Over heating wire and fuse

dwaned

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Over heating wire and fuse

· Posted: 28.08.2016 · #1

Hi all,
I've a problem with a wire overheating and a fuse getting so hot it's melting. Don't worry, I've disconnected it until fixed.

Right it's a converted van camper, who ever did it has used a combimaster E11 V2 for charging the leisure batteries. It's the wire that comes from the main vehicle battery to the combimaster that's overheating where it is fused. The fuse is a 25amp which is correct according to the instructions for the combimaster and melted so badly there was no plastic left on it! No other part of the wire seems to be heating up, at least not in the immediate area.

I do think it was wired wrong, but I have wired it as per instructions now and it is still the same.
Although I have two leisure batteries connected to it there is nothing major running off the batteries, lights, chargers and a coolerbox. Even with everything disconected and only one battery being charged it is still getting hot.

So I am thinking there is something wrong with the combimaster but before I replace it should I just buy the same thing again or is there something better that will do the job and maybe charge the batteries when I'm connected to mains?

Sorry for the long post.
TIA
Dwane

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Re: Over heating wire and fuse

· Posted: 28.08.2016 · #2

Dwane I had a similar problem on the road recently. I have my rear view camera linked in to the habitation circuit and on the bumpy roads Ithe camera started to cut out and then on again. Initially I thought that the problem was the camera or camera wiring but when it quit altogether I went back and saw that the habitation circuit was down. I checked the fuses and the plastic had melted on the habitation fuse but it had not blown and although roasting hot it reactivated the circuit when I touched it. The contacts in the fuse holder were too slack allowing arcing as it jiggled around so I removed the cover and gave the contacts a squeeze with a pair of pointy pliers making sure not to short against any other contacts

dwaned

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Re: Over heating wire and fuse

· Posted: 28.08.2016 · #3

Hi Chevy, thanks for that. The fuse holder is badly scorched and deformed from the heat. I've ordered a new one. If it is as simple as that it will be great!

mad max

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Re: Over heating wire and fuse

· Posted: 28.08.2016 · #4

Also cheap fuses cause trouble aswell,
Replace with a fuse from a motor factors, not the ones from the pound shop,

the fat controller

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Re: Over heating wire and fuse

· Posted: 28.08.2016 · #5

The cable being used may also not be heavy duty enough or the wrong type, I.e. 240v cable used instead of 12v cable

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Re: Over heating wire and fuse

· Posted: 28.08.2016 · #6

Quote by mad max

Also cheap fuses cause trouble aswell,
Replace with a fuse from a motor factors, not the ones from the pound shop,

Would agree with Mad Max. More than likely just a bad Fuse holder if the melting is just on that and not the cable. Replace with a decent holder from a reputable Motor Factors!

Flipperdipper

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Re: Over heating wire and fuse

· Posted: 28.08.2016 · #7

Hi Dwaned, from what you say it's either a loose fuse or loose cable connection at the fuseholder. One other cause could be a dirty/badly made connection at the fuseholder. If the cable was overloaded it would be hot for its entire length.

dwaned

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Re: Over heating wire and fuse

· Posted: 28.08.2016 · #8

Thanks for all the replies.
The cable is heavy duty and definitely only hot around the holder so what you are all saying makes good sense. I'll change the holder and fuse and report back as soon as I do.
Thanks again all!
Dwane

dwaned

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Re: Over heating wire and fuse

· Posted: 02.09.2016 · #9

Hi All,

Just fitted the new fuse holder and fuse and guess what, it's perfect!

I never would have thought that was the problem and although I would have had to replace the fuse holder anyway I would have spent a lot of time looking for another fault that was causing it in the first place.

Can't thank you all enough!

Dwane

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Re: Over heating wire and fuse

· Posted: 02.09.2016 · #10

Well done just keep an eye on it for a while to be on the safe side

mad max

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Re: Over heating wire and fuse

· Posted: 02.09.2016 · #11

Happy days

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