Victron’s new Orion Smart DC-to-DC converter, exciting developments

DC-to-DC converters might not be the most exciting component you will find on a boat, but they play an important role in many modern power systems. Perhaps in part because of their lack of sex appeal, the selection and features of DC-to-DC converters have, until now, been limited. Fortunately, that seems to be changing.

DC-to-DC converters can play quite a few roles in a boat’s DC power system. Their two most common applications are charging batteries of different chemistries — like LiFePO4 from an alternator setup for lead-acid — or batteries of different voltages. Until recently, the main voltage conversions were between 12 and 24-volt systems, but the increasing use of 48-volt systems has increased the demand for conversion between 48 volts and both 12 and 24 volts.

However, as demand has increased, Victron has been slow to increase the size and voltage options. Supply chain issues and scarce engineering resources have delayed Victron’s rollout of additional models. In fact, they currently don’t offer an Orion-TR Smart model that converts to or from 48 volts. In Victron’s terminology, DC-to-DC converters are available as converters and smart chargers. The converters don’t have Bluetooth connectivity and output fixed voltages. The smart chargers offer three-stage charging, tunable engine shutdown detection, and Bluetooth connectivity with app control via Victron Connect.

The new model

You may notice the photos from Victron’s METSTRADE booth (and even Victron’s product page for the new model currently) show the new model as the Smart BuckBoost DC-DC Charger. Victron has decided to change the product name to Orion Smart 12/12-50A Orion XS 12/12-50A DC-DC battery charger (per a late breaking update from Victron on 11/22/2023). I’m going to get into the nitty-gritty of the specs and compare the new Orion-TR Smart to the existing models. But before we get in the weeds, let me just tell you that every spec I’ve compared is better for the new model. In some cases, by a little, but in quite a few by a lot.

	Orion XS 12/12-50 (new)	Orion-TR Smart 12/12-30 (existing)
Input voltage range	9-17 V	10-17 V
Output voltage range	10-17 V	10-15 V
Output noise	10 mV rms	2 mV rms
Continous output power at 40°C	700 W	360W
Efficiency	98.5 %	87 %
No-load current consumption	< 100 mA	< 80 mA
Operating temperature range	-20 – +60°C (derate 1.5% per °C above 40)	-20 – +55°C (derate 3% per °C above 40)
Bluetooth communications	Yes	Yes
VE.Direct communications	Yes	No
Weight	0.33 kg (0.73 lb)	1.8 kg (3 lb)
Dimensions (H x W x D)	137 x 123 x 40 mm / 5.4 x 4.9 x 1.6 inch	130 x 186 x 80 mm / 5.1 x 7.3 x 3.2 inch
Protection	IP 65	IP 43 (electronics) IP22 (connection area)

The table above is dense with specs but, I promise, these are just the most significant ones and the ones I think might make a difference to most users. The three main opportunities for improvement with the existing Orion XS chargers are: The largest 12-volt to 12-volt model maxes out at 30 amps or 360 watts, the devices get quite warm when they’re producing full rated power, and although current models have Bluetooth communications, they lack VE.Direct and hence don’t integrate with Victron GX devices running Venus OS.

I’m pleased to report that each of the three shortcomings I mentioned above is being addressed by the new unit. The 12-volt to 12-volt, 50-amp model is the first to be released but more will follow. Just looking at the 12-volt, 50-amp model we see power handling a little shy of doubling. Future models likely will handle even more power, plus adding 24 and 48-volt options.

Heat generation and dissipation

The 30-amp 12/12 Orion-TR Smart is pretty notorious for the heat it generates. A quick scan of Victron’s community shows many threads discussing the potentially alarming heat. These units generate the heat despite large aluminum heat sinks on the rear of the unit. You can see the size of the heat sinks in the left image above and the fairly extreme heat generated in the right image.

The table above gives quite a few hints about how much cooler the new unit runs. First, take a look at the efficiency. The old models claim a maximum efficiency of 87% compared to 98.5% for the new ones. Equally telling is the complete lack of visible heat sinks on the new models and drastically reduced weight. Plus, we see a significant reduction in derating that occurs as the units get hot. The new model loses 1.5 percent per degree Celsius, compared to 3 percent per degree for the existing chargers.

GX Connectivity

Until this model, none of the Orion line has been capable of communicating with GX devices. That communication would allow monitoring and configuration of the Orion XS chargers. Because current Orion-TR Smart chargers don’t have GX communications, any power they supply is lumped into the DC power.

Current control

Previous Orion-TR Smarts didn’t have configurable power outputs. Instead, the units output the maximum power they could, up to their rated capacity. The new model offers fine-grained control based on both input and output current. The values can be set from 1 amp up to 50 amps in 0.1 amp increments.

Availability, pricing, and future models

Victron expects to start shipping the 12/12-50A model in January. It will list for $445. At a list of $445, it costs the exact same per amp ($8.90) as the outgoing 12/12-30A model. Given all the additional features and capabilities, that seems very fair. It appears this unit is the first of quite a few to come based on the new design and architecture. I’m looking forward to seeing models in differing capacities and voltage configurations.