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

The automatic engine shutdown detection simplifies the Orion XS system by detecting whether the engine is running, without wiring additional switches or sensors. The factory default setting will work with most conventional and smart alternators but can be re-configured with the VictronConnect App.

The detection is based on the alternator voltage. Conventional alternators will generate a fixed voltage (e.g. 14V), whereas the voltage of smart alternators can vary between 12.5V to 15V (for a 12V system). Smart alternators in a regenerative braking system often show large voltage variations.

Engine shutdown detection is only active in charger mode. The feature can be configured, disabled and reactivated as described in the Engine shutdown detection & input voltage lock-out section. In power supply mode, the Input voltage lock-out determines when the output is active.

In installations where the alternator voltage does not give the detection enough to work with, an external engine running signal can be used instead; see the Using an external engine running signal section.

4.1.1. How it works

The following procedure describes the operation of the engine shutdown detection sequence.

Engine shutdown detection sequence

1. 0 → 1: If the engine runs, the alternator voltage will ramp up. When V_starter > V_start, charging is enabled.

2. 1 → 2: The input current produces a voltage across the input cable (V_cable); this voltage reduces the voltage measured by the charger (V_IN). If V_IN > V_shutdown, the charger will operate at I_max.

3. 2 → 3: If V_IN ≤ V_shutdown, the charge current will be reduced to prevent V_IN to drop below V_shutdown.

4. 3 → 4: If V_IN < V_shutdown for longer than 1min (t_shutdown), “engine off” is detected and charging is disabled. If V_IN > V_shutdown before t_shutdown runs out, charging remains enabled.

5. 4 → 5: If V_start(delay) < V_IN < V_start, charging is enabled after t_start delay (configurable).

The emergency reverse charge function charges a depleted starter battery from the auxiliary battery, so that the engine can be started again. It is intended for situations where the starter battery no longer holds enough energy to crank the engine, for example after the vehicle has been parked for a long time or when the starter battery has been drained by a load.

During an emergency reverse charge, the Orion XS temporarily reverses its normal charge direction: energy flows from the auxiliary battery connected to the output to the starter battery connected to the input. In the VictronConnect App, this reversed flow is shown as negative input and output current values.

For the procedure, see Starting an emergency reverse charge.

Start conditions

The emergency reverse charge button on the Status screen of the VictronConnect App is always present, but it is only active while an emergency reverse charge is possible.

An emergency reverse charge is only possible when the Orion XS is in charger mode and the charger is off for one or both of the following reasons:

A remote off does not block an emergency reverse charge. The function stays available when the Orion XS is switched off via remote on/off.

The emergency reverse charge sequence

An emergency reverse charge runs for a fixed time and consists of two phases:

Emergency reverse charge, 15 minutes. The Orion XS draws energy from the auxiliary battery and uses it to charge the starter battery. The app shows Emergency reverse charge together with the time remaining. Settling period, 5 minutes. The charger is disabled, so that it cannot draw energy from the starter battery or the alternator. This allows the starter battery to settle and the engine to be started. The app shows Battery ready together with the time remaining.

After the settling period has ended, the Orion XS resumes normal operation.

Reverse charge current

The reverse charge current is half the rated charge current of the device. If a lower input or output current limit is configured for normal charging, the lowest configured limit is used instead. The app states the limit that will be applied before the emergency reverse charge is started.

The starter battery is charged to a maximum of 14,4 V.

To protect the auxiliary battery against deep discharge, the Orion XS maintains the auxiliary battery voltage at 12 V. As the auxiliary battery approaches this level, the reverse charge current is reduced, so that as much energy as possible is transferred without deeply discharging the auxiliary battery.

If the auxiliary battery is already at or below this level when the emergency reverse charge starts, the function still runs but no current is transferred. Current only begins to flow if the auxiliary battery voltage rises above the level again during the charge, for example because another charging source is charging the auxiliary battery.

The requested reverse charge current is not always reached. See The reverse charge current is low or zero for the possible causes.

Monitoring and settings

The state, the input and output voltages and the input and output currents can be followed in the VictronConnect App. It is not necessary to stay connected to the Orion XS while the sequence runs.

The settings cannot be changed while an emergency reverse charge is in progress, including during the settling period. The Settings page of the VictronConnect App shows a message stating that the settings will be available again once the emergency reverse charge has finished.

4.2.1. Starting an emergency reverse charge

An emergency reverse charge is started from the VictronConnect App. The Orion XS must be set to charger mode; the emergency reverse charge button is greyed out in power supply mode.

For a description of the function and the conditions under which an emergency reverse charge can take place, see Emergency reverse charge.

Caution

In systems with more than one Orion XS connected in parallel, either start an emergency reverse charge on all of them or switch the others off first.

A Orion XS that is reverse charging raises the starter battery voltage. Another Orion XS that is still in normal operation reads that rise as a running engine and starts charging forward, so the two units charge against each other.

The result is a circulating current between the units. Energy is drawn from the auxiliary battery without reaching the starter battery, and the engine may still not start.

Connect to the Orion XS with the VictronConnect App. On the Status screen, tap the engine icon in the top left corner. The Start emergency reverse charge window opens. It states the voltage the starter battery will be charged to and the maximum reverse charge current that will be applied. Select I understand the feature and tap START. The app shows Emergency reverse charge together with the time remaining. After 15 minutes the app shows Battery ready. Start the engine while the app shows Battery ready.

Stopping an emergency reverse charge

An emergency reverse charge can be stopped before it has finished. Tap the engine icon again and confirm with STOP in the window that opens. Note The settling period does not run in this case: the Orion XS returns to normal operation directly.

The Orion XS has 3 coloured LEDs showing the charger's status. Their meaning and behaviour are explained below.

LED status:

LED behaviour	Description	Symbol
On	Permanently on
Off	Permanently off
Very slow blinking	Blinking 1x per 1.6s
Slow blinking	Blinking 2x per 1.6s
Blinking	Blinking 4x per 1.6s
Fast blinking	Blinking 8x per 1.6s
Pulsating	Short pulses per 1.6s

LED indications overview:

Orion XS status	Bulk LED	Absorption LED	Float LED
Off
Error mode
Identify
Power supply mode
Emergency reverse charge
Battery ready
Bulk mode
Absorption mode
Float mode
Storage mode
Equalisation mode
Repeated absorption mode
BatterySafe
Software update
Other

This chapter will help you get the most out of your Orion XS using the VictronConnect App and requires minimal knowledge of this battery charger.

For more general information on the VictonConnect App, how to install it, how to pair it with your device and how to update the firmware, see the VictronConnect manual.

4.4.2. Charger mode settings

When in Charger Mode, these are the available settings:
Function: Allows for the choice between “Charger” or “Power supply” mode. When Charger mode is selected, the Orion XS will follow the charge algorithm. For more information about the charge algorithm, please read the Features section.
Charger enabled/disabled: The charger is enabled by default. Use the switch to disable the charger if necessary.
Input current: Limits the maximum current drawn from the input source. This is particularly important to avoid overloading an alternator or other weak input sources. The value can be adjusted between 1 A and 50 A in 0,1 A increments.
Output current: Limits the maximum output current. The value can be adjusted between 1 A and 50 A in 0,1 A increments.
Battery settings: Allows to change the battery settings in order to adjust the absorption voltage, float voltage, and others to fit the battery being charged; see the Charger mode - Battery settings section for details.
Engine shutdown detection: Allows three voltage limits and a delay time to be selected. One voltage limit is used to determine whether the engine has stopped, and two are used to detect whether the engine is running (again). Normally, a minimum difference of 0,2 V is used for optimal operation. If desired, the protection can still be disabled by the user. For more information, please read the Automatic engine shutdown detection and Engine shutdown detection & input voltage lock-out sections.
Input voltage lock-out: Allows to choose between two thresholds, one to set the lock-out value and another for the restart value. Normally, a minimum difference of 0.5 V is recommended for proper operation. The protection can still be disabled if desired by the user. For more information about the input voltage lock-out, please read the Automatic engine shutdown detection section.

4.4.3. Charger mode - Battery settings

Battery preset: Battery preset allows to select the battery type, accept factory defaults, or enter your own preset values to be used for the battery charging algorithm. The Absorption voltage, Float voltage, Storage voltage, Bulk time limit, Re-bulk voltage offset, Adaptive absorption time and Absorption time settings are all configured to a preset value - but can also be user-defined. User-defined presets can be stored in the preset library - in this way, installers will not have to define all the values each time they are configuring a new installation. By selecting Edit Presets, custom parameters can be set depending on the selected preset (battery type). Be sure to follow the battery manufacturer's recommendations for your battery type. The main parameters are as follows: Absorption voltage Float voltage Storage voltage Equalization voltage (disabled for the Victron Lithium Smart Battery preset) Temperature compensation (disabled for the Victron Lithium Smart Battery preset) Low temperature cut-off (configurable for lithium batteries) Note that this setting only takes effect when the battery temperature is shared by other devices, for example, by a BMV-712 or SmartShunt in a VE.Smart network. This setting is not effective if a BMS controls the charger. Expert mode: Activating Expert mode enables additional settings, depending on the selected preset. Note that the defaults work well for most cases. Change expert settings only if your equipment and battery has special requirements: BatterySafe (prevent excessive gassing by automatically limiting the rate of voltage increase) Bulk time limit Set the maximum bulk time allowed for the charger. Re-bulk voltage offset (when the battery voltage drops 0.1V below the re-bulk voltage for one minute, the charge cycle will restart) The re-bulk offset voltage determines what is the offset between the float voltage (or absorption if it is lower) and the re-bulk voltage. The re-bulk voltage is the battery voltage threshold that triggers another charge cycle. For example, when the charger cannot maintain the battery voltage due to a high load, the battery voltage will fall, and a new charge cycle will be started once the battery voltage drops below the re-bulk voltage. Absorption duration (Adaptive, fixed absorption) The absorption time depends on whether the adaptive absorption time algorithm is used or not. If Adaptive absorption time is not enabled, the charger uses a Fixed absorption time that is user-selectable. When the Adaptive absorption time is enabled, the charger will determine the absorption time based on the bulk elapsed time of that charge cycle. The Maximum absorption time is also set by the user in this case. Maximum absorption time Tail current (the charger will end absorption and switch to float or recondition when the charge current drops below the tail current threshold) Repeated absorption Equalization current percentage (maximum current during equalization will be this percentage of the max charge current) Equalization stop mode (Automatic on voltage, fixed time) Maximum equalization duration Manual equalization

4.4.4. Power supply mode

Orion XS [serial number] or a specified custom name confirms the connected device.
Mode icon: indicates which mode the Orion XS is operating in (in this case Power Supply Mode).
Output voltage: Voltage measured at the output terminals of the device.
Output current: Output amperage.
Output power: Output power in Watts.
Input voltage: Voltage measured at the input terminals of the device.
Input current: Current drawn by the charger.
Input power: Input power in Watts.
Why is the power supply off?:  Appears instead of the Power Supply Mode text and displays the reason why the Orion XS is turned off.

4.4.5. Power supply mode settings

Function: Allows you to choose between Charger and Power Supply Mode. When the Power Supply Mode is selected, the Orion XS keeps the output voltage stable as specified in the setting.
Output enabled/disabled: Output is enabled by default. Use the switch to disable the output if necessary.
Input current: Limits the maximum current drawn from the input source.
Output current: Limits the maximum output current.
Output voltage: Allows to choose the output voltage when Power Supply Mode is selected. Note that the minimum and maximum voltages needs to be within the product limit (i.e.: 10V to 17V for a 12V output Orion XS).
Input voltage lock-out: Allows to choose between two thresholds. One to set the shutdown level and another for the restart value. Normally, a minimum difference of 0.5V is recommended for proper operation.

4.4.6. Engine shutdown detection & input voltage lock-out

Engine shutdown detection

To configure engine shutdown detection settings, open VictronConnect, connect to your Orion XS and from the status page press the cog icon to get to the Settings page.

The following settings can be changed with VictronConnect:

Engine shutdown detection enabled/disabled: The engine shutdown detection is always enabled by default whenever the charger mode is selected. When the function is disabled or when power supply mode is selected, the engine is considered to be running, so no shutdown detection will take place. Leave the engine shutdown detection enabled when an external engine running signal is connected: the signal only forces charging on, and disabling the detection makes the charger charge continuously regardless of the signal. See Using an external engine running signal.
Alternator type: For the type of alternator you can choose between “Smart alternator”, “Regular alternator” and “User defined”. When the "Smart alternator" option is selected, the default values for the smart alternator will be applied to the engine shutdown detection settings. The same will happen when "Regular alternator" option is selected. When any of the settings differs from the default values of the last two option, the "User defined" option will be selected. Default: smart alternator.
Start voltage (Vstart): At this level, charging starts immediately.
Delayed start voltage (Vstart(delay)): Smart alternators can generate a lower voltage when the engine is running, therefore a lower start level is necessary for these systems. To ensure that the starter battery is recharged after starting the engine, charging of the auxiliary battery is delayed during this condition. The energy used during starting must be replenished to ensure that the starter battery remains properly charged.
Delayed start voltage delay (tstart delay): Recharge time for the starter battery during start voltage mode. Example: If the starter draws 150 A for 5 seconds to start the engine, approx. ~0,2 Ah is drawn from the starter battery. If, during engine idling, the alternator can only generate 20 A, it takes 150 A/20 A x 5 s = 37,5 s to recharge the starter battery.
Shutdown voltage (Vshutdown): This level corresponds with the engine being off. This keeps the starter battery fully charged and provides a hysteresis with respect to the start level. The hysteresis must be large enough to prevent VIN to drop to Vshutdown which would result in charge current reduction. Action will be taken after tshutdown runs out (1 minute); this allows charging during temporary low-voltage conditions. Setting range for start and stop voltages: 9 to 35 V

The default values depend on the selected alternator type. Values are given as 12V system / 24V system.

Setting	Smart alternator	Regular alternator
Start voltage (Vstart)	14 V / 28 V	14 V / 28 V
Delayed start voltage (Vstart(delay))	13,3 V / 26,6 V	13,8 V / 27,6 V
Delayed start voltage delay (tstart delay)	120 s	120 s
Shutdown voltage (Vshutdown)	13,1 V / 26,2 V	13,5 V / 27 V

When the charger is off because the engine shutdown detection has determined that the engine is not running, or because the input voltage lock-out is active, an emergency reverse charge can be started from the VictronConnect App. See Emergency reverse charge.

Input voltage lock-out

Setup input voltage lock-out: Input voltage lock-out is the minimum level at which charging is allowed, below this level charging stops immediately. Default (in charger mode): lock-out: 12,5 V/25 V; restart: 12,8 V/25,6 V. Default (in power supply mode): lock-out: 10,5 V/21 V; restart: 12 V/24 V. When ‘forced charging’ is enabled, current will be drawn from the starter battery if the engine is not running. Setting the lock-out level very low or deactivating the input voltage lock-out can result in a depleted starter battery.

To setup input voltage lock-out, two criteria are important: Minimum alternator voltage: A smart alternator can operate at very low alternator voltage (< 12,5 V/25 V) e.g. when the vehicle accelerates. Charging during this low voltage is allowed during tshutdown as shown in “engine shutdown detection sequence 3→4”. If charging must remain enabled during this period, the lock-out level must at least be set below the minimum alternator voltage. Note: When the input undervoltage period exceeds tshutdown, engine shutdown detection will disable charging. Voltage drop across the input cable: As seen in “engine shutdown detection sequence 1→3”, VIN will be lowered by Vcable. When the alternator voltage drops quickly (smart alternator), the voltage control needs some time to reduce charge current and keep VIN at Vshutdown. During this adjustment period, VIN can even drop below Vlock-out, which activates the undervoltage protection and stops charging. To prevent this, Vlock-out must be set as follows: Vlock-out ≤ Vshutdown – Vcable. Example: Calculate the input cable voltage drop: Distance between starter battery and charger: 5 m Vshutdown = 13,1 V. Recommended wire gauge: 16 mm2 Cable resistance: ~1,1 mΩ/m @20 °C, thus Rcable = 1,1 mΩ x 10 m (2 x 5 m) = 11 mΩ At a maximum input current of 50 A, this results in: Vcable = 11 mΩ x 50 A = 550 mV Vlock-out ≤ Vshutdown – Vcable = 13,1 V – 550 mV = 12,55 V. Cable connections, external fuses, temperature, etc. influence the total cable resistance.

4.4.7. Product information page

By clicking the  button on the top right of the Settings menu, it is possible to access the product information screen:

Product shows the Orion XS model.
Serial number shows the serial number of the unit.
Pin code allows the pin code to be changed. This is recommended to be done so settings and information won't be easy to access.
Custom name allows you to change a custom product name to your liking. By default, the product name “Orion XS” plus the serial number is displayed.
Firmware shows the firmware version currently installed on the device and also allows the charger to be updated if required.
Bluetooth: Bluetooth is enabled by default and can be disabled if necessary. To re-enable Bluetooth, please see the "How to disable and re-enable Bluetooth" chapter in the VictronConnect manual. Note that re-enabling Bluetooth requires a VE.Direct to USB interface connection between the Orion XS and a PC, Mac or Android device. iOS devices such as the iPhone and iPad do not support serial USB devices.
Instant readout via Bluetooth: Use the slider to disable/enable Instant readout.
Instant readout details: Displays the MAC address and encryption key for the unit.

4.4.9. Charger mode - Status screen

Orion XS [serial number] or a specified custom name confirms the connected device.
Mode icon: indicates which mode the Orion XS is operating in (in this case Charger Mode).
Charger State: Bulk: During this stage, the Orion XS supplies the set charging current to quickly charge the batteries. When the battery voltage reaches the Absorption voltage setting, the Orion XS activates the Absorption stage. Absorption: From this stage, the Orion XS switches to the constant voltage mode, where a pre-set absorption voltage suitable to the battery type (see Charger mode - Battery settings) is applied. When the Absorption time has elapsed, the Orion XS activates the Float stage. Float: During this stage, the float voltage is applied to the battery to maintain a fully charged state. When the battery voltage drops below Re-bulk voltage for at least 1 minute, a new charge cycle will be triggered. Storage: During this phase, storage voltage is applied to the battery. If the battery has been connected to the battery charger for more than 48 hours, further lowering the charging voltage can prevent corrosion in lead-acid batteries. Emergency reverse charge: The starter battery is being charged from the auxiliary battery, and the time remaining is shown. During an emergency reverse charge, the input and output currents are shown as negative values, indicating the reversed direction of the energy flow. See Emergency reverse charge. Battery ready: The emergency reverse charge has finished and the engine can be started. The time remaining of the settling period is shown, after which the Orion XS resumes normal operation. Other possible states depending on the system and battery settings are: Off (engine not running or other reason), Repeated absorption, Equalize, Auto-equalize, BatterySafe, External control (controlled by a BMS), Power Supply Mode
Output voltage: Voltage measured at the output terminals of the device.
Output current: Current measured at the output terminals of the device.
Output power: Output power in Watts.
Input voltage: Voltage measured at the input terminals of the device.
Input current: Current measured at the input terminals of the device.
Input power: Input power in Watts.
Why is the charger off?:  Appears below the battery icon and indicates the reason why the Orion XS is turned off.

4.4.10. Charger mode - Graph screen

Orion XS [serial number] or a specified custom name confirms the connected device.
Charger State Graph: indicates the current charging state of the Orion XS and provides a short description of the current state.

4.4.11. History screen

The history page shows a summary of the charge cycles over the previous 40 cycles. Swipe the screen to the right or left to show any of the 40 cycles. Each column represents a cycle. Tapping on one of the bars reveals further information about duration and current for each of the charge states. Other items are:
Status
Elapsed
Charge: The accumulated charge current
Maintain: The current that keeps the battery fully charged during the float or storage phase.
Type: Battery profile used
Vstart: The lowest battery voltage at the start of the charge cycle
Vend: The lowest battery voltage at the end of the charge cycle
Operation time: Accumulated run time of the Orion XS
Cycles started: Number of charge cycles started
Cycles completed: The number of charge cycles completed (must have reached float or storage voltage stage)
Charged Ah:Total amphours charged with the Orion XS

4.4.12. Trends screen

The VictronConnect app allows data to be displayed graphically via the trends screen. The prerequisite is that the VictronConnect app must be open and connected with the Orion XS. The data is not stored permanently. The following parameters can be displayed:
Input voltage Input current Input power Output voltage Output current Output power Battery temperature (only if it is provided by an external device, for example, a BMV via a VE.Smart Network).

4.4.13. Instant readout over BLE

VictronConnect can display key data of the Orion XS (and other compatible smart products) on the Device list page without the need to connect to the product. This includes visual notifications of warnings, alarms, and errors that enable diagnostics at a glance. Please see the Instant Readout chapter in the VictronConnect manual for more information and how to set it up.

The advantage is:

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

When the Orion XS is connected to the GX device via its VE.Direct port, it can also be monitored and turned on/off via a GX device's remote console or the VRM portal. The following requirements are necessary for this:

Setup

Connect the Orion XS to the GX device using a VE.Direct cable. It will then automatically appear in the device list of the GX device.

Monitoring

To get to the Orion XS detail page, tap the Orion in the Device list. The detail page offers the following options:

Switch: Turns the Orion XS on and off. Depending on the configuration made in VictronConnect, either charger or power supply mode will be started.
Input: Shows the input voltage,current and power as measured at the input terminals.
Output: Shows the output voltage, current and power as measured at the output terminals.
State: Displays the current status of the charger or power supply mode. Possible states depending on the device mode and settings are: Off (engine not running, or other reason, check the Off reason in VictronConnect), Bulk, Absorption, Float, Storage, Repeated-absorption, Equalize, Auto-equalize, BatterySafe, Ext. control (controlled by a BMS), Power Supply.
Network status: This can be either Slave if controlled by DVCC or Standalone device if not controlled by DVCC.
Error: If the Orion XS is in an error state, the error code will be displayed here.
Overall history: Provides an overview of operation time, number of charge cycles, charged Ah, etc.
Charge cycle history: Provides an overview of the last 30 charging cycles.
Settings: Provides access to a submenu in which the application type of the Orion XS can be configured. Alternator charging the main battery - Select this when the Orion XS is used to charge the main battery from an alternator. When selected, an additional charging source tile named Alternator is shown in the graphical overview. Charging another battery from the main battery - Select this when the Orion XS charges a secondary (service) battery from the main battery. BMS controlled - Indicates whether the Orion XS is currently controlled by a Battery Management System (BMS). BMS control – Resets BMS control detection. Use Reset if the system configuration has changed or if no BMS is present but the device remains in BMS-controlled mode. Device: Provides additional device information and allows to assign a custom device name.

With VE.Smart Networking, remote battery voltage, temperature and current sensing can be added to your Orion XS when paired with a battery sensor like a BMV, SmartShunt or Smart Battery Sense. The Orion XS will receive the available information from the battery and use that data to optimise its charge parameters.

The sensed battery current is used for the tail current setting, while the battery temperature is used for temperature voltage compensation and protection.

The sensed battery voltage is used to compensate for voltage drop over the battery cables. Compensating for voltage drop creates a mismatch between the voltage measured at the Orion XS connector and the battery terminals:

V_{OrionXSconnector} = V_battery + V_compensation

Effects when the battery is disconnected

By disconnecting the battery, the physical connection between the charger and the remote sensing device is lost. The charger is not aware that the battery is disconnected and will increase its output voltage to compensate for the voltage difference. In this case, the output voltage will rise until it reaches the saturation level (=2V). E.g. with V_battery=12.6V, the output voltage (V_connector) saturates at 14.6V.

Although it is not a problem that the Orion XS outputs a higher voltage, it can be confusing when analysing the voltage levels in a system and comparing them with the readings of the VictronConnect/GX device. Therefore, when analysing, make sure that all necessary physical connections are made.