Zooz Zen31 - Melted Wire?

So I've been having this issue where randomly my light strip would stop working. Was driving my crazy cause i'd do reconfigs, and reboot HE, then re-tighten connections, and it would eventually start working again.

Yesterday, I found that by wiggling the cable I have connected to the light strip it flickered back on. No big deal i have a bad connection, I left it with plans to fix/replace the wires.

But now today I find this:

It's clearly melted, but what on would cause this? I'm using the same 12v power supply that came with the light strip. I have to imagine it's something wrong with the Zooz unit, so I guess I'll contact their support... but wondering if anyone has a diagnosis

That isn't part of the Zooz device itself, is it?

Poor connections, loose connections, or too small wire usually cause this. It would be very unlikely to be the driver device causing this.

Yea i know it's not the driver. but all the wires are pretty thin as it is! i'm using standard pinned jumpers.

and no, it's not part of the Zooz device, just my jumpers

I’ve seen that sort of thing happen when loose or poor connections, on circuits of fairly high current, cause arcing. The arcing then heats the area....
If there’s been a poor connection for a while the arcing can cause carbon build up, which make the connection worse, which increases the arcing etc etc...

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I agree, poor connection. I've seen many field returns where bad connections have generated enough heat to eventually over heat the plastic housing.

In addition, the wires coming off the connector pins looks too small for a typical strip light application. Much of the capacity of a connector comes from expecting cooling from the crimped wire. The dupont jumpers from china have much more insulation than actual wire AND often the wire is not copper but copper clad steel.

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Thanks to all!

My light strip is a cheap light strip from China as well! lol The wires were meant as a very temporary thing, and then weeks passed and I never did anythign with it. I'll clean it all up and strip the original cables to put them right into the Zen31.

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njanda is totally correct. The resistance from the bad connection creates heat, and as he explained, it's a vicious cycle.

Glad you caught it before it got worse

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