Melted wires in my transfer switch

[flynbanjo]

Discovered today the we have a burnt wire in our IOTA 50amp transfer switch and a burnt wire inside the top box on our 12KW 220volt powertech generator.  With the generator off and plugged into shore power there appears power feeding back to the generator through one leg.  The generator nolonger seems to be producing power.

My working theory is that for some reason an overvoltage situation occurred in the generator and melted the wires in the transfer switch.  Does this sound plausible and what would cause an overvoltage in just one leg of the generator.  I should note that one of the circuit breakers on the generator was tripped. 

Assuming that I want to continue using an automatic transfer switch, any recommendations on a new transfer switch.  I believe IOTA is no longer producing transfer switches. 

[muldoonman]

Had a simular problem and determined that lugs had come loose over time and started arcing.

[luvrbus]

If you didn't melt the relays it is probably ok,mine welded the relay contacts and electronics so I replaced the Iota with a Surge Guard 40100

[Handyjim]

Check the blog

wheelingit.us

They just posted a long article on that switch. It nearly caused a fire on their rig. Well written post. Very complete.

[thomasinnv]

I had an iota 50 amp in the mc8 nearly cuaswd a fire as well. Fortunately I was there at the time and smelled electrical burning, opened the bay door to find the transfer switch melting down. A wire going to one of the relays from the junction block caught on fire. Could have been catastrophic.

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[Timkar]

Quite a few recalls on the IOTA 50A transfer switch were initiated by RV manufacturers.
A lot of the issues were blamed on lugs not being torqued correctly

[flynbanjo]

Thanks guys,

Powertech says $3000.00 to replace the generator head.  I am thinking of replacing the transfer switch with a progressive dynamic switch.  Anyone have any experience with this switch?

[Oonrahnjay]

... I replaced the Iota with a Surge Guard 40100

      What company makes the Surge Guard 40100, Clifford?  Is it a transfer switch only or does it have other features?  Thanks,  BH