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Basically, I've had the same problem with my FAL 220s. Make sure, if you haven't already, to wire every circuit associated with the fan controller with 10 gauge wire, bigger is not required, but don't use any size smaller. The switched 12V source wire doesn't have to be as hefty (usually 16 or 18 gauge), but again, the battery + and -, and the fans + and - wires must be 10 gauge which is rated for 20 Amps. I essentially melted the male spade end on the fan controller PCB because of overheating the 14 gauge wire I originally used.
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