(seeking advice) Furnace Wiring Burning up!
** WE FIXED THIS ISSUE!!! I WISH THERE WERE A WAY TO THANK EVERY SINGLE PERSON WHO HELPED WITH THIS ISSUE!!! Here is the fix. The previous owner built the battery/solar system without a camper chassis...
Forum Discussion
Clearly you have a high current flowing through that wire from time to time. The source of this current is not the furnace supply wire, as it shows no signs of overheating and is the same gauge as the ground wire. I rather doubt it would be the disused fridge wires, either, though it would not be at all unwise to pull the fuse for the fridge if there's nothing else on that circuit and to inspect the wire nutted ends to make sure they can't short out against anything.
Guessing from the amount of heat generated (to melt the insulation etc), I suspect you may somehow have the full DC return current for the camper going through this wire, or a short circuit from the battery or converter going through it. I would carefully inspect the wiring between the battery, converter, DC distribution panel, and their chassis ground connections--especially the ground connections. I have seen battery wires that look OK on the outside but have corroded internally to the point of not working, so give them more than a mere visual once-over. Somewhere I think you'll find a broken ground or a positive lead shorting out against something (perhaps part of the ductwork).
It would not be a bad idea to put an inline fuse holder and appropriately sized fuse in this ground wire until you get the problem found and fixed.
Guessing from the amount of heat generated (to melt the insulation etc), I suspect you may somehow have the full DC return current for the camper going through this wire, or a short circuit from the battery or converter going through it. I would carefully inspect the wiring between the battery, converter, DC distribution panel, and their chassis ground connections--especially the ground connections. I have seen battery wires that look OK on the outside but have corroded internally to the point of not working, so give them more than a mere visual once-over. Somewhere I think you'll find a broken ground or a positive lead shorting out against something (perhaps part of the ductwork).
It would not be a bad idea to put an inline fuse holder and appropriately sized fuse in this ground wire until you get the problem found and fixed.
