Orion-Tr Smart Charger Isolated - Victron Energy

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vändarhandbokSEManualeITOrion-Tr Smart Charger Isolated

1. General DescriptionDEESSEIT1FRThe Orion-Tr Smart DC-DC Charger is fully programmable withthe VictronConnect app.Discover all setup possibilities nect:startNLThe Orion Smart DC-DC charger can be set up to only providepower when the engine is running. This is possible thanks to thebuilt-in engine shutdown detection. This also prevents theonboard voltage of the vehicle from becoming too low. It is notnecessary to intervene in the system of the vehicle, to install aseparate motor run sensor or to intervene in the CAN-bussystem. Apart from this detection, the Orion Smart DC-DCcharger can also be activated by a forced allowed to chargefeature, e.g. connected to the ignition switch.ENThe Orion Smart DC-DC chargers can be used as a power supplyor as a battery charger. In charger mode the three-state chargealgorithm will increase battery life by properly charging thebattery. Especially in the case of vehicles with a smart alternator,or voltage drop caused by long cable runs, controlled charging isindispensable. Controlled charging will also protect the alternatorin lithium systems where direct charging can overload thealternator due to the low impedance of the lithium battery. In fixedoutput mode the output voltage will remain stable independent ofthe applied load or varying input voltage (within the specifiedrange).

2. FeaturesSmart alternator compatibilityVehicle manufacturers are now introducing smart ECU (EngineControl Unit) controlled alternators to increase fuel efficiency andreduce emissions. Smart alternators deliver a variable outputvoltage and are shut down when they’re not needed. Theconverter has a engine running detection mechanism. Thisprevents the converter from discharging the starter battery whenthe alternator does not supply power. See section 5 of thismanual for more details.Separation of the starter battery and the service batteryThe Orion-Tr Smart Isolated DC-DC charger separates the starterbattery from the service battery when the engine is not running.Extensive electronic protectionOver-temperature protection and power derating whentemperature is high.Overload protected.Short circuit protected.Connector over-temperature protection.Adaptive three step chargingThe Orion-Tr Smart Isolated DC-DC charger is configured for athree-step charging process:Bulk – Absorption – Float.BulkDuring this stage the controller delivers as much charge currentas possible to rapidly recharge the batteries.AbsorptionWhen the battery voltage reaches the absorption voltage setting,the controller switches to constant voltage mode. For lead acidbatteries it is important that during shallow discharges theabsorption time is kept short in order to prevent overcharging ofthe battery. After a deep discharge the absorption time isautomatically increased to make sure that the battery is2

IT3SERemote on-offUse the remote function to enable and disable the converterESInput voltage lock-outShutdown if the input voltage drops below the lock-out value andrestart when the input voltage increases above the restart value.Configurable with Victron Connect.DEConfiguring and monitoringBluetooth Smart built-in: the wireless solution to set-up, monitorand update the controller using Apple and Android smartphones,tablets or other devices.Several parameters can be customized with the VictronConnectapp.The VictronConnect app can be downloaded oads/software/Use the manual – VictronConnect - to get the most out of theVictronConnect App when it’s connected to an Orion nnect:startFRAdaptive absorption timeAutomatically calculates the proper absorption time.Configurable with Victron Connect.NLFlexible charge algorithmProgrammable charge algorithm, and eight preprogrammedbattery settings.Configurable with VictronConnect.ENcompletely recharged. For lithium batteries absorption time isfixed, default 2 hours. The fixed or adaptive mode can be chosenon the battery settings.FloatDuring this stage, float voltage is applied to the battery tomaintain it in a fully charged state. When the battery voltagedrops substantially below this level, due to a high load forexample, during at least 1 minute, a new charge cycle will betriggered.

remotely with the remote on/off connector or using theVictronConnect app. Typical use cases include a user operatedhard wired switch and automatic control by for example a BatteryManagement System. If the minus of the service battery is not atthe same potential as the minus of the alternator or starter batteryan isolated remote on/off cable between the BMS and the on/offport is required, see chapter 4.4 for details.4

3. Safety instructionsENNLSAVE THESE INSTRUCTIONS – This manual containsimportant instructions that shall be followed duringinstallation and maintenance.Danger of explosion from sparkingFRDanger of electric shockDESEIT5ES Please read this manual carefully before the product is installedand put into use. Install the product in a heatproof environment. Ensure thereforethat there are no chemicals, plastic parts, curtains or othertextiles, etc. in the immediate vicinity of the equipment. It is normal for the Orion Smart DC-DC charger to get hotduring operation, keep any objects that are heat-sensitiveaway. Ensure that the equipment is used under the correct operatingconditions. Never operate it in a wet environment. Never use the product at sites where gas or dust explosionscould occur. Always provide proper ventilation during charging. Avoid covering the charger. Refer to the specifications provided by the manufacturer of thebattery to ensure that the battery is suitable for use with thisproduct. The battery manufacturer's safety instructions shouldalways be observed. In addition to this manual, the system operation or servicemanual must include a battery maintenance manual applicableto 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 chargedcould emit explosive gasses.

This device is not to be used by persons (including children)with reduced physical, sensory or mental capabilities, or lack ofexperience and knowledge, unless they have been givensupervision or instruction. Use flexible multistranded copper cable for the connections.The maximum diameter of the individual strands is0,4mm/0,125mm² (0.016 inch/AWG26). The installation must include a fuse in accordance with therecommendations in the table ”CABLE AND FUSERECOMMENDATIONS”.6

4. InstallationNLFRDEES4.2 Connection setup for power supply mode1. 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 inparallel 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.EN4.1 General Mount vertically on a non-flammable surface, with the powerterminals facing downwards. Observe a minimum clearance of10 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).SEITFigure 1: Typical connection setup as DC-DC converter7

4.3 Connection setup for charger mode1. 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 beforeconnecting 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 charger8

FRL-H pin wiringb)H-pin wiringNLNote: Voltage tolerance L & H pin: /- 70VDCa)EN4.4 Connection remote on-offThe recommended use of the remote on-off is:a) A switch wired between the L-H pins (On-level impedancebetween 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)c)L-pin wiringDEESThe 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 4below.9IT4.5 Engine detection overrideApplying 7V to the L-pin of the remote on/off circuit activates the“engine detection override” function. The charger is on as long asthe “engine detection override” is active. With this function anexternal control (e.g. ignition switch, CAN bus engine on detector)can determine if charging is allowed.SEFigure 3: Remote on/off connections

Only an ignition switchBMSFigure 4: Engine Detection Override connection diagram4.6Cable and fuse recommendationsFigure 5: Cable and fuse recommendationsMinimum cable gaugeVoltage rating(input or output)12V24V10External batteryProtection Fuse60A30A1m2m5m10mm26mm210mm26mm216mm210mm2

Recommended torqueEN4.7NLFRDEESSEFigure 6IT11

5. Smart alternator compatibilityThe engine is running detection is based on the voltage of thestarter battery. The charger is not always able to measure theexact starter battery voltage because of voltage drop over theinput cable. The voltage drop is determined by variables likecurrent, cable length and cable gauge. The “engine on detectionsequence” (see figure 7) will perform periodic tests to determinethe exact starter battery voltage during charging. The test resultdetermines if the engine is running and charging can be enabled.This feature is only active in charger mode and when “enginedetection override” is not activated. In converter mode the “inputvoltage lock-out” determines when the output is active.Configurable with VictronConnectFigure 7: Engine on detection sequence12

ENNLFRDEES0 1:When the engine runs the alternator voltage will ramp-up, whenVstarter increases above Venable, charging starts.1 2:Due to the charge current a voltage drop will occur across theinput cable (Vcable), this voltage reduces the voltage at the input ofthe charger (VIN). While VIN remains above Vtest, charging isenabled.2 3:If VIN drops below Vtest, the “engine on detection sequence” isstarted. Every 2 minutes the charger is paused for 10 seconds tomeasure the voltage. Without current flow VIN is equal to Vstarter, ifVIN is above Vtest, charging will resume. While remaining in thisstate, the test is performed every 2 minutes.3 4:During the detection sequence VIN dropped below Vtest, thismeans that the engine stopped running and charging must bestopped, the charge sequence is paused.4 5:VIN increases above Venable, the charge sequences continues.SEIT13

6. LED statedThe blue LED is dedicated to Bluetooth functionality and thegreen LED to product state.Status LED (Green LED) LED off:o No input voltage;o Remote shutdown;o Shutdown by the user;o Connector over-temperature protectiono User defined under voltage lock-outo Engine off detected (when in Charger mode) LED on:o Output active on DC/DC Converter Mode;o Charger in Float State (Battery charged); LED Blinking at 1.25Hz:o Charger in Bulk or Absorption State (Battery is beingcharged);BLE LED (Blue LED) LED off:o No input voltage; LED Blinking at 0.33 Hz:o Error – needs to be checked on VictronConnect; LED Blinking at 1.25 Hz:o Connected via Bluetooth; LED Blinking at 2.5 Hz:o Identify; LED on:o All other conditions;14

7. Specifications12/12-18 (220W)8-17V7V7,5V24,2V20-30V /- 0,2V2mV rmsFR10A25A15A40A280W220W87% 80mA25A280W240W88% 100mASEITLess than 1mA200V dc between input, output and case-20 to 55 C (derate 3% per C above 40 C)Max. 95% non-condensingScrew terminals16mm² AWG61,3 kg (3 lb)130 x 186 x 70 mm (5.1 x 7.3 x 2.8 inch)EN 60950EN 61000-6-3, EN 55014-1EN 61000-6-2, EN 61000-6-1, EN 55014-2ECE R10-5ES18ADE1512/24-10 (240W)8-17V7V7,5V12,2V10-15VNLInput voltage range (1)Under voltage shut downUnder voltage restartNominal output voltageOutput voltage adjust rangeOutput voltage toleranceOutput noiseCont. output current at nominaloutput voltage and 40 CMaximum output current (10 s)at nominal output voltageShort circuit output currentCont. output power at 25 CCont. output power at 40 CEfficiencyNo load input currentStandby currentGalvanic isolationOperating temperature rangeHumidityDC connectionMaximum cable cross-sectionWeightDimensions hxwxdStandards: SafetyEmissionImmunityAutomotive DirectiveENOrion-Tr Smart ChargerIsolated 220-280 Watt

Specifications - continuationOrion-Tr Smart ChargerIsolated 220 – 280 0-15V16-35V14V15V24,2V20-30VInput voltage range (1)Under voltage shut downUnder voltage restartNominal output voltageOutput voltage adjust rangeOutput voltage toleranceOutput noiseCont. output current at nominaloutput voltage and 40 CMaximum output current (10 s)at nominal output voltageShort circuit output currentCont. output power at 25 CCont. output power at 40 CEfficiencyNo load input currentStandby currentGalvanic isolationOperating temperature rangeHumidityDC connectionMaximum cable cross-sectionWeightLess than 1mA200V dc between input, output and case-20 to 55 C (derate 3% per C above 40 C)Max. 95% non-condensingScrew terminals16mm² AWG61,3 kg (3 lb)Dimensions hxwxdStandards: SafetyEmissionImmunityAutomotive Directive130 x 186 x 70 mm (5.1 x 7.3 x 2.8 inch)EN 60950EN 61000-6-3, EN 55014-1EN 61000-6-2, EN 61000-6-1, EN 55014-2ECE R10-516 /- 0,2V2mV rms20A12A25A15A50A300W240W88% 100mA30A320W280W89% 80mA

Orion-Tr Smart ChargerIsolated 360 – 400 Watt10-17V7V7,5V24,2V20-30V /- 0,2V2mV rms30A15A40A25A60A430W360W87% 80mA40A430W360W88% 100mAEN 60950EN 61000-6-3, EN 55014-1EN 61000-6-2, EN 61000-6-1, EN 55014-2ECE R10-51) If set to nominal or lower than nominal, the output voltage will remain stable within the specifiedinput voltage range (buck-boost function).If the output voltage is set higher than nominal by a certain percentage, the minimum inputvoltage at which the output voltage remains stable (does not decrease) increases by the samepercentage.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.17IT12V input and/or 12V output models: 1,8 kg (3 lb)Other models: 1,6 kg (3.5 lb)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)SELess than 1mA200V dc between input, output and case-20 to 55 C (derate 3% per C above 40 C)Max. 95% non-condensingScrew terminals16mm² AWG6ESStandards: SafetyEmissionImmunityAutomotive Directive10-17V7V7,5V12,2V10-15VDEDimensions hxwxd12/24-15(360W)FRWeight12/12-30(360W)NLInput voltage range (1)Under voltage shut downUnder voltage restartNominal output voltageOutput voltage adjust rangeOutput voltage toleranceOutput noiseCont. output current at nominaloutput voltage and 40 CMaximum output current (10 s)at nominal output voltageShort circuit output currentCont. output power at 25 CCont. output power at 40 CEfficiencyNo load input currentStandby currentGalvanic isolationOperating temperature rangeHumidityDC connectionMaximum cable cross-sectionENSpecifications - continuation

Specifications - continuationOrion-Tr Smart ChargerIsolated 360 – 400 WattInput voltage range (1)Under voltage shut downUnder voltage restartNominal output voltageOutput voltage adjust rangeOutput voltage toleranceOutput noiseCont. output current at nominaloutput voltage and 40 CMaximum output current (10 s)at nominal output voltageShort circuit output currentCont. output power at 25 CCont. output power at 40 CEfficiencyNo load input currentStandby currentGalvanic isolationOperating temperature rangeHumidityDC connectionMaximum cable cross-sectionWeightDimensions hxwxdStandards: SafetyEmissionImmunityAutomotive 2,2V10-15V20-35V14V15V24,2V20-30V /- 0,2V2mV rms30A17A45A25A60A430W360W88% 100mA40A480W400W89% 80mALess than 1mA200V dc between input, output and case-20 to 55 C (derate 3% per C above 40 C)Max. 95% non-condensingScrew terminals16mm² AWG612V input and/or 12V output models: 1,8 kg (3 lb)Other models: 1,6 kg (3.5 lb)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)EN 60950EN 61000-6-3, EN 55014-1EN 61000-6-2, EN 61000-6-1, EN 55014-2ECE R10-51) If set to nominal or lower than nominal, the output voltage will remain stable within the specifiedinput voltage range (buck-boost function).If the output voltage is set higher than nominal by a certain percentage, the minimum inputvoltage at which the output voltage remains stable (does not decrease) increases by the samepercentage.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.18

ENNLFRDEESSEIT19

1. Algemene beschrijvingDEESSEIT1FRDe Orion-Tr Smart DC-DC-acculader is volledigprogrammeerbaar via de VictronConnect-app.Ontdek hier alle live/victronconnect:startNLDe Orion Smart DC-DC-oplader kan worden ingesteld om alleenstroom te leveren wanneer de motor aan staat. Dit is mogelijkdankzij het ingebouwde motordetectie-uitschakelmechanisme. Ditvoorkomt ook dat de spanning aan boord van het voertuig te laagwordt. Het is niet nodig om in te grijpen in het systeem van hetvoertuig, om een afzonderlijke motordetectiesensor te installerenof om in te grijpen in het CAN-bussysteem. Afgezien van dezedetectie kan de Orion Smart DC-DC-acculader ook wordengeactiveerd door een geforceerde oplaadfunctie, bijvoorbeeldaangesloten op de contactschakelaar.ENDe Orion Smart DC-DC-acculaders kunnen worden gebruikt alsvoeding of als acculader. In de laadmodus zal het drietrappenlaadalgoritme de levensduur van de accu verlengen door de accuop de juiste manier op te laden. Vooral in het geval vanvoertuigen met een slimme wisselstroomdynamo, of bij eenspanningsval veroorzaakt door lange kabels, is gecontroleerdopladen onmisbaar. Ook beschermt het gecontroleerd opladen dedynamo in lithiumsystemen, terwijl direct opladen de dynamo kanoverbelasten vanwege de lage impedantie van de lithiumaccu. Inde vaste uitgangsmodus blijft de uitgangsspanning stabiel,onafhankelijk van de toegepaste belasting of variërendeingangsspanning (binnen het opgegeven bereik).

2. KenmerkenSlimme dynamocompatibiliteitVoertuigfabrikanten introduceren vandaag de dag slimme doorECU's (Engine Control Unit) gestuurde dynamo's om hetbrandstofverbruik te verlagen en de uitstoot te verminderen.Slimme dynamo's leveren een variabele uitgangsspanning enworden uitgeschakeld wanneer ze niet nodig zijn. De omvormerheeft een mechanisme om te detecteren of de motor draaiendeis. Dit voorkomt dat de omvormer de startaccu ontlaadt wanneerde dynamo geen stroom levert. Zie sectie 5 van deze handleidingvoor meer informatie.Scheiding van de startaccu en de dienstaccuDe Orion-Tr Smart Isolated DC-DC-acculader scheidt destartaccu van de dienstaccu wanneer de motor niet draait.Uitgebreide elektronische beschermingOvertemperatuurbescherming en vermogensreductie wanneer detemperatuur hoog is.Beveiligd tegen overbelasting.Beveiligd tegen kortsluiting.Beveiligd tegen overtemperatuur.Aangepast opladen in drie trappenDe Orion-Tr Smart Isolated DC-DC-acculader is geconfigureerdvoor een laadproces in drie stappen:Bulk — Absorptie — Druppel.BulkTijdens deze fase levert de controller zoveel mogelijk laadstroomom de accu's snel op te laden.AbsorptieWanneer de accuspanning de ingestelde limiet van deabsorptiespanning bereikt, schakelt de controller over naar deconstante spanningsmodus. Voor loodzuuraccu's is het belangrijkdat tijdens beperkte ontladingen de absorptietijd kort wordtgeh

separate motor run sensor or to intervene in the CAN-bus system. Apart from this detection, the Orion Smart DC-DC ated 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:

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