QUOTE(ozak @ Nov 29 2016, 03:23 PM)
It is not much different because the wire is really not that long. Cut it short is to make it more proper and have some space for the hot air out. (not much also)
You won't get risk of fire if
1) the time using is short.
2) The heater KW doesn't exit the max wire ampere carry. Maybe around 20A. or 4.8kw.
3) the connection not loose and tight secure. switch and heater side.
Get a better higher Amp switch.
Its not the cable length that's the problem..
The higher the current carrying capacity the more the contact area and contact pressure becomes critical..
For round conductors like wires carrying heavy current you
MUST use terminal lugs which are properly suited flat and make capacity for the application..
Take a thermal imaging device and point it at the load..
The heat is always at the contact points where the contact area and pressure is the least..
Your item 3 is correct and primary.. Emphasize it more..