Ray,

I've broken a couple of those myself and agree that the lug isn't very strong. Once it bends just a little, the tab on the back comes out and the lug torques right off. Here's my solution, it has to be done in advance and it is a PITA: fill the gap between the back of the lug and breaker body with JB weld.

Kent Osterberg
Blue Mountain Solar, Inc.
www.bluemountainsolar.com
t: 541-568-4882


On 12/16/2011 9:14 PM, Ray Walters wrote:
Hi Folks;

Anybody else having trouble with the small Outback DC breakers snapping posts off? I just took over a GTB job from another reputable GT solar company, after they twisted off a post on an 80 amp breaker with #4 wire. I know those are delicate breakers with low torque limits when tightening, so I took over. I dropped the breaker mounting plate, so that I could work on the breakers, and then I saw how weak the posts looked, just bending the #4 wires gently still cause another breaker post to stress, and then break. I worked as gently as I could, but I could not even get the plate back in position without damage. In my opinion, those breakers are suspect with #6 wire, and they just can't handle #4 or larger, unless maybe it was a flex type. The old medium body Heinemans (125 amp) used to come in an 80 amp variety, which was much sturdier. Is there an adapter that would let me use that type of breaker on the Flexware box?


Ray Walters





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