"I have a 2002 38' Regal w
"I have a 2002 38' Regal which has a persistent yet intermittant electrical problem (with apologies in advance that this is not specifically engine related but this is the brightest bunch of people I know!). When (and only when) the boat is used for 10 or 12 hours or more, and often 80% of this time spent at anchor with the Kohler generator running for several hours, the 60 amp circuit breaker at the main switch for my house battery trips.
So far I know the following:
-no 12 volt circuit is drawing excessive current per the ampmeter and combined they are no where near 60 amps
-I have switched breakers with the engine batteries and the issue still occurs
-I have made sure that the generator was not powering the battery charger with the thought that perhaps the charger, combined with the alternator on the Kohler combined sometimes but not always with the alternators on the Mercruisers was causing excessive charging current to the battery.
-There is no evidence that the wiring to the breaker (which is not massive or extremely heavy gauge) is getting hot, melting etc. as I would have expected with wire of this gauge and the thought of 60+ amps.)
-The issue has occurred with two different house batteries over the three years I have owned the boat and happens virtually every time I am out for more than a few hours.
-Unlike the breakers on each of the engine batteries which have one heavy (i.e. auto battery sized gauge) wire going to each side, the house battery breaker has an additional smaller gauge wire (i.e. 20 gauge) on one side.
The problem only seems to occur when the generator has been used. The panel is always very warm after such voyages but I think this is easily attributed to the fact it is located in the highest pocket in the engine room and would naturally trap heat behind it (it is accessed from within/under a cockpit seat)
In the three years I have put up with this while trying to fix it I have replaced the one smaller gauge wire mentioned above from the main house battery switch to the breaker which appeared too small a gauge with no improvement. I have never experienced the problem when the generator was not run on a trip though most trips of 10 hours plus do involve some use of the genny even if it is short. I have never experienced the problem when at the marina even running all 12 volt systems for days or weeks on end, hence my thought that the issue is related to charging.
Hopefully someone can shed some light on this puzzle. I am willing to try anything.
Thanks so much-Michael"
