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Old 05-28-2019, 10:03 PM   #13
Island Cessna
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Join Date: Feb 2011
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Since it has run for years you should be looking for what changed causing it to quit, not looking at faults in the original installation.

The Duo Charge manual says the input and output wires are both 10 gauge with 30 amp fuses. All fuses blow after a duration of time at a particular amperage. If your Duo Charger has been running for extended periods at exactly 30 amps the fuse may not have blown, but the element is running at a temperature just below it’s melting point, and the clips in the fuse holder will be at the same temperature, oxidizing and loosing their tension. The result is increased resistance in the junction with the fuse terminals, causing additional heat and the 30 amp fuse overheats and blows at an amperage below 30. The fix would be to replace the fuse holder.

While it violates my “ look for why changed” advice, this may be worth a quick look. The Balmar manual says that the input wire should be short, no longer than the supplied pigtail and the output wire should be 10 gauge, and a minimum of 8 feet long beyond the supplied pigtail. From their description it appears they use the resistance of the output wire as part of their regulation scheme. Quote from the manual: “the reason for the extra wire length is to act like an electric spring which allows the Digital Duo Charge to produce a higher current.” Do you have this length of 10 gauge wire? Since it has run for years I assume so, but worth checking, and adding length if needed.
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