Yet Another Immersion Heater Tripping Question

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Sorry - another one! We don't use our immersion heater much, but we had a problem with the usual boiler heating method so turned on the immersion. It worked ok the first time ... but a day later, tried it again, all the lights went out.

The immersion is on its own circuit (actually shared with a socket for the shower pump) protected by an MCB. The RCD covers the whole house and it is that which is tripping every time I try to turn on the immersion.

What I've tried so far:
- I've tested the thermostat and it seems to be working correctly. Resistance between terminals is either 0 or infinite (using multimeter). No detectable connection from either terminal to the probe sheath. In any case, I also tried removing the thermostat completely and connecting the element directly to the supply - that tripped when turned on, so its not the thermostat.
- I've tested the resistance of the heating element - 19ohms, which I think is correct. No detectable connection from either terminal to the tank itself, though I'm only using a multimeter and not an insulation tester.
- the cable leading to the immersion heater looked a bit iffy - some heat damaged insulation - so I replaced it with a new rubber sheathed "immersion heater" cable. No difference.
- in case there is something weird going on elsewhere, I plugged a 2kW heater into the shower pump's socket (same circuit as the immersion) and ran it - no problem, from which I infer that the general cabling is probably ok.

What's left?
 
- I've tested the resistance of the heating element - 19ohms, which I think is correct. No detectable connection from either terminal to the tank itself, though I'm only using a multimeter and not an insulation tester.


I think you've answered your own question :-) A multimeter is unlikely to find an insulation fault between the element & the sheath because the test voltage is not high enough. You've eliminated everything else so its time to get the immersion heater out of the tank...when you do, I suspect that you'll find the sheath has split.
 
As the immersion element gets older it can lead to leakage from the neutral to the earth and hence tripping the RCD. Unless you have access to an insulation resistance tester it’s unlikely you will be able to confirm this
 

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