B2B CHARGER.

wildebus said:
If you want to tell me the cable lengths (remember to factor in the twists and turns the cables might need to go through), I can make up a full cable set for you if you want. (installed an Orion-XS a couple of days ago actually :) )
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I'll pop out tomorrow and get some measurements. 👍
 
Mtbcol said:
I'll pop out tomorrow and get some measurements. 👍
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rather than measure bits and pieces and add them up, see if you can use some some string where the cable would route and then measure that :) And leave a bit of slack to avoid strains and be able to easily access fuse holders to replace if needed without having to take other stuff out (y)
 
You must have read my mind. I was going to use a bit of 240v three core of about the same diameter so as to be as accurate as possible 😁
 
wildebus said:
rather than measure bits and pieces and add them up, see if you can use some some string where the cable would route and then measure that :) And leave a bit of slack to avoid strains and be able to easily access fuse holders to replace if needed without having to take other stuff out (y)
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Hi wildebus.

I've done my measurements, and once you start running them where they actually need to go, it's a bit more than I estimated🙄, so hope the 16mm2 will still be ok🤞?.

So, starter battery pos+ to Orion unit pos+ =190cm.

Leisure bank pos+ to Orion unit pos+ = 95cm.

Starter battery neg - (if it's acceptable to connect this to the Orion unit neg - ?) to Orion unit neg - = 176cm.

Hope your still happy to do this for me, and more than happy to send you payment upfront for cables, fuses, fuse holders, labour etc. just let me know. If you need anymore info just let me know. I've attached photos of the battery terminals if this helps.
P.S. The 240v fridge/ inverter set up you recommend several years ago now is still going strong 🙂👍
 
Here's the photos of the battery terminals.

I've got some post connectors with the longer cable attachments as shown as I may need to use them once if got extra cables attached. Any other advice or recommendations gratefully received 🙂
 

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Mtbcol said:
Hi wildebus.

I've done my measurements, and once you start running them where they actually need to go, it's a bit more than I estimated🙄, so hope the 16mm2 will still be ok🤞?.
Click to expand...
It's always more than you think I have found :) And better a metre too long than 10cm to short :D
At the lengths you have quoted below, I would be happy with 16mm2 cable. In actual fact, the next standard step up in size is 25mm2 and the Orion doesn't even accept a 25mm2 cable directly, so Victron don't really expect a bigger cable to be used normally!

Mtbcol said:
So, starter battery pos+ to Orion unit pos+ =190cm.

Leisure bank pos+ to Orion unit pos+ = 95cm.

Starter battery neg - (if it's acceptable to connect this to the Orion unit neg - ?) to Orion unit neg - = 176cm.
Click to expand...
What I think is missing from the above is a note of what Neg/Ground you have between the Leisure Battery and Starter Battery?
If it is not upto scratch already, or you want to make sure it is good enough, I would have a 4th cable - from Orion B2B to Leisure Battery. So what I would suggest is the following:
+VE - Starter to Orion IN - 2 Metres
+VE - Leisure to Orion OUT - 1 Metre
-VE - Starter to Leisure - ? Maybe 2.5 Metres? Maybe 2 Metres?
-VE - Leisure to Orion COM - 1Metre
(this way you would only have a single ground connected to Orion. Two cables into one Orion terminal would be awkward to manage and service)

You need a fuse at the Starter Battery +ve end and you also need a fuse at the Leisure Battery +ve end.
I would also recommend a fuse at the other end of that 2M cable from Starter to Orion IN. Strictly speaking it is not needed but I tend to put a fuse at both ends of that long run as a precaution.
What is the cable run like in that metre between the Orion OUT and Leisure +VE? You might want to consider a fuse at the Orion OUT possibly if there is any risk of cable damage in that run?
The above would mean a total of 4 fuses so bit more than typical but makes the install very safe.

Mtbcol said:
Hope your still happy to do this for me, and more than happy to send you payment upfront for cables, fuses, fuse holders, labour etc. just let me know. If you need anymore info just let me know. I've attached photos of the battery terminals if this helps.
P.S. The 240v fridge/ inverter set up you recommend several years ago now is still going strong 🙂👍
Click to expand...
Ref the terminals, looks like a mix of 5mm and 6mm bolts there with possibly an 8mm on the last one? If you can confirm the sizes needed at each battery ends, that would be good. Not the biggest fan of stacking lots of cables on a battery terminal, but if supported well, it is ok.
The +ve leads at the battery ends will have a short lead from Battery +ve to Fuse, so if you are switching in the future to Lithium, that will almost certainly need 8mm rings - I could send a couple of loose 8mm lugs to swap over when the time comes. You could potentially have 8mm to start with if you can arrange the connections so they are securely clamped down and making a good connection.

I'll check what cable I have in stock - I think I have what is needed and that would save extra shipping costs to me on a new order and so save you a bit of money as well.
 
Thank you so much. Just having a bit of tea and cake in the garden, then I'll get you the further info.🙂👍
 
Mtbcol said:
Spooky🙂
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I'm just about to sit down to our Easter Sunday roast, so I'll give you those cabling details afterwards. Sorry I got carried away with sorting out our big shed earlier 🙄. Have to do these things while the weather's dry👍
 
wildebus said:
It's always more than you think I have found :) And better a metre too long than 10cm to short :D
At the lengths you have quoted below, I would be happy with 16mm2 cable. In actual fact, the next standard step up in size is 25mm2 and the Orion doesn't even accept a 25mm2 cable directly, so Victron don't really expect a bigger cable to be used normally!


What I think is missing from the above is a note of what Neg/Ground you have between the Leisure Battery and Starter Battery?
If it is not upto scratch already, or you want to make sure it is good enough, I would have a 4th cable - from Orion B2B to Leisure Battery. So what I would suggest is the following:
+VE - Starter to Orion IN - 2 Metres
+VE - Leisure to Orion OUT - 1 Metre
-VE - Starter to Leisure - ? Maybe 2.5 Metres? Maybe 2 Metres?
-VE - Leisure to Orion COM - 1Metre
(this way you would only have a single ground connected to Orion. Two cables into one Orion terminal would be awkward to manage and service)

You need a fuse at the Starter Battery +ve end and you also need a fuse at the Leisure Battery +ve end.
I would also recommend a fuse at the other end of that 2M cable from Starter to Orion IN. Strictly speaking it is not needed but I tend to put a fuse at both ends of that long run as a precaution.
What is the cable run like in that metre between the Orion OUT and Leisure +VE? You might want to consider a fuse at the Orion OUT possibly if there is any risk of cable damage in that run?
The above would mean a total of 4 fuses so bit more than typical but makes the install very safe.


Ref the terminals, looks like a mix of 5mm and 6mm bolts there with possibly an 8mm on the last one? If you can confirm the sizes needed at each battery ends, that would be good. Not the biggest fan of stacking lots of cables on a battery terminal, but if supported well, it is ok.
The +ve leads at the battery ends will have a short lead from Battery +ve to Fuse, so if you are switching in the future to Lithium, that will almost certainly need 8mm rings - I could send a couple of loose 8mm lugs to swap over when the time comes. You could potentially have 8mm to start with if you can arrange the connections so they are securely clamped down and making a good connection.

I'll check what cable I have in stock - I think I have what is needed and that would save extra shipping costs to me on a new order and so save you a bit of money as well.
Click to expand...
Thank you. That's great. And I agree with all you have said. I definitely want it to be safe. Regarding the terminal sizes. Would it be possible to just send those cable ends with no terminals, and supply me with the various sizes? I have a manual crimping tool that I can use to put the correct sizes on, and it would give me a bit of practice 😁. I will be fitting feruls to the Orion ends, as I believe this is the best way? (I have a hex crimper and 16mm2 feruls now). I trust you to do, and supply what I would need for a safe installation. 🙂👍. If you do actually need anymore measurements, I'll get them for you in the morning.....I think I've had a little too much vino with my roast for accuracy at the moment 😁🤪. If you could give me an approx. Ideal of the cost when you are able that would be great so I can raid the piggy bank in readiness. As I say, happy to send some payment up front.🙂
 
Mtbcol said:
Thank you. That's great. And I agree with all you have said. I definitely want it to be safe. Regarding the terminal sizes. Would it be possible to just send those cable ends with no terminals, and supply me with the various sizes? I have a manual crimping tool that I can use to put the correct sizes on, and it would give me a bit of practice 😁. I will be fitting feruls to the Orion ends, as I believe this is the best way? (I have a hex crimper and 16mm2 feruls now). I trust you to do, and supply what I would need for a safe installation. 🙂👍. If you do actually need anymore measurements, I'll get them for you in the morning.....I think I've had a little too much vino with my roast for accuracy at the moment 😁🤪. If you could give me an approx. Ideal of the cost when you are able that would be great so I can raid the piggy bank in readiness. As I say, happy to send some payment up front.🙂
Click to expand...
I'll work out the cost tomorrow and message you.
Victron recommend that ferrules are not used on their kit for some reason. On the 30A unit, you couldn't use Ferrules on the 16mm2 cable as the hole was so tight the ferrule took it oversized! the 50A unit is less of an issue - I tend to use 16mm Pins on kits as they tend to be a lot less problem.
 
wildebus said:
I'll work out the cost tomorrow and message you.
Victron recommend that ferrules are not used on their kit for some reason. On the 30A unit, you couldn't use Ferrules on the 16mm2 cable as the hole was so tight the ferrule took it oversized! the 50A unit is less of an issue - I tend to use 16mm Pins on kits as they tend to be a lot less problem.
Click to expand...
Ahh, ok, I'll see if my feruls kit has any pins.
🙂👍
 
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