We have an electric vehicle, and we decide to install an AC inverter on it to power up some heavy AC devices from its DC-DC converter, which provides up to 1800 watts. As can be shown in image below, a 100-amp fuses at both ends of the line were connected. enter image description here
The fuse value matches the maximum device consumption and is less than the maximum wire rating. However, the wires are 2 AWG, which are capable of carrying that current. We used a wire crimping tool to tie the cable to the terminals. To insure the crimping process, we followed the tool guide. And then, the wires are isolated by heat-shrink pipes.
However, the system was working fine, and no issues were encountered with the power. The wires were burned from the terminal side after roughly four months, as seen in the image below. Also, the fuses were burned out. Moreover, some fluid spilled from the 12-volt vehicle auxiliary battery.
enter image description here enter image description here
We checked the system's connection, wires, current, and power, and there were no changes with the current consumption. Moreover, neither the engine's nor the ambient temperatures change.
We haven't been able to figure out why it happened until now.
Any one has any ideas about that?
Give me suggestions for the problem. And offer some recommendations.
