SEAT IBIZA II FL: Climatronik Radiator Fans, AC Fuse Melting Issue & Bypass Solution

Hello! Gentlemen, the problem is that when the air conditioning is on, the fuse socket melts. I was at an electrician, a smart guy, he made a bypass, he installed another fuse, thicker cables, but the fuse's plastic is very hot and does not go until you touch it. Evidently, the problem was not solved, and he only made a workaround to prevent the main fuse box from melting, which is on the battery. I know that the fuse is responsible for the fans because the first 2 in the box are probably ABS.? When I unplug the fans, I start the air conditioning, the compressor is cycling and the fuse is cold, I connect the fans, it becomes hot immediately. I bought a second set of fans, still connected the same .. In addition, the fuse is mega hot and the cable within 1 cm from the fuse, the rest is cold ..

If you can, measure the current in the fan circuit and compare it with the fuse size.
If only the contact area becomes overheated, it indicates bad contact, too high contact resistance and heat is generated. You can measure the resistance of the socket with a fuse.

driver400 wrote:

I was at an electrician, a smart guy, he made a bypass, he installed another fuse, thicker cables, but the fuse's plastic is very hot and does not go until you touch it. Evidently, the problem was not solved, and he only made a workaround to prevent the main fuse box from melting, which is on the battery. I know the fuse is responsible for the fans

The fuse is in the correct position and does not blow? If 2x yes, then the fans are not to blame, the repair should consist of replacing the fuse box or, as you have done - adding a fuse on the bypass, but using the right material and not the fuse socket for PLN 1 and thin wires (the fuse is 30A installed as I see it) ). In addition, the wires should not dangle in the engine compartment and the soldering points should be insulated before the car is handed over to the customer, because the fire brigade usually arrives to put out the rest of the vehicle, you won't do much with a half-kilo fire extinguisher.

Either a poor contact on the fuse or too high current flowing through the fuse heats it up. I would measure the current flowing through this wire with an ammeter, preferably a clamp meter, and try to solder this fuse directly to the wires.
Of course, after detecting and eliminating the cause of this defect, the replacement of the fuse box is obligatory!

Gentlemen, the new box is already in the garage, I just don't know whether to replace it now and then check it. The org fuse is 30A. I am only surprised that the old box melted so much. The fact that the mechanics did not show off by doing this workaround because it blew my eyes ... I have a universal digital meter in my garage and at this point I have to measure the current consumption when the AC is turned on on this fuse ?? The fuse does not blow but I say the temperature is high because after 15 minutes it burns my fingers when you touch it and the housing becomes flexible so I have AC still turned off, but summer is coming and it's scary to go with the air conditioning ..

driver400 wrote:

I am only surprised that the old box melted so much.

The poor contact on the fuse was (the reason - perhaps a poor quality safety), the contacts burned out.

driver400 wrote:

The fact the mechanics also did not show off by doing this workaround because it stings the eyes

I don't know who did it, but don't be called a car electrician ... ;)

driver400 wrote:

I have a universal digital meter in my garage and at this point I have to measure the current consumption when the AC is turned on on this fuse ??

As originally was the 30 A fuse, there is nothing to play with in the measurements (it is difficult to measure 30A with a universal meter anyway), and the installation to these 30A is to be adapted, both the wires and the fuse socket. as you assume 1mm2 wires and a fuse socket suitable for the top of the car radio (10A fuse), you see the result.

So what to try to install a new box and then check? If it's okay, leave it, if it continues to heat, remove the fuse and go to an electrician, but one who is an electrician and not an amateur

driver400 wrote:

So what to try to install a new box and then check? If it's okay, leave it, if it continues to heat, remove the fuse and go to an electrician, but one who is an electrician and not an amateur

How old is this car? If it is not right after the warranty, I would rather put the fuse next to it in a suitable holder because the replacement of the entire box should also be done professionally, if a shoemaker does it again, it will start to smoke in the new box in places where everything was OK so far, there are much greater currents than for air conditioning fans.

And is the old box dirty by any chance? I think I can see the greasy dirt in the photo. It is possible that the contamination caused poor contact at the fuse contacts and hence the problem.

dare23 wrote:

And is the old box dirty by any chance? I think I can see the greasy dirt in the photo.

It looks like pyrolysis products to me, the result of a burned out fuse socket.

I have installed a new case. The fuse is not as hot as it was before, but still it is slightly lukewarm. So the problem is still ..

driver400 wrote:

yet it is lukewarm gently. So the problem is still ..

When it is lukewarm, there is no problem.
Of course, you put the fuse new?

Yes, the fuse is new. Today I checked, I did a 20 km route, the fuse is slightly lukewarm. Pulling it out, you can easily grab the pins. Then there was no way after 5 minutes to catch him. We will see what will happen next, at most, I can still think of the fan module of what is under the stringer at the bottom of the battery.

Gentlemen, I have to connect to the topic because the problem seems to be the same
I also have an Ibiza 2Fl 1.9 and I put photos on the same problem. The only thing that melts the fuse on my bypass because someone previously melted the m socket, is it worth installing a new bypass (also already melted) or give it to an electrician right away? I have different experiences with handymen, unfortunately, hence I prefer to ask here first
I bought a new single fuse socket looks solid what do you think?

hugo_boss86 wrote:

I bought a new single fuse socket looks solid what do you think?

What is the cross-section of this cable? 1mm2 or more?