Orion-Tr Tr Smart DC-DC Charger User Manual & Service Guide PDF

Table of Contents

Orion-Tr Smart DC-DC Charger Isolated Table of Contents 1. Safety precautions ................................................................................................................... 1 2. Introduction ........................................................................................................................... 2 3. Features ................................................................................................................................ 3 4. Installation ............................................................................................................................. 4 4.1.

Mounting ...................................................................................................................... 4 4.2. Cable and fuse recommendations ......................................................................................... 4 4.3. Polarity check before connecting the battery ............................................................................. 6 4.4. Recommended torque ...................................................................................................... 6 4.5. Connection setup for DC-DC power supply mode ....................................................................... 7 4.6.

Connection setup for charger mode ....................................................................................... 7 4.7. Remote on/off wiring ........................................................................................................ 8 4.8. External engine running signal wiring ..................................................................................... 9 5. Automatic engine shutdown detection ........................................................................................ 11 5.1. How it works ............................................................................................................... 11 5.2.

Engine shutdown detection setup with VictronConnect ............................................................... 12 5.3. Setup for Euro 6 vehicles ................................................................................................. 13 5.4. Using an external engine running signal ................................................................................ 14 6. LED Indicators ...................................................................................................................... 15 7. Troubleshooting & Support ...................................................................................................... 16 7.1.

The is not operational ..................................................................................................... 16 7.1.1. Visual check ..................................................................................................... 16 7.1.2. Battery supply check ............................................................................................ 17 7.1.3. Reverse battery polarity ........................................................................................ 18 7.2. Battery is not charged ..................................................................................................... 18 7.2.1.

Remote terminal is missing, disconnected or external control is active ................................... 19 7.2.2. The charger is disabled ......................................................................................... 19 7.2.3. Input voltage lock-out is active ................................................................................. 19 7.2.4. Engine shutdown is detected .................................................................................. 20 7.2.5. Battery is full ..................................................................................................... 20 7.3.

Battery is undercharged .................................................................................................. 20 7.3.1. Too much DC load .............................................................................................. 20 7.3.2. Battery charge voltages are too low ........................................................................... 20 7.3.3. Battery is almost full ............................................................................................ 20 7.3.4. Battery cable voltage drop ..................................................................................... 21 7.3.5.

Insufficient alternator power .................................................................................... 21 7.4. Battery is overcharged .................................................................................................... 22 7.4.1. Battery charge voltages are too high .......................................................................... 22 7.4.2. Battery old or faulty ............................................................................................. 22 7.5. Full rated output not reached ............................................................................................ 23 7.6.

Bluetooth connection issues with VictronConnect ..................................................................... 24 7.7. Error codes ................................................................................................................. 25 8. Specifications ....................................................................................................................... 26 9. VictronConnect - Orion Smart DC-DC Charger ............................................................................... 28 9.1. Introduction ................................................................................................................. 28 9.2.

Live Data Information ..................................................................................................... 28 9.2.1. Instant Readout over BLE ...................................................................................... 28 9.2.2. Charger Mode - STATUS tab .................................................................................. 28 9.2.3. Charger Mode - GRAPH tab ................................................................................... 29 9.2.4. Power Supply Mode ............................................................................................ 29 9.3.

Settings ..................................................................................................................... 30 9.3.1. Charger Mode ................................................................................................... 30 9.3.2. Charger Mode - Battery Settings .............................................................................. 30 9.3.3. Power Supply Mode ............................................................................................ 31

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Table of Contents

Orion-Tr Smart DC-DC Charger Isolated 9.4. Product Information ....................................................................................................... 32 10. Appendix ........................................................................................................................... 33 10.1. Dimension drawing ...................................................................................................... 33

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1. Safety precautions

Orion-Tr Smart DC-DC Charger Isolated 1. Safety precautions Read this manual carefully before installing and operating the product. It contains important instructions that must be followed during installation, operation and maintenance. Save these instructions for future reference on operation and maintenance. Never use the product at sites where gas or dust explosions could occur. 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. Install the product in a heatproof environment.

Ensure that there are no chemicals, plastic parts, curtains or other textiles, etc., in the immediate vicinity of the equipment. Ensure that the equipment is used under the correct operating conditions. Never operate it in a wet environment. It is normal for the Orion Smart DC-DC charger to get hot during operation; keep any heat-sensitive objects away and provide proper ventilation. For very hot environments, consider mechanical air extraction. The Orion-Tr Smart DC-DC Charger is potted inside. Because of this, there is a noticeable smell when running at maximum power (or close to it) and getting warm/hot. This smell is not harmful to health. Avoid covering the charger.

Refer to the specifications provided by the battery manufacturer 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. 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 multi-stranded copper cables for the connections.

The maximum diameter of the individual strands is 0,4mm/0,125mmІ (0.016 inch/AWG26). Check the Cable and fuse recommendations [4] section for details. The installation must include a fuse in accordance with the recommendations in the table Cable and fuse recommendations [4] . The product is not protected against reverse polarity. Be sure to check polarity before and during battery connection. For details, see Polarity check before connecting the battery [6] . Page 1 Safety precautions

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2. Introduction

Orion-Tr Smart DC-DC Charger Isolated 2. Introduction The Orion-Tr Smart DC-DC Charger can be used as a power supply or battery charger. In charger mode, the three-state charge algorithm will increase battery life by properly charging the battery. Especially in the case of vehicles with a smart alternator, 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).

The Orion-Tr Smart DC-DC Charger can be set up to 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 vehicle system, to install a separate motor run sensor or to intervene in the CAN-bus system. Apart from this detection, the Orion smart charger can also be activated by a forced allowed-to-charge feature, e.g. connected to the ignition switch. The Orion-Tr Smart DC-DC Charger is configured and monitored via the VictronConnect app. Discover all setup possibilities in the VictronConnect manual . Page 2 Introduction

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