I have a electric kettle and I use a 2000W element from Home Depot. I use a Ranco controller and Shock Buster GFCI from Lowes. I have used my system about a dozen times and no problems. The other day I started an electrical fire. The black cable melted. I technically saw no flames, just smoke. Luckily I was in the room and was able to disconnect the cords before much more damage could have happened. Do you have any idea for what might have caused this. I'll try to describe my setup as much as possible and give some possible problems:
1. The ground wire came lose on the kettle. It also had JB Weld on the end of it because my hole was cut to large so I had to patch it.
2. I have a 220v dryer connector and I had an electrician re-wire it to make two 110v receptacles instead of the 220v. (I know I should just use a 220v element, but then I can't use my ranco controller)
3. The Shock Buster says 1875 Watts on the back and the element is 2000 (I think, again it's from Home Depot)
4. The Ranco controller is using a standard orange extension cord. I tried to use heavy gauge wire, but it always came loose, so now it is braided wire, not solid copper. I opened the Ranco controller and there was not burns on any of the cables inside, just the male plug that went into the Shock Buster. The other male and female connectors from the element to the Ranco also did not have any burns.
5. The steam from the boil was pretty close to the electrical outlet. I actually though the smoke was steam from the boil at first.
Thanks for any help.