a year or so ago my hedgehog failed , the connector was fubard so I replaced it and rewired it and with a new one in place all was well , till yesterday that is , no fan again , so I removed the hedgehog to find it was roasting hot to the touch , ive asked for it to be replaced under warranty but I was wondering if I may have got the wires mixed up and its overheating the resistor ??

If it's worked for a year, I can't see how you could have mixed the wires up.

If you had, it would have failed almost immediately.

It may be the fan that has stopped working, thus letting the hedgehog heat up.

Can you check that the fan's running?

Mike

The fsr heats up during normal operation, that's why the cooling fins are located in the heater incoming airstream to cool it.
The slower the fan speed the hotter it gets and it can get really hot.
From what you describe it sounds as though the fsr has failed again
Just a thought, when did you last change the pollen filter?

I kept the old one ( which was stuck on all the time ) plugged it in and it worked straight away so the fan itself is ok , ive got a new FSR coming tomorrow which im hoping to get replaced FOC , its was a Hella one so good quality and certainly should of lasted longer than a year I feel