Heater Cartridge PCB Mount Very Hot

Hey, everyone. I was wondering if anyone else has noticed this problem. In my case it seems to have cropped up in the last month. The point where you screw down the wires for the extruder heater has become very hot, to the point where the green plastic housing has started scorching (see photo).

I checked the tightness of the screws and they were OK. I print something every day or two but it’s not running non-stop. I only print lower-temperature PLA, not ABS. The area can’t be affected by any fan mods I’ve made downstream.

In fact, what flashed into my mind is my old 1990 Mustang which once got a recall for the ignition switch connector. The wires inside the plastic housing were too thin to handle the current needed for the job and would overheat, melting the housing. I can imagine the K8400 heater draws similarly much current, perhaps it eventually overcomes the rated ability of the connector? I’ll eventually tear it down and look for worn PCB traces/solder joints and etc., but I wanted to know if I’m an isolated incident or not. Thanks!

Please don’t compare a top notch piece of Belgian engineering with a ford mustang :stuck_out_tongue: :wink:
But back on topic: mine doesn’t have any “melt spots” how does it look on the inside? Does the inserted piece of the wire have any black marks?
I did solder the end tips of the wires, imho that lowers the risk of having the screws come loose after a while.
Anyway, great idea to write H and S on the connectors :stuck_out_tongue: I’m going to steal that one!

It’s possible that you have a transition-resistance in the connector due to a bad connection. Loosen the screws, re-seat the wires and fasten them tightly. Also check that the wires are properly clamped as the small connectors can make it hard do do correctly sometimes.