Updated August 2017

Battery charging via generator is often slow and shallow or barely works at all. This article shows just why, and how to find and fix the causes.

Charging via generator 12 volt output

In many a campground, generators plug away all day, vainly attempting to charge an RV battery. You can do it successfully if you know how and why.

Most small generators have a 12 volt dc output socket possibly even marked ‘Battery Charging’. This output is really intended to run small 12 volt dc devices without a battery. The output on light loads is about 13.6 volts. That voltage is not regulated. It can and does drop to 12.6 volts or less. Its usual maximum current is only 8 amps.

Such low voltage may charge a flat 100 amp hour battery to 40% or so within 6-8 hours. But that’s about all. From thereon charging virtually ceases. That voltage and current output is not nearly enough for battery charging fully or speedily.

Successful battery charging via a 230 volt generator is nevertheless feasible. What is needed is a high quality multi-stage 230 volt ac battery charger run from the generator’s 230 volt output.

Honda Jeneratör

A good inverter generator charges batteries quickly and safely via a good quality charger from its 230 volt ac output. Pic: Honda.

 What type charger for battery charging via generator ?

Most portable generators produce their rated output for only a few minutes. Their limit is usually 80% for continual use. In reality a 1000 watt generator is an 800 watt generator. They are most fuel efficient around 70% load. That is 700 watts for a 1000 watt unit. This is sufficient to power a quality 30-40 amp charger. Chargers this size will fully charge a flat 12 volt 100 amp hour battery within 3-4 hours. Adequate for typical small RV back-up.

To run air-conditioning etc you need a 2000 or 3000 watt generator and 50 amp + charger. These are best run from a Onan or similar generator.  Consider also Dometic’s TEC 29 petrol generator. It generates a continuous 2600 watts. It is quiet and has low emissions. 

Onan gen

Onan 2800 watt generator uses about 1.4 litres/hour. Pic Onan. 

 

Avoid cheap generators and chargers

Do not even think about doing this with a $99 chain store generator. They are hideously noisy and polluting. Worse – their electrical output is very ‘dirty’. They produce voltage spikes that can and do damage so-called switch-mode chargers (or may not even run them at all).

 

dometic TEC 29

The late 2015 released Dometic TEC 29 petrol generator produces up to a constant 2.6 kW. It is quiet and has low emissions. Pic: Dometic.

 

High quality chargers are not cheap. Expect to pay $350 upwards. Do not skimp on this. Any savings on a battery charger will be wiped out by inefficiency – more fuel is used in running the generator longer. High quality chargers work quickly, deeply and reliably. Some top brands are better than 90% efficient.

 

Battery charger Xantrex 201 small

High quality Xantrex charger is not cheap, but charges fast and safely 

Generator apparently big enough – but the charger does not perform

This arises with battery charging via a generator by so-called adverse power factor. This is an effect not unlike two rowers in a boat pulling out of synchronisation. It precludes a generator’s full power being exploited by the charger. The generator may also be hard or impossible to start unless the charger is initially off.

A quick and dirty fix is to plug a 100 watt or so soldering iron across the generator. It’s not the heat that does the job! The iron (being purely resistive) tricks the generator into working properly.

A better, but costly fix, is to have an electrician fit correcting capacitors fitted to the battery charger. It is only worthwhile, however, with battery chargers of 50 amps or more. It is otherwise cheaper to buy a high quality charger.

Problems with switch-mode battery charging  via generator

Some problems arise with switch-mode technology chargers and switch-mode inverter-chargers. These are smaller and far lighter than transformer-based chargers. Switch-mode chargers are reasonably efficient (plus 90% is common). Some work properly from the grid 230 volt supply but produce low output, or even none, from certain generators. This is because all switch-mode devices demand ‘clean’ electricity. And that from some generators is ‘dirty.’ 

The cause is that generator speed varies slightly but constantly, typically 50 times a second. This causes it to overlay multiples of 50 cycles a second. That resultant ‘dirty’ ac may cause switch mode charger protection circuits to cut off the supply. In some cases the generator wrecks the charger.

Fixing problems with switch-mode battery charging  via generator

This is mostly a problem with generator’s whose flywheel is too small. Generator vendors usually deny responsibility. Their products will drive most electrical loads without problems. Switch mode battery charger vendors too may deny responsibility as they are just fine of clean electricity.

Fortunately, this situation is mostly historical. Most generators used by RV owners are the quiet inverter type units. These, made by Dometic, Honda, Yamaha, Robin etc, do not suffer from this. Nor do Mastervolt or Fischer Panda.

In Australia, Power Protection Systems (suppliers of Mastervolt etc) has an electrical fix (for Dakar inverter chargers). It partially cleans up the dirty ac. This partially tricks the charger into accepting ‘noise’ that remains. It’s designed for specific generators, but the company says it enables Dakar chargers to work with other generators with similar problems.

Another fix is a flexible rubber coupling between engine and electrical generating bits. This absorbs the speed changes.

Buying Books

If you found this article of value you will find Collyn Rivers’ books even more so. They cover topic like this in depth. And in plain English. These include the best selling Caravan & Motorhome Electrics, The Camper Trailer Book, Solar That Really Works (for RVs), Solar Success (for homes and property systems) and the Caravan & Motorhome Book.

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