What size DC-DC chargers are you using?

Submitted: Monday, May 12, 2025 at 12:22
ThreadID: 150382 Views:2105 Replies:11 FollowUps:18
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Hi people, hoping to get an idea of what's being used and what is reasonable. I am running an enerdrive 40a dc-dc in the canopy of the car, but have it set to 20a at the moment. I am now towing a caravan (god help me!) and it is currently running 1 x 25a dc-dc to the van batteries. There is another 25a unit available if required (taking it to 50a- see how good my maths were there?)

This in a 2017 Ranger with 150a alternator. I have been told(!) 60% draw is reasonable, taking into account the general requirements of the vehicle- not sure about this. So I can leave it as is (45a total), switch up the unit in the canopy back to 40a (65a total), leave the canopy unit at 20A and connect the second unit in the van (70a) or let it all go free and draw 40a in the canopy, 50a in the van!!!.

Or I can get a larger alternator fitted (prefer not...).

Any comments/recommendations?

PS: posted in Grey Nomads as well, I know some of you are on both forums...


Cheers, Mark
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Reply By: Peter_n_Margaret - Monday, May 12, 2025 at 13:26

Monday, May 12, 2025 at 13:26
What capacity batteries and what loads on them?
Any solar on the van?

We don't use a DC-DC charger. In the unlikely event that we need any extra charge I get it direct from the alternator.

Cheers,
Peter
OKA196 motorhome
AnswerID: 647900

Follow Up By: Member - silkwood - Monday, May 12, 2025 at 14:26

Monday, May 12, 2025 at 14:26
200ah in canopy, 600ah in van. Fed by 200w panel on canopy, 700w on van (when it works- having it looked at tomorrow!). I have a300w panel to use remotely for either.

Loads vary, 60lt fridge in canopy (usually fine with existing dc-dc and solar), van loads vary, but 75l fridge constantly.

Cheers,
Mark
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Follow Up By: Peter_n_Margaret - Monday, May 12, 2025 at 14:34

Monday, May 12, 2025 at 14:34
I can't imagine that you would ever need more than you have.
I might move the existing DC-DC charger to the van and be able to charge the canopy battery direct from the alternator.
Cheers,
Peter
OKA196 motorhome
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Follow Up By: Member - silkwood - Monday, May 12, 2025 at 15:24

Monday, May 12, 2025 at 15:24
No, leaving it as is, for now. Simply looking to get an idea of alternator capacity. I agree, particularly the van solar being more than adequate... if it works!

Cheers,
Mark
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Reply By: RMD - Monday, May 12, 2025 at 21:55

Monday, May 12, 2025 at 21:55
Mark.
You may have a 150 amp alternator, but that is it's maximum and if used near that maximum the alternator will have a short life. Do you carry a spare?
Perhaps I am confused somewhat, not able to fully understand what is really your situation. Seeing you have 3 DC DC units running off the alternator. If ALL batteries are Lithium, there won't be much backing off of current demand from whatever DCDC units are operating until the Lithium's are near fully charged. That means a CONSTANT high drag on the alternator, which, although rated at 150 amps, it ISN'T made to run hard ALL the time.
If an Alternator is supplying high demand. the ROTOR CURRENT will be way higher than average or normal and Brushes may erode quite quickly due to the current across the brush faces.
AnswerID: 647902

Follow Up By: qldcamper - Tuesday, May 13, 2025 at 09:22

Tuesday, May 13, 2025 at 09:22
I wouldn't be too concerned about the brushes wearing out, it is the heat generated and the flexing of the stator windings with the high energy of the magnetic forces at play that will lead to a shortened alternator life.
I'd be leaving your settings as low as possible then increasing it if ever required.
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FollowupID: 928989

Follow Up By: RMD - Wednesday, May 14, 2025 at 21:26

Wednesday, May 14, 2025 at 21:26
QLD
Yes that too, plenty of magnetic vibes happening.
His vehicle also has/most likely has, ELECTRIC steering and lots of steering in hilly terrain will be using MORE amps to drive the steering motor. Not sure when they changed to Electric PS!
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FollowupID: 929003

Follow Up By: qldcamper - Thursday, May 15, 2025 at 06:25

Thursday, May 15, 2025 at 06:25
Good point. I know nothing about electric power steering as I got out of the light vehicle side of the industry just as they were being introduced, I saw it as a step towards autonomony. All of the autonomous machines I have been maintaining for almost a decade and a half are electric over hydraulic so they have minimal ELV electrical consumption and most come STD with a 90 to150 amp alternator (24v).
The point I was getting at is under conditions when the vehicle is operating under full electrical load there isn't much left to supply the draw of the DCDC units, if the alternator saves itself by derating it wouldn't take long to completely drain the start battery.
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Reply By: Member - McLaren3030 - Tuesday, May 13, 2025 at 07:16

Tuesday, May 13, 2025 at 07:16
Hi Mark,

Let me start by saying that I am not an Auto. Elec. or a 12 volt expert.

You haven’t stated what battery chemistry your batteries are, LiFePo4 or AGM?

AGM batteries do not like a high current charge as they can get quite hot. LiFePo4 on the other hand are fine with 50 amps plus charging current.

If your alternator is a “smart alternator”, it may not like a constant high current output, as others have suggested, it may wear out the brushes very quickly.

If you know a good reputable Auto. Elec. it might be worthwhile checking with them before making any final decisions.

Macca.
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AnswerID: 647903

Follow Up By: Member - silkwood - Tuesday, May 13, 2025 at 10:21

Tuesday, May 13, 2025 at 10:21
LifePo4.

Cheers.
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Reply By: qldcamper - Tuesday, May 13, 2025 at 09:29

Tuesday, May 13, 2025 at 09:29
I would recomend not exceeding about 30% of your alternator rating for accessory batteries. They will cope with more but one day you might fire up the car after depleting all of your batteries and drive with your lights, wipers and AC on and your dcdc chargers demanding as much as they can get for a few hours, if the alternator is going to let go it will be then.
AnswerID: 647905

Reply By: Member - silkwood - Tuesday, May 13, 2025 at 10:32

Tuesday, May 13, 2025 at 10:32
Thanks all for the comments. I was mainly curious to see what others are running. Almost every modern van has a dc-dc charging system, and a great many of those I meet on the road (we travel permanently at the moment) also have a fridge and some kind of controller in the rear. Mostly dc-dc I am finding.

After talking to one guy who has a 40a unit in the van and another 40a dc-dc in the rear of his ute, I started thinking this might be feasible for me, but worried about the load. He had a d-max, he thought his alternator was 160a. From what I can tell his 2023 vehicle has a 90a alternator as standard?

So my query was based upon what I have as options, not what I am using. Currently I have the canopy unit set at 20a and the caravan using the one 25a unit only. I spoke to the auto electrician checking my solar panel connections today (and hopefully getting the system working at last, very frustrating having an "off-grid' van which won't work off-grid!), he has suggested that, given my travel style (usually no more than 200km per day) I would be best off leaving the units as they are (total 45a) and thinks this will be absolutely no problem for my alternator. All this providing I can get the solar panels operating as they should.

This appears to concur with most comments here, so I'll be leaving it as is.

Cheers,
Mark
AnswerID: 647906

Follow Up By: Member - nick boab - Wednesday, May 14, 2025 at 06:20

Wednesday, May 14, 2025 at 06:20
Mark I think that people that have high output alternators and DC charges those that need a lot of power in a short period to charge many batteries in a quick period
, people that are doing long days of driving would not necessarily need fast charging as well as they wouldn't be using a lot of accessories depleting their batteries .
keep in mind the DC charger will only be at its full rate while the unit is still cool and Will throttle itself back when it starts to get hot and also throttle back as it goes through its charging stage of bulk absorption and float.

Note: I thought the principal of a DC charger was not only to give the battery a proper charging but also to protect the alternator ?

Regarding solar . I just recently wired my solar array to series after seeing a tip on YouTube , buy way of increasing the time that the panels will produce power .. I.e higher voltage keeping the panels charging earlier in the morning and later in the evening , but this comes at a cost if in a shaded area they don't work as well . this system apparently is good if adding extra panels to a caravan where running extra wires is a problem .
Cheers .
Cheers Nick

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Reply By: SCUBADOO - Tuesday, May 13, 2025 at 10:50

Tuesday, May 13, 2025 at 10:50
Like Peter I see no need for any DC-DC charger unless your setup is not supplying a sufficient charge rate.

Sure I have read all this "you will damage the alternator" forum chatter and Youtube videos MULTIPLE times over the years.
I have been warned by many theorists.

Entirely your decision but I will tell you like it is for us.

We have been travelling full-time for the last 11 years in our 3.9l TD Mitsubishi Canter truck based motorhome.
The original untouched 100A rated alternator has been charging our 11 year old 300Ah LiFePO4 battery and now also a near 3 year old paralleled 280Ah battery at 70-85A until all but full.
I'm still waiting for all that magic smoke to be released that all the doomsayers say is inevitable.

We must be very lucky.
I'm almost looking forward to the day that it eventually fails.
The 250A replacement may charge the battery just a little quicker.

I have seen the results of three or four 40-60A DC-DC chargers releasing ALL their smoke over the same period. A couple were more expensive than any alternator replacement.
AnswerID: 647907

Follow Up By: Peter_n_Margaret - Tuesday, May 13, 2025 at 11:14

Tuesday, May 13, 2025 at 11:14
The primary purpose of a DC-DC charger is to boost the charging voltage to overcome the voltage drop from long cables from the alternator to the van battery, and they do that well.
If you have not got excessive voltage drop, then there is little value in spending lots of $$s on a DC-DC charger because the alternator voltage output is designed to be ideal for battery charging (including LiFePO4) and the charge rate will be much less constrained.

I used to charge our 400Ah of AGMs direct from the alternator from time to time. The initial charge rate was about 70A from the 85A alternator (plus whatever solar was available). That rate would drop off fairly quickly (as is the case with lead acids).
Providing the charge voltage offered is not excessive (and an alternator is not), lead acid batteries self regulate the charge rate.
There was never an issue with either the batteries or the alternator.

Since then I have increased the solar and changed to a 320Ah LiFePO4 battery. I have not needed to charge them from the alternator, but have a couple of times (from about 50% SOC to near full), "because I could". Again, the charge rate dropped off initially as charging progressed (but I don't have the actual rates). And again, no issues for the battery or the alternator.

The maximum charge rate for Li is typically a limitation of the BMS rather than the battery itself. 250A is common.
Cheers,
Peter
OKA196 motorhome
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FollowupID: 928993

Follow Up By: RMD - Wednesday, May 14, 2025 at 21:37

Wednesday, May 14, 2025 at 21:37
SCUBADOO
Maybe your vehicle has FAR MORE airflow than the modern dual cab utes with 3 heat delivery cores to the airflow. Therefore the ALTERNATOR TEMP and the AIR temp flowing through it could possibly be significantly cooler than a HIGH heat stressed ute engine bay. Unless having to charge the whole battery pack from low discharge, would mean less total heat generated for the time it takes for amp flow to reduce.
So your system works OK!

Silkwoods situation might be quite the reverse of yours and causing lots of heat energy inside the ALT for a long time.
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Follow Up By: qldcamper - Thursday, May 15, 2025 at 07:10

Thursday, May 15, 2025 at 07:10
It's always good to hear of people's personal experiences of one or maybe two practical experiences but you seem to think that every machine out there will behave like yours has done. Do you even know what the duty cycle spec is for your alternator is and how far through the designed tolerance buffer you pushed it doing things you have done? Ignorance is bliss. A 100 amp alternator in a light commercial is vastly different to a 100 amp alternator in a passenger vehicle.
When people seek professional advice they trust the advice is based on sound knowledge and experience of similar systems, not just "I have done it a couple of times and gotten away with it so I'm an expert". Also the professionals giving the advice are legally liable for any expense or injuries coming from their advice, not a lot of people know that when banging on about shit in forums. Are you willing to take legal responsibility if someone does as you have advised them in writing they can do and comes to grief because you had no idea of their circumstances? You better take out a professional liability pollicy just in case.
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Follow Up By: SCUBADOO - Thursday, May 15, 2025 at 10:32

Thursday, May 15, 2025 at 10:32
Seeking professional advice on a forum. Who in their right mind?

"but you seem to think that every machine out there will behave like yours has done" .
Your mind reading words, not mine.

From my last post:
"Entirely your decision but I will tell you like it is for us."

I don't give advice on forums. Friends and professionally - occasionally.

Just facts, opinions and what I have done.
Others are free to read, follow or ignore. I care not.



OT
Despite the many doomsayers that abound on these forums I have thankfully gathered more than a few great ideas over the last 11 years of fulltime travel.
Like many others my alternator is still charging the battery with no DC-DC charger involved.
Our domestic 255l Samsung fridge compressor and associated tubing has not shaken to pieces on corrugated and potholed roads.
Our 4 cell 300Ah LiFePO4 battery has both started the truck engine perhaps a few thousand times and powered the motorhome without self destructing because there is no internal BMS or cell balancing.
The 3x 270W solar panels mounted without holes in the roof are not departing anytime soon.
The single Victron 50A controller is still in one piece in its enclosed stairwell location.
The domestic 32" permanently wall and swivel mounted TV is still in one piece without a daily hide under the pillows.
The motorhome has not been connected to mains power for at least 3 years.
We do not need or own a generator.

The list goes on.
No advice given, just facts.



3
FollowupID: 929007

Follow Up By: Member - silkwood - Thursday, May 15, 2025 at 12:37

Thursday, May 15, 2025 at 12:37
Which is why I asked here from curiosity and to see if the answers were relevant, then discussed with an auto electrician...
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FollowupID: 929009

Reply By: Batt's - Tuesday, May 13, 2025 at 19:03

Tuesday, May 13, 2025 at 19:03
It would be a bit of mucking around but I would put the 25amp charger in the 4wd canopy.
The larger adjustable charger I would put in the caravan on 40amps.
The 3rd charger I would either keep for a spare or sell it.
Monitor how it goes over time.
AnswerID: 647908

Reply By: Member - McLaren3030 - Thursday, May 15, 2025 at 07:21

Thursday, May 15, 2025 at 07:21
Hi Mark,

To answer your original question, I run a 45 amp DC/DC Charger in the back of my MY17 200 Series GX Landcruiser, plus a 25 amp DC/DC charger in the caravan. My 200 series has the standard 180 amp Alternator, however, being a GX, it still has 2 x 70 amp cranking batteries, and a single 175 amp LiFePo4 auxiliary battery in the back of the wagon. The caravan has 2 x 100 amp LiFePo4 batteries.

Macca.
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Follow Up By: Member - silkwood - Thursday, May 15, 2025 at 12:40

Thursday, May 15, 2025 at 12:40
I thought answering the original question was against the vibe of internet forums?

:) :)

Cheers,
Mark
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Follow Up By: Batt's - Thursday, May 22, 2025 at 12:12

Thursday, May 22, 2025 at 12:12
Variety is the spice of life
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Reply By: Member - LeighW - Thursday, May 15, 2025 at 09:54

Thursday, May 15, 2025 at 09:54
Ok what choices do you have, you can use a small DCDC charger to charge your batteries and limit the load on the alternaotor but then if you can't charge the batteries in a reasonable amount of time then the setup is not going to work. Other option is you use a DCDC that can charge your batteries but puts a heavy load on the alternator.

There your choices if your relying on the alternator to power everything, some cars have self protecting alternators others dont. A self protecting alternator will limit its ouput if it gets to hot and most DCDC I have seen these days will derate when they see the alternators voltage, no good quailty DCDC should discharge the cranking batteries but they will load up the alternator as much as they can.

In the OP's case he really needs those with the same model car or very familar with the vehicles specific electrics and what it can handle to give advice.

Bottom line is if the batteries need to be charged by the vehicles alternator and it can't handle the load then he either changes to another vehicle or installs an alternator that can handle the load.

AnswerID: 647918

Follow Up By: Member - silkwood - Thursday, May 15, 2025 at 12:43

Thursday, May 15, 2025 at 12:43
Thanks Lee, as stated earlier, checked with auto electrician doing work on my van and he has confirmed my current settings (no pun intended) are all good...

Though I think your post would have more impact if you suggested others and myself are idiots and used lots of capitals...

Cheers,

Mark
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FollowupID: 929011

Reply By: Bob Y. - Qld - Thursday, May 22, 2025 at 17:12

Thursday, May 22, 2025 at 17:12
After a few different variations on the same theme, as much charge as possible in the battery in the shortest possible time, I finally settled on the following, Silkwood.

Alternator(2015 LC single cab: with full alloy canopy) to Enerdrive 40A DCDC, and Victron 100/30 MPPT working off LG 375w panel on canopy, Both into an ATG 300Ah lithium battery.

We bought a 2nd hand van a few years ago, and it had a Redarc BCDC 40A fitted, running off both alternator and 340w of solar. Have since added another 400w to van roof. Seems to work well now, so much so my wife soon tires of receiving verbal bulletins every 15 minutes, about how much power we’re producing!


Bob

Seen it all, Done it all.
Can't remember most of it.

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Follow Up By: Allan B (Sunshine Coast) - Saturday, May 24, 2025 at 16:24

Saturday, May 24, 2025 at 16:24
.
Bob, wives are so often unsympathetic about the extraordinary efforts we men go to in order for them to be able to charge their phones, hey?
Cheers
Allan

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Follow Up By: Bob Y. - Qld - Monday, May 26, 2025 at 17:47

Monday, May 26, 2025 at 17:47
So true, Allan!

Bob

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Can't remember most of it.

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Reply By: Member - Cuppa - Friday, May 30, 2025 at 18:20

Friday, May 30, 2025 at 18:20
Our OKA came with the following & we find it quite adequate & sustainable after 3 months of travel.

350Ah lithium battery, 90ah alternator, 45amp dc to dc charger, 700w solar.

Unlike our previous 40amp dc to dc charger (Redarc) in our previous vehicle which had the limitation of EITHER dc to dc OR Solar, this one seems to be able to charge from both at the same time which makes recharging whilst driving much quicker.
See 'My Profile' (below) for link to our Aussie travel blog, now in it's 8th year.

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AnswerID: 648032

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