I am on replacement #3, last purchased September 2016, this replacement heating element is either a design or manufacturing fault and could short out and the occurrence of a fire. This time the main heater power cord was blown off the plug and floated free and the black and white wires they were tied to melted the insulation to bare wires (see photo). It is evident that the wires have become very hot due to current leakage and should be fitted with a high temperature sheath rather than a plastic sheath. The fan spins freely, so it's not the fan that's causing power draw issues. The old 1975 fan heater still worked when I replaced it, just looked dated for our renovated bathroom, wish I'd kept it as modern Broan/NuTone stuff from China, just rubbish. I'm not sure there's an easy alternative solution, but $33 a year to replace a heating element makes finding a quality alternative attractive pretty soon.
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