SYSTEM PROPOSALS
THE MODERN, MODULAR TRUCK
The modern truck-tractor/semi-truck is an absolute work-horse. Powerful, reliable and featuring living cabins for particular long-distance operations. The nature of their build necessitates their hardiness, and by being built intentionally to haul loads they are fundamentally modular in how they can be applied and manipulated.
Within a modern haul, we have two primary halves that are frequently interchanged. The front tractor (the main driving block) and the rear trailer. Depending on what is needed, what is being moved and indeed what the job is- these can be changed around to meet that need.
With a Sterling system, outlined in the above image, we can maximise your possible capabilities to meet a range of operations and requirements in both halves of the system... But, let's approach the system first.
OVERVIEW OF CAPABILITIES
- 3KW CONTINUOUS 48V BATTERY CHARGE CAPABILITY WHEN DRIVING VIA TWIN BB1248120 SATURN UNITS
- REVERSE CHARGE CAPABILITY TO MAINTAIN THE STARTER BATTERY - OR TO RECOVER IT IN AN EMERGENCY NON-START SITUATION
- LITHIUM SUITABILITY, TO ENSURE YOU CAN UTILISE MODERN BATTERY EVOLUTIONS WITHOUT PUTTING YOUR VEHICLE OR DRIVER AT RISK
- TWO PRIMARY USER-BANKS, ONE FOR THE DRIVER CABIN AND ONE FOR THE TRAILER SYSTEM, MAXIMISING OPERATOR COMFORT AS WELL AS MAXIMISING TRAILER UTILITY WITHOUT COMPROMISE.
- SAFE CHARGE BETWEEN 48V BATTERY BANKS- NO RISK OF EXCESSIVE CURRENT BETWEEN TRUCK AND TRAILER, EVEN IF ONE BANK IS MASSIVELY DISCHARGED.
- KEEP YOUR TRAILER-BANK CHARGED UP AND HEALTHY WHILE DRIVING
- UTILISE YOUR 48V BANKS WITH MODERN INVERTER SOLUTIONS, MAXIMISING EFFICIENCY, FLEXIBILITY AND CAPABILITY.
There's numerous benefits to using a Sterling system and the capabilities we can unlock.. But how?
SECT1 - TRACTOR
A modern semi-truck has a powerful, reliable engine. It has to be trusted to be capable of hauling super-heavy loads in a range of conditions, and this available power can also be linked to powerful alternators- both from-factory and after-market. With powerful-enough alternators, and a properly rated system, we would be recommending the following items.
- SATURN BB1248120 - requiring a 150A 12V alternator per unit, or a 24V 80A alternator per unit minimum.
- PCU4815
- A 48V (51.2V) LFP BATTERY BANK
- A 48V INVERTER CHARGER (Domestic will likely be excellent here)
- A shunt based battery monitor (Sterling BM2 or equivalent)
Our Saturn BB1248120 is a powerhouse. Super high efficiency, bidirectional capable, and able to boost from either a 12V or 24V input up to a 48V output at a power rating of ~1.5kW per unit. This allows safe, controlled and correct charge to be made available to a secondary Lithium system, without putting the alternator and engine block at risk.
Lithium batteries can be 'complicated'. A lot of the knowledge people have regarding Lead Acid batteries are no longer applicable to Lithium- and thus, sometimes the charge environment needs to be updated to be suitable. Current limiting is key, as is ensuring the safe and correct charge voltages are being made available, two things that the Saturn DC/DC chargers excel at.
These chargers will utilise the excess alternator power on their input, via the starter battery, to maintain and charge an onboard battery bank that the main driver/operator has the first luxury of using. Pairing this onboard battery with a PCU4815 48V battery charger and a domestic style 48V inverter/charger means that your operator won't need to leave his home comforts behind- and nor will they need to run a generator all night- with all the expenses and irritation that this can bring.
Silent onboard power- without a returning generator upkeep and fueling cost, charged just by doing the job through the day... That's what our systems can provide.
SECT2 - MODULAR TRAILER
This part is harder to write for- because, ultimately, it can be whatever you want. Your trailer isn't just a frame for boxes- it's raw and portable potential, limited only by what you need to do.
Whether you're supporting infrastructure, delivering essential services, or running high-performance systems at remote sites, a Sterling-powered trailer setup transforms possibility into action.
The core of the system is a dedicated 48V lithium battery bank installed in the trailer, paired with one or more of our upcoming BB484830 DC-DC converters. These units manage the power relationship between the trailer and the tractor safely, intelligently, and with complete isolation control.
Why this matters:
- You cannot safely connect high-capacity battery banks (especially lithium) of differing voltage states or chemistries without precise control.
- A simple direct cable between truck and trailer creates uncontrolled current spikes, potentially damaging both banks—or worse, creating a fire risk.
- The BB484830 ensures only the correct current and voltage flows, managing bulk, absorption, and float charging phases based on programmable parameters.
Whether the trailer is tethered to the tractor, or has been dropped at a site to do its job- power remains safe, autonomous, regulated. Your trailers can operate as standalone field systems, or as live operational extensions of your main vehicle.
POSSIBLE TRAILER SYSTEMS:
- Emergency Medical Units – Keep refrigeration, defibrillators, surgical lights, IT systems, and communications fully operational in off-grid or complex-access crisis zones.
- Command, Security, Protection – Sustain radio, GPS, networking, and drone systems for remote security, disaster relief, or keeping everyone and everything informed. You don't need to turn an incident into an emergency because of poor organisation or communication. Reliable information stops problems early. Reliable information requires reliable power.
- Long-Distance Freight – From perishable foods to pharmaceuticals, ensure temperature-controlled environments remain stable—even when stopped or decoupled.
- Culinary/Event Installations – Replace unreliable, noisy, messy generators with quiet, long-run battery systems. Power fridges, hot plates, lighting, and tills without exhaust fumes in customer faces or engine rumble. You've got a full crowd to please, let's not go home because the power ran out.
- Broadcast / Satellite Vehicles – On-site news demands reliable comms and clean audio. Use 48V inverters to support AV systems, transmission capability, lighting rigs, editing stations and your whole crew- or bring a whole studio space with you.
- Mobile Workshops / Mechanics – Run welders, lifts, diagnostics, and air compressors directly off the trailer bank. No mains? No issue.
There's tonnes of possibility when you have such a flexible and powerful core offered by a semi-truck. The above is not exhaustive- we can work on solutions to meet a broad range of needs- so be in contact if you want to hear more.
SPECIALIST VANS AND SMALL TRUCKS
SECTOR – SPECIALIST & COMMERCIAL VANS
Compact Chassis. Full Capability.
Vans are the backbone of countless industries—from rapid-response paramedical units through to mobile workshops and street food operators. But none of these roles function without a stable, powerful, and intelligently managed electrical system.
Space is limited. Weight matters. Noise is a liability. You need clean, compact power that works silently and continuously. Sterling provides the critical components to build high-performance van-based power systems: DC-DC charging, reliable AC/DC charging, lithium capabilities, and cross-voltage charge... Your system can be as modern as your service.
WHAT WE SUPPLY
SATURN SERIES High-efficiency bidirectional DC-DC chargers with alternator care, lithium compatibility and cross-voltage capabilities being critical to doing modern high power solutions properly.
PRO CHARGE ULTRA PLUS High reliability, global capable multi-output AC/DC chargers. Flexible, configurable, and the Marine choice for years.
COMMON VAN CONFIGURATIONS & USE CASES
Trades & Utilities – Electricians, Plumbers, Mechanics, Cleaners
Power tools, charge equipment, and run diagnostics from a safe, regulated lithium bank. Drive to your job- do the job, move to the next one.
Street Food, Coffee & Catering Vans
Fridges, heaters, grinders, lighting—all powered quietly and cleanly. Silent systems improve working conditions and customer experience alike. No-one wants a generator by their food- especially if you're inside at a show!
Security and Protection
Operate communications, cameras, routers, or drone bays without grid connection. A properly balanced lithium system keeps equipment ready for deployment, ensures full capacity and usability, and protects your operators from the risk of a hot lead acid spill.
Medical & Welfare Vans
Provide off-grid welfare support, vaccinations, or emergency triage. Power lighting, pharma-refrigeration, diagnostics, and IT systems stably and predictably- a life might depend on it.
Breakdown & Mobile Repair
Run air compressors, diagnostics tools, impact guns, or even welders (when paired with a suitable inverter). Keep your tools working wherever the job takes you.
DOG UNITS- OR GROOMING VANS
Whether your job means you have to have a canine menace to deter intruders- or trimming down a LA Expats beautiful poodle- you want to be comfortable, and you want your canine friend (or client) to be comfortable, too.
48V REVOLUTION
Lots of power systems use basic relays and lead acid batteries for their usage- but this is not the best way of doing things.
Lead acid batteries are heavy, can overheat catastrophically and can be damaged by over-discharge very easily. Lithium has a volatile reputation in the media- but in terms of giving you a lightweight and energy dense battery, safely, it's incredible. You can use the full capacity of a LFP battery and charge it back up quickly and responsibly, without losing capacity.
You can also benefit from moving to 48V systems by using our chargers. Thinner cabling, higher efficiency and more powerful equipment means that you can complete more powerful jobs.
BUILT TO FIT. BUILT TO LAST.
Sterling systems are modular at their core. We can provide a range of items around your requirements, even solutions you might not have thought possible.
COMPACT PLATFORMS (CARS, SMALL BOAT)
Specialist cars—used by police units, first responders, enforcement agencies, and most normal people—are expected to support onboard systems well beyond standard vehicle loads. The challenge is clear: limited space, limited alternator capacity, utility priority.
Sterling’s systems are designed to integrate into these constraints, providing silent, efficient power delivery without compromising the vehicle’s primary systems. Whether you're running ANPR, dash cams, lighting, or onboard diagnostics, the underlying requirement is the same: power, in your hands.
Design Priorities
– compact DC-DC units and battery systems that fit under seats, in footwells, or rear compartments - Or, our Waterproof range of DC/DC chargers for fitting in more exposed areas.
– current limiting to avoid overload on small engines, and compatibility with all battery types (including Lithium)
– reverse charging paths for emergency starter recovery
These systems are typically built around a Saturn series DC/DC charger, drawing from the alternator to charge an auxiliary battery safely. This battery supports purpose-specific loads without draining the starter or requiring idle time.
Example Configurations
Police / Law Enforcement Units
Continuous operation of radios, blue-light systems, dash cams, and onboard terminals—all while maintaining enough reserve to ensure a guaranteed engine restart. Add bodycam docking, external comms, or license plate scanning systems, and you're well past what a stock system can handle.
K9 Response Cars
HVAC systems must be able to maintain cabin temperature without the engine running. A lithium auxiliary bank allows this to happen reliably, paired with a BB charger that ensures the system is refilled with every drive.
First Response Vehicles
In-field refrigeration, oxygen, or medical IT requires stable voltage and the ability to hold charge over long periods of inactivity. LiFePO4 banks paired with our chargers maintain long standby capacity with rapid top-ups during transit.
Surveillance
Low-noise, zero-emission standby power for passive sensors, AV systems, and uplinks. Our systems isolate critical loads from the ignition loop and ensure sustained operation during long-duration deployments.
Smaller Vehicle. Same Demands.
There’s no difference in the mission profile—only in the available space. With the right system design, a compact car becomes a fully functional platform capable of sustained field operation.
Let us help build a system that fits properly—and works reliably.