ok maybe I have trouble to understand the problem, can you please explain a little more ? hard for now to see what could be a good answer or way to search, I mean the ortho frustrum should be over the 3D volum you want to shadow :
bigger => lower quality for a bigger area shadowed
smaller => higher quality for a smaller area shadowed
you want it to :
fit the visible area from current camera ?
or
fit the object you want to shadow ?
in the second case you can do a projection of the object vertices (or faster surrounding sphere/box) onto the ortho camera plane and pick xmin/max ymin/max on this plane to get both x/y scale.
using the light direction vector and its 3d location, you have to choose an arbitrary perpendicular axis for y and then a x vector. using those normalized vector (x/y) compute vertice projection relative to light pos on the plane using scalar product.
I guess I am going to be wrong way again 