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I have built a few heating element control panels for myself over the years using ssr, and ohm control pots and have had no troubles with them. I recently decided to build a new panel with a auberin dspr210 as the head of the panel. All my other builds were set up to just run one element. I decided i wanted to try and run 2 elements off of one panel. So i installed 2 auberin 25 amp ssr's i fed the box with 8 awg cable in and ran 10 awg cable out to each heating element. i have din mount breakers inside the box and built everything to be as safe as i possibly could. I got two runs out of it with no issues. The last time i used it i had a over heating issue and melted down a wire. I repaired it and started monitoring things very closely.
Just a little bit more information before i get into my questions.
I am running 2 4500 watt low watt density elements off of the control panel. After i started watching things more closely i noticed the temp of the wires inside the panel are running around 115 degrees F, That is higher then i would like to see
is that to high to be safe though? What should the temp be?
When i was building the panel my thoughts were as follows 4500 watts/ 240 volts =s 18.75 amps if my understanding is correct so that should be low enough for 10 awg wire out to the elements and should also be under and 37.5 amps combined for the 8 awg main power line. (and yes i understand it is just barely under)
I did some more checking with a volt meter and my main power line to the panel runs right around 230 volts so by doing the math that comes out to 19.56 amps 4500/230 =19.56 amps would that be correct? should still be just under the 40 amp max rating that i see by google searching cable ratings.
So then i thought well if i back the power down with the auberin 210 to 60 percent that should help. But under use the wires are still around 115 degrees. So i started to wonder if simply just backing the power out put down while effectively cutting the power to the element if that might be just creating that much more heat and energy for the ssr to try and dissipate and why it is still running hot? What is my best bet for fixing this issue? backing the heating elements down to 3500 watt each? I obviously do not wish to have a fire starter prone unit on my hands. thanks in advance for any suggestions