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Ever Repair a Electric Popcorn Kettle Before? Answered

We have a popcorn machine at work.   The kettle died and I took it home to fix.
I didn't know a ton about them before but after working on it it seems to mainly consist of a heating element, a thermostat and an in-line fuse.

I replaced the fuse but each time I would turn the thing on it would cook one batch of popcorn (much faster than before and not as well) and then not be able to do another.  It seemed like the fuse was burning out.   I had replaced it with the same model number as before.

So I replaced the thermostat too.   Still, the same thing happens.   I tried reversing the poles in case I put the wires back in backwards and didn't realize it, in case that mattered, but no effect.

I adjusted the thermostat, both old and new turning them down and down by what should be 200 degrees in the end but was getting the same effect, like the thermostat wasn't the issue.

Does anybody have any ideas what is going on here?   Is there maybe some inline resistor in the heating element I'll never be able to get to or see or something?

Adding a picture.   The two white wires are power, the green is a ground.  There's nothing but wire beyond where they go.



1 year ago

Where did you buy the replacement thermostat?


3 years ago

Did you ever end up fixing this?


Reply 3 years ago

Nope. The heating element was welded into the bottom of the pan. It was designed so it couldn't be replaced without buying a whole new pot.


4 years ago

The heating element is one big resistor. It is usually a thin nichrome wire encased in ceramic or from the pics, a metal tube to protect it and to help transfer heat. Those wires glow red hot and can in time break from the heat, expansion and cooling. It might work erratically as the wire shifts inside when it heats up and then short out to the casing tripping the fuse. I don't know if it is worth it to get a replacement part or maybe you have a waffle maker appliance to scavenge. Good luck.


Ah! Thank you so much for explaining this. I couldn't figure out how it was still heating up if something had shorted in there. That makes sense.