Victron energy Orion-Tr Smart 12/12-18 User manual

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Orion-Tr Smart DC-DC Charger Isolated

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1. General Description
The Orion-Tr Smart DC-DC Charger Isolated can be used as a
power supply or as a battery charger. In charger mode the three-
state charge algorithm will increase battery life by properly
charging the battery. Especially in the case of vehicles with a
smart alternator, or voltage drop caused by long cable runs,
controlled charging is indispensable. Controlled charging will also
protect the alternator in lithium systems where direct charging can
overload the alternator due to the low impedance of the lithium
battery. In fixed output mode the output voltage will remain stable
independent of the applied load or varying input voltage (within
the specified range).
The Orion-Tr Smart DC-DC Charger Isolated can be set up to
only provide power when the engine is running. This is possible
thanks to the built-in engine shutdown detection. This also
prevents the onboard voltage of the vehicle from becoming too
low. It is not necessary to intervene in the system of the vehicle,
to install a separate motor run sensor or to intervene in the CAN-
bus system. Apart from this detection, the Orion-Tr Smart DC-DC
Charger Isolated can also be activated by a forced allowed to
charge feature, e.g. connected to the ignition switch.
The Orion-Tr Smart DC-DC Charger Isolated is fully
programmable with the VictronConnect app.
Discover all setup possibilities here:
https://www.victronenergy.com/live/victronconnect:start

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2. Features
Smart alternator compatibility
Vehicle manufacturers are now introducing smart ECU (Engine
Control Unit) controlled alternators to increase fuel efficiency and
reduce emissions. Smart alternators deliver a variable output
voltage and are shut down when they’re not needed. The
converter has a engine running detection mechanism. This
prevents the converter from discharging the starter battery when
the alternator does not supply power. See section 5 of this
manual for more details.
Separation of the starter battery and the service battery
The Orion-Tr Smart DC-DC Charger Isolated separates the
starter battery from the service battery when the engine is not
running.
Extensive electronic protection
Over-temperature protection and power derating when
temperature is high.
Overload protected.
Short circuit protected.
Connector over-temperature protection.
Adaptive three step charging
The Orion-Tr Smart DC-DC Charger Isolated is configured for a
three-step charging process:
Bulk – Absorption – Float.
Bulk
During this stage the controller delivers as much charge current
as possible to rapidly recharge the batteries.
Absorption
When the battery voltage reaches the absorption voltage setting,
the controller switches to constant voltage mode. For lead acid
batteries it is important that during shallow discharges the
absorption time is kept short in order to prevent overcharging of
the battery. After a deep discharge the absorption time is

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automatically increased to make sure that the battery is
completely recharged. For lithium batteries absorption time is
fixed, default 2 hours. The fixed or adaptive mode can be chosen
on the battery settings.
Float
During this stage, float voltage is applied to the battery to
maintain it in a fully charged state. When the battery voltage
drops substantially below this level, due to a high load for
example, during at least 1 minute, a new charge cycle will be
triggered.
Flexible charge algorithm
Programmable charge algorithm, and eight preprogrammed
battery settings.
Configurable with VictronConnect.
Adaptive absorption time
Automatically calculates the proper absorption time.
Configurable with Victron Connect.
Configuring and monitoring
Bluetooth Smart built-in: the wireless solution to set-up, monitor
and update the controller using Apple and Android smartphones,
tablets or other devices.
Several parameters can be customized with the VictronConnect
app.
The VictronConnect app can be downloaded from:
http://www.victronenergy.nl/support-and-downloads/software/
Use the manual – VictronConnect - to get the most out of the
VictronConnect App when it’s connected to an Orion Smart:
https://www.victronenergy.com/live/victronconnect:start
Input voltage lock-out
Shutdown if the input voltage drops below the lock-out value and
restart when the input voltage increases above the restart value.
Configurable with Victron Connect.

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Remote on-off
Use the remote function to enable and disable the converter
remotely with the remote on/off connector or using the
VictronConnect app. Typical use cases include a user operated
hard wired switch and automatic control by for example a Battery
Management System. If the minus of the service battery is not at
the same potential as the minus of the alternator or starter battery
an isolated remote on/off cable between the BMS and the on/off
port is required, see chapter 4.4 for details.

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3. Safety instructions
SAVE THESE INSTRUCTIONS – This manual contains
important instructions that shall be followed during
installation and maintenance.
•Please read this manual carefully before the product is installed
and put into use.
•Install the product in a heatproof environment. Ensure therefore
that there are no chemicals, plastic parts, curtains or other
textiles, etc. in the immediate vicinity of the equipment.
•It is normal for the Orion-Tr Smart DC-DC Charger Isolated to
get hot during operation, keep any objects that are heat-
sensitive away.
•Ensure that the equipment is used under the correct operating
conditions. Never operate it in a wet environment.
•Never use the product at sites where gas or dust explosions
could occur.
•Always provide proper ventilation during charging.
•Avoid covering the charger.
•Refer to the specifications provided by the manufacturer of the
battery to ensure that the battery is suitable for use with this
product. The battery manufacturer's safety instructions should
always be observed.
•In addition to this manual, the system operation or service
manual must include a battery maintenance manual applicable
to the type of batteries used.
•Never place the charger on top of the battery when charging.
•Prevent sparks close to the battery. A battery being charged
could emit explosive gasses.
Danger of explosion from sparking
Danger of electric shock

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•This device is not to be used by persons (including children)
with reduced physical, sensory or mental capabilities, or lack of
experience and knowledge, unless they have been given
supervision or instruction.
•Use flexible multistranded copper cable for the connections.
The maximum diameter of the individual strands is
0,4mm/0,125mm² (0.016 inch/AWG26).
•The installation must include a fuse in accordance with the
recommendations in the table ”CABLE AND FUSE
RECOMMENDATIONS”.

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4. Installation
4.1 General
•Mount vertically on a non-flammable surface, with the power
terminals facing downwards. Observe a minimum clearance of
10 cm under and above the product for optimal cooling.
•Mount close to the battery, but never directly above the battery
(in order to prevent damage due to gassing of the battery).
4.2 Connection setup for power supply mode
1. Disconnect the remote on/off (remove wire bridge).
2. Connect the input supply cables.
3. Open the VictronConnect App to setup the product.
(always adjust the output voltage before connecting in
parallel or connecting a battery)
4. Connect the load. The converter is now ready for use.
5. Reconnect the remote on/off to activate the product.
Figure 1: Typical connection setup as DC-DC converter

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4.3 Connection setup for charger mode
1. Disconnect the remote on/off (remove wire bridge).
2. Connect the input supply cables.
3. Open the Victron Connect App to setup the product.
(always setup the correct charger algorithm before
connecting a battery)
4. Connect the battery to be charged.
5. Reconnect the remote on/off to activate the product.
Figure 2: Typical connection setup as charger