Victron energy Orion User manual

Manual
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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