Originally Posted by MikelB:
I have a fuse on the incoming #30 terminal on the relay but it never popped so I guess I need a smaller fuse as the fan is rated at 5 Amps but not sure if that is running or start up draw.
I wouldn't be too concerned with the start-up draw. Fuses require current above their rating for a certain amount of time before they fail. For example, this 10 amp "fast-acting" fuse (http://www.farnell.com/datasheets/1633611.pdf) will carry 13.5 amps for 0.35-600 seconds before it fails, it'll carry 20 amps for 0.1-5 seconds. A "slow blow" type fuse can increase those times many fold, so they deal with those initial current spikes even better.
The fuse is really there to protect the wiring, not necessarily the attached devices. And because of the above issue, you wouldn't put a 15A fuse on an 18 gauge wire even though the wire is rated to 15A. Worst case, if you put in too large a fuse, the circuit resistance might be too high (undersized wiring or corroded contacts for example) to blow the fuse even if you have a short. And "high" in this case can still be less than 1 ohm. You always want to use the smallest practical fuse.