Orion XS 1400 DCDC DC-DC Battery Charger User Manual PDF

Table of Contents

Manual - Orion XS 1400 DC-DC battery charger Table of Contents 1. Safety instructions ................................................................................................................... 1 2. General ................................................................................................................................. 2 2.1. Introduction ................................................................................................................... 2 2.2. Features ...................................................................................................................... 2 2.3. What's in the box?

........................................................................................................... 4 3. Installation ............................................................................................................................. 5 3.1. Mounting ...................................................................................................................... 5 3.2. Cable type recommendations .............................................................................................. 5 3.3. Cable and fuse recommendations ......................................................................................... 7 3.4.

Recommended torque ...................................................................................................... 7 3.5. GND connection ............................................................................................................. 8 3.6. Strain Relief .................................................................................................................. 8 3.7. Connection setup for DC-DC power supply mode ....................................................................... 9 3.8. Connection setup for charger mode ....................................................................................... 9 3.9.

Connection setup for remote on/off ...................................................................................... 10 3.10. Wiring examples for BMS-controlled operation ....................................................................... 11 3.11. External engine running signal wiring .................................................................................. 12 4. Operation, configuration and monitoring ...................................................................................... 13 4.1. Automatic engine shutdown detection .................................................................................. 13 4.1.1.

How it works ..................................................................................................... 13 4.1.2. Setup for Euro 6 vehicles ....................................................................................... 13 4.1.3. Using an external engine running signal ...................................................................... 14 4.2. Emergency reverse charge ............................................................................................... 15 4.2.1. Starting an emergency reverse charge ....................................................................... 16 4.3.

LED indicators ............................................................................................................. 19 4.4. Setup & monitoring with VictronConnect ............................................................................... 20 4.4.1. Setup ............................................................................................................. 20 4.4.2. Charger mode settings ......................................................................................... 20 4.4.3. Charger mode - Battery settings ............................................................................... 21 4.4.4.

Power supply mode ............................................................................................. 22 4.4.5. Power supply mode settings ................................................................................... 22 4.4.6. Engine shutdown detection & input voltage lock-out ........................................................ 23 4.4.7. Product information page ....................................................................................... 26 4.4.8. Monitoring ........................................................................................................ 27 4.4.9.

Charger mode - Status screen ................................................................................. 27 4.4.10. Charger mode - Graph screen ............................................................................... 28 4.4.11. History screen .................................................................................................. 28 4.4.12. Trends screen .................................................................................................. 29 4.4.13. Instant readout over BLE ..................................................................................... 29 4.5.

Monitoring with a GX device ............................................................................................. 30 4.6. Remote sensing with VE.Smart Networking ............................................................................ 32 5. Troubleshooting & Support ...................................................................................................... 33 5.1. The Orion XS is not operational ......................................................................................... 33 5.1.1. Visual Check ..................................................................................................... 33 5.1.2.

Battery supply check ............................................................................................ 34 5.1.3. Battery not charged ............................................................................................. 34 5.1.4. Reverse battery polarity ........................................................................................ 35 5.1.5. Battery full ........................................................................................................ 35 5.1.6. Remote terminal is missing, is disconnected or external control is active ................................ 35 5.1.7.

The charger is disabled ......................................................................................... 36 5.2. Batteries are undercharged .............................................................................................. 36 5.2.1. Too much DC load .............................................................................................. 36 5.2.2. Battery charge voltages are too low ........................................................................... 36 5.2.3. Battery is almost full ............................................................................................ 37 5.2.4.

Battery cable voltage drop ..................................................................................... 37 5.2.5. Temperature difference between Orion XS and battery ..................................................... 38 5.2.6. Insufficient alternator power .................................................................................... 38 5.2.7. Wrong temperature compensation setting ................................................................... 38 5.2.8. Battery charge current too low ................................................................................. 38

Page 2

Table of Contents

Manual - Orion XS 1400 DC-DC battery charger 5.3. Batteries are overcharged ................................................................................................ 38 5.3.1. Battery charge voltages too high .............................................................................. 38 5.3.2. Battery unable to deal with equalization ...................................................................... 39 5.3.3. Battery old or faulty ............................................................................................. 40 5.4. Full rated output not reached ............................................................................................ 40 5.5.

Communication issues .................................................................................................... 41 5.5.1. VictronConnect issues .......................................................................................... 41 5.5.2. VE.Direct port communication issues ......................................................................... 41 5.5.3. Bluetooth issues ................................................................................................. 41 5.6. Emergency reverse charge issues ...................................................................................... 42 5.6.1.

The emergency reverse charge button is greyed out ....................................................... 42 5.6.2. The reverse charge current is low or zero .................................................................... 42 5.6.3. The engine does not start after Battery ready ............................................................... 42 5.7. Settings or firmware issues ............................................................................................... 42 5.7.1. Incorrect settings ................................................................................................ 42 5.7.2.

Firmware issues ................................................................................................. 43 5.7.3. Interrupted firmware update .................................................................................... 43 5.8. Error and warning code overview ........................................................................................ 44 6. Technical data ...................................................................................................................... 46 6.1. Technical specifications ................................................................................................... 46 6.2.

Compliance ................................................................................................................ 48 6.3. Enclosure dimensions .................................................................................................... 49

Page 3

1. Safety instructions

Manual - Orion XS 1400 DC-DC battery charger 1. Safety instructions SAVE THESE INSTRUCTIONS – This manual contains important instructions that shall be followed during installation and maintenance . Danger of explosion from sparking and danger of electric shock General Please read the safety instructions below before installing and using the Orion XS to avoid risks of fire, electric shocks, personal injuries or equipment damage. This product is designed and tested in accordance with international standards. The equipment should be used for its designated application only and in accordance with the specified operating parameters.

Installation For electrical work, follow the local national wiring standards, regulations and these installation instructions. 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 XS to get hot during operation. Keep any objects that are heat-sensitive away. Never install or use the product at sites where gas or dust explosions could occur. Use flexible multi-stranded copper cables for the connections (UL: Class I; IEC: Class 5).

The installation must include a fuse in accordance with the recommendations in the table Cable type recommendations [5] . Operation, service and maintenance Ensure that the equipment is used under proper operating conditions. 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. Always provide proper ventilation during charging. Avoid covering the Orion XS. Never place the battery charger on top of the battery during charging. Prevent sparks close to the battery. A battery being charged could emit explosive gasses.

Refer to the battery manufacturer's specifications to ensure that the battery is suitable for use with this product. The safety instructions of the battery manufacturer must 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. Do not use the device if it shows any signs of damage or does not function properly. Do not use the Orion XS if it is broken, defective, cracked, damaged, or malfunctioning. The Orion XS contains no serviceable parts. Regular maintenance of the Orion XS is not required. Avoid moisture, oil/soot/vapours, and keep the device clean.

Clean the front side of the Orion XS using a dry cloth. Page 1 Safety instructions

Page 4

2.2. Features

Manual - Orion XS 1400 DC-DC battery charger 2. General 2.1. Introduction The Orion XS can be used as a battery charger or as a power supply with a wide input and output voltage range. In charger mode, the four-stage charge algorithm will increase battery life by properly charging the battery. Especially in the case of vehicles with a Euro 5 or 6 smart alternator, which often supplies charging voltage that is too low even with the engine running or in the event of a voltage drop over long cables, controlled charging is crucial. Controlled charging also protects the alternator in lithium systems from overloading, as the low impedance of lithium batteries results in a high alternator current.

In power supply mode, the output voltage remains stable regardless of the applied load or fluctuating input voltage (within the specified range). The output voltage is fully adjustable and remains independent of the input voltage, thanks to the automatic buck-boost control. This control also guarantees that the current will never exceed the set value, even when the input voltage is higher than the output voltage. The Orion XS can be set only to supply power when the engine is running. This is possible thanks to the integrated engine shutdown detection. This eliminates the need to adjust in-vehicle wiring or add an engine detection sensor to determine if charging can start.

It also prevents the voltage on board the vehicle from getting too low. In addition to this detection, an external engine running signal from the vehicle can be used to force charging on instead. If the starter battery is depleted, the emergency reverse charge function can charge it from the auxiliary battery, temporarily reversing the normal charge direction. The Orion XS is fully programmed and monitored using the VictronConnect App .

This also includes remote access via VictronConnect-Remote (VC-R) when connected to a GX device (requires a GX device connection to the VRM Portal ) via the integrated VE.Direct port, monitoring via the GX Remote Console or from a PC, Apple computer with macOS or Android device in conjunction with a VE.Direct to USB interface and VictronConnect. Discover all setting and monitoring options in the Setup & monitoring with VictronConnect [20] chapter and the VictronConnect manual . 2.2. Features Smart alternator compatibility It is common for vehicle manufacturers to install "smart" ECU (Engine Control Unit) controlled alternators to increase fuel efficiency and reduce emissions.

Smart alternators provide variable output voltage and shut down when not needed. The Orion XS has an integrated mechanism that detects whether the engine is running (engine shutdown detection), so the charger is only activated when the alternator is supplying power. This ensures that the charger only draws power when the alternator supplies power. Please refer to the Automatic engine shutdown detection [13] chapter and the Setup for Euro 6 vehicles [13] section for more information. Separation of the starter battery and the auxiliary battery The Orion XS separates the starter battery from the auxiliary battery.

Emergency reverse charge If the starter battery is depleted, the emergency reverse charge function can charge it from the auxiliary battery, temporarily reversing the normal charge direction. The function is started with the VictronConnect App: the Orion XS reverse charges the starter battery for 15 minutes, followed by a 5-minute settling period during which the engine can be started. The auxiliary battery is protected against deep discharge at all times. See the Emergency reverse charge [15] section for more information.

Comprehensive electronic protection The charger is protected against overtemperature (heat sink >90 °C) by reducing the output power when the maximum product temperature is reached. Protected against overload Protected against short circuit Protected against excessive temperatures Adaptive charging in four stages The Orion XS is configured by default for a four-stage charging process. Bulk — Absorption — Float — Storage Page 2 General

Page 5