In the cases where happened a melted connector(s), it is almost always due to
either of two reasons:
1. Incompatible connector types been used together.
2. Faulty crimping of DC cable.
the connection is not secure, there is a resistance across the connection,
which causes heat. As DC power is constant, the heat builds up and will cause
the connection to oxidise even more,
causing more resistance. Eventually the
heat builds up and melts the plug casing. In rare cases, it can catch fire.
How do we know it was caused by the bad connection?
It’s easy to know that the damage will be concentrated at the point of maximum heat.
In the below example, we can clearly see that the areas just above and below are not