Hello,
New to the forum after struggling with my new Van and elec. system where the sellers are of little help.
Recently purchase a newly build MAN TGE 3.180 with one factory installed smart alternator (200W) and dual AGM battery. (One starter and one for auxiliary consumers. The aux. battery is charged by the factory installed alternator via de starter battery. The latter disconnects from the aux. battery if the engine is killed. The starter battery thus won’t drain.)
The Van is converted by a ‘specialist’ and they installed a 2 x 200AH/2.560WH 12V LiFePO4 in parallel that each can handle up to 70A charge safely. (100A mpeak)
Charging of this battery pack is done by an Orion XS connected in parallel with the starter battery and the factory installed alternator. This system doesn’t work to my needs since the ECU is steering the alternator, meaning at times (most of the time!) the Orion is not charging. This has to be looked into at a later stage.
A third party ‘specialist’ installed a second, similar as the first, VW original, smart alternator and connected that directly towards an Orion-Tr Smart 30A Dc-Dc to also charge the leisure battery (LiFEPo4). (No ‘buffer’ battery, i.e. direct charging.)
Only the XS (called “the first”) is running over a Victron Shunt that is like the Orion XS itself is connected to the Cerbo GX system controller.
I am about to change this second Orion (The ‘Tr’) for a second Orion XS because it is getting way too hot and doesn’t produce enough power.
It only produces 300W at max. Even together with the XS (that most of the time is not even working!) I get to charge some 900Watts maximum on the leisure battery bank. With some 3% charging losses I need several hours to run to get the system charged back up to full! Not good enough if you are only have a couple of hours daylight to drive in the arctic winter… (you also need to supply energy to the heating and light systems… )
The whole Victron (2 x Orion, one MPPT charger, one MultiPlus 30/2000/220) setup is also such that it gets over 40 degrees inside the well insolated technical cabinet. The ‘XS’ became 35C on the frontside, the Tr 75C! When the MultiPlus is working from shore power or inverting to supply an aircon in heating mode it sends multiple heat alarms. Same for the MPPT tracker and the XS lowered its output due overheating and the Tr even knocked off at times… Not a good installation to say the least!
So, several actions to be taken to get a better cooled and producing system.
So, installed thermostatic controlled forced ventilation on the cabinet that helps a lot. Waiting to install some extra vents on the Multiplus and this heating source called “Orion-Tr Smart” has to go. It will be replaced by a new XS presently on my desk.
Hopefully these changes will reduce a lot on the heat issues and also increase my power input from the alternators into the leisure battery system.
The system should have been designed to work in the winter-artic where there will be no sun for weeks or months to charge the battery, very little chance to charge by shore power. So it’s the alternators that have to do the bulk of the work. If the 2560WH bank is drained to 10 or 20% we need a lot of energy to get them back ‘filled’. Hence I need to make as much as good on the two alternators with the two Orions. At the moment with the poor installation and how its been configured I need to run the engine (driving..) for over 12 hours to get the leisure battery from 10% to 90%. That is not good enough!
The first, ‘original’ Orion XS has to be configured better then at present. Probably I have to make the ‘drop off’ voltage lower so it will charge for more prolonged times, even if the ECU lets the starter battery drop to just above 12V for ‘Euro6/7’ homologation. This I think I know what to do to make it happen. But for now I leave this to be as it is.
First the new, Orion XS. That will be connected directly towards that second third party installed alternator. (Like the present ‘Tr’.)
No battery buffer, no shunt connected to the Cerbo. The only monitoring will be by Bluetooth/VictronConnect app. when it runs. (I will probably install a shunt with a Volt/amp meter in my dashboard to monitor the output of this alternator.)
My question is now; What would be the best way to configure this second Orion XS?
Somewhere in my Van is a D+ cable available from a engine vibration sensor. It can tell the Orion when the engine is running. Or I need to find a D+ connection in the fuse box under my seat (LHD) to feed into this Orion XS by its ‘H’ switch port.
What I do want to avoid is that the alternator starts to run while the engine is still idle after a (very-)cold start. (At the moment the ‘old’ Tr only starts the alternator to produce energy when the engine is pushed over the 3500rpm. How this is done is not clear to me. Can’t find any documentation nor can the installer tell me. “The alternator came configured like that…” !?! )
I also don’t want to over-charge the battery bank (although it seems to me all combined maximum currents are well within the installed wiring, bushbar, shunt and battery etc.). I think the BMS should handle the power coming from both Orions? (Any input in this?)
Any advices about the recommended settings of this new Orion are appreciated. I need this system to work. Can’t have issues this coming winter stranded with a low battery system in minus 30 to 40 Celsius while not able to drive prolonged times. Don’t want to run my engine all day neither…
(Hence I also need to look at that 1st installed XS… It needs to work more.
(One last note; in some circumstances (the trigger is not identified yet by me) the engine will run at higher idle revs to help the 1st (and thus the second) alternator to run. Engine runs at 1000 rpm where standard is 800-850 rpm.)
A long and complicated topic, yes I know.



