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kind of hard to blame it on efans themselves when we don't know what was used. (i'm assuming it's the troyer setup)
faulty connections, and undersized wire for a given distance will increase resistance. resistance turns into heat and that can easily melt connections like you're talking about. this is another reason why i like the DC Controller with it's soft-start feature. it's not throwing all the current at the fan at once.
you can create an efan setup relatively cheaply (not that the troyer kit is cheap) but for reliability, you must absolutely over-engineer the electrical system.
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