GENERAC 22KW FAILURE TO TRANSFER TO GENERATOR POWER PART II

THE WEATHER WAS SUPPOSED TO BE REASONABLY NICE FOR THIS TIME OF YEAR. 39*F. RAIN IN THE AFTERNOON.
I WANTED TO SHOW THE STEPS IN PERFORMING THE TRANSFER BUT THE WEATHER TURNED A LITTLE UGLY. SO THE VIDEO ONLY SHOWS THE TESTING OF THE TRANSFER SWITCH FOLLOWING THE REPAIRS.
I HOPE THAT EVERYONE NOTICED THE CONDITION OF C2 IN THE FIRST PART. IT LOOKED NEW, IN GREAT CONDITION - BUT IT WASN'T. IT ACTUALLY BROUGHT ABOUT THE DESTRUCTION OF THE SACM (SMART AC MODULE).
I DISCONNECTED C2 COMPLETELY SO THAT IT COULDN'T BE INVOLVED IN ANOTHER INCIDENT. MANUAL TRANSFER WOULD BE NECESSARY IN THE EVENT GENERATOR POWER WERE REQUIRED. (AND I'M NOT A BIG FAN OF MANUAL TRANSFER.)

WHEN UTILITY POWER GOES OUT THERE IS NO POWER IN THE TRANSFER SWITCH, SO NO TRANSFER TO GENERATOR POWER CAN BE ACHIEVED,
(12VDC ON WIRE 194 IS PRESENT BUT THAT'S NOT POWER.)
THE GENERATOR STARTS - AND IF THE GENERATORS BREAKER IS "ON" - GENERATOR POWER WILL BE ON THE TRANSFER SWITCH'S LUGS E1 AND E2.
LUG E1 IS TAPPED AND 120VAC IMMEDIATELY TRAVELS BY WIRE TO THE LIMIT SWITCH XB1. (THE WIRE I DISCONNECTED WITH MY NEEDLE NOSE PLIERS TO KEEP THE 120VAC FROM GETTING TO C2. ALSO WHY I SHUT OFF THE GENERATOR BREAKER TO WORK ON THAT SIDE OF THE TRANSFER SWITCH.)
THIS E1 VOLTAGE TRAVELS THROUGH THE LIMIT SWTCH TO ONE SIDE OF COIL C2. (AS LONG AS THE LINKAGE IS WORKING CORRECTLY.)
COIL C2 REQUIRES 240VAC IN ORDER TO PERFORM A TRANSFER SO E2 120VAC TRAVELS DIRECTLY TO THE SACM MODULE RELAY.

IF THE GENERATOR IS ONLY EXERCISING, THAT'S ALL THAT SHOULD HAPPEN.

THE UTILITY POWER SIDE IS TAPPED FOR 240VAC AND N1 AND N2 ALSO GO TO THE SACM. THEY ARE FUSED BEFORE LEAVING THE TRANSFER SWITCH AND TRAVELING TO THE GENERATOR. THIS IS SO THAT THE CONTROLLER CAN MONITOR THE UTILITY POWER.

IF THE CONTROLLER SEES A LOSS OF UTILITY POWER, THE GENERATOR STARTS AND THE POWER - AS I SAID - IS PRESENT AT LUGS E1 AND E2.
AFTER SOME DELAY, THE CONTROLLER APPLIES A GROUND TO WIRE 23 WHICH TRAVELS TO THE TRANSFER SWITCH.
TOGETHER, WIRES 194 AND 23 NOW ENERGIZE THE TRANSFER TO GENERATOR RELAY COIL.
THE 120VAC FROM E2 NOW TRAVELS THROUGH THE RELAY AND OUT TO THE OTHER SIDE OF COIL C2 PROVIDING THE 240VAC REQUIRED TO ENERGIZE C2 AND ITS MAGNETIC FIELD PULLS THE METAL PLUNGER DOWN.
IF THE MECHANICAL SIDE OF THIS OPERATION IS IN GOOD WORKING ORDER, THAT YELLOW BOX WILL TRAVEL DOWN DISCONNECTING THE UTILITY SIDE AND CONNECTING THE GENERATOR SIDE. THE LIMIT SWITCH WILL OPEN THE CIRCUIT SO THAT THE COIL NO LONGER GETS 120VAC FROM E1. ITS JOB COMPLETE.

WHEN UTILITY POWER IS RESTORED.
THE CONTROLLER SEES IT AND REMOVES THE GROUND ON WIRE 23.

WHAT HAPPENED HERE?
A DEAD SHORT BETWEEN E1 AND E2, A BANG AS SPARKS FLEW AND SACM WAS SCORCHED.

WAS THIS A FACTORY BUILD FAILURE?
I CAN'T PROVE ANYTHING FOR A ROOT CAUSE. I CAN THINK OF WAYS IT COULD HAPPEN, INCLUDING A BUILD USING A BAD COIL. BUT I CAN ALSO BELIEVE THAT SOMETHING ELSE HAPPENED.
I ONLY KNOW THAT THIS INSTALLATION HASN'T WORKED FOR THE BETTER PART OF ITS EXISTENCE. FIX IT SO THAT IT PROVIDES THE TYPE OF SECURITY IT WAS INTENDED FOR.