Two years ago, I moved my dryer from one room to another (built a new laundry room). At the time there was a straight run 220 line (it's own double 30-amp circuit). Because of the basement being finished where I could not run an entire new direct line for the dryer I decided to use two-thrids of the existing line, cut it, and continue to run the remainder of the line with new wire from that point to the dryer.

The dryer is 3-prong (newer Kenmore). Where I connected the new and the old wire together I used red wire nuts, then electrically taped each connection (black to black, white to white, red to red, not sure about the ground)... this was done in a plastic junction box. Dryer has been running fine for 2 yrs. Until...

This week it stopped working and I found this juntion box with total meltdown with the 2 red wires burnt to a crisp for about 3 inches...

One note: when I say the old wire (house is only 20 yrs old) this wire is some big-time fat cable-appears to have more than 3 wires running in it, whereas the newer wire for the new room is what Home Depot told me aI needed (it an orange 4 wire for 220 circuit), but this wire is definitely not as beefy as the pre-existing, which is a concern of mine.

Now, I don't know what to do. Reconnect the wires as before and assume it might have been loose? Need to replace the new orange wire to dryer because it is not sufficient like the original? (I hope not because there is no easy way to do this without ripping apart the new room). Or... any other ideas? Thanks

First, may I suggest that you verify the circuit breaker is a 30 amp breaker.

Second, NM cable with an Orange protective sheath should be #10 AWG, which is rated for 30 amps or less.

Check further up the wiring to verify the size of the conductors.

Yes, the double breaker has 30 on each handle. I cannot see up the wiring very far either direction to verify wire. Does Type SE on the BIG grey wire (original) mean anything? Where it was cut off seems to have 2 or 3 big insulated wires and then many small bare wires... if that helps... thanks

SE cable markings stand for "Service Entry" these are the cables that bring power in from your meter.

SKUENKEL,

Did you wire nut alum to copper--using red wire nuts?

When you connected the wires together, did you twist them together or just put them together and twist the wire nut around them? 10 gauge wire should be sufficient, but if you didn't fasten the wires tight enough they will generate heat and possibly burn off the insulation. And then again it's possible you have a problem with the dryer.