Victron energy Orion-Tr User manual

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Orion DC-DC Smart Charger Non-Isolated

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1. General Description
The Orion Smart DC-DC chargers are specially developed DC-
DC converters for controlled charging or fixed output mode. In
charger mode the three-state charge algorithm will increase
battery life by properly charging the battery. Especially in the case
of vehicles with an alternator smart control, 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).
To ensure that the starter battery of the vehicle is always loaded
with priority, the Orion Smart DC-DC charger will 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, install a
separate motor run sensor or 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 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
lower emissions. Smart alternators deliver a variable output and
are shut off when they’re not needed. The converter has a unique
engine running detection in order to be able to detect a running
vehicle engine. This prevents the converter from discharging the
starter battery if the alternator does not supply power. See
chapter “5. Smart alternator compatibility” for more details.
Configurable with Victron Connect.
Separation of the starter battery and the service battery
The Orion DC-DC Smart Charger non-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 DC-DC Smart Charger Non-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
automatically increased to make sure that the battery is

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completely recharged. For lithium batteries absorption time is
fixed, typically 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 below re-bulk voltage, due to a high load, 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
continuous 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 device
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.

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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 multistrand 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 DC-DC converter 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 VictronConnect 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) Connection between “VE.BMS charge disconnect” and H-pin
d) 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) H-pin wiring BMS
d) L-pin wiring
Figure 3: Remote on/off connections

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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.
4.6 Cable and fuse recommendations
Figure 5: Cable and fuse recommendations
Only an ignition switch
BMS
Figure 4: Engine Detection Override connection diagram

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Minimum cable gauge
Voltage
rating
(Input or
output)
External
battery
protection
Fuse
0.5m 1m 2m 5m 10m
12V
60A
6mm2
10mm2
10mm2
16mm2
16mm2
24V
30A
4mm2
6mm2
6mm2
10mm2
10mm2
4.7 Recommended torque
Figure 6 Tightening torques

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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 LEDs will change its state to warn what the Orion Smart is
doing at the moment. There are two LEDs, 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 Blinking once every 5 seconds:
oCharger off due to non-error conditions as:
Remote shutdown;
Shutdown by the user;
User defined under voltage lock-out;
Engine off detected (when in Charger mode);
•LED on:
oAll other conditions;

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7. Specifications
Orion-Tr Smart Charger
non-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
+/- 20mV
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%
No load input current
< 80mA
< 100mA
Standby current
< 1mA
< 1mA
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
16 mm² 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.

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Specifications - continuation
Orion-Tr Smart Charger
non-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
+/- 20mV
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%
No load input current
< 100mA
< 80mA
Standby current
< 1mA
< 1mA
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
16 mm² 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.

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1. Algemene beschrijving
Orion Smart DC-DC-acculaders zijn speciaal ontwikkelde DC-DC-
omvormers voor het gecontroleerd opladen of vaste
uitgangsmodus. In de laadmodus zal het driefasen-laadalgoritme
de levensduur van de accu verlengen door de accu op de juiste
manier op te laden. Vooral in het geval van voertuigen met een
slimme dynamo of een spanningsval als gevolg van lange kabels,
is gecontroleerd laden essentieel. Gecontroleerd laden
beschermt tevens de dynamo in lithiumsystemen waarin direct
laden de dynamo kan overbelasten vanwege de lage impedantie
van de lithiumaccu. In vaste uitgangsmodus blijft de
uitgangsspanning stabiel onafhankelijk van de toegepaste
belasting of variërende ingangsspanning (binnen het opgegeven
bereik).
Om ervoor te zorgen dat de startaccu van het voertuig altijd eerst
wordt geladen, levert de Orion Smart DC-DC-acculader alleen
stroom wanneer de motor draait. Dit is mogelijk dankzij het
ingebouwde mechanisme om de activiteit van de motor te
detecteren. Hiermee wordt ook voorkomen dat de spanning aan
boord van het voertuig te laag wordt. Het is niet nodig om in te
grijpen in het systeem van het voertuig, een afzonderlijke sensor
voor de detectie van de activiteit van de motor te installeren of in
te grijpen in het CAN bussysteem. Afgezien van deze detectie
kan de Orion Smart DC-DC-acculader ook worden geactiveerd
door een oplaadfunctie die bijvoorbeeld is aangesloten op de
contactschakelaar.
De Orion Smart DC-DC-acculader is volledig programmeerbaar
met de VictronConnect app.
Ontdek hier alle instelmogelijkheden:
https://www.victronenergy.com/live/victronconnect:start

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2. Kenmerken
Slimme dynamocompatibiliteit
Voertuigfabrikanten introduceren nu slimme ECU (Engine
Control Unit)- gestuurde wisselstroomdynamo's om het
brandstofverbruik en de uitstoot te verlagen. Slimme dynamo's
leveren een variabele uitvoer en worden uitgeschakeld wanneer
ze niet nodig zijn. De omvormer heeft een uniek mechanisme
voor de detectie van motoractiviteit om een draaiende
voertuigmotor te kunnen detecteren. Hierdoor wordt voorkomen
dat de omvormer de startaccu ontlaadt als de dynamo geen
stroom levert. Zie hoofdstuk 5. "Slimme dynamocompatibiliteit”
voor meer informatie.
Configureerbaar met Victron Connect.
Scheiding van de startaccu en de serviceaccu
Orion DC-DC Smart Charger Non-Isolated scheidt de startaccu
van de serviceaccu wanneer de motor niet draait.
Uitgebreide elektronische bescherming
Bescherming tegen te hoge temperatuur en vermogensreductie
wanneer de temperatuur hoog is.
Beschermd tegen overbelasting.
Beschermd tegen kortsluiting.
Beschermd tegen te hoge temperaturen.
Adaptief opladen in drie stappen
De Orion DC-DC Smart Charger Non-Isolated is geconfigureerd
voor een laadproces in drie stappen: Bulk — Absorptie —
Druppel.
Bulk
Tijdens deze fase levert de regelaar zoveel mogelijk laadstroom
om de accu's snel op te laden.
Absorptie
Wanneer de accuspanning de ingestelde absorptiespanning
bereikt, schakelt de regelaar over naar de constante
spanningsmodus. Voor loodzuuraccu's is het belangrijk dat