Thanks for the photos.

What was the rated wattage of the heating element?

Can't quite tell if the heat came from the cables and termination or
from within the device.  My guess is from within.  You would have
noticed any arcing or hot cables.  Unless the cables have insulation
which won't show that.

Voltage drop of 1.6V at 25C suggests that at 25A the device would have
to release 40W.  That's a fair bit of heat for no heatsink.

http://www.fotek.com.hk/solid/SSR-1.htm

Did it do this while on or off?

Did you make a measurement of the switching voltage when off?
Datasheet suggests anything more than 1.0V means it isn't off.
Accidental high resistance of your microswitch or cabling may bring
the switching voltage up.

Did you capture temperature of the device at any time?

On Tue, Dec 16, 2014 at 06:52:07PM -0700, NOPE9 YES wrote:
> Here are photos of the SSR
> https://www.flickr.com/photos/48808176@N08/sets/72157649733342556/
>=20
> The FOTEK SSR-25DA was switching power to a clothes dryer heating element=
 at 240VAC.
> 12VDC was supplied to the + side of the relay input through a 500 ohm res=
istor.  A micro-switch ( normally open )
> grounded the + side to shut off the heating element.
>=20
> Is the FOTEK likely to be counterfeit ?
> Although it is hard to tell in the photos , it appears the heatsink got v=
ery hot.  I had it screwed to the metal frame of the appliance.  I did not =
fasten it tightly or use thermal paste.
>=20
> I tried the SSR on the bench ( using 120VAC and a 200W lamp ) and it stil=
l appears to work.
>=20
> Does the PIClist have any suggestions ?
>=20
> Gus in Denver
>=20
>=20
> --=20
> http://www.piclist.com/techref/piclist PIC/SX FAQ & list archive
> View/change your membership options at
> http://mailman.mit.edu/mailman/listinfo/piclist

--=20
James Cameron
http://quozl.linux.org.au/
--=20
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View/change your membership options at
http://mailman.mit.edu/mailman/listinfo/piclist
.