4. I cannot recall the particulars of this case as it
occurred over 1 year ago already. Definitely salt water
entering gang box either through bad or missing gasket
or a warped frame.
Break it down
The circuit breaker lugs were all frozen
8. Pull down on on/off plunger to remove spring,
interlock mechanism and plunger
9.
10. Remove the 4 screws securing breaker handle
actuator unit, top plate and breaker to frame. Lift off
breaker with actuator unit and ground pin.
11. Observe alignment with circuit breaker handle as it is
removed. Be careful not to disturb cam positioning
inside actuator. The plastic housing can separate.
18. Stainless steel and brass clean up nicely. The brass is a
little more work but is necessary for the new receptacle
to slide into the bore. Wire brush and medium grain
crocus cloth work well. Some brass housings have a
groove at base end for a retaining ring which needs to
be scraped and brushed clean.
Once brass housings are polished clean a thick coating
of LPS 3 left to dry overnight will keep the creeping
corrosion at bay.
19.
20. Reassemble
The top 1/3 at flange end of the brass housing internal
bore needs to be super clean for an easy fitting of new
receptacle so only apply a light coat of LPS 3 if any here.
Below the receptacle resting ledge a thick layer will be
good.
Dow Corning 111 valve lubricant and sealant works
well on internal bore as well as Molykote 55 o-ring
grease around receptacle o-ring. This will extend the life
of your module and reduce your maintenance load.
21.
22.
23. To prepare the receptacle wires for a quick and
smooth installation into the circuit breaker lugs they
must be shaped for a compressible helical spiral. The
wires are thick stranded gauge so a 3/8 closed end
wrench can be slipped over for bending leverage.
24. Do not try to cut the wires to length because
the circuit breaker lugs are not in direct
alignment with receptacle.
25. Install receptacle into brass housing aligning tab at
base of receptacle with notch in brass housing flange.
This prevents rotation of receptacle within housing.
After shaping the wires, the ends will need to be
trimmed flat or the contact surface between wire and
lug will be reduced. Poor contact area will result in
overheating and reduced life of circuit breaker and
receptacle.
31. With circuit breaker switch in off position align circuit
breaker switch handle with actuator mechanism.
Install circuit breaker and secure to frame with the 4
screws.
Lightly lubricate receptacle mating gasket with 111
and place over housing flange.
While guiding actuator ground plunger into bore of
receptacle ground pin insert wires into circuit breaker
lugs being careful not to bend any wire strands.
Tighten lugs. Bend the B phase wire to the side to
allow free movement of ground pin plunger.
Tighten the 4 receptacle housing screws evenly until
gasket touches frame plus ¼ turn or so being careful not
to squeeze out the gasket.
41. To reassemble on/off plunger first place interlock
release mechanism in position on its actuator.
42. The sliding cam actuated block mounted on circuit
breaker is aligned with plunger in interlock release
mechanism.
With o-ring and shaft greased, insert on/off plunger
through faceplate and interlock release.
The cam actuated release plunger will interact with
deep groove in on/off plunger shaft.
47. The module is now complete and is ready for testing
in same manner as shown in 480V version with ohm
and meggar meter test equipment before installation
for use.
