Strathead,
per your itemized list below:
1. We have put monitoring equipment on and tracked amperage for a couple weeks (maybe a month) at a time. It never pulled over 72 amps on any leg. Voltage never dropped or went haywire.
2. We are now on our 4th disconnect (numbers 3 & 4 are 200A HD disconnects for the 100A load). So not sure how high resistance would be a recurring issue across 3 disconnects at the same point.
3. High surrounding temperature is legit, it is above a gun range, outside of all HVAC cooled areas. But wouldn't that cause the issue to happen on more than just the B leg every time?
4. So you suggest maybe upsizing the conduit and wire to give more area for the conductors to breathe?
5. Not sure what would cause high heat to be focused on the line side of the middle leg of a disconnect.... in the picture i was sent it doesnt look like our conduit penetration is directly above.... which i now have the ability to attach pictures. so please see attached!
Thanks all!