Hello All,
overlooking my deep disappointment with the lack of smart integration on the Orion "Smart" DC chargers I purchased, I read that they tend to run quite hot. The heat efficiency losses that I expected from reading seemed quite poor but i was determined to come up with a basic solution so that everything could be Victron and on the same smart network. Although I am extremely disappointed with the lack of actual smart-integration with these and the IP-22, I think that the following modification solves the overheating problem. At least they have kept mine down to a comfortable touching temperature with this compact and low profile cooling solution.
It may not be perfect, though I give it here free to all so you can print your own. It is sized for two* "6015 brushless turbo fans" which i ordered from ali express. The design fetures a cable channel to run the cables nicely away from things. I have wired all of them to the same 12v switch that activates the orions in my van. (I would not recommend wiring them directly to your engine as in my opinion they can overcharge the batteries a bit due to the lack of smart integration (since they always go into bulk mode first even if at high SOC!!!!)). In the future I might add a temperature relay in front of them so they only turn on above 40C or something like that but who knows. See attached photos and Files.
I printed with supports but they were a pain to remove. I would probably go supportless for future prints and it should turn out with a decently calibrated printer regardless of the roof and overhangs (has an interior slope to help this) Also, I printed them with PETG due to low cost and decent temperature resistance. I would highly recommend the same. Overall the print could be tuned a lot more to use less plastic and such but I just wanted them a bit over built to avoid multiple prototyping to just get something done and installed quickly for an upcoming trip.
Hope this keeps your orions as cool as mine. here is the STL file for printing: OrionCoolerMount.zip
If you do not have access to a 3D printer, many libraries have one and will only charge you consumable materials (peraps a few dollars/euros (3-5) for two of these). Ask them to print out of "P.E.T.G." since it will be in close proximity with something that gets hot. I used maybe 30% infill but with 4 wall layers and 5 upper layers making most of it (apart from the fan bases) effectively solid. Many libraries may only print out of PLA which I am not sure can withstand the heat in the summer with these things. Maybe yes, Maybe no.
some extra keywords: Orion, OrionSmart, Orion smart, Overheating, hot, Cooling, TR
here is the orion fin modeled (blue) and then the final fan holding apparatus.
multiple views of the fan cooler
cheap fans that i bought on aliexpress
Final prouct installed
