Charles 5000 Charger Overheat!

Charles 5000 Charger Overheat!

We had this happen on our IP380-115 last week. It was the original 15 year old factory installed kit. Luckily we were onboard to deal with it. First indication was an ozone smell followed by acrid burning smell. No smoke, and no fuses tripped! I had a marine electrician check the dock side power, no reverse polarity and all systems on the boat were good. Conclusion, was the coil had overheated, which started the insulation to melt and smolder; however, it still produced charging voltage, so breakers didn't trip. We had caught it at this stage. The explanation from Charles was the next stage would be the transformer would quit then the breakers trip...too long for my liking. Pics attached. Anyone else has had this issue? Or a good idea to check out your charger. We have replaced it with a ProNautic 40 amp charger. The fittings are nearly a match.

Dave