System Review– Isolating System from Steel Hull

Hi, I’m new to this forum but have completed a few off-grid installs mostly in campers.

I’m currently installing a 990 AH 12v system with 5000va multiplus in my steel sailing boat.

As this is a steel hull we have decided for corrosion prevention a single shared bonding point should be used between the engine starter battery and the lithium bank.

However, using double pole battery switches we plan to isolate the system leaving only a floating MPPT and floating bilge pumps connected to the batteries when we are not on the boat.

Is there any Victron support or any community sources that could review our planned schematics before assembly? Our local Victron dealer has reviewed the system and given it the green light, but it would be great to get some second opinions on potential issues.

Cheers,

Olly

Make sure you get the isolated Orion DC-DC charger when charging different chemistry. You could look at using the inverter trickle charger instead of the AC charger.

Thanks for the heads-up, Owen. After thorough research and consideration, I’ve opted to establish a single common ground point at the engine.

Given the steel hull, my primary focus is on mitigating electrolytic corrosion. There are certainly varying schools of thought on the matter, but I believe a shared neutral at the engine will provide the most reliable and corrosion-resistant setup for my system.

With this configuration, my understanding is that the non-isolated DC-DC charger is the logical choice. Please let me know if you think otherwise as I appreciate the advice.

Yes use the isolated charger, if it fails internally the current and voltage from the lithuim will be seen on the AGM.

DC Grounding
Should the DC system remain floating (ungrounded)?

Recommendation: On a steel hull, the DC negative should generally be bonded to the hull at a single point. This avoids accidental grounding through equipment, which can lead to corrosion. A floating system may inadvertently ground through components like the engine block, creating uncontrolled paths.

Use sacrificial anodes (e.g., zinc, aluminum, or magnesium depending on water type) on the hull to protect against galvanic corrosion.
Ensure that grounding is deliberate, with a single bonding point to the hull to minimize stray currents.

Where to establish the grounding point?

Preferred Option: Bond the DC negative bus to the hull at a single, intentional point. Ensure this point is clean, unpainted, and in a central location near the distribution panel.
If using a submerged plate, ensure it is not isolated from the hull but bonded properly to provide a consistent grounding path.

AC Grounding
Reconciling AC and DC ground systems:

Standard Practice: Tie the AC ground to the DC negative bus, which should also be bonded to the hull. This complies with ABYC regulations and ensures a fault path to water via the hull.
Use an isolation transformer or galvanic isolator in the AC system to prevent stray currents between the shore power ground and the boat’s electrical system.
Safety of marine-rated equipment:

Marine-rated chargers and inverters are designed to minimize risks, but proper grounding and bonding are still necessary. Equipment chassis should be tied to the DC negative bus to provide a fault path.

Bonding

Is bonding unnecessary in a floating system?

Bonding is critical on a steel hull. Even in a “floating” system, there’s a risk of stray currents finding unintended paths through bonded hardware (e.g., thru-hulls or prop shafts). Bond all metal components exposed to seawater (rudders, thru-hulls, etc.) to the common bonding system.

Bond the hull directly to the DC negative bus to ensure it serves as the primary ground plane. Coating the hull with epoxy and antifouling paint minimizes corrosion, but the hull still needs to be electrically bonded.

Sacrificial Anodes: Regularly inspect and replace anodes to ensure they are providing protection.
Galvanic Isolators: Install on the shore power connection to prevent stray AC currents.
Single Ground Point: Maintain one deliberate connection between the hull, DC negative, and bonding system to avoid ground loops.
Inspections and Maintenance: Periodically check all connections and bonding systems for wear or corrosion.
This approach ensures compliance with safety standards like ABYC while minimizing corrosion risks and protecting the boat’s electrical system. If doubts remain, consulting a marine electrician—even remotely—can provide additional assurance.

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I would prefer the isolated version, more isolation is never wrong.

With a steel hull isolation of DC negative and AC ground is dangerous.
DC negative and AC ground should be bonded to the hull as close as possible to each other but not on a single bolt as if the bolt becomes detached from the hull in the event of an AC earth fault the DC negative becomes live. Similarly if there is no AC bond to hull then there is a chance in the event of an AC fault (live to hull) of the hull becoming live.

J

Ofc the infeed from landside should be grounded, but the individuall components can be isolated.

One thing I should have said is that on a steel hull the AC ground should only be bonded to the hull on the boat side of the isolation transformer / GI. If you bond on the shore supply side then the boat will dissolve :astonished:

Thanks everybody for the feedback and advice. I will replace the non-isolated DC DC with an isolated one.

I am thinking I will upgrade my alternator soon with a Balnmar alternator that can charge Lithium directly via a regulator.

Am I right to assume I can use the DC DC charger in the reverse, to float the engine starter battery FROM the lithium bank when the engine is running?

No

Yes, the charger has a remote switch that can turn on when the engine is running. Have a look in the manual to see how you would like to set it up.

We have a glass cat with lots of isolation.
Engines are seperated with Dual Pole Blueseas isolators when not running.
AC and DC are NOT bonded.

Anode life is outstanding
I highly recommend it.

We found ground paths through the throttle cables and hydraulic steering hoses.

Caution. Victron Canbus is not ground isolated. N2K is.