2020+ AI New OrionXS Unhappy w/ Chassis Solar Panel output

[3OnOurWay]

I’ll try to keep this short and in a chronological order.

The original set up on our Airstream Interstate was with the OEM. Victron DC DC. Buck boost controller wired into the battery and vehicle alternator providing power into the battery.

Also OEM is the front solar panel that provides charging through an inexpensive solar controller to keep the chassis battery charged. No issues here prior to next part:

We changed the DCDC charging to a Orion XS removing the DC DC buck boost charger. We kept all wiring paths the same. On the first long drive and a few hours into DCDC charging and solar panel charging battery we lost the OrionXS. ( I posted about that here on an earlier thread and was advised the only way to restart. It was to disconnect power and reconnect power, and that worked flawlessly) . I think that due to solar shading, underpasses which would trigger a fault in the Orion XS and shut down the Orion.

After the third time this happened, diagnosed that it was likely the solar panel creating an issue with the perceived voltage going into the Orion. XS? We , removed the fuse from the existing inexpensive solar controller and have had no issues with the Orion XS working as needed for the last three months and 5000 miles.

My quick solution was to install an on off button or a fuse block, but then felt for really $30 more. I could buy a Victron SmartSolar 15 amp controller for the chassis battery and solar panel ?

App now I’m gonna go that route, though has anyone experienced this and what did you decide as awork around?

Thanks and Happy Thanksgiving !!!!

[Kindly Solar]

It sounds like you’ve done a great job troubleshooting your system and identifying the likely conflict between the solar panel's voltage input and the Victron Orion-Tr Smart DC-DC charger. The issue you describe is not uncommon when multiple charging sources interact with each other, especially with basic solar controllers.

What Likely Happened:

Voltage Confusion at the Orion XS Input:
The inexpensive solar controller for the chassis battery may have caused voltage fluctuations or spikes that confused the Orion XS. Underpasses and shading could lead to erratic solar input, potentially mimicking fault conditions or triggering protection circuits in the Orion XS.

Resetting the Orion XS:
Disconnecting and reconnecting power resolves the fault because it resets the charger’s internal safety mechanisms.


Solution and Workaround:

Your plan to upgrade to a Victron SmartSolar MPPT 15A controller is a solid one. Victron’s SmartSolar controllers are much better at managing shading and fluctuating solar input compared to basic controllers. They also allow fine-tuned voltage settings and integration with other Victron devices, reducing potential conflicts.



Key Benefits of the Victron SmartSolar Upgrade:

1. Improved Voltage Regulation:
The MPPT controller provides stable output voltages to the chassis battery, preventing the Orion XS from misreading or faulting.


2. Remote Monitoring and Control:
Using the Victron Connect app, you can monitor solar performance and adjust settings as needed, adding flexibility.


3. Future-Proofing:
If you ever add more solar panels or other Victron components, the SmartSolar controller integrates seamlessly.



Additional Tips:

1. Separate Charge Sources:

With multiple charging sources (solar and alternator), it’s important to isolate and regulate each one. Using a quality MPPT controller ensures that the solar input remains consistent and independent of the alternator's charging profile.



2. Solar Controller Placement:

Install the SmartSolar controller close to the battery to minimize voltage drops and ensure accurate sensing.



3. Fuse Protection:

Add a properly rated fuse between the solar panel and the MPPT controller, and between the controller and the chassis battery, for safety and ease of maintenance.



4. System Monitoring:

Consider linking the SmartSolar controller to the Victron VRM portal (via a Cerbo GX or similar) for complete system monitoring, especially if you’re traveling long distances.



Alternate Workaround (if upgrading isn’t immediate):

Your idea of an on/off switch or fuse block for the solar input is a cost-effective and functional workaround. This allows you to manually isolate the solar controller when necessary to prevent interference with the Orion XS.


It sounds like you’re on the right track with the Victron SmartSolar upgrade, which should eliminate the conflict entirely and add reliability to your setup. Once installed, it’s worth keeping an eye on system performance through Victron Connect to confirm everything is operating as expected. Great job diagnosing the issue and planning a thoughtful solution!

[vanderwielen]

Ill add... consider adding a Victron Shunt. Then create a Victron Bluetooth charging network between the shunt, Orion and a new Victron solar charger. Victron addresses the issue you're seeing by creating such a network allowing all the charging sources to play well together.

[3OnOurWay]

Hi thanks to you both. Especially KindlySolar
So in our install we do have a Victon shunt and victron smart solar for house batteries and Orion XS.

I ordered and was about to install Smart solar for chassis battery and figured there wasn’t much room under the driver seat and I was making a simple problem more complex.

I stuck with KISS and installed on/ off switch.
On for parked in driveway to charge / maintain chassis battery needed when we are parked for a few weeks.

When I prep to leave for a trip, switch off, so chassi solar panel doesn’t trigger / spike a weird voltage into the OrionXS. I think unlikely a MPPT for chassis battery would talk/ play nicely with OrionXS I think shading and spikes are to frequent to let system catch up and figure if it’s alternator issue. Etc.

So far a month post install. All seems to be working well.