Victron Energy Orion-Tr Smart DC-DC Charger Isolated
The Orion-Tr Smart DC-DC Charger can function as a power supply or a battery charger. In charger mode, its three-state charge algorithm enhances battery lifespan. This is particularly beneficial for vehicles with smart alternators or where voltage drops occur over long cable runs, making controlled charging essential. Controlled charging also safeguards the alternator in lithium systems, preventing overload due to the battery's low impedance. In fixed output mode, the output voltage remains stable regardless of the load or input voltage variations within the specified range.
The Orion-Tr Smart DC-DC Charger features an engine shutdown detection mechanism, allowing it to operate only when the engine is running. This prevents the starter battery from discharging when the alternator is not active and avoids excessively low onboard vehicle voltage. This functionality eliminates the need for separate motor run sensors or CAN-bus system interventions. Additionally, the charger can be activated via a forced allowed-to-charge feature, such as connection to the ignition switch.
The Orion-Tr Smart DC-DC Charger is fully programmable using the VictronConnect App. Detailed setup options are available in the VictronConnect manual.
2. Features
Smart alternator compatibility
Modern vehicle manufacturers utilize smart ECU-controlled alternators to improve fuel efficiency and reduce emissions. These alternators provide variable output voltage and can shut down when not required. The Orion-Tr Smart DC-DC Charger incorporates an engine running detection mechanism to prevent the starter battery from discharging when the alternator is inactive. Refer to section 5 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 at high temperatures.
- Overload protected.
- Short circuit protected.
- Connector over-temperature protection.
Adaptive three-step charging
The Orion-Tr Smart DC-DC Charger Isolated supports a three-step charging process: Bulk - Absorption – Float.
- Bulk: The controller delivers maximum charge current to rapidly recharge batteries.
- Absorption: When battery voltage reaches the absorption voltage setting, the controller switches to constant voltage mode. For lead-acid batteries, maintaining a short absorption time during shallow discharges prevents overcharging. After a deep discharge, the absorption time is automatically extended for a complete recharge. For lithium batteries, the absorption time is fixed at 2 hours by default. This can be set to fixed or adaptive mode in the battery settings.
- Float: A float voltage is applied to maintain the battery in a fully charged state. If the battery voltage drops significantly below this level for more than one minute due to a high load, a new charge cycle is triggered.
Flexible charge algorithm
The charge algorithm is programmable, with eight preprogrammed battery settings configurable via VictronConnect.
Adaptive absorption time
Automatically calculates the optimal absorption time, configurable via VictronConnect.
Configuring and monitoring
Built-in Bluetooth Smart allows wireless setup, monitoring, and firmware updates using smartphones and tablets. Parameters can be customized via the VictronConnect App. Download the app from: https://www.victronenergy.com/support-and-downloads/software. For detailed usage, refer to the VictronConnect manual.
Input voltage lock-out
The output shuts down if the input voltage drops below a configurable lock-out value and restarts when it rises above a restart value. Configurable via VictronConnect.
Remote on-off
The remote function allows enabling and disabling the converter remotely via the remote on/off connector or the VictronConnect App. This is useful for manual switches or automatic control by a Battery Management System.
3. Safety Instructions
SAVE THESE INSTRUCTIONS - This manual contains important instructions for installation and maintenance.
Danger of explosion from sparking
Danger of electric shock
- Read this manual carefully before installation and use.
- Install the product in a heatproof environment, away from chemicals, plastic parts, curtains, or other textiles.
- The Orion Smart DC-DC charger may get hot during operation; keep heat-sensitive objects away.
- Ensure the equipment is used under correct operating conditions. Never operate in a wet environment.
- Do not use the product in environments where gas or dust explosions could occur.
- Ensure proper ventilation during charging.
- Avoid covering the charger.
- Refer to the battery manufacturer's specifications to ensure battery compatibility and always observe their safety instructions.
- 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 near the battery, as batteries can emit explosive gases during charging.
- This device is not intended for use 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 connections. The maximum diameter of individual strands is 0.4mm / 0.125mm² (0.016 inch/AWG26).
- The installation must include a fuse as per the recommendations in the table "CABLE AND FUSE RECOMMENDATIONS".
4. Installation
4.1. General
- Mount vertically on a non-flammable surface with power terminals facing downwards. Maintain a minimum clearance of 10 cm above and below the product for optimal cooling.
- Mount close to the battery, but not directly above it, to prevent damage from battery gassing.
4.2. Connection setup for DC-DC converter mode
- Disconnect the remote on/off (remove wire bridge).
- Connect the input supply cables.
- Open the VictronConnect App to set up the product. Always adjust the output voltage before connecting in parallel or connecting a battery.
- Connect the load. The converter is now ready for use.
- Reconnect the remote on/off to activate the product.
Figure 1: Typical connection setup as DC-DC converter
4.3. Connection setup for charger mode
- Disconnect the remote on/off (remove wire bridge).
- Connect the input supply cables.
- Open the VictronConnect App to set up the product. Always set up the correct charger algorithm before connecting a battery.
- Connect the battery to be charged.
- Reconnect the remote on/off to activate the product.
Figure 2: Typical connection setup as charger
4.4. Connection remote on-off
The recommended remote on-off connections are:
- a) A switch wired between the L-H pins (On-level impedance between L-H pins: < 500kΩ)
- b) A switch wired between the (input/starter) battery plus and the H-pin (on level: > 3V)
- c) A switch between the L-pin and (input/starter) ground (on level: < 5V)
- d) Isolated remote on-off cable, e.g., controlled by a small BMS.
Voltage tolerance L & H pin: +/- 70VDC
Figure 3: Remote on/off connections
4.5. Engine shutdown detection override
In charger mode, the "engine shutdown detection sequence" determines if conditions are met to enable charging (see chapter 5). The "engine shutdown detection override" forces the charger to allow charging independently of the engine shutdown detection. Engine shutdown detection override is activated by applying >7V to the remote L-pin. This allows external control (e.g., ignition switch, CAN bus engine on detector) to enable charging.
Note: This function does not override the remote on-off function. Remote connection a), b) or d), as shown in Figure 3, must be configured in combination with engine shutdown detection override. See examples in figure 4.
Figure 4: Engine shutdown detection override connection diagram
If the ignition switch in Figure 4 is switched off, the charger will return to "engine shutdown detection" mode; it will not turn off the charger.
To force enable/disable charging (i.e., turn the ORION on/off) without the "engine shutdown detection", a remote option as given in chapter 4.4 must be wired, and the engine shutdown detection must be switched off in VictronConnect (see figure 5).
Figure 5: Disable engine shutdown detection
When engine shutdown detection is switched off in Victron Connect ('forced charging'), current will be drawn from the starter battery even if the engine is not running. During 'forced charging', the input voltage lock-out is the only remaining limit for automatic charging disablement. Ensure this level is not set too low; 12.5V is sufficient in most applications.
4.6. Cable and fuse recommendations
Figure 6: Cable and fuse recommendations
| Voltage rating (Input or output) | External battery protection Fuse | Minimum cable gauge | ||||
|---|---|---|---|---|---|---|
| 0.5m | 1m | 2m | 5m | 10m | ||
| 12 V | 60 A | 6mm² | 10mm² | 10mm² | 16mm² | 16mm² |
| 24 V | 30 A | 4mm² | 6mm² | 6mm² | 10mm² | 10mm² |
4.7. Recommended torque
Figure 7: Tightening torques
Torque: 1.6Nm
5. Engine shutdown detection
The engine shutdown detection mechanism allows the ORION-Tr DC-DC Charger system to detect if the engine is running without requiring additional switches or sensors. The factory default settings are compatible with most regular and smart alternators but can be reconfigured using the VictronConnect App.
Configuring engine shutdown detection depends on the alternator's voltage output when the engine is running. Regular alternators provide a fixed voltage (e.g., 14V), while smart alternators offer a variable output voltage ranging from 12.5V to 15V. Smart alternators in regenerative braking systems exhibit significant voltage variations.
Engine shutdown detection is active only in charger mode. It can be disabled via "engine shutdown detection override" or within VictronConnect (as shown in figure 5). In power supply mode, the "input voltage lock-out" determines output activity.
Note: This feature is updated from software version v1.05 onwards.
5.1. Engine shutdown detection sequence
Figure 8: Engine shutdown detection sequence
0 → 1: Engine runs, alternator voltage ramps up. Charging is enabled when Vstarter > Vstart.
1 → 2: Input current creates a voltage drop across the input cable (Vcable), reducing the voltage measured by the charger (VIN). If VIN > Vshutdown, the charger operates at Imax.
2 → 3: If VIN ≤ Vshutdown, charge current is reduced to prevent VIN from dropping below Vshutdown.
3 → 4: If VIN < Vshutdown for longer than 1 minute (tshutdown), "engine off" is detected, and charging is disabled. If VIN > Vshutdown before tshutdown expires, charging remains enabled.
4 → 5: Charging is enabled after tstart delay (configurable) if Vstart(delay) < VIN < Vstart.
5.2. Engine shutdown detection setup with VictronConnect
Open VictronConnect and press the Cog symbol ⚙️ to access settings.
Figure 9: Engine shutdown detection setup menu
The following settings can be adjusted with VictronConnect:
- Engine shutdown detection enabled: This is enabled by default in charger mode. If disabled by the user or when in power supply mode, the engine is considered running, and no shutdown detection occurs.
- Alternator type: Select between "Smart Alternator", "Regular Alternator", or "User defined". Default is "Smart Alternator". The "User defined" option is selected if any setting deviates from the defaults for the other two.
- Start voltage (Vstart): Charging begins immediately at this level. Default: 14V.
- Delayed start voltage (Vstart(delay)): Smart alternators can produce lower voltages when the engine is running. A lower start level is necessary for these systems. To ensure the starter battery is recharged after starting, charging of the auxiliary battery is delayed under these conditions. The energy used during starting must be replenished to keep the starter battery charged. Default: 13.3V (Smart Alternator), 13.8V (Regular Alternator).
- Delayed start voltage delay (tstart delay): Recharge time for the starter battery during the delayed start level. Example: If the starter draws 150A for 5 seconds, approximately 0.2Ah is drawn from the starter battery. If the alternator only provides 20A during idling, it takes 37.5 seconds (150A / 20A * 5s) to recharge the starter battery. Default: 2 minutes.
- Shutdown voltage (Vshutdown): This level indicates the engine is off. It maintains the starter battery's charge and provides hysteresis relative to the start level. The hysteresis must be large enough to prevent VIN from dropping to Vshutdown, which would reduce charge current. Actions are taken after tshutdown (1 minute) expires, allowing charging during temporary low voltage conditions. Default: 13.1V (Smart Alternator), 13.5V (Regular Alternator).
- Range for engine start/shutdown levels:
- 12|12; 12|24: 8V to 17V
- 24|12; 24|24: 16V to 35V
- Setup input voltage lock-out: This is the minimum level at which charging is permitted; charging stops below this level. Default (charger mode): lock-out: 12.5V / restart: 12.8V. Default (power supply mode): lock-out: 10.5V / restart: 12V.
Important considerations for input voltage lock-out:
- When 'forced charging' is enabled, current is drawn from the starter battery even if the engine is not running. Setting the lock-out level too low can deplete the starter battery.
- Minimum alternator voltage: Smart alternators can operate at very low voltages (e.g., <12.5V) during vehicle acceleration. This low voltage is permissible during tshutdown (as shown in "engine shutdown detection sequence 3→4"). If charging must remain enabled during this period, the lock-out level must be set below the minimum alternator voltage.
If the low voltage period exceeds tshutdown, charging will be disabled based on engine shutdown detection.
- Voltage drop across the input cable: As seen in "engine shutdown detection sequence 1→3", VIN is reduced by Vcable. When the alternator voltage drops rapidly (smart alternator), the charge control needs time to reduce charge current and maintain VIN at Vshutdown. During this time, Vcable must not trigger the voltage lock-out. Therefore, the lock-out value should be: Vlock-out ≤ Vshutdown - Vcable.
Example: Calculate the input cable voltage drop:
- Distance between starter battery and charger: 5m.
- Vshutdown = 13.1V. Recommended wire gauge: 16mm².
- Cable resistance: ~1.1mΩ/m @20°C, thus Rcable = 1.1mΩ x 10m (2x 5m) = 11mΩ.
- A 12|12-30A Smart Charger will draw approximately 35A from the input at full capacity, resulting in:
- Vcable = 11mΩ x 35A = 385mV.
- Vlock-out ≤ Vshutdown - Vcable = 13.3V - 385mV ≈ 12.9V.
Cable connections, external fuses, temperature, etc., influence total cable resistance.
6. LED's
The LEDs indicate the Orion Smart's current status. The blue LED is for Bluetooth functionality, and the green LED indicates the product state.
Status LED (Green LED)
- LED off: No input voltage; Remote shutdown; Shutdown by user; Connector over-temperature protection; User-defined under voltage lock-out; Engine off detected (in Charger mode).
- LED on: Output active in Power Supply mode; Charger in Float State (Battery charged).
- LED Blinking at 1.25Hz: Charger in Bulk or Absorption State (Battery is being charged).
BLE LED (Blue LED)
- LED off: No input voltage.
- LED Blinking at 0.33 Hz: Error - check VictronConnect.
- LED Blinking at 1.25 Hz: Connected via Bluetooth.
- LED Blinking at 2.5 Hz: Identify.
- LED Blinking once every 5 seconds: Charger off due to non-error conditions (Remote shutdown; Shutdown by user; User-defined under voltage lock-out; Engine off detected in Charger mode).
- LED on: All other conditions.
7. Specifications
| Orion-Tr Smart DC-DC Charger Isolated | 12/12-18 (220W) | 12/24-10 (240W) | 24/12-20 (240W) | 24/24-12 (280W) |
|---|---|---|---|---|
| Input voltage range (1) | 8-17 V | 8-17 V | 16-35V | 16-35V |
| Under voltage shut down | 7 V | 7 V | 14V | 14V |
| Under voltage restart | 7.5 V | 7.5 V | 15V | 15V |
| Nominal output voltage | 12.2 V | 24.2 V | 12.2V | 24.2V |
| Output voltage adjust range | 10-15 V | 20-30 V | 10-15V | 20-30V |
| Output voltage tolerance | +/- 0.2 V | |||
| Output noise | 2 mV rms | |||
| Cont. output current at nominal output voltage and 40°C | 18 A | 10 A | 20 A | 12 A |
| Maximum output current (10 s) at nominal output voltage | 25 A | 15 A | 25 A | 15 A |
| Short circuit output current | 40 A | 25 A | 50 A | 30 A |
| Cont. output power at 25° C | 280 W | 280 W | 300 W | 320 W |
| Cont. output power at 40° C | 220 W | 240 W | 240 W | 280 W |
| Efficiency | 87% | 88% | 88% | 89% |
| No load input current | < 80 mA | < 100 mA | < 100 mA | < 80 mA |
| Standby current | Less than 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 | 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 | EN 60950 | |||
| Emission | EN 61000-6-3, EN 55014-1 | |||
| Immunity | EN 61000-6-2, EN 61000-6-1, EN 55014-2 | |||
| Automotive Directive | ECE R10-5 |
| Table 1. Specifications Orion-Tr Smart DC-DC Charger Isolated 360 - 400 Watt | 12/12-30 (360 W) | 12/24-15 (360 W) | 24/12-30 (360W) | 24/24-17 (400W) |
|---|---|---|---|---|
| Input voltage range (1) | 10-17 V | 10-17 V | 20-35 V | 20-35 V |
| Under voltage shut down | 7 V | 7 V | 14 V | 14 V |
| Under voltage restart | 7.5 V | 7.5 V | 15 V | 15 V |
| Nominal output voltage | 12.2 V | 24.2 V | 12.2 V | 24.2 V |
| Output voltage adjust range | 10-15 V | 20-30 V | 10-15 V | 20-30 V |
| Output voltage tolerance | +/- 0.2mV | |||
| Output noise | 2 mV rms | |||
| Cont. output current at nominal output voltage and 40°C | 30 A | 15 A | 30 A | 17 A |
| Maximum output current (10 s) at nominal output voltage | 40 A | 25 A | 45 A | 25 A |
| Short circuit output current | 60 A | 40 A | 60 A | 40 A |
| Cont. output power at 25°C | 430 W | 430 W | 430 W | 480 W |
| Cont. output power at 40°C | 360 W | 360 W | 360 W | 400 W |
| Efficiency | 87% | 88% | 88% | 89% |
| No load input current | < 80 mA | < 100 mA | < 100mA | < 80mA |
| Standby current | Less than 1 mA | |||
| Galvanic isolation | 200 V 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 | 12 V input and/or 12 V output models: 1.8 kg (3 lb) Other models: 1.6 kg (3.5 lb) | |||
| Dimensions hxwxd | 12 V input and/or 12 V 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 | EN 60950 | |||
| Emission | EN 61000-6-3, EN 55014-1 | |||
| Immunity | EN 61000-6-2, EN 61000-6-1, EN 55014-2 | |||
| Automotive Directive | 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 DC-DC Charger Isolated is not equipped with a VE.Direct port.
8. VictronConnect - Orion Smart DC-DC Charger
8.1. Introduction
Thank you for using VictronConnect. This guide helps you maximize the use of your Orion Smart DC-DC Charger. It assumes basic knowledge of the charger, as detailed in the introduction. The information provided applies to all Orion Smart DC-DC Chargers. For simplicity, references to the Orion Smart DC-DC Charger will be shortened to "Orion Smart" in this guide.
For general information on the VictronConnect App, including installation, device pairing, and firmware updates, refer to the overall VictronConnect manual. For app-related inquiries, consult the VictronConnect manual.
Note: Input and battery voltages mentioned in these instructions assume a 12V input and battery. For 24V installations, multiply the values by 2.
8.2. Live Data Information
8.2.1. Charger Mode - STATUS tab
Orion Smart [SERIAL NUMBER] confirms the connected device. A custom name can also be set.
- Mode icon indicates the Orion Smart's operating mode (Charger in this case).
- Charger State:
- Bulk: The Orion Smart delivers maximum charge current to rapidly recharge batteries. When the battery voltage reaches the Absorption voltage setting, the Orion Smart transitions to the Absorption stage.
- Absorption: The Orion Smart switches to constant voltage mode, applying a pre-set absorption voltage suitable for the battery type (see Settings below). Upon completion of the absorption time, the Orion Smart enters the Float stage.
- Float: The float voltage is applied to maintain the battery in a fully charged state. If the battery voltage drops below the Re-bulk voltage for at least one minute due to a high load, a new charge cycle is triggered.
- Input Voltage displays the voltage measured at the device's input terminals.
- Output voltage displays the voltage measured at the device's output terminals.
- When the Orion Smart is Off, it does not measure output voltage, indicated by '-'.
- Off Reason shows why the Orion Smart is disabled (appears under "Charger State" when the Orion Smart is Off).
8.2.2. Charger Mode - GRAPH tab
Orion Smart [SERIAL NUMBER] confirms the connected device. A custom name can also be set.
- Charger State Graph shows the charger's current state with a brief description.
8.2.3. Power Supply Mode
Orion Smart [SERIAL NUMBER] confirms the connected device. A custom name can also be set.
- Mode icon indicates the Orion Smart's operating mode (Power Supply in this case).
- Input Voltage displays the voltage measured at the device's input terminals.
- Output voltage displays the voltage measured at the device's output terminals.
- When the Orion Smart is Off, it does not measure output voltage, indicated by '-'.
- Off Reason shows why the Orion Smart is disabled (appears under "Power Supply Mode" when the Orion Smart is disabled).
8.3. Settings
VictronConnect allows users to change and adjust various settings for the Orion Smart. Access these settings by clicking the settings icon ⚙️ in the top right corner of the screen. The available options differ based on the selected operation mode.
8.3.1. Charger Mode
When in Charger Mode, the following settings are available:
- Function: Choose between "Charger" or "Power supply". In Charger mode, the Orion Smart follows the three-state charge algorithm. Refer to the Orion Smart manual for details on the charge algorithm.
- Battery settings: Adjust battery settings to configure absorption voltage, float voltage, and other parameters for the battery charge algorithm. Battery settings are explained in the next section.
- Input voltage lock-out: Set two thresholds: one for lock-out and one for reset. Typically, a minimum 0.5V difference (for 12V input Orion Smart) is used for better performance. This protection can be disabled by the user. For more information, consult the Orion Smart manual.
- Engine shutdown detection: Set two thresholds: one to detect engine shutdown and another to detect when the engine is running. Typically, a minimum 0.2V difference (for 12V input Orion Smart) is used for better performance. This detection can be disabled by the user. For more information, consult the Orion Smart manual.
8.3.2. Charger Mode - Battery Settings
- Charger enabled: Toggling this setting turns the Orion Smart off; batteries will not be charged.
- Charger settings - Battery preset: Select the battery type, use factory defaults, or enter custom preset values for the battery charge algorithm. Absorption voltage, Float voltage, Bulk time limit, Re-bulk voltage offset, Adaptive absorption time, and Absorption time settings are configured to preset values but can be user-defined.
- User-defined presets can be stored in the library, simplifying configuration for installers.
- Edit Presets: Custom parameters can be set, including:
- Absorption voltage: Set the absorption voltage.
- Float voltage: Set the float voltage.
- Bulk time limit: Set the maximum bulk time allowed for the charger.
- Re-bulk offset voltage: This determines the offset between the float voltage (or absorption voltage if lower) and the re-bulk voltage. The re-bulk voltage is the battery voltage threshold that triggers a new charge cycle. For example, if the charger cannot maintain battery voltage due to high load, the battery voltage will drop, and a new charge cycle will start once it falls below the re-bulk voltage.
- Absorption time: This depends on whether the Adaptive absorption time algorithm is used. If not, the charger uses a Fixed absorption time set by the user. If adaptive absorption time is enabled, the charger determines the absorption time based on the bulk elapsed time of that charge cycle. The Maximum absorption time is also set by the user.
8.3.3. Power Supply Mode
When in Power Supply Mode, the following settings are available:
- Function: Choose between "Charger" or "Power supply". In Power Supply mode, the Orion Smart maintains the set output voltage.
- Output voltage: Set the output voltage for power supply mode. Ensure the voltage is within the product's limits (10V to 15V for 12V output Orion Smart).
- Input voltage lock-out: Set two thresholds: one for lock-out and one for reset. Typically, a minimum 0.5V difference (for 12V input Orion Smart) is used for better performance. This protection can be disabled by the user. For more information, consult the Orion Smart manual.
8.4. Product Information
Access the product information screen by clicking the settings icon ⚙️ in the top right of the settings menu.
- Product: Displays the Orion Smart model.
- Serial number: Shows the unit's serial number.
- Pin code: Allows changing the pin code for enhanced security.
- Custom name: Allows renaming the product. By default, it shows a short product name "Orion Smart" plus the serial number.
- Firmware: Shows the current firmware version and allows updates.
- Bootloader: Displays the bootloader firmware version.
