Victron Energy Orion-Tr Smart DC-DC Charger Non-Isolated

1. General Description

The Orion-Tr Smart DC-DC Charger serves a dual purpose: it can function as a power supply or as a battery charger. In charger mode, its three-state charge algorithm is designed to enhance battery lifespan by ensuring proper charging. This is particularly beneficial for vehicles equipped with smart alternators or systems experiencing voltage drops due to long cable runs, where controlled charging is essential. Controlled charging also protects the alternator in lithium battery systems, preventing overload caused by the battery's low impedance. In fixed output mode, the charger maintains a stable output voltage, irrespective of load variations or input voltage fluctuations within the specified range.

The Orion-Tr Smart DC-DC Charger can be configured to provide power only when the engine is running, utilizing its built-in engine shutdown detection. This feature prevents the vehicle's onboard voltage from dropping too low and eliminates the need for external 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, offering extensive setup possibilities detailed in the VictronConnect manual.

2. Features

Smart Alternator Compatibility

Modern vehicle manufacturers are implementing smart ECU (Engine Control Unit) controlled alternators to improve fuel efficiency and reduce emissions. These alternators provide variable output voltage and can shut down when not needed. The Orion-Tr Smart DC-DC Charger incorporates an engine running detection mechanism to prevent it from discharging the starter battery when the alternator is not supplying power. Refer to Chapter 5 for more details.

Separation of Starter and Service Batteries

The Orion-Tr Smart DC-DC Charger Non-Isolated effectively isolates the starter battery from the service battery when the engine is not running.

Extensive Electronic Protection

• Over-temperature protection with 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 Non-Isolated employs a three-step charging process: Bulk, Absorption, and Float.

• Bulk: The controller delivers maximum charge current to rapidly recharge batteries.
• Absorption: When the battery voltage reaches the set absorption voltage, the controller switches to constant voltage mode. For lead-acid batteries, a shorter absorption time is crucial after shallow discharges to prevent overcharging. After deep discharges, the absorption time automatically increases for a full recharge. For lithium batteries, the absorption time is fixed at a default of 2 hours. Both fixed and adaptive modes can be selected in battery settings, with adjustable minimum absorption time via VictronConnect.
• 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 at least one minute (e.g., due to a high load), a new charge cycle is triggered.

Flexible Charge Algorithm

Features a programmable charge algorithm and eight pre-programmed 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 Apple and Android smartphones and tablets. Parameters can be customized via the VictronConnect App. The app can be downloaded from: Victron Energy Software Downloads. The Victron Connect manual provides further guidance.

Input Voltage Lock-out

The unit shuts down if the input voltage drops below a configurable lock-out value and restarts when it rises above a restart value.

Remote On-Off

The remote function enables and disables the converter remotely via the dedicated connector or the VictronConnect App. Common applications include a manual switch 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, ensuring no chemicals, plastic parts, curtains, or other textiles are nearby.
• The charger may get hot during operation; keep heat-sensitive objects away.
• Ensure the equipment is used under correct operating conditions; never operate in wet environments.
• Do not use the product in locations where gas or dust explosions could occur.
• Always ensure proper ventilation during charging.
• Avoid covering the charger.
• Refer to the battery manufacturer's specifications and safety instructions to ensure battery compatibility.
• System operation or service manuals must include a battery maintenance manual for the specific battery type used.
• Never place the charger on top of a battery during charging.
• Prevent sparks near the battery, as a charging battery can emit explosive gases.
• 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 supervised or instructed.
• Use flexible multistranded copper cable for connections. The maximum diameter of individual strands is 0.4mm / 0.125mm² (AWG26).
• Install a fuse according to the recommendations in the "CABLE AND FUSE RECOMMENDATIONS" table.

4. Installation

4.1. General

• Mount vertically on a non-flammable surface with power terminals facing downwards. Ensure 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

1. Disconnect the remote on/off (remove wire bridge).
2. Connect the input supply cables.
3. Open the VictronConnect App to set up 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.

Diagram Description (Figure 1): A typical connection setup for DC-DC converter mode is shown. The alternator connects to the input terminals, the load connects to the output terminals, and the remote on/off connection is also depicted.

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 set up the product. Always set up 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.

Diagram Description (Figure 2): A typical connection setup for charger mode is illustrated. The alternator connects to the input terminals, the auxiliary battery connects to the output terminals, and the remote on/off connection is shown.

4.4. Connection Remote On-Off

The recommended methods for using the remote on-off function 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) BMS control through the H-pin.

Voltage tolerance for L & H pins: +/- 70VDC.

Diagram Description (Figure 3): Illustrates various remote on/off connection configurations: L-H pin wiring, H-pin wiring, L-pin wiring, and BMS control through the H-pin.

4.5. Engine Shutdown Detection Override

In charger mode, the "engine shutdown detection sequence" determines charging conditions. The "engine shutdown detection override" forces the charger to allow charging, bypassing the standard detection. This override is activated by applying >7V to the remote L-pin, enabling external control (e.g., ignition switch, CAN bus engine detector) to enable charging.

This function does not override the primary remote on-off function. Remote connections a), b), or d) (as shown in Figure 3) must be configured with the engine shutdown detection override. See examples in Figure 4.

Diagram Description (Figure 4): Shows connection diagrams for enabling charging with an ignition switch and remote on-off, illustrating configurations using remote connection 'a' and 'd'.

If the ignition switch in Figure 4 is turned off, the charger reverts to "engine shutdown detection" mode and does not turn off.

To force enable/disable charging (turn the Orion on/off) without using "engine shutdown detection", a remote option from chapter 4.4 must be wired, and engine shutdown detection must be disabled in VictronConnect (see Figure 5).

Diagram Description (Figure 5): Depicts screenshots from the VictronConnect app showing how to disable engine shutdown detection and configure input voltage lock-out. It notes that with 'forced charging' enabled, current is drawn from the starter battery even when the engine is off, and the input voltage lock-out is the primary limit for automatic charging disablement.

4.6. Cable and Fuse Recommendations

Diagram Description (Figure 6): Illustrates cable and fuse recommendations, showing input and output cable connections with external battery protection fuses. A table provides recommended cable gauges for different voltage ratings, fuse amperages, and cable lengths.

4.7. Recommended Torque

Torque: 1.6Nm

Diagram Description (Figure 7): Shows the Orion-Tr Smart DC-DC charger with a tool indicating the torque point for connections, specifying 1.6Nm.

5. Engine Shutdown Detection

The engine shutdown detection mechanism simplifies the ORION-Tr DC-DC Charger system by detecting engine operation without requiring additional switches or sensors. The factory default settings are compatible with most regular and smart alternators and can be reconfigured via the VictronConnect App. Configuration depends on the alternator voltage during engine operation; regular alternators provide a fixed voltage (e.g., 14V), while smart alternators offer variable voltages (12.5V to 15V), especially during regenerative braking.

This 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" controls output activation. The engine shutdown detection feature is available from software version v1.05 onwards.

5.1. Engine Shutdown Detection Sequence

Diagram Description (Figure 8): A graph illustrates the engine shutdown detection sequence, showing voltage levels (Vstarter, Vstart, Vstart(delayed), Vshutdown, VIN, Vcable) and current (Imax, ICharge) over time. The sequence describes how charging is enabled/disabled based on these parameters.

• 0 → 1: Charging is enabled when the engine runs and alternator voltage rises above Vstart.
• 1 → 2: Input current creates a voltage drop (Vcable) across the input cable, reducing the measured voltage (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 over 1 minute (tshutdown), "engine off" is detected, and charging is disabled. If VIN rises above Vshutdown before tshutdown, charging continues.
• 4 → 5: If Vstart(delay) < VIN < Vstart, charging is enabled after a configurable start delay.

5.2. Engine Shutdown Detection Setup with VictronConnect

Open VictronConnect and access settings via the Cog symbol [⚙].

Diagram Description (Figure 9): Shows screenshots of the VictronConnect app's engine shutdown detection setup menu, detailing configurable settings.

The following settings can be adjusted with VictronConnect:

• Engine shutdown detection enabled: Default is enabled in charger mode. If disabled or in power supply mode, the engine is considered always running, and no shutdown detection occurs.
• Alternator type: Options include "Smart Alternator", "Regular Alternator", and "User defined". Default is "Smart Alternator".
• Start voltage (Vstart): Charging begins immediately at this level. Default: 14V.
• Delayed start voltage (Vstart(delay)): For smart alternators with lower running voltages, a lower start level is used. Charging of the auxiliary battery is delayed to allow the starter battery to recharge after starting. Default: 13.3V (Smart Alternator) and 13.8V (Regular Alternator).
• Delayed start voltage delay (tstart delay): The time for the starter battery to recharge. Example: 37.5 seconds to recharge a 0.2Ah draw. Default: 2 minutes.
• Shutdown voltage (Vshutdown): Corresponds to the engine being off, maintaining starter battery charge and providing hysteresis. Action is taken after tshutdown (1 minute). Default: 13.1V (Smart Alternator) and 13.5V (Regular Alternator).
• Range for engine start/shutdown levels: 12|12; 12|24: 8 to 17V; 24|12; 24|24: 16 to 35V.
• Setup input voltage lock-out: The minimum input voltage for charging. Default (charger mode): lock-out: 12.5V / restart: 12.8V. Default (power supply mode): lock-out: 10.5V / restart: 12V. Setting this too low can deplete the starter battery when 'forced charging' is enabled.

Key considerations for input voltage lock-out:

• Minimum alternator voltage: Smart alternators can operate at very low voltages (e.g., <12.5V) during acceleration. The lock-out level should be set below this minimum voltage if charging must remain enabled during such periods.
• Voltage drop across the input cable: The lock-out value should be Vlock-out ≤ Vshutdown - Vcable to account for voltage drop in the cable, ensuring the charge control has time to adjust current. Example calculation: For a 5m cable, 16mm² gauge, and 35A current, Vcable is 385mV, suggesting Vlock-out ≤ 13.3V - 385mV ≈ 12.9V. Cable resistance is influenced by connections, fuses, and temperature.

6. LEDs

The Orion features two LEDs: a blue LED for Bluetooth functionality and a green LED for product status.

Status LED (Green LED)

• LED off: No input voltage, Remote shutdown, Shutdown by user, Connector overtemperature protection, User-defined undervoltage lock-out, Engine off detected (Charger mode).
• LED on: Output active (Power supply mode), Charger in Float State (Battery charged).
• LED blinking every 0.8 seconds: Charger in Bulk or Absorption State (Battery being charged).

Bluetooth LED (Blue LED)

• LED off: No input voltage.
• LED blinking every 3 seconds: Error – check VictronConnect. Refer to the Orion-Tr Smart DC-DC charger error code overview for details.
• LED blinking every 0.8 seconds: Connected via Bluetooth.
• LED blinking every 0.4 seconds: Identify.
• LED Blinking once every 5 seconds: Charger off due to non-error conditions (Remote shutdown, Shutdown by user, User-defined undervoltage lock-out, Engine off detected).
• LED on: All other conditions.

7. Troubleshooting

7.1. Orion-Tr Smart DC-DC Charger Error Code Overview

Error codes are displayed in the VictronConnect app. For the latest list, visit: Victron Energy Error Codes.

• Error 2 - Battery voltage too high: Auto-resets when battery voltage drops. May indicate other charging equipment or a controller fault.
• Error 26 - Terminal overheated: Power terminals are overheated. Check wiring, strand type, and bolt tightness. Auto-resets.
• Error 27 - Charger short circuit: Indicates an over-current condition on the battery side, possibly due to a contactor or an inverter with large input capacitance. Auto-resets. If it persists after a power cycle, the controller may be faulty.
• Error 116 - Calibration data lost: If the unit malfunctions with this error, it is faulty; contact your dealer. If it only appears in history data and the unit operates normally, it can be ignored. This error is logged if calibration data is missing during the first power-up.
• Error 119 - Settings data lost: The charger cannot read its configuration and stops. It does not auto-reset. To resolve: 1. Restore to factory defaults via Victron Connect. 2. Disconnect all power sources. 3. Wait 3 minutes and power up. 4. Reconfigure the charger. Report this issue to your Victron dealer.

8. Specifications

Table 1. Specifications

(1) If set to nominal or lower than nominal, the output voltage remains 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 for stable output 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.

9. VictronConnect - Orion Smart DC-DC Charger

9.1. Introduction

This guide helps users maximize the functionality of their Orion Smart DC-DC Charger with the VictronConnect App. It applies to all Orion Smart DC-DC Chargers. For general information on the VictronConnect App (installation, pairing, firmware updates), refer to the overall VictronConnect manual.

Note: Voltage references assume a 12V input and battery. Multiply values by 2 for 24V installations.

9.2. Live Data Information

9.2.1. Instant Readout over BLE

VictronConnect displays key data for the Orion Smart and other compatible smart products on the Device list page without requiring a direct connection. This provides immediate diagnostics, including warnings, alarms, and errors.

Advantages:

• Better range than regular Bluetooth.
• No need to connect to the smart product.
• Key data at a glance.
• Encrypted data.

Refer to the VictronConnect manual's "Instant Readout" chapter for setup details.

9.2.2. Charger Mode - STATUS Tab

The STATUS tab in VictronConnect displays:

• Orion Smart [SERIAL NUMBER]: Confirms the connected device; a custom name can be set.
• Mode icon: Shows the current operating mode (e.g., Charger).
• Charger State:
  • Bulk: Delivers maximum charge current to rapidly recharge batteries.
  • Absorption: Switches to constant voltage mode at a pre-set absorption voltage, suitable for the battery type.
  • Float: Applies float voltage to maintain a fully charged state. A new charge cycle is triggered if the battery voltage drops below the re-bulk voltage for at least 1 minute.
• Input Voltage: Displays the voltage measured at the input terminals.
• Output Voltage: Displays the voltage measured at the output terminals. If the Orion Smart is off, this will show '--'.
• Off Reason: Explains why the Orion Smart is disabled when in the "Charger State" text.

9.2.3. Charger Mode - GRAPH Tab

The GRAPH tab shows the charger's current state and provides a short description.

9.2.4. Power Supply Mode

In Power Supply Mode, the app displays:

• Orion Smart [SERIAL NUMBER]: Confirms the connected device; a custom name can be set.
• Mode icon: Shows the operating mode (Power Supply).
• Input Voltage: Voltage at the input terminals.
• Output Voltage: Voltage at the output terminals. If the Orion Smart is off, this will show '--'.
• Off Reason: Explains why the Orion Smart is disabled under "Power Supply Mode".

9.3. Settings

VictronConnect allows adjustment of various Orion Smart settings via the settings icon [⚙]. Options vary by operating mode.

9.3.1. Charger Mode

Available settings in Charger Mode:

• Function: Choose between "Charger" or "Power supply". In Charger mode, the Orion Smart follows the three-state charge algorithm.
• Battery settings: Adjust absorption voltage, float voltage, etc., to match the battery type.
• Input voltage lock-out: Set two thresholds for lock-out and reset. A minimum 0.5V difference is recommended for 12V input models for optimal performance. This protection can be disabled.
• Engine shutdown detection: Set two thresholds to detect engine shutdown and operation. A minimum 0.2V difference is recommended for 12V input models. This can also be disabled.

9.3.2. Charger Mode - Battery Settings

• Charger enabled: Toggling this setting turns the Orion Smart off; batteries will not be charged.
• Charger settings - Battery preset: Select battery type, use factory defaults, or enter custom values for the charge algorithm. Settings include Absorption voltage, Float voltage, Bulk time limit, Re-bulk voltage offset, Adaptive absorption time, and Absorption time. User-defined presets can be saved.
• By selecting "Edit Presets", custom parameters can be set:
  • Absorption voltage
  • Float voltage
  • Bulk time limit: Set the maximum bulk time allowed.
  • Re-bulk offset voltage: Determines the difference between float voltage (or absorption if lower) and the re-bulk voltage (battery voltage threshold for a new charge cycle).
  • Absorption time: Can be fixed (user-selectable, down to 0) or adaptive. Adaptive mode calculates absorption time based on bulk elapsed time, with a user-set maximum absorption time (minimum 30 minutes).

9.3.3. Power Supply Mode

Available settings in Power Supply Mode:

• Function: Choose between "Charger" or "Power supply". In Power Supply mode, the Orion Smart maintains the set output voltage.
• Output voltage: Set the desired output voltage, ensuring it is within the product's limits (e.g., 10V to 15V for 12V output models).
• Input voltage lock-out: Set lock-out and reset thresholds. A minimum 0.5V difference is recommended for 12V input models. This protection can be disabled.

9.4. Product Information

Access product information by clicking the settings icon [⚙].

• Product: Shows the Orion Smart model.
• Serial number: Displays the unit's serial number. Changing the PIN code is recommended for security.
• Custom name: Allows users to set a custom name for the product.
• Firmware: Shows the current firmware version and allows updates.
• Bootloader: Displays the bootloader firmware version.