So I am in the middle of building 6 more boxes and getting ready to cut
grooves for the tops and bottoms of the boxes. I had just mounted my
dado set and switched out the SS brake for the dado set.

The blade spins freely, the saw boots and indicates no error, and all is
good. Or so I thought. I neglected to increase the air gap between the
blade and the brake. Apparently the gap can be too small. Anyway I
attempted to turn on the saw and I hear a click, the blade does not
move, and I see a small flash come from the brake. I tripped the brake.

Whew.... No harm to the Forrest dado set and my local Woodcraft was more
than happy to sell me a new brake. I told them what was going on and
they indicated to call SawStop and tell them the situation. They would
probably send me a new brake and then I should return the one SS sends
to me and get a refund.

I thought for a second and said naaaaa, you had the part I needed and
you are here to run a business. You filled my need and I am not going
to use you for my mistake.

Anyway a call to SawStop resulted them sending me a free replacement
since I was a new user. Mind you that saw has paid for itself time and
again, is 2.5 years old and I have probably switched brake cartridges
50~75 times. I simply asked them if I made a mistake by having an air
gap that was too small and the reply was this will happen 99% of the
time if the gap is not adequate. The sensors tell you if the gap is too
great for the brake to function properly to prevent an accident.

Anyway, lesson learned and kudo's to SawStop for replacing consumables
past their warranty and to Woodcraft for the generous offer to let me
return the brake for a refund.