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I don't think the Melzi is a fire hazard. I would bet that most of the burned connectors are due to improper assembly. If you don't tighten those connections properly, they will produce heat. I did however upgrade the wire that goes from the power supply to the Melzi on my 2nd printer. I used 10 gauge stranded. I've printed plenty of ABS with it and have had no issues. The wires stay cool to the touch.