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Melted block heater plug

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A small heads up to members:
I had the truck plugged in the other night, heavy rain falling. I use a heavy duty extension cord with 3 outlets molded into the end. I let it hang off of the block heater plug so it ends up with the extension cord receptacle facing "up".
Observed the plug after the rainy night and saw that one of the block heater prongs (male side) was almost completely burned through and the plastic on the face of the extension cord was melted.
I can only guess that water got into the extension cord (female side) and pooled there creating excess heat.
Scary to think that I might have burned the truck and house up never mind the damage to electronics from a possible short circuit!(I Don't think I will tell the wife).
Members: you might want to rig up something to make sure the extension cord faces DOWN so no water,snow or other moisture gets in!
A lesson learned,


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98 QC 4X4
"The Silver Bullet"
 
Thumbs up illflem!
I just built an entrance way and installed a GFI handy to where I park! Just in case.
Gene

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1997 Cummins Dodge 4x4 Bombed & Amsoiled. Amsoil Premiere Direct Jobber, Member of: NRA Business Alliance, GLTDR, WANTED: Wrecked Dodges.
www.awdist.com
 
Pooling (fresh) water shouldn't bother an outdoor receptacle. Melting is caused by heat. Most unwanted heat in electrical circuits is caused by loose connections. Sounds as though your heavy duty cord doesn't have heavy duty receptacles. Receptacles do wear out. I periodically replace the recptacles in the house and on the extension cords that are used for serious amperage.

Bill;
GFCI only works if the juice escapes to ground. Your regular circuit breaker or fuse is for the overload (heated wires) protection.

Gene;
GFCI is required for all garage, basement, exterior, or damp located outlets. Smart thinking on the entryway where you might also feed an exterior load.

Cheers;
 
Originally posted by JohnE:
Pooling (fresh) water shouldn't bother an outdoor receptacle. Melting is caused by heat. Most unwanted heat in electrical circuits is caused by loose connections. Sounds as though your heavy duty cord doesn't have heavy duty receptacles. Receptacles do wear out. I periodically replace the recptacles in the house and on the extension cords that are used for serious amperage.

Bill;
GFCI only works if the juice escapes to ground. Your regular circuit breaker or fuse is for the overload (heated wires) protection.

Gene;
GFCI is required for all garage, basement, exterior, or damp located outlets. Smart thinking on the entryway where you might also feed an exterior load.

Cheers;
 
Well, somehow I balled the response up. I'll try again:

John, Its an 8 month old, heavy duty gauge construction type cord, plugs into a heavy duty outdoor timer. Plug fits nice and snug. To be clear, it was the plug on the block heater cord that cooked, not on the house end. My immediate guess was the water but I am certainly interested in hearing other causes.
Am I correct in thinking that the GFCI would not solve the underlying cause but would protect against a short circuit? I still want to find the original cause so it won't happen again.
Thanks for the info so far. If anyone has ideas, I am all ears (quite literally)!
Steve
 
HI Steve;

  1. OK you got me thinking now. I still hold to a loose connection theory with one of the two the most likely cause:
  2. Somehow the (almost) new extension cord had a single loose connection in a receptacle. The other two connections were snug enough to give a <em>positive</em> connection feel, but the loose one went toast when hit with the steady current draw of the block heater.
  3. The plug-in point of the extension cord has a loose connection. This may not show up at this point, but cause problems downstream. [/list=a]

    GFCI or <em>ground fault circuit interupt</em> is a device that trips if the current flow goes to a ground source only. This protects a person if you are in the circuit path to a ground. If the current flow stays on the hot & neutral within the circuit, even to overload or your with your body, it will not trip.

    The fuse or circuit breaker is designed to trip for overload or short circuit conditions whether it be hot-neutral or hot-ground.
    By code, GFCI is reguired on numerous hazardous locations.

    Did you check the connection at the block? I haven't checked that connection, but it is subject to environmental abuses, such as engine heat & road debris.

    I stuff the end of the extension cord into the stow location of the block heater cord under the hood. This keeps it dry and <em>prevents the cord from sprouting legs overnight. </em>

    Sorry if I got wordy, but just trying to help.

    -John


    [This message has been edited by JohnE (edited 12-17-2000). ]
 
Hey John,

Thanks for the info. I will have to check the engine side of the cord for sure. Good idea. Also have to replace plug end and try a new cord. Good info too on the GFCI stuff. Gonna have to get one of them too. Maybe Santa will bring me one.....
Thanks again -
Steve

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98 QC 4X4
"The Silver Bullet"
 
IMHO, the block connection for the heater cord is pretty well designed. I agree it is subject to heat but not road debris. I would be more concerned with the routing of the cord. Numerous locations to rub against the frame or something.
 
A GFCI will trip even if there is not a current leak to ground. If there is an inductive or physical loss of current, it can also trip. That's why it is legal (acoording to the NEC) to use GFCI's on ungrounded circuits. Many times as an electrican, I ran into situations like that.

Also, most of the extension cords I have seen with the triple tap on the end have VERY bad connections. More than a few times I have seen smoke pluming from the cord when a compressor is plugged in. It is best to avoid the molded triple-tap style cords.

Another note about GFCI's... There are REQUIRED under the following circumstances:

--Outlet is outside*
--Outlet is within 6 feet or a water source
--Bathrooms
--Garages

Another place where a GFCI protected circuit must be, is when there is a light in a shower area.

*An interesting place where a GFCI outlet is NOT required, is if the outlet is more than 12 feet off the ground. An example would be in a soffit, for Christmas lights. The reason for that is because there is very little chance of anything being plugged into the outlet that is on the ground.

Some of the most stringent GFCI requirements are when hot tubs are involved. A separate GFCI disconnect must be visible from the hot tub, but no closer than 5 feet, and no farther than 50 feet. The inspectors love to nail homeowners for this one.

Here's a copy of my post from another topic on how GFCI's work:

(posted 12-12-00)

Time to go back to my days as an electrician...

First, let's go over the basics on a how a GFCI (Ground Fault Circuit Interrupter) works.

Basically, the GFCI or GFI (same thing) monitors the current flow going in and out of the outlet. And by current, I do not mean voltage... . Rather, I am talking about the wattage/amperage that is flowing in & out of the outlet when an aplliance or something is plugged in. Inside the GFI, there is a microprocessor that does all of the "thinking" to monitor the current flow. It compares the current being used on the "hot" side, and the current coming back on the "neutral" side. For the GFI to trip, the difference between the two has to be greater than a certain amount, which is as low as 5 milliamps (mA). The GFI constantly monitors it, and if a current "leak" is detected, it will actuate a small solenoid inside the housing, cutting off the power to the outlet. The time it takes to do this is very short, about 0. 0002 of a second. Make sense?

The panel-box style GFCI works the same way. However, if you install one of these, make sure the circuit you are using it on is LESS than 250 feet. If it is longer than that, it could trip due to inductive loss of current.

Here's some more info on GFCI's...

Some things have a tendency to trip GFI's more often than others. Lights typically do not trip GFI's. In fact, I have never in my 3 years as an electrician seen one trip due to a light. What does trip them is motorized aplliances/tools. The motors and magnetic equipment can play havoc with the GFI's microprocessor, and casue it to trip. Usually it occurs on startup, which is when there is the greatest chance for current leakage.

So how does this help you when you drop a hair dryer in the tub while giving Fido a bath? Well, the time it takes the GFI to "see" and kill the power, is FASTER than the time it takes for the electricity to fry your dog. Much faster than the standard circuit breaker as well. The regular breaker would trip, but by the time it does that, Fido will be boiled... What it comes down to, is the GFI is a watchdog to make sure you stay alive.

What the GFI will NOT do is protect against shocks, such as taking two bare wires in your wet hands and inserting them into the parallel slots on the outlet. That will nail you pretty good if your hands are wet. If your hands are dry and callused from workin' on a Cummins, then you will feel only a minor shock. Kinda tingly, actually... *LOL*

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[This message has been edited by Evan A. Beck (edited 12-17-2000). ]
 
Evan;
Old code specs in your post.
GFCI is required for ALL outdoor receptacles as of the last code change.

All;
A GFCI uses current transformer (CT) technology and looks for a power leakage from the hot & neutral in the circuit only. It does not differentiate if the leakage is to the ground in the romex sheath or to the grounded water lines or to damp earth. This is why ungrounded circuits (2 wire) are protected by GFCI.

Inductive loss is nothing more than voltage drop on the line which sensitizes the CT to think the cicuit is leaking to a ground source. That's why rotational machinery (motors) tends to trip them.

UL® standard specifies a 5 (average) milliamp trip for GFCI. This is the same for both a circuit breaker combo unit or an outlet unit. I tend to prefer the outlet style as the reset is at the point of use. That's also why code required separate GFCI for each point of use circuit, meaning bathrooon, kitchen, outdoor, basement, etc. PIA to run upstairs to reset the GFCI that protects the backyard outlet because the electrical contractor cut corners.

Engineer with Square D®: for over 2 years which made me realize I didn't know <em>how things worked</em> versus <em>why things worked</em> when I was a building mechanic and doing electrical work.

Cheers;
-John


[This message has been edited by JohnE (edited 12-18-2000). ]
 
"Heat" in the electrical world comes from resistence. I would bet that the heater plug on your truck was sorta "cruddy" somehow, i. e. , more resistence. Heat built up there because of the high current flow of the block heater circuit.

Keep those plugs clean and sparkling!

Tim in Nebraska

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In the heart of the Droughtland
NRA and ATA Life Member
'97 SLT w/NAPA fan belt
What if the Hokey Pokey really is what it's all about?
 
John, thanks for the brush-up on the NEC. I always thought that 12 foot rule was stupid, I mean the thing is outside! I always made it a point to put GFCI's everywhere, even in low-risk areas.

There was one remodel we did where the homeowner had done some of the wiring... Man, everything was all screwed up, he had GFCI's protecting bedroom outlets, and some lights as well. This guy thought he could do it because he read a couple of books. *LOL* was he wrong... Homeowners and electricity can be a nasty combination. Most of the time, they will mess with everything else (plumbing, gas, carpentry) BUT electrical. Oh well, job security I guess!
 
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