Victron Orion XS Troubleshooting Guide

This MultiPlus/Quattro Troubleshooting Guide and Checklist is designed to help users identify and resolve common issues with their Orion XS DC DC Charger. Whether you’re an off-grid enthusiast, a mobile adventurer, or managing a marine power system, this guide provides step-by-step instructions to help you troubleshoot problems on your own. It’s an essential resource for anyone experiencing system malfunctions, including power outages, charger failures, or battery charging issues.

At EXPLORIST.life, we are committed to providing top-notch support to our customers. If you’ve purchased your Orion XS from shop.explorist.life, you can reach out to us at shop.explorist.life/support for additional personalized guidance and troubleshooting assistance. Our team is here to help you with any issues that may arise.

If you purchased your unit elsewhere, we hope this guide and checklist will still help you resolve any issues with your system. While direct support is reserved for our customers, we invite you to consider EXPLORIST.life for your future purchases and projects where you will get access to personalized expert support.

Step 1: Share Your Order Information

• Only applicable to customers via our support ticketing system at https://shop.explorist.life/support

Step 2: Check the Basics

• Why It’s Important: Many issues with the Orion XS can be resolved by ensuring basic system operations are correct.
• What to Do:
  1. Is the master battery switch on?
     • What to Do Next: If the switch is off, turn it on and check if the system starts working.
  2. Are other 12V loads functional (e.g., lights, fans)?
     • Why It’s Important: If other 12V loads, such as lights or fans, aren’t working, this may indicate an issue with the battery or the main system fuse rather than the Orion XS itself.
     • What to Do Next: If no 12V loads are functioning, inspect the battery connections and check the main system fuse for a possible failure. If the fuse is blown or the batteries are low, address these issues before troubleshooting the Orion XS.
  3. Are other devices like the solar controller or battery monitor functional?
     • What to Do Next: If none of the devices are functioning, there could be an issue with the overall system wiring. Inspect all system connections, ensure all breakers or switches are turned on, and check for any error lights on other devices.
  4. Is your vehicle running?
     • What to Do Next: If your vehicle is not running, start it to activate charging. Ensure that the alternator is working and that the Orion XS is detecting input voltage.
  5. Is your house battery bank not full?
     • What to Do Next: If the house battery is full, the Orion XS will not engage charging. You can wait until the battery discharges or temporarily disable other charging sources (solar/shore power) to observe Orion XS charging behavior.
  6. Note any lights on the Orion XS unit:
     • What to Do Next: If the lights indicate an error, consult the troubleshooting section of the guide for the specific error code, and follow the recommended steps.
  7. Is the remote wire in place?
     • What to Do Next: If the remote wire is disconnected, reconnect it and check if the system starts charging.
  8. Is solar charging overriding the DC-DC charger?
     • What to Do Next: If solar charging is active, turn off the solar isolator to prevent solar charging and test whether the Orion XS begins charging.
  9. Is shore charging overriding the DC-DC charger?
     • What to Do Next: Disconnect shore power if connected and check if the Orion XS starts charging from the alternator.

Step 3: Check Your Settings

• Why It’s Important: Incorrect settings can cause the Orion XS to malfunction or underperform.
• What to Do:
  1. Refer to the settings outlined in the troubleshooting guide to ensure that your configuration matches the recommended settings.
  2. What to Do Next: If your settings do not match, adjust them according to the guide and monitor the system’s performance.

Step 4: Inspect the System Installation

• Why It’s Important: Many problems can arise from incorrect wiring, loose connections, or other physical issues with the installation. A visual inspection can help spot potential issues that are not immediately obvious through software diagnostics.
• What to Do:
  1. Inspect All Wiring Connections:
     • What to Do Next: Gently tug on each connection to ensure it’s secure. Look for any signs of wear, corrosion, or fraying. Tighten any loose connections and clean off any corrosion that may be affecting performance.
  2. Check for Signs of Overheating:
     • What to Do Next: Look for discoloration, melting, or any other signs of heat damage around wire lugs, terminals, and connection points. If you notice any signs of overheating, replace the affected cables and ensure proper connections.

Step 5: Inspect the Component Wiring

• Why It’s Important: Wiring issues at the component level can directly affect the Orion XS’s ability to charge and deliver power. Ensuring that each component is wired correctly is crucial for the system to work efficiently.
• What to Do:
  1. Inspect the Wiring Between the Orion XS and the Battery:
     • What to Do Next: Ensure that the positive and negative connections between the Orion XS and the battery are secure and correctly wired. Double-check the polarity and verify that all wires are properly crimped and attached.
  2. Check for Blown Fuses or Tripped Breakers:
     • What to Do Next: Inspect all fuses in the wiring circuit and confirm they are intact. If any fuse is blown, replace it with the same amperage rating. If a breaker has tripped, reset it and monitor the system for further issues.
  3. Look for Discoloration or Melting:
     • What to Do Next: If any wires or terminals show signs of heat damage, replace them immediately and inspect the system for other contributing factors like loose connections or insufficient cable size.

Step 6: Review the Orion XS Home Screen

• Why It’s Important: The home screen in the VictronConnect app displays critical information, such as input/output voltages and error codes, that can help identify any issues with the system’s performance.
• What to Do:
  1. Open the VictronConnect app, view the Orion XS device, and capture a screenshot of the home screen.
  2. What to Do Next: Compare the input/output voltages shown on the app with the voltages you’ve measured using a multimeter. Acceptable voltage ranges for the Orion XS are:
     • For 12V systems: Input/output voltage should typically be above 13V.
  • If the readings are outside this range, check the system’s wiring and settings for potential issues.

Step 7: Review the Orion XS ‘History’ Tab

• Why It’s Important: The ‘History’ tab in the VictronConnect app provides key data on how long the charger was actively charging and how many amp hours it pushed into the batteries.
• What to Do:
  1. Look at the ‘elapsed’ row, which shows how long the charger was charging during the day.
  2. Check the amp-hour graph at the top to see how many amp hours the charger provided to the batteries.
  3. What to Do Next: If both the ‘elapsed’ row and amp-hour graph are missing, there may be an issue with the charger, wiring, or settings. If data is present, the charger may be functioning normally, and you should investigate other parts of your system.

Step 8: Verify Output Voltage

• Why It’s Important: Ensuring the Orion XS is delivering the correct output voltage confirms it is charging the house battery correctly.
• What to Do:
  1. Use a multimeter to measure the voltage between the ground and OUT terminals of the Orion XS.
  2. What to Do Next: If the multimeter reading doesn’t match the expected output (above 13V for a 12V system), inspect the wiring and recheck the charger settings in the VictronConnect app. Ensure that no other charging sources are active.

Step 9: Verify Input Voltage

• Why It’s Important: Ensuring the Orion XS is receiving the correct input voltage from the alternator or other power source is crucial for proper operation.
• What to Do:
  1. Use a multimeter to measure the voltage between the ground and IN terminals of the Orion XS.
  2. What to Do Next: If the input voltage is lower than expected (above 13V for a 12V system), inspect the alternator and the wiring leading to the Orion XS. Ensure that the alternator is functioning properly and that the wiring is intact.

Step 10: Check for Error Codes

• Why It’s Important: Error codes provide insight into what specific issue the Orion XS is encountering.
• What to Do:
  1. View any error codes displayed in the VictronConnect app.
  2. What to Do Next: Follow the troubleshooting steps in the guide to resolve the specific error. Some errors may require inspecting the wiring or adjusting settings in the app.