Cable size to minimise voltage drop?

Submitted: Thursday, Apr 01, 2021 at 11:49
ThreadID: 141323 Views:6295 Replies:12 FollowUps:23
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Hello.

I'm looking at powering a CPAP machine from a dedicated lithium battery mounted within our vehicle. We will be sleeping in a roof top tent or a swag just outside the vehicle.

I've roughly measured how far the CPAP machine will be from the battery and it comes to around 5-6 metres.

With the aim of minimising voltage drop, I'm thinking of using 3B&S cable.

I'm wondering if those with more experience than I, think this will be adequate, overkill, underkill or whatever?

Thanks for any help.
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Reply By: RMD - Thursday, Apr 01, 2021 at 12:29

Thursday, Apr 01, 2021 at 12:29
Siringo
Is the CPAP machine designed to run only off 12v directly or does it use 12v and an inverter to create 240v ac for the machine. I f so, use a 240v lead to the machine with the inverter close to the battery.
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Follow Up By: Phil B (WA) - Thursday, Apr 01, 2021 at 14:20

Thursday, Apr 01, 2021 at 14:20
Agree with RMD, I've been doing it this way for 20 plus years. CPAP works fine, I can also run/charge phones etc with the 240volt into my tent.


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Follow Up By: Member - Siringo - Thursday, Apr 01, 2021 at 15:04

Thursday, Apr 01, 2021 at 15:04
From memory, the CPAP has a 240VAC and 12v input (typing this up at work).

If I remember my electronics theory from way too long ago, it uses a full wave rectifier and regulates the output to 12.x volts DC out which then plugs into the CPAP.
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Follow Up By: Allan B (Sunshine Coast) - Thursday, Apr 01, 2021 at 15:17

Thursday, Apr 01, 2021 at 15:17
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Siringo, if you are right about that, then taking the path of bumping your 12v battery up to 230vac via an inverter, then putting the 230v into the CPAP 230vac-to-12vdc converter will incur two lots of losses. Then you have the cost of the inverter.....
Clearly, the CPAP is designed to run on 12vdc..... why not use that?
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Follow Up By: Member - Siringo - Thursday, Apr 01, 2021 at 16:04

Thursday, Apr 01, 2021 at 16:04
My comment above about inputs is totally incorrect.

I found a tech guide. The CPAP converts 240VAC to 24VDC at 3.75 amps via an inline adapter.

We purchased an adapter so we could run it off a car battery, the adaptor must have a step up transformer in it.

The CPAP has a single DC input.

So am I better off placing the adaptor near the battery or the CPAP?

I'd think near the battery, with the thought that voltage drop my be less pushing 24v through a length of cable rather than 12v?

Any thoughts?
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Follow Up By: Allan B (Sunshine Coast) - Thursday, Apr 01, 2021 at 16:24

Thursday, Apr 01, 2021 at 16:24
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I would still use 8B&S cable and place the adaptor near the battery.
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Allan

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Reply By: Nomadic Navara - Thursday, Apr 01, 2021 at 12:50

Thursday, Apr 01, 2021 at 12:50
3B&S cable looks like a way overkill to me. What is the current draw of your machine on 12 V? If you can tell us, someone can work out the size cable for you to use. That will probably be around 6 mm2 or so. That size was commonly used to run the small Dometic fridges.
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Reply By: Allan B (Sunshine Coast) - Thursday, Apr 01, 2021 at 12:54

Thursday, Apr 01, 2021 at 12:54
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Hi Siringo,

I would consider 3B&S cable to be very oversize. That size is often used on starter motors.

On the basis that the CPAP draws no more than 5 Amps then a 8B&S cable cable of 6m (pair) would produce 0.26 volt drop. That should be quite satisfactory.
Cheers
Allan

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Follow Up By: Member - Siringo - Thursday, Apr 01, 2021 at 13:00

Thursday, Apr 01, 2021 at 13:00
Hi Allan,
How do you work out the voltage drop?
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Follow Up By: Allan B (Sunshine Coast) - Thursday, Apr 01, 2021 at 13:18

Thursday, Apr 01, 2021 at 13:18
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Peter (below) has provided a formula but here is a online simple calculator which is adequate for most practical purposes. With this one, you nominate the cable size you are considering and it will provide the voltage-drop. There are others that require nomination of an acceptable volt-drop and the calculator provides the required cable size.

The value of "acceptable volt-drop" can vary by user tolerance and appliance requirement but 0.2v would be OK for most situations. It is 1.6% of 12v.
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Allan

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Reply By: Member - Siringo - Thursday, Apr 01, 2021 at 13:00

Thursday, Apr 01, 2021 at 13:00
Thanks everyone for the help. I'll look into that inverter question.
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Follow Up By: Allan B (Sunshine Coast) - Thursday, Apr 01, 2021 at 13:24

Thursday, Apr 01, 2021 at 13:24
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I would not consider using an inverter to be a useful solution if you already have a CPAP that can operate from 12vdc. It is a lossy and expensive solution.
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Allan

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Reply By: Peter_n_Margaret - Thursday, Apr 01, 2021 at 13:00

Thursday, Apr 01, 2021 at 13:00
"I recon, he reckons .... " is pretty worthless.
You MUST know the amps involved and the cable length (which includes the earth return, so 10-12m in your case?), then calculate the voltage drop for various cable sizes.
VOTLAGE DROP = [cable length (in metres) X current (in amps) X 0.0164] divided by cable cross-section in mm.sq.
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Peter
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Follow Up By: Allan B (Sunshine Coast) - Thursday, Apr 01, 2021 at 13:29

Thursday, Apr 01, 2021 at 13:29
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Peter, it's also "pretty worthless" if you cannot nominate how much voltage-drop is acceptable.
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Allan

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Follow Up By: Peter_n_Margaret - Thursday, Apr 01, 2021 at 13:37

Thursday, Apr 01, 2021 at 13:37
What voltage drop is acceptable varies with the appliance being powered.
You or I can not specify that. The product specs or manufacturer should.
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Peter
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Follow Up By: Allan B (Sunshine Coast) - Thursday, Apr 01, 2021 at 16:27

Thursday, Apr 01, 2021 at 16:27
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Your'e right Peter, on both counts.

This thread illustrates the futility of trying to respond to a question with false or inadequate information!
You just get led up the garden path. Think I'll go back to my solitaire app. lol
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Follow Up By: Peter_n_Margaret - Thursday, Apr 01, 2021 at 22:36

Thursday, Apr 01, 2021 at 22:36
You also need to know the voltage starting point, which can very significantly depending on the batteries and other loads.
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Peter
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Reply By: Member - Cuppa - Thursday, Apr 01, 2021 at 13:59

Thursday, Apr 01, 2021 at 13:59
3B&S is overkill.

I'd use 8 B&S twin sheath. It too is overkill as far as voltage drop goes, but it's size will make it better in regards to the stresses & strains of a regularly handled cable.
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Reply By: Member - Racey - Thursday, Apr 01, 2021 at 15:46

Thursday, Apr 01, 2021 at 15:46
I have a Philips CPAP machine and it draws 6.7 amps when on 12 volts. I believe twin 6mm2 would be quite adequate.

Cheers
Racey
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Reply By: Member - Siringo - Thursday, Apr 01, 2021 at 16:06

Thursday, Apr 01, 2021 at 16:06
Thanks again everyone.
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Reply By: Erad - Thursday, Apr 01, 2021 at 17:07

Thursday, Apr 01, 2021 at 17:07
You are going to need a large battery if you intend to use the CPAP machine all night. Assume that it pulls 5 amps for 8 hours. This is 40 Ah of energy. A Century N70ZZL battery (as used in larger 4WD's ) has a storage capacity of 85 Ah, so one night will take half of the capacity of the battery. If you are pulling 7 amps, it will be much worse. So the dedicated Lithium battery will have to be fairly large. Yes - it is doable, but look into the capacity carefully.
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Follow Up By: Member - Cuppa - Thursday, Apr 01, 2021 at 20:24

Thursday, Apr 01, 2021 at 20:24
I expect Siringo already has the cpap he intends to use, but for those reading this in the future if you know you will be travelling take a look at the Devilbiss Blue. Runs natively on 12v . The ‘natively’ is the important part - no internal voltage conversions & no need for an inverter. Different technology humidification to any other make. Result is a machine comparable to the market leaders which uses far less power. Using humidification I average around 20 to 25Ah per night.
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Reply By: Member - Siringo - Friday, Apr 02, 2021 at 10:06

Friday, Apr 02, 2021 at 10:06
We've used the CPAP a few times while camping.

The last 2 times we had it hooked up to a 105 AH deep cycle battery, a fridge was also connected and set very low, it was barely ticking over.

On both times the CPAP stopped working, but the fridge kept going. The next morning I checked the battery and it was at mid 11 volts.

This got me thinking that the CPAP must be input voltage sensitive, hence my interest in a lithium battery & hence my concern about voltage drop.

I've purchased a cheap DC voltage supply and am going to see at what voltage the CPAP turns off at.

Thanks everyone for the input and suggestions.
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Follow Up By: RMD - Friday, Apr 02, 2021 at 12:40

Friday, Apr 02, 2021 at 12:40
Siringo
If you had the fridge set LOW it will draw more out of the battery than if set higher. So what is "hardly ticking over"? Whenever the fridge starts it will be drawing the same current each time, ie, same tick over, and ALSO at startup the initial loading will do a sudden voltage drop for an instant. The CPAP will detect that lower voltage as the fridge starts and if at critical voltage it will drop out when the battery dips to a lower voltage. One item or the other will possibly be OK, but both is asking a fair bit when considering the total load. Allowing your deep cycle to discharge to below 12 is going to shorten it's life. If done a few times, although you think it is 105ah, it may now be operating at say 80ah max, ie, possess less total capacity, and that will definitely exacerbate your problem. If the CPAP is inverter based power from 12v source, as the battery voltage lowers, for whatever reason, the CPAP WILL draw more and more 12v current to attempt to continue making it's set working voltage to operate. That increase will hasten the discharge. You haven't got enough battery reserve to do both items it seems. A105 ah battery is, if your lucky, only a 105 ah if in top condition AND you know for sure it was charged to the max before nightfall. If the fridge dragged off it for a while beforehand, pre Cpap. then 105 goes out the window.
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Follow Up By: Member - David M (SA) - Friday, Apr 02, 2021 at 12:59

Friday, Apr 02, 2021 at 12:59
There you go Siringo. You haven't got enough battery. :)
Dave.
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Follow Up By: Member - Siringo - Friday, Apr 02, 2021 at 17:25

Friday, Apr 02, 2021 at 17:25
Thanks RMD, that has cleared up a few things. I appreciate your input.
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Follow Up By: Peter_n_Margaret - Friday, Apr 02, 2021 at 19:01

Friday, Apr 02, 2021 at 19:01
The Danfoss compressors will continue to run down to 10.5V.
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Peter
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Reply By: Member - Siringo - Friday, Apr 02, 2021 at 17:46

Friday, Apr 02, 2021 at 17:46
OK, I think I've got this sorted out.

The CPAP requires 90W, which it makes up of 24v @ 3.75 amps (from the tech sheet).

So therefore if I supply the CPAP DC adapter we have, with 12v @ 7.5 amps I still supply 90W and can work out how long a battery will last, theoretically in a perfect, no loss scenario.

If a 100AH battery supplies 1 amp for 100 hours, that same battery can supply 7.5 amps for 13.33 hrs. At this point, the battery is fully discharged.

If we sleep for 9 hours, 9 hours is approximately 80% of 13.33 hours, so the battery is 80% discharged.

This fits in with the LifePo4 'lifestyle'. But we need to accommodate for losses, so a bigger battery or less sleep would be the way to go.

Does that theory sound reasonable?
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Follow Up By: Gronk - Friday, Apr 02, 2021 at 22:21

Friday, Apr 02, 2021 at 22:21
Theory sounds good, but in reality you should have more battery capacity. After one night I'd like to have only 20% of battery capacity used, maximum of 50% after 2 nights.

Lithium can be discharged lower, but you still have to recharge with something, and lithiums can accept higher recharge currents, so you can have more solar panel sizes, which means more money for more solar because you used the lithium for longer than an AGM....vicious circle sometimes. Nothing that money can't fix...if you have it !!
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Follow Up By: Member - Siringo - Saturday, Apr 03, 2021 at 09:47

Saturday, Apr 03, 2021 at 09:47
Thanks Gonk. I wanted a 2nd pair of eyes on my workings. Now I can work out which way to go.
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Follow Up By: Allan B (Sunshine Coast) - Saturday, Apr 03, 2021 at 10:52

Saturday, Apr 03, 2021 at 10:52
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Siringo,

Gronk is right. Your assessment is based on an ideal battery, fresh out of the box, fully charged with no other discharge than the CPAP. And the certain ability to recharge it fully before the next CPAP demand.
The reality is never as good as our aspirations.
Try it out, But be prepared to upgrade!
Cheers
Allan

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Follow Up By: Member - Siringo - Saturday, Apr 03, 2021 at 12:15

Saturday, Apr 03, 2021 at 12:15
Yep, you're right Allan, but we can only work out these figures based on 'advertised' known figures. I'm also using worst case consumption figures for the CPAP, so it's kind of swings & roundabouts.

Lithium recharges faster than other battery types so I'm expecting to be able to recharge daily either via solar or driving or both.

Thanks again.
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Follow Up By: RMD - Saturday, Apr 03, 2021 at 17:30

Saturday, Apr 03, 2021 at 17:30
Seeing the CPAP is basically to keep you breathing which is more healthy than not, I would be making sure some insurance/over capacity in essential items/components is present, so next day Breakfast is achieved. Borderline figures with all this stuff is probably not a good idea, as Gronk mentioned, it is only money to make it right.
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Reply By: Member - Andrew - Friday, Apr 09, 2021 at 20:27

Friday, Apr 09, 2021 at 20:27
Hi Siringo

My CPAP only  operates on 240v . I use a 100ah deep cycle battery with an inverter attached and then run a conventional power lead to the CPAP.
If we are traveling every day, I can leave the humidifier turned on but if in doubt I use a lower setting.
If I cannot charge the battery for a few days then I turn the humidifier off.
When 240v is available, I plug into mains power.

If I am really "lucky" ( technical term ) then I may get 2 nights out of the battery with humidification.
Turning off the humidifier can give me an extra 4 to 5 nights, however I suggest lowering the settings at home till you find out if you can live with the drier air.

If you lok at your machine specs it should show that the humidifier draws most of the power unless you are using high pressures. I am currently running at 13. The air pump is fairly efficient.

Regards

A
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Follow Up By: Member - Siringo - Saturday, Apr 10, 2021 at 09:02

Saturday, Apr 10, 2021 at 09:02
Thanks Andrew. I'll see if I can find some more tech specs for our CPAP, I only found it's typical consumption figures. Thanks for the humidification tip.
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