Replace DC Fuse Panel March 13, 2025, 12:20:57 pm This will be part of my electrical upgrade project documented here, but perhaps it deserves its own discussion. It would just get buried in that thread and might be something others wish to tackle as a standalone project.I've an older DC fuse panel in my 2002 MB that I plan on replacing. Primarily because I'll need more circuits than it provides, but having an LED come on for failed fuses is a welcome addition as well.Updating the converter from whatever is in the power center might address this, as it looks like many of the newer units include new fuse panels. However, given I'll be disabling or removing my converter given a Multiplus is coming into the picture, that's not a great option. And yes, I could simply add another fuse box down with the newly installed Victron components and wire new circuits there, but I'd prefer to keep everything in the same place. The power center is the logical location for anyone to look for DC circuits/fuses, old or new.Has anyone updated just the DC fuse panel in the power center, and if so - any ideas which one(s) might fit the 2002 factory power center without significant modification? Pic below showing what's in there now.
Re: Replace DC Fuse Panel Reply #1 – March 13, 2025, 12:46:08 pm Hi Will. You can get a modern fuse panel separately from Bestconverters.com. it has more branch circuits, and does light up if a fuse blows. (I've only had to replace a fuse once and it was something I did). You still need a place for circuit breakers in the power distribution panel. The present converter you have is pretty useless. I use my old one to charge my 6v lead acids at my house. It is located in the compartment under the distribution wiring. Left empty you could store fuses, meters, and other tools there. RonB 1 Likes
Re: Replace DC Fuse Panel Reply #2 – March 13, 2025, 03:04:24 pm Thanks, Ron - ordered up. I've one unused DC circuit on the current board, and the new board has two more than the old board. Three new circuits should be adequate.For anyone else looking, the part is a Parallax 7300 Series Fuse Board. It's a replacement fuse board designed for Magnetek or Parallax 7300/8300 Series power centers and looks to be a direct replacement. Bestconverters has them, but they are pretty widely available. Pic attached.And yeah, I'll be yanking the existing converter which will free up the 15A AC circuit feeding it. I'll repurpose that to supply a dedicated outlet up on the counter for a couple of high draw appliances.
Re: Replace DC Fuse Panel Reply #3 – March 13, 2025, 03:07:07 pm That looks like a nice replacement. Much better quality than the one that came with my PD4655 converter.jor
Re: Replace DC Fuse Panel Reply #4 – March 13, 2025, 04:36:54 pm On my midbath, I replaced the entire power center with components from Victron and Blue Sea. The fuses were replaced with this Blue Sea DC breaker panel. It was mounted in a cutout below the drawers in the kitchen counter, hinged at the bottom for easy access to the wiring. (A similar but smaller breaker panel handled AC power.) 2 Likes
Re: Replace DC Fuse Panel Reply #5 – March 13, 2025, 06:46:40 pm Will, just a thought, I installed the very board when I updated my converter. Just a little precaution, when you install the 12V leads make sure you use some kind of backup on the terminal when you tighten the flat blade screw. They are pretty flimsy.Jon 1 Likes
Re: Replace DC Fuse Panel Reply #6 – March 13, 2025, 08:48:18 pm Quote from: JonS - March 13, 2025, 06:46:40 pmWill, just a thought, I installed the very board when I updated my converter. Just a little precaution, when you install the 12V leads make sure you use some kind of backup on the terminal when you tighten the flat blade screw. They are pretty flimsy.I have seen several broken terminals, it's better to check the screws a little more frequently than to overtighten tighten, and potentially damage something. Copper wire is malleable and will compress over time, loosening the connection.All the terminal screws in the Power Center need to be checked periodically, I do it every year or so. The more you drive, the more often the screws need to be checked. Make sure to disconnect all sources of 120 VAC power.The fuse board from Best Converter is the one to get and it comes with many aftermarket converters.it's an attractive upgrade if not just for the LED blown fuse indicators.Larry 1 Likes
Re: Replace DC Fuse Panel Reply #7 – March 13, 2025, 11:56:35 pm One of the reasons I used the Blue Sea breaker panel (and in other cases, Blue Sea fuse blocks) is that all connections are made with wires ending in ring terminals, rather than compressed bare copper wires. I will never use compression-type terminals if I can avoid it, for exactly the reasons Larry and others have pointed out. A ring terminal held down by a screw and lockwasher is very unlikely to loosen.That's about my only complaint against Victron products, at least the smaller ones: most of the ones I've used can't take ring terminals. I don't trust compression terminals! 1 Likes
Re: Replace DC Fuse Panel Reply #8 – March 18, 2025, 04:58:12 pm Quote from: Andy Baird - March 13, 2025, 11:56:35 pmOne of the reasons I used the Blue Sea breaker panel (and in other cases, Blue Sea fuse blocks) is that all connections are made with wires ending in ring terminals, rather than compressed bare copper wires. I will never use compression-type terminals if I can avoid it, for exactly the reasons Larry and others have pointed out. A ring terminal held down by a screw and lockwasher is very unlikely to loosen.I don't discount the concern with compression terminals, and few will argue with the quality of Blue Sea components. However, I can't say I've ever been bitten by compression connections when torqued appropriately. Along those lines, when I do use them - I always come back a day after installing and give them a final snug, as I've found any loosening usually happens early on.Regardless, for those that don't care for them - there's no need to go with an aftermarket fuse panel, along with whatever custom mounting and/or wire relocation it might require. You can still use ring terminals with the stock or replacement fuse panel that has compression connections. A #10 ring terminal works perfectly with the existing compression screws. If one wanted to fit a flat or star/lock washer under the screw head, those could easily be added. Pic below shows a couple ring terminals in place, and I can confirm they snug up fine and there's plenty of room - both between circuits, as well as below the fuse panel in the power center for the added length of ring terminals.I'm sure the main feed screws could be attached in the same manner, but the stock compression screws would need to be replaced with equivalent button head machine screws. 1 Likes
Re: Replace DC Fuse Panel Reply #9 – March 18, 2025, 07:48:04 pm Amazingly, you can look at something like a fuse board for decades and never think to to use a ring terminal.Good tip.Larry 1 Likes
Re: Replace DC Fuse Panel Reply #10 – March 19, 2025, 06:19:12 am Nice idea with the ring terminals!I do a fair amount of 3-to-12V work and use ferrules as a solution for stranded wire and compression terminals. Sometimes I'll use heat shrink around the ferrule barrel and wire to strengthen that joint.I bought an SK500 kit (link here) from Ferrules Direct and a used crimp tool off an auction site. The kit covers AWG sizes 10 to 24.Mark H. 1 Likes
Re: Replace DC Fuse Panel Reply #11 – March 19, 2025, 01:39:31 pm I've never used ferrules, anywhere. I'm a little gun shy with them given both AM Solar (when they were in business) and Victron recommend against them. I spoke with Garret at AM Solar when they were in business, and he was particularly adamant against using them having seen ruined solar charge controllers and Multiplus inverters that used them. Per him, they were more prone to loosening than bare wire when used in Victron equipment - especially in moving installations, i.e. vehicles, trailers, RV's and boats.They certainly look nice and make for a very tidy install. And, the Victron and DIYSolar forums are filled with many people claiming they work just fine. Nate over at Explorist.life is a fan, and he seems well respected. From what little I've read on them, the most critical parts are making sure the ferrule is the proper type and size for the compression fitting (square, hex etc.) and like anything with wire, have a proper crimp from a high quality tool.Again, I'm no authority - but given the debate I've seen, it's probably wise to do one's own research before use. 1 Likes
Re: Replace DC Fuse Panel Reply #12 – March 19, 2025, 10:07:29 pm I suspect the ferrule crimper tool has a lot to do with it. At my last job, I had the opportunity to test a $20 Chinese crimper vs a $350 model from Phoenix Contact. With the cheap one, it was virtually impossible to tell when the ferrule was sufficiently squished, and in every case I was able to easily pull the connector off. With the good one, there was very obvious positive feedback when the ferrule was crimped (ratcheting mechanism), and it was impossible to pull the connector off afterwards.Not sure I could justify that expense for a one-time job, but if I were looking for somebody to do the work I'd be very interested in what kind of crimper they were using.Steve 1 Likes
Re: Replace DC Fuse Panel Reply #13 – March 20, 2025, 06:37:52 am I think I paid about $75 for a used Phoenix Contact 1212034 "Crimpfox 6" model crimper. It appears new units at Mouser and Digi-Key run from $145 to $185. I use mine on enough projects that it was worth it to me to pay $75. As Joan said: "Your mileage may vary."I tug pretty hard on the wire-connector joint after crimping, and have yet to have one pull out.I've used a range of connectors and have several decent crimpers. All are the ratcheting type. Ferrules are one option among several to terminate stranded wire, and I've installed them all well and poorly!Mark H.
Re: Replace DC Fuse Panel Reply #14 – March 21, 2025, 03:19:25 pm Quote from: l1v3fr33ord13 - March 20, 2025, 06:37:52 amI think I paid about $75 for a used Phoenix Contact 1212034 "Crimpfox 6" model crimper. It appears new units at Mouser and Digi-Key run from $145 to $185. I use mine on enough projects.Eleven years ago, we had a discussion that included using ferrules. I bought a tray and tried them but had similar issues with the ferrules compressing and loosening. I feel the problem is not having the right tool to fully compress the ferrules completely.In retrospect, the use of ring terminals seems to be the best approach.FYI, I have never seen ferrules used in off-road. equipment, boats or high-performance vehicles, crimped ring terminals are considered the best for high vibration levels applications, such as motorhomes. When I took Jetway Tech training many years ago, we were told to always use crimped ring terminals and to never solder any connections, solder joints can fail under high-vibration conditions.Larry 1 Likes
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