I checked again to see if the element would get hot when you just plugged the unit in and it does,
How hot will it get? Will it come up to full temp? over temp? If you just plugged it in without turning it on, obviously something is still amiss. Again- Test this signal wire from the control board to the relay FIRST!
took the cover off over the element so it could be seen and right off I thought I found the problem the element was laying on the chip tray support so I found a small piece of ceramic placed It between the support and the element
It is normal for the element to touch what you are calling the chip tray support. You shouldn't need that ceramic, but not sure if it would hurt anything either. I would leave it out myself
plugged unit into 120 it heat up without turning unit on.
Something is still not right.
A while back we checked with the volt meter on the connections to the element one side has 120 volts to ground the other side reads 0 volts,
This would be correct depending on how you had your leads. With the terminals to the element disconnected, check Ohms (continuity) through the element.
as I was doing this I looked inside the unit the element was red hot for about 1/2 in. on the lead that checked 0 volts to ground, also there was a small hole in that 1/2in circle. Could the element be the problem??????????????
Possibly. It is possible you have more than one issue. If there is a small hole in the element, I would replace it. That little hole is what it looked like on the bad element I just changed this week. BUT. If the element is heating and getting to full temp, then it is working . It either is, or it isn't.
dlake- I don't mean to insult you and I hope I don't sound condescending, but do you have a buddy or someone you can call that understands electronics and electricity a little better? You know what you are working with can kill you, right?