Victron Upgrade Series Part 1: Orion XS 50A DC-DC Charger Install

This upgrade will be completed in multiple phases. Over time, all, or at least most, of the coach battery system will be converted to Victron components, excluding the lithium batteries themselves. I am starting with the DC-DC charger. The wiring schematics remain the same. Check the SFK lithium battery installation on this link (click here).

The original 40-amp Renogy DC-DC charger has been replaced with a Victron Orion XS 50-amp DC-DC charger. For reference, you can view the original 40-amp Renogy DC-DC charger installation at this link (click here). Here’s how a changeover switch can be used to activate either the ACR or the DC-DC charger, ensuring only one charger is active at a time (click here)

The DC-DC charger will remain in the same location, which required fabricating a new mounting system for the Orion. This time, the mount is designed in two pieces. The baseplate is secured to the firewall using three existing OEM bolt studs. A separate L-bracket holds the Orion and bolts to the baseplate, allowing for easy removal if needed.

There is ample space under the dashboard for the Orion, and this location may even accommodate a second Orion in the future if expansion is required. The L-bracket is made from aluminum plate, while the baseplate is steel. Both components were powder coated black to maintain an OEM appearance.

Both the input and output of the Orion are protected by 60-amp circuit breakers, as recommended by Victron.

Parts/ Materials used:

• Victron Orion XS 50-Amp Smart DC-DC charger (With Bluetooth)
• Eaton Bussmann 60A Marine Rated Circuit Breaker
• (optional) 4-Gauge cable and lug

Shown is the basic DC wiring diagram.

Fabricating the bracket and testing the fit.

The aluminum plate includes vent holes to improve airflow and help keep the charger cool.

Fitting the L-bracket to the baseplate to ensure proper alignment.

Components preassembled following powder coating.

After installation, the unit sits under the dash, just to the right of the fuse box and above the driver’s left footrest.

Here is the 3D-printed fiber optic cable holder. The inside is coated with a chrome finish to reflect and channel the LED indicator light into the fiber optic cable. The other end of the cable terminates at the dashboard, allowing for easy and quick visualization of the charger’s LED lights.

See the 50-Amp Victron Orion-XS at Work.

Note: I tried using a ferrule on the 4-gauge cable with a bootlace crimper, but it wouldn’t fit the Orion connectors. My 4-AWG tinned stranded cable only fits as bare wire, and you have to compress the strands carefully so every strand fits into the terminal (see short vid below).

How to connect a 4-AWG cable to Victron Orion-XS without using ferrule.

That’s a wrap for this upgrade! Next up, I’ll be tackling the Victron solar charge controller, the inverter/charger under the driver’s seat, and adding a Victron Erkano GX energy management system controller and monitor. The SFK batteries have a built-in communication port for Victron Venus OS, so it’ll be interesting to see how that works. Thanks for following along, don’t forget to subscribe for more updates!