MES Rewire Simple Guide - No Back Removal Needed!!!

[mr_whipple]

"All worked well and was heating for about 7 minutes and then the heater element started arcing turned red and is now open."
Everything was working, PID was set at 225 F and controlling the heater. When the temp reached about 105 F ( approx 7 minutes ) I heard a loud buzz and through the front window I could see arcing at the heater end where it exits the smoker box. Now an ohm meter placed across the heater contacts shows infinite ohms ( open circuit ).

"For whatever it's worth I disconnected the wires from the heater and connected them to a volt meter."
Just to see if the voltage from the PID controller was correct I disconnected the wires that go to the heater and attached them to a volt meter. I started the PID controller and turned on the original control box, the voltage across the heater wires was a steady 118 VAC.

I hindsight I wish that I would have tested the new PID setup without running the old controller at the same time but I guess I blew that opportunity.

Gotcha, just wanted to be sure we were on the same plane as far as the lingo goes.

First thing, I would ditch the notion of using the controller for anything and not power that at all, but that's an opinion...

As to the heating element opening, that was more than likely caused by a bad connection at one of the element terminals, which at that level of current flow need to be well done, corrosion free and secure. Any looseness will cause arcs and sparks like you experienced. Not sure how you fabricated to cord that goes from the PID to the element. Sounds like the PID is still putting out good voltage, so you're element is open, and can easily be replaced. Now, the other scenario I see in my head is somewhere in the element /corded connection circuit may have shorted to the case of the smoker somehow, or internal to your plug...but that's unlikely since you saw the arcing at the element. Without seeing firsthand, I'm guessing in order of most to least likely. We love pictures here. Anyhow, hope this helps. Keep us posted!