Victron energy Orion-Tr Smart Series User manual

Manual
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Handleiding
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Manuel
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Anleitung
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Manual
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Användarhandbok
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Orion-Tr Smart Charger Isolated

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1. General Description
The Orion Smart DC-DC chargers 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 Smart DC-DC charger 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 Smart DC-DC
charger 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 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 Isolated DC-DC charger 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 Isolated DC-DC charger 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
automatically increased to make sure that the battery is

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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.
Remote on-off
Use the remote function to enable and disable the converter

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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 Smart DC-DC charger 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

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4.4 Connection remote on-off
The recommended use of the remote on-off is:
a) A switch wired between the L-H pins (On-level impedance
between L-H pins: <500kΩ)
b) A switch wired between (input/starter) battery plus and H-pin
(on level: >3V)
c) A switch between the L-pin and (input/starter) ground (on level:
<5V)
Note: Voltage tolerance L & H pin: +/- 70VDC
a) L-H pin wiring
b) H-pin wiring
c) L-pin wiring
Figure 3: Remote on/off connections
4.5 Engine detection override
Applying >7V to the L-pin of the remote on/off circuit activates the
“engine detection override” function. The charger is on as long as
the “engine detection override” is active. With this function an
external control (e.g. ignition switch, CAN bus engine on detector)
can determine if charging is allowed.
The remote on/off function also needs to be activated so option a)
or b) in figure 3 must also be connected. See examples in figure 4
below.

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Only an ignition switch
BMS
Figure 4: Engine Detection Override connection diagram
4.6 Cable and fuse recommendations
Figure 5: Cable and fuse recommendations
Minimum cable gauge
Voltage rating
(input or output)
External battery
Protection Fuse
1m 2m 5m
12V
60A
10mm2
10mm2
16mm2
24V
30A
6mm2
6mm2
10mm2

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4.7 Recommended torque
Figure 6

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5. Smart alternator compatibility
The engine is running detection is based on the voltage of the
starter battery. The charger is not always able to measure the
exact starter battery voltage because of voltage drop over the
input cable. The voltage drop is determined by variables like
current, cable length and cable gauge. The “engine on detection
sequence” (see figure 7) will perform periodic tests to determine
the exact starter battery voltage during charging. The test result
determines if the engine is running and charging can be enabled.
This feature is only active in charger mode and when “engine
detection override” is not activated. In converter mode the “input
voltage lock-out” determines when the output is active.
Configurable with VictronConnect
Figure 7: Engine on detection sequence

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0 1:
When the engine runs the alternator voltage will ramp-up, when
Vstarter increases above Venable, charging starts.
1 2:
Due to the charge current a voltage drop will occur across the
input cable (Vcable), this voltage reduces the voltage at the input of
the charger (VIN). While VIN remains above Vtest, charging is
enabled.
2 3:
If VIN drops below Vtest, the “engine on detection sequence” is
started. Every 2 minutes the charger is paused for 10 seconds to
measure the voltage. Without current flow VIN is equal to Vstarter, if
VIN is above Vtest, charging will resume. While remaining in this
state, the test is performed every 2 minutes.
3 4:
During the detection sequence VIN dropped below Vtest, this
means that the engine stopped running and charging must be
stopped, the charge sequence is paused.
4 5:
VIN increases above Venable, the charge sequences continues.

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6. LED stated
The blue LED is dedicated to Bluetooth functionality and the
green LED to product state.
Status LED (Green LED)
•LED off:
oNo input voltage;
oRemote shutdown;
oShutdown by the user;
oConnector over-temperature protection
oUser defined under voltage lock-out
oEngine off detected (when in Charger mode)
•LED on:
oOutput active on DC/DC Converter Mode;
oCharger in Float State (Battery charged);
•LED Blinking at 1.25Hz:
oCharger in Bulk or Absorption State (Battery is being
charged);
BLE LED (Blue LED)
•LED off:
oNo input voltage;
•LED Blinking at 0.33 Hz:
oError – needs to be checked on VictronConnect;
•LED Blinking at 1.25 Hz:
oConnected via Bluetooth;
•LED Blinking at 2.5 Hz:
oIdentify;
•LED on:
oAll other conditions;

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7. Specifications
Orion-Tr Smart Charger
Isolated 220-280 Watt
12/12-18 (220W) 12/24-10 (240W)
Input voltage range (1)
8-17V
8-17V
Under voltage shut down
7V
7V
Under voltage restart
7,5V
7,5V
Nominal output voltage
12,2V
24,2V
Output voltage adjust range
10-15V
20-30V
Output voltage tolerance
+/- 0,2V
Output noise
2mV rms
Cont. output current at nominal
output voltage and 40°C
18A 10A
Maximum output current (10 s)
at nominal output voltage
25A 15A
Short circuit output current
40A
25A
Cont. output power at 25°C
280W
280W
Cont. output power at 40°C
220W
240W
Efficiency
87%
88%
Off load current
< 80mA
< 100mA
Galvanic isolation
200V dc between input, output and case
Operating temperature range
-20 to +55°C (derate 3% per °C above 40°C)
Humidity
Max. 95% non-condensing
DC connection
Screw terminals
Maximum cable cross-section
16mm² AWG6
Weight
1,3 kg (3 lb)
Dimensions hxwxd
130 x 186 x 70 mm (5.1 x 7.3 x 2.8 inch)
Standards: Safety
Emission
Immunity
Automotive Directive
EN 60950
EN 61000-6-3, EN 55014-1
EN 61000-6-2, EN 61000-6-1, EN 55014-2
ECE R10-5

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Specifications - continuation
Orion-Tr Smart Charger
Isolated 220 – 280 Watt
24/12-20
(240W)
24/24-12
(280W)
Input voltage range (1)
16-35V
16-35V
Under voltage shut down
14V
14V
Under voltage restart
15V
15V
Nominal output voltage
12,2V
24,2V
Output voltage adjust range
10-15V
20-30V
Output voltage tolerance
+/- 0,2V
Output noise
2mV rms
Cont. output current at nominal
output voltage and 40°C
20A 12A
Maximum output current (10 s)
at nominal output voltage
25A 15A
Short circuit output current
50A
30A
Cont. output power at 25°C
300W
320W
Cont. output power at 40°C
240W
280W
Efficiency
88%
89%
Off load current
< 100mA
< 80mA
Galvanic isolation
200V dc between input, output and case
Operating temperature range
-20 to +55°C (derate 3% per °C above 40°C)
Humidity
Max. 95% non-condensing
DC connection
Screw terminals
Maximum cable cross-section
16mm² AWG6
Weight
1,3 kg (3 lb)
Dimensions hxwxd
130 x 186 x 70 mm (5.1 x 7.3 x 2.8 inch)
Standards: Safety
Emission
Immunity
Automotive Directive
EN 60950
EN 61000-6-3, EN 55014-1
EN 61000-6-2, EN 61000-6-1, EN 55014-2
ECE R10-5

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Specifications - continuation
Orion-Tr Smart Charger
Isolated 360 – 400 Watt
12/12-30
(360W)
12/24-15
(360W)
Input voltage range (1)
10-17V
10-17V
Under voltage shut down
7V
7V
Under voltage restart
7,5V
7,5V
Nominal output voltage
12,2V
24,2V
Output voltage adjust range
10-15V
20-30V
Output voltage tolerance
+/- 0,2V
Output noise
2mV rms
Cont. output current at nominal
output voltage and 40°C
30A 15A
Maximum output current (10 s)
at nominal output voltage
40A 25A
Short circuit output current
60A
40A
Cont. output power at 25°C
430W
430W
Cont. output power at 40°C
360W
360W
Efficiency
87%
88%
Off load current
< 80mA
< 100mA
Galvanic isolation
200V dc between input, output and case
Operating temperature range
-20 to +55°C (derate 3% per °C above 40°C)
Humidity
Max. 95% non-condensing
DC connection
Screw terminals
Maximum cable cross-section
16mm² AWG6
Weight
12V input and/or 12V output models: 1,8 kg (3 lb)
Other models: 1,6 kg (3.5 lb)
Dimensions hxwxd
12V input and/or 12V output models:
130 x 186 x 80 mm (5.1 x 7.3 x 3.2 inch)
Other models: 130 x 186 x 70 mm
(5.1 x 7.3 x 2.8 inch)
Standards: Safety
Emission
Immunity
Automotive Directive
EN 60950
EN 61000-6-3, EN 55014-1
EN 61000-6-2, EN 61000-6-1, EN 55014-2
ECE R10-5
1) If set to nominal or lower than nominal, the output voltage will remain stable within the specified
input voltage range (buck-boost function).
If the output voltage is set higher than nominal by a certain percentage, the minimum input
voltage at which the output voltage remains stable (does not decrease) increases by the same
percentage.
Note 1) The VictronConnect App will not display current in or current out.
Note 2) The Orion-Tr Smart is not equipped with a VE.Direct port.

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Specifications - continuation
Orion-Tr Smart Charger
Isolated 360 – 400 Watt
24/12-30
(360W)
24/24-17
(400W)
Input voltage range (1)
20-35V
20-35V
Under voltage shut down
14V
14V
Under voltage restart
15V
15V
Nominal output voltage
12,2V
24,2V
Output voltage adjust range
10-15V
20-30V
Output voltage tolerance
+/- 0,2V
Output noise
2mV rms
Cont. output current at nominal
output voltage and 40°C
30A 17A
Maximum output current (10 s)
at nominal output voltage
45A 25A
Short circuit output current
60A
40A
Cont. output power at 25°C
430W
480W
Cont. output power at 40°C
360W
400W
Efficiency
88%
89%
Off load current
< 100mA
< 80mA
Galvanic isolation
200V dc between input, output and case
Operating temperature range
-20 to +55°C (derate 3% per °C above 40°C)
Humidity
Max. 95% non-condensing
DC connection
Screw terminals
Maximum cable cross-section
16mm² AWG6
Weight
12V input and/or 12V output models: 1,8 kg (3 lb)
Other models: 1,6 kg (3.5 lb)
Dimensions hxwxd
12V input and/or 12V output models:
130 x 186 x 80 mm (5.1 x 7.3 x 3.2 inch)
Other models: 130 x 186 x 70 mm
(5.1 x 7.3 x 2.8 inch)
Standards: Safety
Emission
Immunity
Automotive Directive
EN 60950
EN 61000-6-3, EN 55014-1
EN 61000-6-2, EN 61000-6-1, EN 55014-2
ECE R10-5
1) If set to nominal or lower than nominal, the output voltage will remain stable within the specified
input voltage range (buck-boost function).
If the output voltage is set higher than nominal by a certain percentage, the minimum input
voltage at which the output voltage remains stable (does not decrease) increases by the same
percentage.
Note 1) The VictronConnect App will not display current in or current out.
Note 2) The Orion-Tr Smart is not equipped with a VE.Direct port.