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Orion xs dc/dc charger?

Meeko

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Joined
Jan 5, 2023
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USA:Buxton Maine 04093
Hello everyone. I was in the process of connecting our new DC-to-DC charger, the Orion xs Smart 12/12-50A. One of the advertised features was its compatibility with 4 AWG (25 mm²) cables. However, I encountered a challenge when attempting to insert all the copper strands into the designated hole due to the tight fit.

The ferrule crimping tool we acquired creates a square crimp, which is incompatible with the hole. We experimented with a 6 AWG ferrule, but it was still too large to fit. I would like to know if anyone else has encountered this issue.

Additionally, I would like to clarify whether the settings on the Orion-xs, should be identical to those on our Victron solar controller. While I assume they should be the same, I understand the potential consequences of making assumptions. I would appreciate any guidance or advice on this matter. Thank you in advance for your assistance.
 
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4ga is severely oversized for 30amps. Whenever I oversize like that I just trim the finely stranded wires with a knife on one side.
 
Indeed, utilizing a higher amperage rating is preferable in this scenario. Considering the 50 amp DC to DC conversion and the 25 feet run, I opted for 4 AWG cables. The price difference between 4 AWG and 6 AWG was negligible.
 
Indeed, utilizing a higher amperage rating is preferable in this scenario. Considering the 50 amp DC to DC conversion and the 25 feet run, I opted for 4 AWG cables. The price difference between 4 AWG and 6 AWG was negligible.
Isn't that a 30 amp DC-DC charger, though? Maybe I am missing something.
 
Does your 4 AWG fit w/out a ferrule? I know this can become an endless internet argument but I don't use ferrules with Victron connectors and I believe Victron supports both methods.
 
I just ordered an Orion XS. I like that I can adjust the input current. Will set it to 30A and see what comes out the other side. I like it because it can now play with my Cerbo GX, although I am out of VE.Direct slots on the Cerbo so will have to use a USB slot.
 
I also have a new Orion XS 50A. I am using 6 AWG cable, without a ferrule. I don't think a 6 AWG (or larger) ferrule would fit.

The XS documentation states that a ferrule is not required for 4 AWG through 8 AWG wire. They suggest using a ferrule for smaller wires. 6 AWG wire is recommended for <5m cable runs. Read it here:

 
I just ordered an Orion XS. I like that I can adjust the input current. Will set it to 30A and see what comes out the other side. I like it because it can now play with my Cerbo GX, although I am out of VE.Direct slots on the Cerbo so will have to use a USB slot.
I really like the adjustable current. If you adjust the input max to 30A, and leave the output set at the default 50A, the output may be higher or lower than 30A, depending on relative in/out voltages. Here are a couple of examples with the input limit set to 10 A (the limit of my bench PS). The other thing I really like is the efficiency. I look forward to trying this at 50A, once I install it in the truck.


10A in, 10.2A out

1715195734027.png


10A in, 9.6A out

1715195818460.png
 
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