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Old 03-11-2011, 03:46 PM   #1
Scut_Monkey
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Default Heat Sink Too Small for Mounting

So I'm running into a problem with building my electrical enclosure. I'm following Kal's build but I decided to use the smaller heatsinks that came with my SSRs. I bought the SSRs from ebay and they just like the small heatsink/ssr combo below (middle picture).

The problem is that where the heatsink and SSR attach to each other is almost exactly the same size. This leaves me no room to mount the heatsink to the enclosure like Kal did (first picture). Looking at the heatsink that Auberins provides it shows to have a much larger mounting surface which eliminates this problem (third picture below).

Has anyone run into this for their build? I'm not sure how to overcome it without buying a new large heatsink.

img_6689.jpg   cfrypdgbgk-kgrhqmokoye0gpgc96tbnv9fmwbyg-_12.jpg   40-20ssra.jpg  
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Old 03-11-2011, 03:57 PM   #2
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Firstly the owner of Auber is going to tell you that you need the larger heatsink if you are running 40 amp SSR's, so I took his advice when I bought. I assume that is what you have. If you're dead set on using the smaller (undersized?) sinks, how about a smaller opening and mounting the sink with the first level of plates inside your panel. I'd cut a piece of cardboard or wood and play around with the hole size, making sure you can slip the sink in at an angle.

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Old 03-11-2011, 05:03 PM   #3
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Quote:
Originally Posted by samc View Post
Firstly the owner of Auber is going to tell you that you need the larger heatsink if you are running 40 amp SSR's, so I took his advice when I bought. I assume that is what you have. If you're dead set on using the smaller (undersized?) sinks, how about a smaller opening and mounting the sink with the first level of plates inside your panel. I'd cut a piece of cardboard or wood and play around with the hole size, making sure you can slip the sink in at an angle.
I thought about mounting it with the first level of plates inside. That's a good suggestion to use a piece of wood for practice. I'll probably give this a shot before I put more money towards new parts. The auber instrument sinks are bigger but they don't seem to be that much bigger. I'm also running an SSR that is oversized (40amps capacity) for my application so I don't forsee the heatsink being undersized for my build. However, I'm a novice.
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Old 03-11-2011, 05:21 PM   #4
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Are you using a metal enlosure? If so why not drill the mounting holes only in the enclosure and sandwich it between the heatsink and SSR. Heat will transfer to the enclosure, then directly to the heatsink.

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Old 03-11-2011, 05:36 PM   #5
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Originally Posted by Navy_Brewer View Post
Are you using a metal enlosure? If so why not drill the mounting holes only in the enclosure and sandwich it between the heatsink and SSR. Heat will transfer to the enclosure, then directly to the heatsink.
It is a metal enclosure but I don't think the heat transfer would be very good from the SSR through textured paint. It's an interesting idea but if this was acceptable why would anyone cut a hole in the panel simply to mount the SSRs to the heatsink? As of now the surfaces of the SSR and heatsink are very smooth allowing good heat transfer. To place both the heatsink and SSR onto the textured paint with unknown heat conductivity isn't something I'm crazy about.
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Old 03-12-2011, 01:57 PM   #6
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I'm in the same boat. Since I'm using a metal enclosure, I also thought about sandwiching SSR/enclosure/heat sink, but first would sand the paint off the enclosure to bare metal.

Currently, I have my 40A SSR mounted to my heat sink, both INSIDE my metal enclosure panel. The heat sink is mounted directly to a wall of the metal enclosure. Since I am only running 23 amps max, i'm hoping the SSR doesn't get too hot. When I finally do a test run, I will operate and take temp readings first when panel is open and then closed.

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Old 03-12-2011, 03:31 PM   #7
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I just now purchased this heatsink. I found it from a thread on Kal's website where others purchased this and had good results. If you click on the link now one will not be listed but this happened to me last night and he/she posts another one quickly. They are currently $20 with $10 shipped. I thought about purchasing the custom built one from Kal's site but this was cheaper and I will get it much quicker. Not discouraging anyone from buying from Kal, this was just why I chose this heatsink.

http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&_trksid=p4340.l2557&rt=nc&n ma=true&item=120670121120+&si=%252FgukdIY0fnsCYHmP ZZZ3UxU%252Bdmw%253D&viewitem=#ht_500wt_1129

The thread on Kal's site.
http://www.theelectricbrewery.com/forum/viewtopic.php?t=24587

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Old 03-12-2011, 03:44 PM   #8
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I ran into the same issue. I tried to make the cuts as close as possible, but I still did not like the fit. I ordered the larger heatsink. I was thinking though, instead of mounting the removable plate. Get a roll of aluminum flashing, cut it to the same size, caulk it and screw it on. Then you can sandwich between the two. If the flashing has any coating, a light sanding will remove it.

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Old 03-12-2011, 04:53 PM   #9
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Quote:
Originally Posted by milldoggy View Post
I ran into the same issue. I tried to make the cuts as close as possible, but I still did not like the fit. I ordered the larger heatsink. I was thinking though, instead of mounting the removable plate. Get a roll of aluminum flashing, cut it to the same size, caulk it and screw it on. Then you can sandwich between the two. If the flashing has any coating, a light sanding will remove it.
I tried a whole bunch of methods to make it work last night including cutting a surgically sized hole that was just big enough for the SSR but just small enough for the heatsink. Nothing worked and I wondered why they even wasted the money making the heatsinks as they are useless for our application.

I found the larger heatsink from your posts on Kal's discussion forum. Thanks! Are you suggesting not buying a different heat sink but installing what I have onto aluminum flashing? What did you end up doing? I already ordered the larger heatsink and I think I would rather go that route than aluminum flashing. I figure I'm spending all the money on this control panel so an extra $30 for the proper and larger heatsink is fine with me. It will work better anyways and look much better.
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Old 03-12-2011, 06:37 PM   #10
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Quote:
Originally Posted by Scut_Monkey View Post
I tried a whole bunch of methods to make it work last night including cutting a surgically sized hole that was just big enough for the SSR but just small enough for the heatsink. Nothing worked and I wondered why they even wasted the money making the heatsinks as they are useless for our application.
Those heat sinks are made to be installed inside the enclosure. They have tabs on them so that they fit a DIN rail if desired. It is not necessary to cut a hole through the enclosure. I remember Kal saying that his heat sink doesn't even get warm.
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