New Generac Homelink 9855 Transfer Switch Dangling Orange Control Wire

Automatic/Manual transfer switch repair, wiring & troubleshooting questions
GeorgeC
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Just received a 9855 manual transfer switch and upon inspection I see a dangling orange control wire with apparently no contact for it to go to (female crimp connector w/clear blue jacket over the connector). There are two orange wires from the upper right to the left, one is plugged in the other dangling nearby the ground bus bar. With how it is cable tied in the control wire harness there isn't too many places for it to go but don't see an open connector it could have wiggled loose from and can't imagine they would leave an unused wire dangling by design. Install manual does not give detailed schematics of control wires. Generac support was useless as they only have access to the same installation manual paper or online that is publicly available.

Thank you
Chris
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Can you post the serial number so I can pull up the wiring diagram for it?
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grsthegreat
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Can you link a picture. And does the wire have a number on it. I can reference schematic, but its by number, not color
GeorgeC
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S/N: 3006445893

To clarify this isn't one of the load side hot or neutrals. It is one of the control wires from the back of the solenoid which don't appear to be numbered.
grsthegreat
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These are the 2 schematics i can find
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GeorgeC
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Appears to be the N/C (Not Connected?) wire. Though it does have the clear blue jacket on the female connector to protect it, the front is open and the wire is dangling and could make contact with something, not exactly safe ended. Or do they mean Normally Closed which it should be connected somewhere?
grsthegreat
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Im really not sure what is meant here by n/c. That usually stands for normally closed. Heres the only other schematic i see for it. Just more detailed, but no major changes
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Chris
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In looking at the schematic for a PowerPact ATS (what I think is the identical 50A contactor setup) it looks to me like that is a separate coil within the coil. Even your diagrams show a second bridge diode which normally isn't there in a single feed coil.

Attached is the PowerPact ATS diagram and it's being used.
PowerPact 50A ATS Wiring Diagram
PowerPact 50A ATS Wiring Diagram
Screenshot_20201011-194344_Drive.jpg (44.7 KiB) Viewed 5974 times
Generac tech for over 12 years. I'm here to help!
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GeorgeC
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These additional schematics look like the optional upgrade to full automatic start/transfer w/compatible generator. Its a kit they sell which fully swaps out the upper half transfer section of the unit. I haven't actually seen one of those but it looks like the fully auto upgrade switches just the hots and the neutrals appear to be isolated or fused in a different manner best I can tell. I just have the base model manual 9855 without the auto upgrade with both hots and the neutral switched all 3 in a row. I can see them re-using the same coil with one lead not used for the base manual model, they could have done a better job safe ending and tying it out of the way though.

At this point I don't think its a live grenade with the pin pulled out as long as I fully cap it off with some tape and tie it up so it doesn't dangle and potentially arc. I'd feel more comfortable if Generac support would escalate it to the next tier support, or at minimum if someone could pop the cover off another 9855/9854 and note if the same lead is unattached.
grsthegreat
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I went ahead and read thru the 9855 owners manual for swapping the manual switch to a full auto switch. That manual sucks. They show adding the 3 fuses, n1,n2 and t1, but dont explain how to power the fuse. Ive never worked on one of these units, hope i never have yo. The manual sucks. Even the schematic dont show how to power the fuses. At least the schematic that chris posted has some better detail. But the owners manual shows none of this.
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