I own a Fahrenheat FUH724 (7500 watts) electric heater for my 2 car, uninsulated garage. I installed this unit 12/2017 along with a Nest thermostat. An Aube rc840t-240 relay was used to step down the 220v to 24v for the Thermostat to properly work and all appeared to work properly until about 3 months later when I began to experience malfunctions and this is where I need the collective help from an informed community found here.
Specs: 40A dedicated circuit breaker 8awg wire.
The electrical connections to the contactor became the point of failure. The OEM wires within the unit were overheating, failed and ultimately broke off and the internals of the contactor revealed signs of malfunction. I contacted the manufacturer, replaced the defect wires, and contactor also checked for loose connections throughout. All seemed acceptable. 4 weeks later, same failure points.
I contacted the manufacturer again and they sent me a replacement and I have yet to install. Could the Aube relay be causing this much heat buildup within the wiring to cause the malfunction? While trying to diagnose the problem, I took temp readings at various connection points with and without the relay in place and the temp at those points didn't change so I'm not sure that is the root of the problem.
I'm also questioning whether or not I may need supply wire exceeding 90c?
Sorry for the long-winded question but I felt it was important to describe the problem with all detail i've experienced. If i've left out any important info please ask away.