In your first pic the wire looks cooked too if you look back a few inches. I think you might need to look into why the wire burned off instead of just attaching it.
Where I live electricity is .07/kw/hr so that heater would cost $0.35/hr to run. Please let me know if I'm figuring it wrong as I'm looking into the same issue.
Hmmm, I pay $1,100 per year to heat and cool a 2,800 square foot house and a 1,000 square foot garage in the Midwest. I'm not sure $10 k in foam could ever pay for itself. Would it save half of the current energy costs?
I don't see any place to look for an error light unless I need to take the control panel off first. I use an old style mechanical thermostat and am usually going up from around 50 or 55 degrees to the high 60s. I'm starting to think maybe the flame sensor is bad as the first cycle is usually for...