you have sort of answered your own question and yes overheating must be the answer but why that’s a different question
anything that leads to the increase in temp for the heater unit which includes low water flow, too much foam ( poss double dosing rinse aid) and the timer not turning off the heater (faulty relays)
one interesting fact I did find is the timer senses the element and will not turn it on unless there is a circuit there. was doing some experiments trying to make sure board was ok before I ordered a heater and fitted it. putting my meter leads into the connection with the faulty element and the unit did not energise the heater. As soon as I put a water valve coil across the leads it energised the coil
last time you fixed this it must have been days out of warranty
Dave