Ask 02Denali - his melted too

 

I was considering e.fans but it seems like everyone has problems with them.....or with the vsc's at least

 

The reason the wires get hot where they connect to the VSC is due to a gradual loosening of the lugs over time from vibration and/or corrosion. The loosening of the contact creates resistance which causes the heat. (If too much heat is generated by the resistance the terminals may become internally unsoldered from the VSC controller board in which case it will be ruined.) The wires connecting to the VSC need to be zip tied together and then zipped to the nearest secure point to completely prevent the wires from vibrating. Another cause is corrosion from road salt. In that case relocation may be a good long-term solution. Either way the wires must be prevented from any movement on the lugs.
Some guys have soldered the lugs onto the VSC with success. Use very high heat and get the job done quickly so the solder inside the VSC holding the terminals is not melted.
Trust me on this guys - it has nothing to do with batteries, fuses, the VSC itself, or even wire size. The wire size included is adequate. It is the contact between the terminals and the lugs themselves that causes this. If it were not for lack of good contact (and hence resistance) at the point, the connection would not heat up in the first place.

 

I had the fuse outta my VSC power wire the other day and there was some corrosion down in the fuse holder. Probably a good idea to clean that out every once in a while.

Otherwise I've had no problems so far.

 

That's my theory on why the fuses melt... poor connection inside the rubber material.

 

James, so a bad ground couldn't be a possibility? If it is a bad ground, don't the wires get hot, and could cause the melting too? I see what you're saying, I'll try to get my wires more secure as well.

 

It could be, but that's where your heat would be. If the ground was bad where it made chassis contact - that is where you'd have heat building up from the resistance and wires melting. A bad chassis ground at that point cannot create resistance and heat between the terminals and lug connections to the VSC.

I suspect that there is some form of mechanical connection (chassis-to-eyelet, lug-to-terminal, or fuse-to-lug) in every instance where these wires are overheating and melting the insulation. It is these mechanical connections that need attention.

 

how much do those electric fans run, whats the best set up for it?

 

Search in the truck section for "ls1 fans" or "flex a lite" there is plenty of info.

 

yes i did melt two of the fuse holders and one complete vsc!!! i went to relays and all kinds of deals. then i found the dc controller. man o man. i am so glad i did to.it is simple to hook up. and it works great. half the amp draw since it stays at 50% and below. and it is keeping it cool easily.

http://www.dccontrol.com/