Thanks everyone, you all helped a lot.
I think it was a few problems. First of all the battery was bad but it wasn't shorted to ground. However I believe as you guys said, the DPI charger was putting out it's full 45 amps. I know this as I did buy a Maxi type fuse holder rated at 60 amps and a 50 amp fuse. The fuse did not blow and you could hear the battery popping, gurgling, and hissing. I pulled the AC plug to shut it off. The 10 gauge charging wire never did get hot with the 45 amp draw( somewhere between 30 amps and 50 amps obviously).
Took the battery to auto zone and it showed bad. Put a new group 27 battery in, replaced the 50 amp fuse with a Maxi type 30 amp fuse, and it did not blow. The battery was already charged from Auto zone though.
So what I learned is that the ATC fuse holder rating is not safe when a battery goes bad. The fuse and fuse holder are not rated at the full load of the charger. When the fuse didn't open all the way, it caught on fire as well as the ATC fuse holder. The fuse and fuse holder were not rated high enough and are safety problem.
I did replace the fuse holder with a 60 amp Maxi type fuse holder so it's 'over rated' for protection and will use the 30 amp fuse with the 10 gauge charging wire. If it ever blows from a totally discharge battery, I can use the 50 amp under supervision.
So all in all, 1 defective battery, 1 under rated fuse holder, and 1 under rated fuse. Jayco should had used 6 gauge wire from the converter charger with a Maxi fuse holder and 50 amp fuse.
Talked to my dealer and all the makers supposedly use a 30 amp ATC fuse and holder.
What I was not happy about is the dealers response. I called a head of time in case it was the converter. I was willing to leave it for 4 days for them to fit it in and repair it.
Even after a fire happened and I told them we had hundreds tied up into next weeks trip, they wouldn't try to get it in. Said at least a month out and maybe 2 which would ruin the entire summer camping or all of camping as when the kids go back to school, we have little time to camp with the weekend work schedules.
They wouldn't even give me the parts under warranty to repair myself if needed. If they won't make time to fix it they should allow the customer to with warranty parts.
If this was an auto dealership, the auto makers would punish them and the customer would not tolerate it and they would go out of business.
Completely unacceptable!
Thanks again for all of your help, I really appreciate it.
