Yup, you need heavier wiring AND a HD fuse holder. I have both and the fans are fine now.

 

Do you have pics? The wire I have is 8 AWG. Show us?

 

So how many amps do the fans draw?

 

mine only draw 7 amps at full blast, even when they kick on they never go above it.
stuck an amprobe meter on there to check it out.

 

So why does the fuse holder melt? Too many watts/volts?

 

amps....... to much current over heats the wire and melts anything made of plastic

 

So why is the 40 amp fuse holder melting?

 

your fans are drawing more than 40 amps is all I can tell you with out checking the system out myself....

 

need to make sure your wire is rated for what ever your fans .
if your fans are rated at 50 amps. then the smallest wire should be a #8 or a #6
anything smaller than a#8 and its gonna burn up things.

current is like water going thru a pipe. the bigger the wire on a 50 amp fan the slower the current will be. so to speak. well if you go down to a smaller pipe the water will speed up, and get faster. current does the same thing. BUnch of electrons, trying to flow thru a small piece of wire and it's gonna heat up. give them alot of room and they what wok as hard to get there.
hope that made since.

 

I'm wondering if it's a poor design of the holder itself. Does anyone know if it's the fuse that heats up, or is it something else somwhere in the holder?

If the fuse is not heating up, then it's a poor design of the holder. There would be a "bottle neck" in the fuse-holders wiring, which is acting like a fuse of it's own. (Fuses heat up just before they blow... it's what causes them to blow...) I'd be willing to bet it's a problem with the way the wires are crimped or attached to the "sockets" for the fuse.

Like I said though, my DCC never lets the fuse or fuse holder warm up at all. Even with the A/C cycling the fans on and off at 50 or 60%. Whatever it is. ...I just checked.

The FAL fans are rated to pull something like 30A, I believe. Maybe 28 or so? I'd assume that's a max-draw rating, like when the fans get kicked on 100%. I can't say for sure.

I'm running the 35A DC controller. It'll go into a fault mode if I draw 35A for more than 30 seconds, I believe. (It's been a while since I looked at the fact/spec sheet). It has yet to miss a beat.