Redarc BCDC1240-LV, MEDALLION SERIES User Manual

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40A In-vehicle 3-Stage

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12V Battery Charger

BCDC1240-LV

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 profi le to
each specifi c 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. It is designed to operate with
variable voltage alternators
The BCDC1240-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 & 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 BCDC1240-LV - the internal circuitry contains hazardous voltages.
Attempting to service the unit yourself may result in electric shock or fi re and will void the unit
warranty.

Do NOT use the BCDC1240-LV to charge non-rechargeable batteries. Doing so may result in
harm to the user and/or damage to the BCDC1240-LV. Only use the BCDC1240-LV for charging
Standard Lead Acid, Calcium content, Gel & 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 BCDC1240-LV will achieve best results when proper battery maintenance is regularly
performed. This includes but is not limited to checking water and specifi c gravity levels of the
battery.

Warning! Check the manufacturers data for your battery and ensure that the ‘Absorption’ voltage
of the profi le 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
profi le.

SAL.FOR.Instruction Manual.BCDC1225-LV – DOC483 – Version 1

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CONTENTS

Table of Contents Page

Warnings and Safety Instructions 01
Contents 02
Specifi cations 02
1 Product Function 03

1. Alternator Input 03

2. Solar Input 03

3. Charging Algorithm 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 12
4 Frequently Asked Questions 11
5 Two Year Warranty 14

Specifi cations

BCDC1240-LV

DC Input Voltage Range 9V-32V

Gel/AGM Std Lead Acid Calcium Content

Absorption Voltage 14.5V 14.9V 15.3V
Float Voltage 13.3V 13.3V 13.3V
No Load Current <100mA
Standby Current <8mA
Input Fuse Rating 12V/24V 50A/30A (Not supplied)
Output Fuse Rating 50A (Not supplied)
Output Power 600W
Ambient Temperature -20°C to +80°C
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

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
signifi cant voltage drop. The BCDC1240-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 Alternator Input

To select the Alternator charging mode the BLUE ‘Source Select’ wire must be
connected to Vehicle Ignition.
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.

1.2 Solar Input

The BCDC1240-LV is also capable of charging the auxiliary 12V battery from a
Solar source, Solar charging mode is selected at time of installation. The 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.

1.3 Charging Algorithm

When the BCDC1240-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 fl oat 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.

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1 PRODUCT FUNCTION

1.4 Turn On/Off Thresholds

12V Solar

Low voltage conditions
(open circuit, tested every
100s)

Low voltage conditions
(loaded, constantly tested)

Over voltage shutdown Turn ON below 15.5V Turn ON below 28V

Under voltage shutdown Shutdown if Output Battery < 4V

1.5 External LED Indication

Turn ON above 12V Turn ON above 17.5V

Turn OFF below 11.9V Turn OFF below 17.2V

Turn OFF instantly below 8VTurn OFF instantly below

8V

Turn OFF after 20 secs
below 9V

Turn OFF instantly above
16V

Turn OFF after 20 secs
above 15.6V

N/A

Turn OFF instantly above
29V

Turn OFF after 20 secs
above 28.2V

A fl ying 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 (fl ying
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 Description

Off constant Not charging

On constant Charging or maintaining charge

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