Melted wires on ceiling hung 5kw garage heater.

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Old 01-13-19, 11:59 AM
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Melted wires on ceiling hung 5kw garage heater.

Installed a comfort zone model cz220 .All went well until I noticed the odor of plastic burning. Shut breaker off .Opened up bottom access door of unit and saw wires L1 L2 that were attached to lugs that mount to plastic block all melting away .The unit has 3 settings 3000 / 4000 / 5000 watt ..( I had it on 5000) The wire I used was approx 15 feet to panel I ran 10 gauge. Little confused where I went wrong .
 
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Old 01-13-19, 12:03 PM
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Hi, what size breaker did you use? Usually a problem like you have was caused by loose connections, either when you landed the wires or possibly connections under the lugs.
Geo
 
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Old 01-13-19, 12:08 PM
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The breaker used was a 30 .Which the install of the breaker and wire connection was done by a licensed electrician friend ( Who is away at the moment) I did the hook up on the heater end .So your saying if the set screws on the lugs were not " tight enough " ?
 
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Old 01-13-19, 12:11 PM
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Welcome to the forums.

Running at 5000w it only uses 22A of power at 240v so #10 was fine for the hookup. As Geo mentioned..... loose connections create heat. Can you post a picture or two for us ?
How-to-insert-pictures
 
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Old 01-13-19, 12:12 PM
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Thatís correct,or something is loose under them , if you can remove the set screws from the lugs and look into the bottom of the lug and see if there are any attachment screws inside those that maybe loose.
Geo
 
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Old 01-13-19, 12:20 PM
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Have to figure out how to post pics .One of my questions was if 10 was sufficient or was 8 needed but you answered that .Thank you. The lugs screws are all ceased up and the plastic mounting block is done ..melted ....I can't seem to find parts for this heater .( Saw new one online for $77 free shipping) Or can I eliminate the lugs and splice every thing together. ( May wait for my electrician friend to return but very cold here in NY) Hard to believe I would not of had those lug screws tight ..but what else could it of been?
 
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Old 01-13-19, 01:22 PM
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Just a couple of ideas...
have seen where the wire was not placed correctly in the lugs....lugs tightened up but wire was not clamped properly. Not uncommon.
New heater could have been (factory) wired wrong, had a high resistance ground, mislabled.
 
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Old 01-13-19, 02:54 PM
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I left you a link in post 4 to posting pictures.
 
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Old 01-14-19, 06:11 AM
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Search found the device can be wired for 208 or 240 vac single phase operation. Did you connect 240 to the 208 terminations?
 
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Old 01-14-19, 06:46 AM
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Cannot rule out a manufacturing defect where the internal wiring of the heater had a loose connection behind the plastic mounting block. But you will need an expert witness and you may not tear apart the heater to find or investigate that for fear of voiding the warranty.

I actually saw a manufacturing defect (with a cord and plug heater) that caused the rececptacle to melt. It was in a hotel. The plug was actually not damaged by the heat and had loose screw terminals on the plug prongs inside which I tightened and repaired the plug to excellent workmanship. Then I moved the heater to another part of the room leaving it unplugged. That evening I found that hotel staff had repaired the receptacle but the heater was not touched. Unfortunately I forgot to notify the hotel what happened although I expected that that heater would no longer cause any problems.
 
 

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