Victron Orion DC to DC charger cooling

[ripperj]

I recently installed a 30 amp Victron Orion charger and I knew from the reviews that it ran hot.
On just a short 1/2hr trip running at about 30 amps it was too hot to touch and scanned at 146F with a non contact thermometer.

I found this 3D printed cooling fan mount on Etsy for $15 including shipping. Not much to it, but I couldn’t model it up for $15, never mind the fact I don’t have a 3D printer.

It mounts to the side of the charger with the factory screws and holds 1-3 10X30mm 12v fans.

I stuck 3 fans in it and wired it to a switch.

The charger runs about 25 degrees cooler with the fans on.

The fans take a while to get to max speed , but move a surprisingly large amount of air, they are actually fairly loud too, but I’m not in the camper when they are in use.
The fans were like $9 for a two pack off Amazon.

Definitely worth the effort I think.

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[ripperj]

The other side with mounting lugs


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[DaveInDenver]

Are you sure 146°F (about ~63°C) is a problem? I don't know just asking.

Victron for my 18A Orion says the maximum operating environment is +55°C but you must derate at 3% per °C above 40°C. So that implies that the internal and heat sink temp can almost certainly exceed 55°C. I assume they have an internal temp sensor that would prevent damage. One of the faults is "terminal over temperature" for example.

Not saying forced air isn't without benefit. Cooler is almost usually better and in this case is without a doubt. Just suggesting the heat sink fin temperature isn't necessarily something the user needs to be excessively concerned with. It's supposed to get warm.

Also don't assume you don't need to derate with ambient above 40°C, that will still apply with or without a fan. The fan just helps lower the heat sink gradient so it cools better but if it's blowing 41°C air across the fins then the internals will still be 41°C. Forced air helps make it so in 35°C air the heat sink can remove more heat and stay closer to 35°C. Without refrigeration or something like that you can't get lower than ambient.

 

[ripperj]

Im not sure 146 is a problem, but I figured cooler was better. Also this was on top of the charger, not the heat sink, I didn’t think to measure the fins, they should be hotter I’d think


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[HWY395ghost]

Please post a pic of wired and mounted unit.
Thank you in advance

 

[TwinStick]

Well, heat and moisture is the enemy of electronics. I have had 2 power amps loose a channel because of heat. That was in the days long before non contact thermometers, lol. But yes heat is definitely the enemy over long periods of time. If you can easily reduce the temperature, it is time and money well spent.