Manual - Orion XS 12/12-50A DC-DC battery charger

For correct connection of a cable to the input/output screw terminals, stranded wires with flexible cores can be used according to:

Cables with twisted cores are very stiff, which means that they are rarely used in practice. The table below provides an overview of how to recognise the different wire classes.

The use of ferrules is not required for cables from the above table. If an even thinner cable is used, a ferrule can help to bundle the loose wires. However, it is up to the installer to make sure that the cable is properly secured. The connecting cable, with or without a ferrule, should be adequately clamped to ensure low contact resistance.

Note: If you prefer using a ferrule, opt for a bootlace ferrule to ensure the strain relief grips the cable insulation as intended. A 16mm² cable with a ferrule will only fit if crimped hexagonally; a square crimp will not fit.

Hexagonally crimped bootlace ferrule

Preparation for correct mounting of fine-strand wires in the screw terminal block

For the cable cover use a torque of <0.7Nm (6 in-lb).

Screwdriver bit information

The screwdriver bit must have a blade thickness of 1,2 mm (0.046”) and minimal taper over at least the first 2 mm (0.08”) of engagement. This reduces the risk of cam-out and ensures correct torque transfer.

Common 6,3 mm (0.25”) screwdriver bits with a thinner 1 mm (0.04”) blade are not recommended.

In many cases, the GND connection is connected to the chassis via a cable lug. For a low-impedance connection, the cable lug must have direct contact with the metal of the chassis, the contact surface must therefore be free of paint, see below images.

The connector type in this charger is sensitive to constant mechanical stress. Prolonged loading (pulling, pushing or twisting) of the connector should be avoided. For this reason, the charger is equipped with a strain relief in the cable cover. It is very important that the strain relief is applied correctly. The weight of the wire or other forces hanging from the connectors should be close to zero.

The strain relief in the cable cover is designed so that wiring with an outer diameter >9mm is sufficiently clamped. With thinner wiring, the diameter must be increased to >9mm; this can be done simply by applying shrink tubing.

Wire diameter too small - not clamped	Wire diameter >9mm - properly clamped	Wire diameter increased >9mm - properly clamped

Typical connection setting as DC-DC battery charger

Typical connection setting as DC-DC battery charger:

The remote on/off function switches the Orion XS on and off via the two-pole remote connector (L- and H-pin), without the need to interrupt the heavy DC cabling. It gives the versatility to choose from four wiring options, depending on what is available in the installation: a simple switch, a switched positive or negative signal already present in the system, or a BMS charge control contact.

The Orion XS is delivered with a wire loop (bridge) installed between the L- and H-pin. With the wire loop in place, the unit is always on. To switch the unit on and off remotely, remove the wire loop and use one of the options below.

a) A switch wired between the L-H pins	b) A switch wired between battery pos. and the H-pin
ON switch level impedance between L-H pins < 30kΩ	ON switch level > 4V

c) A switch wired between the L-pin and ground	d) BMS control via the H-pin
ON switch level < 6V	BMS ATC output controls the H-pin

The Orion XS is on when at least one of the following conditions is met: the L- and H-pin are interconnected, either by the wire loop or by a switch (option a), the H-pin is pulled high (options b and d) or the L-pin is pulled to battery minus (option c). If none of these conditions is met, the unit is off.

Option a) is the simplest: a plain switch or relay contact, with no connection to the battery poles. Options b) and d) suit installations where a switched positive signal is available, such as a BMS charge control (ATC) contact. Option c) suits installations where a switched negative signal is available, for example a signal switched to the chassis of a vehicle. Option c) cannot be combined with an external engine running signal; see section External engine running signal wiring.

To ensure smooth charging and prevent the risk of overcharging, the chargers must be controlled by the BMS. Depending on the BMS model, this control is either digital, via DVCC, or analogue, via the ATC contact.

DVCC-compatible BMS models

The BMS models listed below can control compatible chargers digitally via DVCC.

Connect a VE.Direct cable between the Orion XS and the GX device and follow the DVCC instructions in the user manual of the BMS. There is no need to wire the BMS ATC contact to the remote H-pin.

The Orion XS is controlled by DVCC via a GX device.

Non-DVCC BMS models

The BMS models listed below control chargers via the ATC contact.

Wire the BMS ATC contact to the remote H-pin.

The Orion XS is controlled by the BMS ATC contact.

An external engine running signal tells the Orion XS that the engine is running. See the Using an external engine running signal section for when such a signal is needed and which sources can provide one.

The signal is connected to the L-pin of the remote connector. Applying >8V to the L-pin overrides the engine shutdown detection and activates the charger, even when engine shutdown has been detected.

Wiring examples for the external signal with the various remote on/off options

External signal when remote on/off option a) is used	External signal when remote on/off option b) is used
A switch between the L-H pins, or the wire loop fitted on delivery	A switch wired between battery pos. and the H-pin

External signal when remote on/off option c) is used	External signal when remote on/off option d) is used
The L-pin is already connected to battery minus. Therefore connecting a positive signal to the same terminal is not allowed.	BMS ATC output controls the H-pin

Wiring a signal that is pulled to ground

Some vehicles provide an engine running signal that is pulled to ground (battery minus) while the engine is running, and is open circuit while the engine is off. This is the opposite of what the L-pin expects, so the signal cannot be connected to the L-pin directly. Use a relay to convert it:

While the engine runs, the vehicle terminal pulls the relay coil to ground, the relay energises and the contact applies >8V to the L-pin. When the engine stops, the vehicle terminal opens, the relay releases and the signal on the L-pin is no longer present.