xantrex freedom x 1200 Inverter problem

[georam1]

Over the weekend while we camping my refrigerator quit working. Everything else was on. So I figured I had some issue with the inverter. Didn’t have time to troubleshoot while camping just needed to get the fridge running. So I just bypassed the inverter and wired the fridge plug wire to the ac in wire going to the inverter. It was only an hour drive home so I wasn’t worried about the fridge not running for the trip. Started looking for the issue this afternoon and I found a melted terminal block in the inverter. It was on the ac output side. Here is a picture of it. I must say this is a terrible design. It’s a friction block on something that’s moving a lot. These blocks are made of plastic and soldered to the circuit board. Anyone have any idea how I can safely fix this? I would like to solder the wire to the terminal but don’t see anyway to do this. Also if you have this inverter in your rig I would go check these terminals.

[Grumpy]

Contact XANTREX they may cover it. Others have found loose connections too.

[georam1]

Yea I’m going to do that tomorrow. Just don’t expect them to do anything because it’s over three years old.

[georam1]

So I called Xantrex this morning. They said it was an installation issue with Jayco. Said there is a tool they are supposed to use to place the wires in the terminals but apparently Jayco employees just jam the wire in there and it won't hold. So I guess I'm SOL. I'm sure calling Jayco will just be another waste of time. It's very difficult to find anyone who takes pride in the job they perform anymore.

[TxLoser]

I’d play the fire hazard/safety card when I call. Maybe that’ll make it more interesting to them.

[Cricket59]

I just found the same problem with my xantrex 1200. It wasn’t burned like yours but the wire and insulation was black. It had been sparking for awhile. And acting up like yours. Mine was on the neutral input terminal.
Each one of those terminals are a separate piece that snap together. You may have to unsoldered all three segments to replace the burned section though.
I bought 2 segments from Newark. There only a couple bucks but I got an electronics shop to replace them.
https://www.newark.com/phoenix-contact/zfkds-4-7-5/tb-wire-to-board-1pos-24-10awg/dp/32AC9161?CMP=e-email-sys-orderack-GLB

[georam1]

I was able to take my inverter out. Did some tricky soldering myself and got it back working. Hopefully I won't have anymore problems out of it for awhile.