batteries to 100%, regardless of their type or size. By providing a unique charging
profi le to each specifi c battery type, the BCDC2420(-LV) In-Vehicle Battery Chargers are able to
achieve and maintain an optimal charge in your auxiliary battery, at all times.
The BCDC2420(-LV) In-vehicle Battery Chargers also feature 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.
The BCDC2420 is designed to work with either fi xed voltage or temperature compensating
alternators while the BCDC2420-LV is designed to operate with 12V variable voltage alternators.

WARNING & SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS - This manual contains IMPORTANT SAFETY INSTRUCTIONS for the

BCDC2420(-LV) 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.

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 fi re 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 manufacturer’s data for your battery and ensure that the ‘Maximum’
voltage of the profi le 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 profi le. The Battery
Charger is not intended to supply power to a low voltage electrical system other than to charge a battery.

4. Check the manufacturer’s data for your battery and ensure that the ‘Continuous Current Rating’ of the charger
does not exceed the manufacturer’s recommended maximum charging current.

5. NEVER smoke or allow a spark or fl ame in vicinity of battery or engine. This may cause the battery to explode.

6. 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 fl ood the eye with running
cold water for at least 10 minutes and seek medical assistance immediately.

SAL.FOR.Instruction Manual.BCDC2420 – Version 4

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CONTENTS

Table of Contents Page

Warnings and Safety Instructions 01
Contents 02
Specifi cations 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 Source Positive 05

2. BLUE wire - Source Select 06

3. ORANGE wire - Charging Profi le Select 07

4. BROWN wire - Auxiliary Battery Positive 08

5. BLACK wire - Common Ground 08

6. GREEN wire - Optional External LED Indication 08

7. Cable Sizing 09

8. Wiring 09

9. Fusing 12

3 Troubleshooting 12
4 Frequently Asked Questions 13
5 Two Year Warranty 14

Specifi cations

Part Number BCDC2420(-LV)

Continuous Current Rating 20A

Input Fuse Rating 12V/24V 60A/40A (Not supplied)

Output Fuse Rating 30A (Not supplied)

Output Power 600W

DC Input Voltage Range 9-32V (9V-16V for LV model)

Solar Panel Open Circuit Voltage 17.5V-28.0V

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

Charging Profi le

- Maximum Voltage (refer to section 2.3)

- Float Voltage 26.6V

No Load Current <100mA

Standby Current <8mA

Ambient Temperature -20°C to +80°C

ABC

29.2 30.0 30.8

Minimum O/P Battery Volts 4.2V

Weight 680g

Dimensions 150x120x37mm

Warranty 2 years

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

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1 PRODUCT FUNCTION

CHARGE PROFILE

BCDC2420

24V 20A DC/DC 3 stage battery charger

A

B

C

redarc.com.au

The BCDC2420(-LV) is a three-stage, 24V DC-DC battery charger that operates from an
alternator input of 12V nominal or a 12V nominal solar panel input. The BCDC2420 will

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also charge from an alternator input from a 24V nominal vehicle*

. The input voltage of
the BCDC2420(-LV) can be above, below or equal to the output voltage making it ideal
for charging an auxiliary 24V battery bank where the distance from the main battery
may cause a signifi cant voltage drop. The BCDC2420(-LV) is also designed to isolate the
main battery from the auxiliary battery to avoid over-discharging the main battery. The
BCDC2420-LV operates almost identically to the BCDC2420 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 profi le and charge status.

LED State ‘Charge Profi le’ LED ‘Charge Status’ LED

Off Unit has no Power Output is off

Blinking Unit is in Standby

Unit is supplying power

On Unit is on and can supply power

When blinking, the fl ash duty-cycle of the ‘Charge Status’ LED will increase to
refl ect the amount of current being supplied - If the LED is ON solid, the unit is
supplying full power (e.g. 20A for a BCDC2420).

Figure 1.6.1 - The BCDC2420(-LV) Front Panel

*1 LV Versions not suitable for use in 24V vehicles

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1 PRODUCT FUNCTION

1.2 Charging Algorithm

When the BCDC2420(-LV) 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 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*

1

2

Turn ON above 13.2V 12.0V 17.5V 26.4V

Turn OFF below 12.7V 11.9V 17.2V 25.4V

Turn OFF

instantly below

Turn OFF after

20 secs below

12V

BCDC2420

12V

BCDC2420-LV

Solar

All Models

24V

(standard)*

BCDC2420

8V 17V

9V N/A 18V

3

Turn ON below 15.5V 28V 32V

Input
Over voltage

shutdown

Turn OFF

instantly above

Turn OFF after

20 secs above

Output

Under voltage

shutdown

*1Tested every 100 Seconds.

2

*

Constantly tested.

3

*

LV Versions not suitable for use in 24V vehicles

16V 29V 32.5V

15.6V 28.2V 32.1V

Shutdown if Output Battery < 4V

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