This is driving me a bit nuts. I mentioned previously a Brewtus ground 
fault problem that I traced to the boiler heater leaking current from the 
electrical connections to the outer case. I replaced the heater and the 
machine worked for a few months, but then failed again with the same 
problem (tripping GFCI outlet). The newly installed heater coil again 
developed electrical leakage from heater element to the case (about 
30kOhms). Just to be sure I measured this before installing the heater and 
the same measurement showed infinite resistance.

Todd from WLL responded to my query, guessed that the heater might have 
been faulty, and sent me a new one gratis (Great service from WLL btw). I 
put that in, the machine worked fine for about a month, but amazingly THE 
SAME PROBLEM has now reoccurred! - GFCI trip and measurable resistance from 
the heater element to the case (with the heater power connections 
disconnected of course).

So now I have had the original heater and two replacements fail in the 
exact same way, but only after working OK for month or so in each case. I 
am really at a loss here and looking for ANY ideas about this. I can only 
come up with two guesses, both of which seem unlikely:

1) WLL has got a bad batch of replacement heaters, all of with develop 
electrical leakage after some use, or
2) I am doing something wrong when bringing the machine back up after 
reassembling. All I have been doing after refitting the boiler and pipes is 
fill the reservoir with water and turn on the machine with the cover off to 
check for leaks. If all looks dry I put the covers on and turn it over to 
my wife. She sys the machine worked fine maing espresso up until the GFCI 
tripped.

Is there any special procedure for priming a restarted machine? Is there a 
way that boiler can run partially full and burn up the heater or something 
like that? The reservoir is never allowed to be less than 1/2 full. Also, 
the heater element itself is still good (measures about 14 Ohms) except for 
the electrical leakage.

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