2x Orion 30 Non-Isolated - Hot Cables

[Gloriavan]

Hi,
I have installed 2x 30A B2B chargers to my Crafter campervan, both have their own cables coming from the battery to 2x 60A midi fuses before running the 5/6m or so to the B2B units.

I have a smart alternator and have recently changed the settings so that I was using the engine shutdown sensing and disabled the voltage lockout setting.

Now after a 20 min drive the cable is warm enough that if feels like the plastic cover has separated from the cable, I can wiggle it and it feels very soft. It’s 16mm2 cable and the most current I’m seeing through the units is 28A.

Any ideas on what can be causing the cables to become warm (one of units has disconnected as the fuse has either blown or the holder is damaged, checking this afternoon.)

I have firefly oasis batteries that can take a lot of current but I’d have thought the Orion is drawing a maximum of 30A from the battery per cable and that the 16mm2 cable could cope with this over the 5/6m run.

[chrigu]

Are the Orions runmning for hours on end at those 30A? Hows the input voltage looking if they charge the aux battery? Which side is getting hot, input or output cables? Are the cables getting hot along their whole length or just at the ends? Connection points are an additional resistance, check their tigthness and if theres corrosion.

[Gloriavan]

I’ve only noticed them getting hot around the fuse connections just after the battery.
I’ll have to check the the connections into the Orion’s and see if there are any issues there.

They were only running for about 20 minutes and the battery fuse end got hot hot.