Melting down - plug ends and element ends

codfishhead · Joined: 20 Nov 2019 Posts: 5

1.5” tri clamp 5500w 240v elements (Dernord SS) with twist plugs ends. Blichmann control unit.
Elements as well as the plug ends are melting. Not at the same time. Not all the time. Normally one or the other has issues. I replaced the Blichmann plug ends and still happens. I tried 80 percent power and 100 with same results. Coming off a 30 amp double breaker.

After reading on here I may have issues per I’m sanding the plug ends to clean them because they’re getting burnt. Probably not the best solution especially since its not lasting. The elements themselves are clean and shiny.

After melting down several times I’m thinking I need to start with all new components. Also thinking I should eliminate the plug ends wiring directly to the elements. I have some questions and would love any and all feedback for a solution. I’m mechanical. Not so much electrical.

Questions:
Looks like I’m going to need an adaptor for the threaded elements to a 1.5” tri clamp.
Question, are all thread sizes the same on the 5500w elements? Any link to an adaptor?

My Blichmann cords are 3 wires. To connect to the heating elements does it matter which wire goes where? I see two screws and a ground. Does hot need to go to one side or the other? Told you I’m not electrical lol

Elements? Which ones are best and what ones do I stay clear of?

Anyone know of any issues with Blichmann cords? Should I be replacing them as well?

Very much appreciate any and all help.

Thank you

**kal** · Posted: Wed Jan 26, 2022 9:28 pm Post subject:

Hi!

You're not using any of our products and haven't provided pictures either so it's a bit difficult to assist but I'll try but my response may be somewhat generic in spots. Sorry about that!

You're on the right track on using quality plugs. We only use and sell tough industrial grade nylon locking plug for safety instead of the cheap molded rubber plugs many use to save cost as you're seeing here. Our plugs/receptacles are here:
https://shop.theelectricbrewery.com/collections/heating-elements

I personally do not like disconnects at the kettle for this reason as well. It's another point where failure can occur, and also means that water can get in during a boilover. IMHO that's dangerous. For this reason we only offer heating element assemblies that are 100% waterproof without kettle side disconnects.

codfishhead · Joined: 20 Nov 2019 Posts: 5

Thank you Kal

As for the cord I was just wondering if the backup did any damage. The wires look fine. I'll use the cords to your products.

My system has three 1.5" tri clamp inputs for elements. I need three 5500w element setups.

How do I order what I need from you?

Thx again

**kal** · Posted: Thu Jan 27, 2022 12:07 am Post subject:

codfishhead · Joined: 20 Nov 2019 Posts: 5

Electricity flow backing up producing heat was what I was at.

Thank you Kal

I'll order up and tell you how it works out.

**kal** · Posted: Thu Jan 27, 2022 1:57 am Post subject:

Ah! Gotcha. If heat damaged the wires then replace. If not, it's probably fine. If there's any doubt, best to replace. Cheers!

Kal

codfishhead · Joined: 20 Nov 2019 Posts: 5

Did some reradings and found one side of a 220 outlet wall plug was only showing 124v while all others read 244.Phase out in the plug or breaker. I'm having an electrician come take a look.

I'm still going to upgrade to your setups.
thx again

**kal** · Posted: Fri Jan 28, 2022 1:10 pm Post subject: