1) Both upper and thermostats must be set the same (usually 120 degrees) (do not set them at different temps for any reason as this is the balancing device(s) for temperature in the tank itself. before this make sure bottom of tank is not full of sediment and flush as necessary via the lower element when removed (first shut off the electric power to the heater and keep it off until the tank is full of water again and air is bled from it via a faucet or the relief valve vent )... then inspect condition of lower elelment (no resistance or very little on an ohmeter if you have one available. I don't think it is a non touching thermal disc because it was okay for some time before the overheating problem began, however it could be bad though... Bottom unit as a whole is where i would start and probably find the problem(s). Remember --- electric off when working on this heater especially when you are draining it and refilling untill entirely full of h2o and all air removed(bled).
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