overheating Gerbing jacket & controller plugs

[DanL]

I have had my gerbing jacket, gloves & socks for over 15 years.  The Gerbings have SAE plugs.  I went for a ride yesterday and when I had the jacket's plug connected to the controller the plug began to overheat and but I didn't notice it until  about 20 minutes into the ride.  I ended up with a small burn on my stomach because the plugs burnt me through a tee shirt.

My question is why did this happen and how can I fix it?

The Jacket & gloves did work as normal and kept me warm.
Thanks
Dan

[Bighead]

I think that would probably be best answered by the manufacturer.

[Andy Cote]

There have been similar occurrences to the point that Gerbings.LLC issued a recall.  Original Gerbings Company was always excellent with customer support and replacing items with little question.

However, from what I have read, the new owner that bought out Gerbings.LLC has not been honoring all the warranty provisions included with original purchase.  I am not a member of the bar but seems to me when you buy a company, you buy all assets and all liabilities.

Anyway, since there is a recall listed on the CPSC website, I would think you should have the liner replaced: https://www.cpsc.gov/Recalls/2013/Gerbings-Recalls-Heated-Jacket-Liners/

The company that bought Gerbing is here: http://www.gydesupply.com

This is the original owner of Gerbings who may be able to help but probably not under warranty: http://gordonsheated.com/index.html

[DanL]

Andy
Thanks for the sites. 
I'll  contact them and see what happens.  unsure if replacing the plugs will solve the problem?

[Jess from VA]

Heat at any electrical contact/connection is usually resistance, whether corrosion or something else.  Look for that.  Clean and diaelectric grease.

My gear is old with SAE plugs, and new with coax plugs, and I have to use shorty conversion wires for my gloves (nothing like little loops at the wrists to tangle with the controls.... tuck it in, and it comes out anyway).  

I never had a hot connection, but the first time I used my new jacket liner, I set the temp in the driveway, then 5 minutes later at higher speeds and revs (and amps/volts), it almost burned my nipples off (only a Tshirt, like was recommended).  It spiked up so quickly and painfully, I did not go for the controller, I pulled off the road and yanked out all the wires.  Went home and took it all off and put on heavier gear.

[The emperor has no clothes]

Heat at any electrical contact/connection is usually resistance, whether corrosion or something else.  Look for that.  Clean and diaelectric grease.

My gear is old with SAE plugs, and new with coax plugs, and I have to use shorty conversion wires for my gloves (nothing like little loops at the wrists to tangle with the controls.... tuck it in, and it comes out anyway).  

I never had a hot connection, but the first time I used my new jacket liner, I set the temp in the driveway, then 5 minutes later at higher speeds and revs (and amps/volts), it almost burned my nipples off (only a Tshirt, like was recommended).  It spiked up so quickly and painfully, I did not go for the controller, I pulled off the road and yanked out all the wires.  Went home and took it all off and put on heavier gear.

I've heard some people pay good money for the burnt nipple thing. You got a freebie.

[Jess from VA]

Heat at any electrical contact/connection is usually resistance, whether corrosion or something else.  Look for that.  Clean and diaelectric grease.

My gear is old with SAE plugs, and new with coax plugs, and I have to use shorty conversion wires for my gloves (nothing like little loops at the wrists to tangle with the controls.... tuck it in, and it comes out anyway).  

I never had a hot connection, but the first time I used my new jacket liner, I set the temp in the driveway, then 5 minutes later at higher speeds and revs (and amps/volts), it almost burned my nipples off (only a Tshirt, like was recommended).  It spiked up so quickly and painfully, I did not go for the controller, I pulled off the road and yanked out all the wires.  Went home and took it all off and put on heavier gear.

I've heard some people pay good money for the burnt nipple thing. You got a freebie.

Kinky.  (No thanks)

What is the difference between erotic sex and kinky sex?

During erotic sex you use a feather, during kinky sex you use the whole chicken.

[DanL]

on them & see what happens.
Thanks for the laughs, made my day

[Gryphon Rider]

It could be that they didn't make a good connection between the wires and the terminals before they injection moulded the rubbery plastic body around it, and eventually it loosened up enough to make a bad, high resistance connection. Another thing that can happen is the wires just before they enter the connector do a lot of flexing during normal use, and the wire strands eventually break, leaving just a few strands to carry the entire current, producing heat.

[MarkT]

Dielectric grease in this circumstance will make it worse.  The purpose of DG is to displace oxygen away from connections mainly to prevent galvanic corrosion.  It's NON-CONDUCTIVE.  If you get that in the contact points you will increase resistance and provide fuel for the resulting fire.  You put this grease all over a connection after it's been made to keep the oxygen & water away.  I used it on fuse contacts and had a fire.

As for improving the conductivity, a good cleaning and application of contact cleaner like that made by Radio Shack would be a better idea.

I have contact compound, two types, that are like grease but they are the opposite of dielectric grease. They are conductive - one loaded with copper powder and the other is intended for improving connections especially to aluminum, used on connectors and grounds to improve conduction, displace oxygen and water.  I wouldn't use it on Gerbing plugs however.

I would have written what Gryphon did but he beat me to it.

[Highbinder]

Here's where the company stands on Gerbings warranty...

below states Gyde still warranties Gerbings heating elements to original purchaser with receipt

============

Warranty
General Gyde Warranty
When you purchase a Gyde Supply Co. product within the United States, the heating elements (Microwire TM) are warrantied for life. Electrical plugs, Connectors, and any solder joints, as well as all materials and craftsmanship are covered by a one year warranty from date of purchase. Batteries and Chargers have a 90 day warranty from date of purchase. Normal wear and tear, and or customer negligence is not covered under the Gyde Supply Co. warranty. All warranties are non-transferable and apply solely to the original purchaser. Proof of purchase must be provided if any warranty claim is to be honored. Shipping costs for all warranty claims are the responsibility of the customer. Gyde Supply Co. products are designed to be powered and controlled by using only Gyde Supply Co. accessories and controllers. Using other manufacturers’ accessories and controllers with your Gyde Supply Co. product will void the warranty. Please call (800) 646-5916 for a Return Authorization. Any products shipped into us without a Return Authorization might result in delays or potential loss of that returned item. Gyde Supply Co. will also extend the same lifetime warranty to the heating elements in Gerbing Heated Clothing Inc (GHCI) products, even though they are entirely different companies. GHCI ceased to exist in 2012. Gyde Supply Co. will also continue to repair any of their products or GHCI products that are out of warranty for a fee. We will not charge any premium to our customers for the repair of their garment; your cost is simply our cost. No mark up. No profit. We will continue to value customer feedback and serve our customers to the best of our abilities. Without you and customers like you we would not be able to build such a great brand, and for that we thank you. Our goal at Gerbing will continue to be producing the best wearable technology while offering unmatched customer service.

[DanL]

of pushing & pulling, there just be some broken wires?
I did send an email to Glyde and they answered in a couple hours and asked me to send them the jacket, controller & battery connection for testing & fixing.  I'll mail them off tomorrow and hopefully I get them back before December. 
I'll let you all know what happens with Glyde.
Andy, I did submit a ticket at CPSC but I'm not sure what will happen with the ticket.