3. Installation
3.1. Mounting
Mount vertically on a non-flammable surface, with the power terminals facing downwards.
For optimum performance, a minimum of 10cm space should be kept free around the product for cooling. With limited cooling, e.g. due to insufficient ventilation, the charging current will be reduced sooner than at the specified maximum ambient temperature. With improved airflow (e.g. forced airflow), the performance will greatly improve.
With limited cooling or extreme ambient temperature, the charger can become hot (especially the bottom plate). Due to internal temperature control, the heat sink will never get warmer than 90 °C; this is no problem for the charger. Make sure that the mounting surface can withstand this temperature.
Mount close to the battery but never directly above the battery (to prevent damage from gassing of the battery).
3.2. Cable type recommendations
For correct connection of a cable to the input/output screw terminals, stranded wires with flexible cores can be used according to:
IEC 60228 - Class 2 (stranded), Class 5 (flexible)
UL486A-B - Class B/C (stranded), Class I (flexible)
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.
Single wire diameter in the bundle | ||
|---|---|---|
Nominal cross-section | Class 5 (IEC) | Class I (UL) |
10mm2 / 8AWG (8.4mm2) | 0.4mm | 24AWG |
16mm2 / 6AWG (13.3mm2) | 0.4mm | 24AWG |
4AWG (21.1mm2) | 0.4mm | 24 AWG |
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
Cut the cable straight with no loose or staggered threads. Using wire cutters will result in a straight cut.
Make sure no fine wires are cut when stripping the insulation.
Open the screw on the screw terminal block completely to prevent fine wires from getting caught behind the screw and bunching up. Pay particular attention to this when using the maximum wire diameter.
Tighten the screw with the correct torque; see Recommended torque and note the wire size and wire class. Never apply less than the recommended torque.
Hold the recommended torque for at least 5 seconds; this will give the screw time to settle to the set torque. This maximises the force on the wire, thereby maintaining a gas-tight contact pattern during heating and cooling cycles over time. Take the time to do it right. This is important. This is a UL486 test requirement and a requirement for all factory and field installations.
3.3. Cable and fuse recommendations
External battery protection fuse | Minimum cable gauge | |
|---|---|---|
60 - 70A | <5m | 5 - 10m |
16mm2 / 6AWG (13.3mm2) | 4AWG (21.2mm2) | |
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3.4. Recommended torque
AWG | mm2 | in-lb | Nm |
|---|---|---|---|
4 | 21.2 | 35 | 4 |
6 | 16 | ||
8 | 10 | 25 | 2.8 |
10 | 6 | 20 | 2.3 |
12 | 4 |
For the cable cover use a torque of <0.7Nm (6 in-lb).
3.5. GND connection
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.
Important
Make sure the GND connection on the vehicle's chassis has a low impedance.
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3.6. Strain Relief
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.
Caution
Insufficient strain relief can lead to connector damage in the long term.
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 |
|---|---|---|
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3.7. Connection setup for DC-DC power supply mode
Disconnect the remote on/off (remove the wire bridge or remove the entire remote on/off terminal block).
Connect the input power cables.
Open the VictronConnect app to set up the product (always adjust the output voltage before connecting a load or battery to the output).
For details, see Power supply mode settings.
Connect the load.
Reconnect the remote on/off to activate the product. The product is now ready for use.
Typical connection setting as DC-DC power supply
3.8. Connection setup for charger mode
Disconnect the remote on/off (remove the wire bridge or remove the entire remote on/off terminal block).
Connect the input power cables.
Open the VictronConnect App to set up the product (always set up the correct charging algorithm before connecting a battery to the output).
For details, see Charger mode settings.
Connect the battery to be charged.
Reconnect the remote on/off to activate the product. The product is now ready for use.
Typical connection setting as DC-DC battery charger
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Typical connection setting as DC-DC battery charger
3.9. Connection setup for remote on/off
The recommended use of the remote on/off input is:
A switch wired between the L-H pins (ON switch level impedance between L-H pins: < 30kΩ)
A switch wired between (input/output) battery positive and H pin (ON switch level > 4V)
A switch wired between the L-pin and (input/output) ground (ON switch level < 6V)
BMS control via the H-pin (e.g. between BMS ATC output and H-pin)
Note
Note the voltage tolerance between L- & H-pin: +/- 70VDC
a) L-H pin wiring | b) H-pin wiring | c) L-pin wiring | |||
|---|---|---|---|---|---|
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d) BMS control via H-pin | |||||
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Remote on/off connections | |||||
3.10. Engine shutdown detection override wiring
In charger mode, the engine shutdown detection sequence determines whether the conditions are met to enable charging; see the Engine shutdown detection chapter. Overriding the engine shutdown detection allows the user to decide for himself whether charging is allowed. Applying >8V to the L-pin overrides the engine shutdown detection and activates the charger. This can be done, for example, with an ignition switch, CAN-bus engine running detector, etc.
Notice
This function does not override the remote on/off function. Remote connection a), b) or d), as shown in section Connection setup for remote on/off, must be configured in combination with engine shutdown detection override. See examples in the below images.
Enable charging via an ignition switch i.c.w. remote on/off option a) | Enable charging via an ignition switch i.c.w. external on/off option (e.g. BMS ATC contact) d) |
|---|---|
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Engine shutdown detection override connection diagram
Note
When the ignition switch is switched off, the charger will return to engine shutdown detection mode, it will not turn off the charger.
To force enable/disable charging (i. e. turn the Orion XS on/off) without interference from the engine shutdown detection, a remote option as given in section Connection setup for remote on/off must be wired, and the engine shutdown detection must be switched off in VictronConnect, see figure below.
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Disable engine shutdown detection
Warning
When the engine shutdown detection has been switched off in Victron Connect (‘forced charging’), current will be drawn from the starter battery even if the engine is not running.
Note
During ‘forced charging’ the input voltage lockout is the only limit left to disable charging automatically, make sure this level is not set too low, in most applications 12.5V is sufficiently low.