This is an element plug that had melted. Just one. What ever happened, it wasn't so obvious. I fired a 3/4 full to ^6 kiln. But it never reached ^6. And it run 20 hours on my timer. So I checked my elements for continuity. I opened the control panel and proceeded to measure past the plugs and they were good. I thought they would be since they were brand new and only fired about 4x before. So I put the control cover back on and did a refire. Once again after 10 hours it was still at ^05, so I shut it down. Waited for it to cool and completely removed the control panel, so I could see if any switches, relays, wire or power relay were burnt. But every thing was fine. Not even a smell. So I decided to see if I had a loose connections. Started tightening screws on the wire and busbar connectors. And sure enough the parts broke off as I began to tighten. It was just holding on because of the fusion. It was in a series of 4 elements. The other 3 elements were fine. As where all the rest.
So how did this one brand new element melt and fuse with the ceramic plug? Anyone?
It's working fine now that I put a new element in. But I will continue to monitor.