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Thread: 5500w Elements Melt On Fist Use

  1. #1
    Join Date
    Jul 2017
    Location
    Lake Stevens, WA, USA
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    2

    5500w Elements Melt On Fist Use

    Hi all, I just finished piecing together an electric 1 BBL system, and on the first use, water only the 2 5500w elements on the Boil Kettle melted around the prongs, it looks like liquid entered through the inside of the kettle. Faulty product?
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  2. #2
    Join Date
    Oct 2010
    Location
    Northern CA
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    372
    That looks more like an electrical problem to me - my guess is something is wired incorrectly/sized wrong and when drawing power your plugs are getting hot. Get that looked at ASAP.
    Manuel

  3. #3
    Join Date
    Oct 2014
    Location
    Kent, WA
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    232
    Quote Originally Posted by mmussen View Post
    That looks more like an electrical problem to me - my guess is something is wired incorrectly/sized wrong and when drawing power your plugs are getting hot. Get that looked at ASAP.
    ++1

    The melting/burning of the plastic (bakelite?) is a classic sign of a bad or undersized connection (internal to that element). It might also be poorly engineered. I know it seems like a good idea to have a motor base directly installed on the end of the element, because then all you need to do is plug in an L6-30R cord end on it, so it's easy to remove for cleaning. But there's a lot of heat that is very close to the terminals on that motor base, and I doubt any of it's rated for the actual conductor temperature. Wiring to a heating element typically has high temperature insulation and never with a plug connection that depends on spring tension for the electrical connection.

    But, it also appears that the ground connection overheated...I can't quite tell from the photo if the ground prong is darkened from heat, but it looks like it. This indicates a much worse problem. Possibly a ground fault, but it should have tripped your circuit protection. You do have the kettle well grounded? Do you have GFCI protection on it? The heat damage around the ground prong has me wondering if you have it wired correctly. Of course, it could be transmitted heat from the element...I don't know what the inside of that thing looks like. Sorry to say, the element is toast in my opinion. If the prongs get this hot, they can cause the spring loaded cord end connections to weaken, which will eventually result in an electrical fire.

    Call up the manufacturer of that element right away and get it sorted out before using the kettle again.

    Regards,
    Mike Sharp,

  4. #4
    Join Date
    Jul 2017
    Location
    Lake Stevens, WA, USA
    Posts
    2
    Thanks for the Input. I contacted the manufacturer and they are aware of the issue. It has to do with the inner glue not curing correctly. They will be replaced. My panel operated as it should and the breaker tripped. Any chance there could be damage to the ssr?

  5. #5
    Join Date
    Oct 2014
    Location
    Kent, WA
    Posts
    232
    Quote Originally Posted by Magnitude10.0 View Post
    Thanks for the Input. I contacted the manufacturer and they are aware of the issue. It has to do with the inner glue not curing correctly. They will be replaced. My panel operated as it should and the breaker tripped. Any chance there could be damage to the ssr?
    If it was a magnetic trip breaker, I'm hopeful the SSR survived the fault, but I can only guess. My fingers are crossed, though. If you're concerned, you can probably rig up a load test for it. Or, order a set of spares just in case.

    Regards,
    Mike Sharp

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