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What would cause a fuse to over heat and melt a fuse holder with no shorts?
15 Amp 250 Volt fuse in a 13 Amp, 120 volt system. Onle one end of the fuse was heating up, and the plastic part of the holder melted. The fuse blew. I thought maybe the fuse blew because it was old, and that melted the holder. But after cleaning up the clips, I put a new fuse in and the one end of the fuse started heating up and sparking again. I flipped the fuse around, and the other end of the fuse started heating up on the same end of the holder. So I flipped the holder around. Still the same end of the holder. I tested for shorts, but there were none. It was still pulling 13 amps, as expected. I installed a new fuse holder, which is NOT heating up. It's working fine with the new fuse holder.
So what would cause that to happen? Does plastic get old and become conductive? I know there's no metal in the fuse holder.
If the fuse wire is not securely connected to the terminal on the fuse, or if the Fuse Grip is not making good contact with the Fuse Base , then there will be increased resistance and as a result more heat generated.
The same could happen if the Fuse Wire being used is of lower rating ( thinner). Then also there will be more heat generated.
but I think scenario one is more likely in your case.
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