Burnt red wire to the heating element. Cover has been off after I replaced the heating element 18 months ago. I did have this problem about two months ago when it appeared that the red and black wire touched each other . There was the burnt smell and melting. I cut off the burnt parts and reconnected and all was fine until now.

We need a lot more information or at the very least a couple of pictures from you.

How old is the water heater?

Have any of the heating elements been changed recently?

What is the amperage of the circuit that supplies the water heater?

Normally, a 240 V/20 Amp circuit is sufficient for a water heater/storage tank that is less than 140 gallons. The nameplate amperage on the water heater's metal tag will tell you the base amperage for the tank. However, if the tank is less than 140 gallons, it is considered to be a continuous use device, which means that amperage required for the device is 125% of the nameplate amperage. For example, if the name-pate tell you the heater needs 13 Amps, than the NEC adjustment would be 13 X 1.25 or 16 amps. On a dedicated circuit, which is what is needed for a water heater, a 20 amp circuit would be required.


Is the heater a 120 or 240 water heater?

What is the required amperage of the water heater?

Do you have copper or aluminum wire for the supply conductors?

It is CRITICAL that the circuit breaker on the panel board for this circuit match the requirement of the heater. For example, if the heater requires a 20 amp breaker and you have a 30 amp breaker protecting the circuit you have a fire waiting to happen.

A couple of possible solutions are that there is a short within the heater itself which is causing high current, which in turn starts the melting and burning process.

There could also be a short within the supply cable itself.

Please consider calling a licensed electrician immediately to fix this.

Ummm, is there an actual question?

Connecting wires to heating elements can be difficult, and often need special attention, as the heat from the element often will burn the wire at the connection point.