question

mdbrown avatar image

Orion DC-DC overheating

My Orion Tr Smart 12/12-30 Charger runs hot, and the output current folds back considerably. Anyone else with this problem? When cold, it will output 33A. When hot, it will fold back to 26A or less. Parts of the case may exceed 134dg F, in a cool (60dg F) environment. By adding a 80CFM fan above the fins, the case temperature is lowered by 20 degrees F, and the unit will continuosly output 30A. It would appear that the heat sink is undersized. Comments?

orion-tr smarttemperatureamps
2 |3000 characters needed characters left characters exceeded

Up to 8 attachments (including images) can be used with a maximum of 190.8 MiB each and 286.6 MiB total.

5 Answers
mvader (Victron Energy) avatar image
mvader (Victron Energy) answered ·

Hi all,

Daniel asked me to help here.

After producing x amount of Smart Orions, we changed two things:

- reduced maximum temperature. The first series didnt get so hot that it affected the electronics, but it was still too hot for “common sense”.

- changed max output current to not be more than rated output current. Instead of doing everything it can as long as it wasn’t too hot. Which was nice from a “lets give the customer maximum value for money” point of view; but not when the customer bought this to limit current draw on, for example, an alternator.

I’ll check for serial numbers when those changes were introduced when I get into the office

7 comments
2 |3000 characters needed characters left characters exceeded

Up to 8 attachments (including images) can be used with a maximum of 190.8 MiB each and 286.6 MiB total.

Were the changes a hardware/firmware change, or will a software update be issued? I haven't heard of any heat-related failures, just that they heat up fast and then fold back to effectively protect themselves.

Hi, its hardware changes.


i’ll add a bit more text to second bullet in a minute

mdbrown avatar image mdbrown mvader (Victron Energy) ♦♦ ·

Thank you. I noticed that the case get very hot, but the heatsink just comfortably warm. Could the thermal coupling of the device(s) to the heat sink be improved?

Perhaps yes; buts thats more something for a next generation.

Do you know what the serial numbers are for the newer model? The heat of the prior model is definitely too hot for "common sense".

@mvader (Victron Energy) Hi, do you have the serial numbers for the newer models?

Thanks,

Any update to this? What serial number did the change start at? Also, how much cooler are we talking? Thank you.
rvjim avatar image
rvjim answered ·

Mine is also overheating. The case gets to about 120 degrees and then goes from charging at 30 amps to 0.

The ambient temperature is only 87 degrees. We should not have to use a fan. Is this a bad design.

1 comment
2 |3000 characters needed characters left characters exceeded

Up to 8 attachments (including images) can be used with a maximum of 190.8 MiB each and 286.6 MiB total.

So as mine. I just installed my Orion Tr 12/24-15 yesterday, successfully used it for about 5 hours. First couple hours I could smell the factory oils burning off, then the smell went away after a while. It was very hot to the touch. I didn't get a chance to use my laser temperature gun though.

From the start I would encounter the voltage output showing nothing most of the time, and rarely it would show the proper voltage I set it to. I raised another report a few hours ago about that issue as well. Upgraded to firmware 1.05 in hopes of resolving but no luck.

Now after 5 hours of use, it's dead cold when when my engine is running. I'm able to view the Orion via Bluetooth, and the voltage input is stuck at 12.3v, output voltage showing blank whether the car is on or off.


daveinfl avatar image
daveinfl answered ·

I also had to add a 120mm fan to bring it down about 20 degrees. Curious if it's safe to continuously run this?


I use this on a boat in a small compartment; concerned what "Might Happen" with continuous use.

2 |3000 characters needed characters left characters exceeded

Up to 8 attachments (including images) can be used with a maximum of 190.8 MiB each and 286.6 MiB total.

mateoing avatar image
mateoing answered ·

@Daniël Boekel (Victron Energy Staff) do you know if someone from Victron's staff is already looking into this issue? Is this issues resolved in upcoming manufactured units?

2 |3000 characters needed characters left characters exceeded

Up to 8 attachments (including images) can be used with a maximum of 190.8 MiB each and 286.6 MiB total.

richard-cabesa avatar image
richard-cabesa answered ·

I don't have an answer for you but mine runs at about that same temp. I will admit that it is a new installation and I have only run it for an hour or so. Amps ran about 33-34 and dropped to about 29-30 once hot.

I would also like to know if this temperature is normal

2 |3000 characters needed characters left characters exceeded

Up to 8 attachments (including images) can be used with a maximum of 190.8 MiB each and 286.6 MiB total.