Victron Orion 50 amp DC/DC charger non-isolated Part 1 of 2

[rideadeuce]

Decided it was time to start the DC/DC charger install after I got the breaker replaced and the solar input working. Getting the Tundra wired up turned out to be fairly straight forward. Just followed the wire I had installed to charge the GZ for the old ARB fridge we used to store extra food. No issues once I figured out where to mount the Anderson connector to the Tundra (absolutely no flat places under bumper near hitch to mount), had to use a couple of longer bolts (removed OEM and matched) that were used to hold the bumper and then used a 6 in water clamp to hold right side of an aluminum 3 in wide x 12 in long x 1/4 in base for the Anderson plug to mount. Used 4 AWG wire from Windy Nation, it came with heat shrink and lugs, 60 amp Blue Seas, a manual 60 amp Blue Seas resettable breaker,  3/4 in sheathing for protection, and Anderson SB120 connectors. For my application, should have gotten 50 ft instead of 40ft wire total. You will also need HD crimper, wire cutter and heat gun. I had to get creative but the mount is strong and as conveniently located as I had hoped for... now for the Ollie install. Have to wait for more wire to ship. 

Big thank you to those that preceded me and posted their installs!

Best, 

Mike

Links:

Kit https://www.windynation.com/products/4-gauge-welding-battery-cable-kit-includes-5-pieces-of-3-8-5-pieces-of-5-16-tinned-copper-cable-lugs-and-3-feet-black-heat-shrink-tubing?

Blue Seas https://a.co/d/1DkubaD

Anderson cover https://powerwerx.com/trailer-vision-tv201426-120-sb120variant=43802376339678 Could have used SB50.

Edited June 2 by rideadeuce

[Ronbrink]

5 hours ago, rideadeuce said:

... now for the Ollie install.

The hull passthrough was the most challenging part of my DC-DC install. I used this double cable gland to ensure a waterproof  installation.

 

Here’s a couple of  views.

[rideadeuce]

1 hour ago, Ronbrink said:

The hull passthrough was the most challenging part of my DC-DC install. I used this double cable gland to ensure a waterproof  installation.

 

I like that gland and the fact that you went farther to the right, seems like it might make fishing the wires through the bathroom area a more direct shot. I have already purchased a Blue Seas gland but I will see how anxious I am to start on part 2. Waiting on more 4 awg wire and 3/4" loom. Way underestimated.

Looks like to me you cut away more of the fiberglass propane housing to make a better fit? If so, how did you control depth. Don't want to cut into main shell. 

I am going to try and fish it without removing BR shelf, at least initially. Got this Klein fiberglass fish wire... it's pretty flexible but still stiff. 

Edited June 2 by rideadeuce

[Ronbrink]

2 hours ago, rideadeuce said:

Looks like to me you cut away more of the fiberglass propane housing to make a better fit?

No cutting of the propane housing involved, but did notch the gland for it to fit (see pic); it is slightly under the propane housing at the top. As I recall, I made a single 3/4” hole behind the gland through the hull to route both cables under the bath flooring and forward dinette seat hatch to the aft dinette seat hatch where the charger is staged. The fishing tool should suffice, but in my case the two cables had to be hand-fed by my Son as I pulled from inside forward hatch. 

Edited June 2 by Ronbrink

[rideadeuce]

Part 2/2

Did as much as I could today (waiting on more 4 awg wire.) All I have to do is pull the wire and hook it up. Did have to remove a small area of propane shroud to fit gland securely. Did not have to remove BR shelf (at least it was easy to fish some fiberglass wire.)

Blue Seas gland is well designed, no need for sealant. Clean and easy. Almost bought the @Ronbrink double gland, very nice install. 

Orion DC-DC 50 amp charger is very light weight and has small footprint. Much less heat production, no heat sink needed. 

Best, 

Mike

Test fit the wires. 

 

Edited June 2 by rideadeuce

[rideadeuce]

Finished the install this evening. Everything went as planned but the Orion is only reading 7-10 amps with Tundra parked. Run out of time to problem solve or change the settings too much but everything did seem to be correct in the settings.

 

[Ronbrink]

9 hours ago, rideadeuce said:

Everything went as planned but the Orion is only reading 7-10 amps with Tundra parked.

My DC-DC only puts out a partial charge when idling. Revving the engine should show an increase in output. 

[Geronimo John]

I installed the below pictured Anderson SB 175 amp connection system a couple of seasons ago.  I noticed several weeks ago that one of the plastic termnal guides had broken off.  Yesterday, when I detached, the quick disconnect literally broke into several pieces.  It appears to have either solared out or been chemically damaged.  I'm wondering if it was a knock-off product as I have never had an Anderson Disconnect fail before.  

Have other owners seen this happen?

Also is there a better housing for the TV plug to keep extreme road dirt out of it when in use and not in use?  The below one does not.

Thanks

GJ

 

 

[Ronbrink]

2 hours ago, Geronimo John said:

I'm wondering if it was a knock-off product as I have never had an Anderson Disconnect fail before.

Like many, I have been tempted to purchase from Amazon or eBay for such incentives as less money and free shipping, but it only takes one negative review that a product is a ‘knockoff’ to bring me back to reality! To answer your question, no I have never had or seen a failure as you described. For piece of mind, I buy direct from powerwerx.com to ensure authenticity. 

[katanapilot]

On 6/2/2024 at 11:01 AM, Ronbrink said:

No cutting of the propane housing involved, but did notch the gland for it to fit (see pic); it is slightly under the propane housing at the top. As I recall, I made a single 3/4” hole behind the gland through the hull to route both cables under the bath flooring and forward dinette seat hatch to the aft dinette seat hatch where the charger is staged. The fishing tool should suffice, but in my case the two cables had to be hand-fed by my Son as I pulled from inside forward hatch. 

Nice installation.  I'm about to do this install as well, as I finish up the Victron MP2 and other components.  Were you able to fish the #4 cables under the bathroom floor  and into the drivers side chase without removing the shelf under the bathroom sink?  I have a similar fish tape along with some fiberglass rods that work well for these types of challenges.  I would prefer not to remove the shelf unless absolutely necessary. Thanks.

[Ronbrink]

21 hours ago, Geronimo John said:

Also is there a better housing for the TV plug to keep extreme road dirt out of it when in use and not in use?  The below one does not.

The Anderson Environmental Boot is the only way I know to ensure a waterproof/dust-proof connection with the SB Series products. Although a product-specific mount is not offered, I was able to improvise a secure thru-mount at my TV bumper. 

1of2 mating boots required.

Custom hanger bracket bent and welded to my specific application.

The slight protrusion, as mounted, is of no hindrance.

A familiar pic showing bumper-mounted boot.

A familiar pic showing mated boots.

Edited September 6 by Ronbrink

[Ronbrink]

11 hours ago, katanapilot said:

Were you able to fish the #4 cables under the bathroom floor  and into the drivers side chase without removing the shelf under the bathroom sink?

That was exactly what I did. Used a light and mirror from within the forward dinette seat hatch to eyeball a prospective point of entry; care must be taken to avoid existing plumbing. Once identified, a 1/8” drill bit was used from outside taking care to only penetrate the hull thickness. Then another look from within to verify a clear path with no obstruction for a larger hole to run the cables.

[Geronimo John]

58 minutes ago, Ronbrink said:

That was exactly what I did. Used a light and mirror from within the forward dinette seat hatch to eyeball a prospective point of entry; care must be taken to avoid existing plumbing.

Ditto.  Was not difficult at all.  

[Geronimo John]

22 hours ago, Geronimo John said:

Yesterday, when I detached, the quick disconnect literally broke into several pieces.  It appears to have either solared out or been chemically damaged.  I'm wondering if it was a knock-off product as I have never had an Anderson Disconnect fail before.  

Another "handy" pilot and I did a post mortum on the damaged Anderson connector.  Basically we believe it was crushed.  Since it is under the hitch, we both knew where and how it happenend.  My truck is pretty much daily used to haul a over full load of paraglider pilots and gear up a steep sketchy mountain road.  Since I fly down, I use a trusted driver to take the truck down the mountain in 4L, mostly gear 1 or 2 of ten on the transmission.  There is a switchback that requires "jacking" the truck around.  The angle of repose is such that the mounted Anderson 175 amp connector can be hit.    

One of the plastic guide pins on the TV side of the connector had failed on the way to Idaho.  So I am somwhat suspect that it may be a knockoff.  But the massive damage most likely was from the hillside when backing  to get around a very tight "Y" in the fire road.  

PS:  I used Powerwerk for purchase of three replacement shells and the environmental boot as suggested by RonBrink.  Many thanks!

[SeaDawg]

@rideadeuce, so happy to see your young engineering assistant and his great smile crop up in your photos from time to time. So important to get the young ones interested and involved. 

[katanapilot]

8 hours ago, Geronimo John said:

Ditto.  Was not difficult at all.  

Not difficult for you.  I am challenged with complicated tasks like this 😉 

[rich.dev]

On 6/2/2024 at 4:13 PM, rideadeuce said:

Very nice installation Mike. I'm about to copy your and @MAX Burner's install for my Starlink cable and later DC to DC charger. Which blue sea cable gland did you use, is it the predrilled or THIS one?

[rideadeuce]

@rich.dev I bought the one you linked and drilled the holes to match what I needed. 

[MAX Burner]

@rich.dev - FYI:  We used the 1.4" Blue Sea Cable Gland and drilled the seal to accept the cord - as you tighten the four stainless screws the slightly tapered gland tightens around the cord for a waterproof seal.

Edited October 1 by MAX Burner