More DC to DC charger installation tidbits

[Teaney Hull 292]

On 5/14/2025 at 12:49 PM, Carl Hansen said:

I have consider DC2DC charging for the last 4 years.  I wanted to consider how we use the trailer before installing the DC2DC charging.  We do longer trips and often stay at Harvest Host along the way.  It's nice to pull into a dry camping spot with a full charge on the batteries.  The solar does a pretty good job but not during the night and decreases effectiveness in bad weather.  

The following reasons made me decide to pursue DC2DC charging:

1. You got a guaranteed output of up to 700 watts, rain, night, it doesn't matter

2. Additional panels on the Elite 1 is not an option.  DC to DC is like adding additional solar panels to the rig.

3. How about portable panels? Portable panels are heavy and do not store well.

4. Portable panels only work during the daytime.  We are on the road most days.

5. Portable panels won't run the air conditioner. I do carry a portable generator with us which can run the air conditioner if necessary.

6. DC2DC is guaranteed output.  It is going to work all the time. (Maybe a duplicate of #1 but I think it is worth mentioning again.)

I think it depends on how you use your rig.  If you always stay at places with shore power, maybe the DC2DC charging doesn't make sense.  I believe the decision to install DC charging depends on your use model.  It may not make sense for everyone.

Carl

Well said. I totally agree. 

[Teaney Hull 292]

On 5/16/2025 at 5:51 PM, Carl Hansen said:

Well, I pulled the trigger today and ordered all my DC charging parts.  They will be coming in over the next week or so.  I would like to extend a big thanks to all the members of this forum, who over the years, have helped me with many questions and concerns  I would like to give a special thanks to Coddiwomple (David) who graciously invited me over to his shop to show me how he installed his DC charging in his LE1.  It was extremely helpful to see first hand.  He went beyond the mark by opening up his TV and trailer (including every access panel) and allowed me to photograph and video his trailer. He even went so far to give me copies of all his documentation and notes.  It's people like David and many others that make this community such a great place to communicate and share.

Thanks to everyone!

Carl

BTW... I just got notified by Highway Trailers in Salem that Oliver is sending them the Truma water heater parts replacement for the recall.  There is hope!

Carl, I feel the same way. What a GREAT Community of support. 

[Ronbrink]

3 minutes ago, Teaney Hull 292 said:

I do not have Solar on the roof

Exact same reason why the DC/DC was a great alternative to help keep my Oliver's battery bank charged. 

[Carl Hansen]

Well, it's finished! The installation of the DC to DC charging system in now complete and operational.  I first started the installation in the Oliver Elite I trailer (#924) and finished the installation with the Jeep.  I'm generally a DYI guy, but this was a bit of a stretch for me.  It's not that it was difficult, I stressed on doing something to the Oliver that would ruin it, especially penetrating the hull for the charging cables.  That was a big concern.  But with careful planning and a ton of help from this community, I was able to get this done.  Special thanks to Coddiwomple (David) for his help, patience, and guidance.  I first went out to his place to view his installation in his Elite I.  It's amazing how different his wiring was in just two model years.  Mine is a 2021, and David's is a 2023.  It was a bit confusing for me at first so a second visit was called for.  In the second visit, I pulled my trailer to his place and asked more questions and advice.  That second visit really helped!  Thanks again David!

Here is a few pictures I took during the process:

I followed David's idea of mounting the components on a board that I later installed in front of the street side wheel well.  I used the buss bars to step down in size from 2AWG to 4AWG which was necessary to connect to the Orion XS.

I think pulling the 2AWG wire was the toughest part of the installation.  A shout out to my son-in-law who was there helping that day.  Couldn't have done it without him!

Upon examination of the hull, I realized that under the sink (above picture) the hull is only a single layer thick, not a double hull there.  That made things a bit easier.  There was little existinting space to run additional cables through the hull, so I modified the housing for the propane tanks just a bit.

With the propane tanks and tray removed, it was easy access to the trailer font.  With my oscillating saw, I cut out an addition piece of the propane housing to the left of the three existing cables.  That gave me plenty of room to install two additional cable glands for the DC charging cables.  The way the propane tank housing is constructed and attached to the hull, the small piece I removed does not compromise the integrity of the housing.  The following pictures show the final hull penetration.

 

With the cables pulled, I was able to finish connecting everything to the DC charger.  I finished the umbilical cord that connects to the back of the Jeep.

 

I used the Trailer Vision enclosure to protect the Anderson SB120 plugs.

Onto wiring the Jeep.  (Much easier)

At the battery box, I used a KASS terminal extender to accommodate the fuse and the other cables.

I ran the cable along the chassis and installed the Anderson connector in a Trailer Vision enclosure which allowed me to mount it directly to the rear bumper of the Jeep.  

With everything installed and attached the batteries at both ends (Jeep and Oliver), I plugged it in and tested the amperage.  I was getting between 49 and 50 amps at idle.

Now the next step is to road test this on a long trip.  Can't wait.  Very excited to always have full batteries after a long day driving.

Thanks again to everyone who had a part in making this a success!

 

Carl