I have been reading this thread with great interest.
First add me to the list if you get a group buy going on the Puma compressor.
Second is the issues/confusion with what size fuse to use for the compressor.
Everyone gets confused by fusing. The power line fuse has one purpose and it is not to protect the compressor (or whatever device is at the end of a circuit). The sole purpose of a power line fuse in any power circuit is to protect the WIRE from burning and causing a FIRE. Fuses can also protect the device from overheating. See below for an example. Note that overheating fuses are usually PART OF THE DEVICE.
Fusing for power wiring is simple, but requires some thought:
First you must properly size the wire for the device being powered. For motor wiring: Find or measure the STALL rating ie the maximum the motor can pull when the rotor is locked and cannot turn. If you don't see this on a tag then you have to actually measure it under real world conditions or use the maximum draw while running under maximum load.
Once you know the maximum current you then use a typical amp/distance table (
http://www.freesunpower.com/wire_calc.php ) to find what size wire can handle that current FOR THE DISTANCE NEEDED! Also some of those tables are for 120VAC NOT DC so make sure to use the correct table! There is also the % of voltage drop allowed issue. Some tables use 5% allowable drop, some use 2%. For DC motors 5% is OK, but 2% is better.
Wire Example 1: A 5% voltage drop allowance means you can run 8ga wire, with 40 amps pulled through it, for 10 feet and only loose 5% of the voltage at the end. Yes you can run 10ga, and it would still work, but because more voltage is lost the motor will not run at it's maximum power. It would also run a bit hotter. For wire and motors or lights bigger is always better. (up to a point large gauge cooper wire is not cheap or easy to install and terminate.)
Once you have sized the wire THEN you pick a fuse. Fuses come in two basic types. (there are many types) Slow blow and fast blow. A fast blow fuse will blow quickly as soon as it's rated current flow is reached. A slow blow will allow that current to flow (and more) for a much longer period before blowing. Slow blow is what you want for motors. There are many other factors like inrush current to consider also but that is beyond this thread.
Fuse Example 1: In the case of the compressor motor: If the locked rotor rating is 40 amps and you wire it with 20' of #6 ga wire capable of 50 amps, you would normally choose a slow blow 50 amp fuse to protect the wire. However you don't want to fry the compressor motor if the piston seized right? So in this case you will fuse to protect the motor windings so you would fuse at 40 amps. That way soon after locked rotor conditions are met but way before the power wire gets hot enough to cause a fire the fuse blows. Now if a dead short occurs due to say a pinched 8ga wire to ground (which could allow hundreds of amps to flow from the battery), the fuse will pop almost instantly and you won't even see too many sparks.
One other issue: ALL connections and connectors in the power supply line must also handle the currents involved. A cheap undersized connector (or a twisted together undersized wire with flammable vinyl tape on it) that oxidizes can create a high resistance that can overheat and melt long BEFORE the fuse blows! Examples of this are the melted headlight switch connections on old FJ40's. Put in high current headlights and combined with old oxidized connections at the switch, or fuse panel, OEM undersized and oxidized wire, and you get that classic melted connector or fuse block.
Sorry for the long post but this issue comes up a lot... High current wiring should be done correctly.
