I just installed my FAL 410 why not just do what the instructions suggest and use the fuse tap? Mine worked perfectly and the control module / temperature sensor it comes with controls the fan speeds and when the come on does it not?
When the fans are not running, the initial current rush is about 4x to 5x the running current. So current is 22A x 4 (using the lesser of the two values) 88 amps from when fans are at zero.
I dont have a problem with mine, and am using a 40a relay and a 40a fuse inline, triggered by a toggle switch. I ran 10ga wire to everything, and both fans kick on at the same time. I would say that there is a problem somewhere else.
Just to add to the conversation. I had similar issues with my FAL setup. 2 bad circuit breakers. Yes, at one time, they had circuit breakers instead of fuses with their kits. Then i have had multiple problems with the fan just running when it was suppose to. It has left a very bad taste in my mouth for FAL. I still have the fan sitting on my garage floor. It has been there for a year. Some people luck out with these and have no problems. I was not one of them.
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