REPLACING C1 COIL AFTER A CATASTROPHIC FAILURE IN GENERAC RTS

This is not an easy task even when you make yourself safe by removing power.
The flange on the backside of the coil must go in between the brass looking bracket and the Transfer Switch itself. The head of the screw, and the washers must drop on the left side of the brass looking bracket. The square nut must drop into the black plastic slot of the transfer switch. The screw is just long enough to perform the task. A test of patience at best.
The front screw is much easier to work with. In sight and much more accessible.
Then the coil must drop over the top of the metal plunger and onto the nipple which passes through the backside of the coil.
Tightening the screw in the back is the second test of patience. You can barely see it through the right side of the coil and the fuse block interferes with the miniature screwdriver you need to get in there to tighten the screw.
You don't need loose metal parts inside an electrical enclosure.
It took me two hours to get the coil in and everything back in place and tested.
Generac needs a little better protection from brown outs.

[@ZensationalWellbeing]

Thanks for your video. Any idea what may have caused the coil to burn out/melt?

[@snowman6686]

No root cause to date. The area is somewhat remote. When it's very few customers it usually has to be called in.
When I arrived the power authority had pick up trucks running the dirt road. (And the damage was done.)
The neighbors complained that there was a prolonged brown out.
One neighbor said that he knew something was wrong so he removed the utility company as a source. (On a Whole House Transfer Switch you would turn the breaker off. On an Essential Circuits Transfer Switch you would shut off the breaker in your panel which feeds the transfer switch. Of course you would have to rely on your neighbors - that don't have a generator - to tell you when utility power has been properly restored.)
These neighbors coming into the basement I was working in, curious to see.
I was a little busy focusing on the problem in front of me. (Staying safe. Trying to figure out what I had. Getting the job done in a timely manner.) This much smoke and heat means that "what wasn't destroyed was probably degraded / damaged.")
It also made me wonder about the Manual Transfer ability.
At the same time period that this occurred I had a call that their generator started but wouldn't transfer to generator power. When I checked that generator - the generator power was incorrect. The owner told me that he could manually transfer his switch.
I told him that it was good that he didn't manually transfer his switch because the incorrect voltage could damage sensitive equipment in his house. (Like his furnace which probably uses an electronic module and others you don't always think about.)
The utility would probably generalize the problem to "equipment failure", but I'll keep an ear out.
Hopefully, Generac is looking at a proactive defense.

[@lancecarroll81]

The bottom coil on mine burnt up. Any pointers on replacing the bottom coil?

[@snowman6686]

I don't post my videos as repair instructions - only to show people some of the things that can cause certain problems.
I don't know anyones skill set and I know some electricians that wouldn't attempt some of these repairs.
I recommend a certified technician. As I take no responsibility for the actions of anyone.
Below are steps that I personally follow. I add steps as the job requires when it changes in any manner.
My background is in both electronics and electrical construction which changes daily. This too could change.
The voltage that powers that lower coil should come from your generator once it powers up. So I would shut off the breaker located on the generator and check the generators output voltage on the line side of that breaker. If your generator voltage is bad then any repairs you make are subject to destruction once again. ( There are limit switches built into the transfer switch itself so you need to verify the root cause of the failure. Was it the generator? )
Then, the voltages inside the panel are indeed very dangerous. With two sources available.
You need to make the section you're working in completely clear of any and all voltages as there's very little room to work and very little room for error.
If you need the utility power to your house while you work - you need to know how to shut off the utility power while you move it in order to bypass the transfer switch. Eliminating any backfeed to the transfer switch,
Then you want to make sure that no dropped parts from the top section can enter the bottom section which will be LIVE if you move the incoming utility feed.
I even block any openings from conduits in the bottom of the panel. usually with a rag or two.
I take pictures and videos if I don't fully know the wire connections.
The coil I removed had two screws holding it in place. The only thing holding the nuts stationary is the plastic framework of the transfer switch and I couldn't see them to tell when they traveled to their limit and were about to fall off - and Generac didn't exactly give any room for error. You don't want to lose the nuts anywhere in that panel.
Once free, the coil needs to be gently pulled away from the transfer switch while sliding it off the actuator.
There is a difference between the two coils and you need to get the exact replacement for your transfer switch and its use and location in the panel.
I purchased my coil on eBay from a certified dealer. No "second time around" used part.
I've seen burnt up coils for sale on eBay with "No Returns Accepted" - so there's a need to be vigilant.
If you are qualified enough to get the new coil installed correctly and without any mishaps your next steps are to verify your repairs visually and perhaps manually before restoring energy by putting the electrical feeds back to their original location.
Once complete you need to verify operation by placing your transfer switch on utility power. Your house/structure/whatever should be powered up by the utility power.
Then simulate a power outage by turning off the breaker to your transfer switch. Your generator should start and run. Then transfer your switch to the generator power. The generator should now be providing power to your house/structure/whatever.
For Safety: Always wear the proper protective equipment to protect yourself from shock, arc flash and vaporized copper. Your home/structure/occupants/equipment from harm or damage.
Understand these steps to know the dangers involved.