ok i installed a pair of flex a lite fans on a frinds truck the other day..they are the 290 model..his truck is a 2004 2500hd 8.1 liter..anyways they worked good for a couple of days and now they quit working..it keeps on melting all the wires...but it doesnt blow the fuse...wtf is the problem..i also told him he could use the nelson harness but he doesnt have no money to spend right now...is there anyway i can bypass the vsc and hook the fans up to the computer and then tune it to set the temps w/o using the nelson harness or do i have to have it? thanks

 

it sounds like you are using wire that is to thin and can not handle the amp draw needed to run the fans

 

The black wires are the positive and the blue wires are the negative. You must use 10 gauge wires.

Install care is critical. Anything less than a firm connection will creat resistance and heat. The real enemy of the FAL VSC.

You MUST run the main positive and negative wires comming from the VSC DIRECTLY to the battery. Get audio shop side post accessorie adapters (plated, not raw brass). Some folks get lazy and go to the junction block under the ALT, and ground elswhere. Nooooo, No!
You must make sure you get the spades in the female connectors properly. I have found problems on others installs where they have gotten some of the spades inbetween the plastic insulator and the outside of the female stakon connector. Also the large y-connectors at the fan motors will fool you into thinking they are snapped in. Double check. And use the proper crimper on said male connectors. The kind that spike a blind hole opposite the slpit.
If the female stakons seem to push on too easily, just lightly roll the sides in a we bit with pliers to get it to grip better.

 

My VSC was getting hot not allowing the fans to work. I relocated it under the fuse box. Works GREAT now.

 

only problem i noticed was the little metal terminals you connect your wires to on the vsc are really loose and u can pull them out with your hand..could this be causing anything?

 

This may be an older VSC. Does it have 2 or 4 copper heat sinks? Cal FAL and they will send you an updated replacment ASAP.