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

**rideadeuce** · June 2

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-sb120 variant=43802376339678 Could have used SB50.

Edited June 2 by rideadeuce

**Ronbrink** · June 2

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** · June 2

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** · June 2

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** · June 2

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** · June 6

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.