E-Fan fuseholder melting - Ranger-Forums - The Ultimate Ford Ranger Resource


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  #1  
Old 08-23-2006
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E-Fan fuseholder melting

What would cause this to happen?
Im aware of 'L2en' E-Fan/ battery meltdown problem not sure though if this could be the same.
I havn't used the truck in 3 weeks(iv been away) and went to start it and the Optima is dead so i get the charger open the hood and i see this;





The fan(Black Magic) still works and obviously the fuse is not blown
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  #2  
Old 08-23-2006
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There was an old post about this at least a year or so ago...
but I didnt find it on search :(
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Old 08-23-2006
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Quote:
Originally Posted by Rand
There was an old post about this at least a year or so ago...
but I didnt find it on search :(
about melting fuse holder? WOW thats strange, maybe someone might know whats the deal, thanks anyway.
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  #4  
Old 08-23-2006
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pastfinder(sp?) had this happen recently and posted pics on the "E-fan announcement"

One more pic for me to show TorqFlo/CompressorWorks

https://www.ranger-forums.com/forum2...ad.php?t=26967
Post#19
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  #5  
Old 08-23-2006
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Did you get this from the group buy?? Is that fuse off of a TorqFlo controller?
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  #6  
Old 08-23-2006
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It does not look like it is the fuse holder from the torqflow controller.
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  #7  
Old 08-23-2006
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Wanna see my charred controller?

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Old 08-23-2006
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its from a black magic
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  #9  
Old 08-23-2006
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Quote:
Originally Posted by 4X2XLT
its from a black magic
^^^ he gets the prize, Black Magic model #40 by Flex-a-Lite.

and i don't understand how that could get hot enuff to melt the holder but not blow the fuse, BTW the fuse is within 4" of the 'hot' as someone mentioned in the other post to have it as close as possible.

Her's the new holder a little heavier gauge wire and holder;


Last edited by Rob99; 08-23-2006 at 02:24 PM.
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  #10  
Old 08-23-2006
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It could have been excessive current draw from the fan over time, excessive resistance in the fuse holder terminals or a loose clamp on the fuse. Poor ground for the fan itself may cause it, would wanna think it would have popped the fuse first though.
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  #11  
Old 08-23-2006
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My inline fuse did the same thing on my efan, i was sitting in idle for like 10 mins, and i noticed my truck started to overheat and sure enough the inline fuse holder had melted around the fuse i dont know was caused it but i replaced it and it has been fine since.
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  #12  
Old 08-23-2006
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Usually when a fuseholder melts, it is due to a poor connection inside the fuse holder itself. most inline fuse holders are really cheap-o and don't always make goofd clean contact with the fuse. This causes a lot of heat from resistance and in turn melts the holder.
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  #13  
Old 08-23-2006
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Quote:
Originally Posted by l2en
pastfinder(sp?) had this happen recently and posted pics on the "E-fan announcement"

One more pic for me to show TorqFlo/CompressorWorks

https://www.ranger-forums.com/forum2...ad.php?t=26967
Post#19

That would be me :) Here's what mine looked like...



I cut out the fuse and added another one for the mini style fuses. Works fine now.
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  #14  
Old 08-23-2006
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...and to think I was going to go out and get an e-fan.......LOL

Seems that my stocker works just fine and it won't burn the truck down.

That is just too crazy....all these "wiring" issues and burning trucks......no thanks....I like my Ranger too much to roast it.
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  #15  
Old 08-23-2006
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I agree 100% with FireRanger's comment about high resistance connections in cheap inline fuse holders. A high current circuit like the efan deserves the best fuse holder you can find.

Quote:
Originally Posted by pastfinder


This is a somewhat crappy photo, but you can see how the fuse is misshaped and the plastic inside the holder has melted a bit (shiny). I just added a mini 30Amp fuse holder and it makes a HUGE difference in the efan performance :)


Quote:
Originally Posted by rwenzing
My guess is that the internal terminals for the fuse legs were not as tight as they are on some fuse holders. Mediocre connections have high resistance that can generate heat and limit current flow to the load. That sounds like the two symptoms that you had.

I looked at a few fuse holders that I have and one looked a lot like that one with the folded over edges on the internal terminals. The others had more substantial looking terminals made of heavier metal that looked like they would have much more contact surface area and a tighter fit. The heavier terminals are similar in appearance to the terminals used in an OE Ford fuse box.
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  #16  
Old 08-23-2006
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wow, i also had changed my mind about the efan.....If i did have one i would probably be returning it....

Seems like it should be a smaller fuse? Maybe like a 10 or 15 amp? Maybe that 20 amp is too big and its letting stuff get heated too much.....either way it should have popped but, being 20 amp it might let enough go that it could melt...

Rocky
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  #17  
Old 08-23-2006
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Quote:
Originally Posted by RockysFord
Seems like it should be a smaller fuse? Maybe like a 10 or 15 amp? Maybe that 20 amp is too big and its letting stuff get heated too much.....either way it should have popped but, being 20 amp it might let enough go that it could melt.
Nope. The fuse was fine and sized to match the load placed on the circuit. It is simply a crappy fuse holder making a bad connection. Using a smaller fuse will either pop as soon as the fan comes on or if it is within the limits, the same melting will happen from the heat. This has nothing to do with the fuse size or the wiring or the fan. It is just a crappy fuse holder.
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  #18  
Old 08-23-2006
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10-4
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  #19  
Old 08-23-2006
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The controllers from the group buy had 30 amp fuses....
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  #20  
Old 08-24-2006
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Quote:
Originally Posted by FireRanger
Nope. The fuse was fine and sized to match the load placed on the circuit. It is simply a crappy fuse holder making a bad connection. Using a smaller fuse will either pop as soon as the fan comes on or if it is within the limits, the same melting will happen from the heat. This has nothing to do with the fuse size or the wiring or the fan. It is just a crappy fuse holder.
well as you guys can see i replaced with a new holder and fuse, actually the melted one was as old as the e-fan about 5 years old.
maybe corrision did build up on the connections, anyway it's somthing im going to now check and pull the fuse to look for any buildup on the contacts and replace sooner than 5 years, LOL.
Thanks to all.
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  #21  
Old 08-24-2006
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Oh wow, I figured it was new. If it was 5 years old then it was definately a combination of age, connection, and crap on the connectors.
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  #22  
Old 08-25-2006
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Quote:
Originally Posted by FireRanger
Oh wow, I figured it was new. If it was 5 years old then it was definately a combination of age, connection, and crap on the connectors.
LOL It may be 6 years old i think i originally installed it in 2000 on my 99 Mazda, and i was worried the fan motor would crap out at a inopertune time and here it's a non moveable part, go figure.
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  #23  
Old 08-25-2006
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I installed a fuse holder from tractor supply company.. its very stout comparitively
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