My lights are Hella lights. I'm not sure on the wattage, but they are extremely bright. Cost over $100 new, but I got them for free. Anyway, If I leave the lights on for a while they wires get hot. If I leave them on long enough, the wires will burn. I'm using a relay and decently thick wire. Any ideas on whats going on?

What gauge wire exactly? How far way from the lights is the relay?

Thickness is not everything.....go buy better wire. check your switch too.

But unless he is using 1950 soviet surplus wire he should not be having these symptoms with heavy gauge wire and a properly installed relay. I'd start with old scouts suggestion.....take a look at your relay, and make sure everything is wired properly. I would suspect something is wired up wrong first...or maybe a cheap relay...?

I'm thinking either a cheap relay or an insufficient ground, even though the ground seems fine. Any ideas on where to get a good relay? Seems the ones at 4x4 stores suck.

Check the ground. I would use 14 ga. wire for the hot lead.
Different relays have different amperage ratings. You could run to Desert rat and pick up a relay that comes with the lights originally

Bosch relays are supposed to be good, try one of theres. I know jc whitney carries hd relays :rainbow:

Originally posted by Proeliator
Bosch relays are supposed to be good, try one of theres. I know jc whitney carries hd relays :rainbow:

Shameless plug: Parts Express (http://www.partsexpress.com) The site is kind of a PITA to navigate, but they carry the Bosch 30 amp 5 contact relays for $1.99 each.

If your wires are getting hot, then make sure the wires are big enough for the current, and that you're getting good contact. It's a good idea to relay any high output lamps.

ChiXJeff

I am definitly using big enough wire. So I am gonna try a better relay. I hate that most places sell cheap stuff. Its like you have to wade throught the $hit to find out what is decent.

Originally posted by ChiXJeff


Shameless plug: Parts Express (http://www.partsexpress.com) The site is kind of a PITA to navigate, but they carry the Bosch 30 amp 5 contact relays for $1.99 each.

If your wires are getting hot, then make sure the wires are big enough for the current, and that you're getting good contact. It's a good idea to relay any high output lamps.

ChiXJeff

Thanks for the link. Bought 2. One for the Hellas and one for the rock lights. :bounce: :bounce2:

It seems to me from what you describe, your wires are simply not heavy enough. I assume the entire length is getting hot, right?

A poor ground would cause a voltage drop at the connection, dimming of the lights, and less current to flow in the circuit.

So would a poor relay that was under-rated.

Your hot spots occur wherever there is a voltage drop across some resistance thru which current is flowing.

Ideally you want zero resistance at the relay and thru the wiring so that the entire voltage drop occurs at the bulb. Smaller wiring will be more resistive, cause a voltage drop, and get hot....as will an under-rated relay that has too small of contacts to support a large current flow. But, it sounds like your relay is not getting hot, nor failing, correct?

What happens to your lighting wiring if you take it off the relay and hook it straight to the battery post.....still getting hot?

Jay

Yep, still gets hot when hooked to the battery. What's weird, is I am using a larger wire compared to the ones that come out of the lights. The actual braided copper part of my wire is about 2mm thick...maybe its just crappy wire.

Originally posted by 85runnerAZ
Yep, still gets hot when hooked to the battery. What's weird, is I am using a larger wire compared to the ones that come out of the lights. The actual braided copper part of my wire is about 2mm thick...maybe its just crappy wire.

The wire might actually be too BIG, and somewhere along the line you have cracked the copper inside with a kink. Big heavy wires can snap, thinner wires bend easier. Get a resistance across the wires, it should be small (few ohms). You might very well have a cracked wire, and it's arcing inside the cladding.

Originally posted by Pazuzu


The wire might actually be too BIG, and somewhere along the line you have cracked the copper inside with a kink. Big heavy wires can snap, thinner wires bend easier. Get a resistance across the wires, it should be small (few ohms). You might very well have a cracked wire, and it's arcing inside the cladding.

Good point, though I doubt you'll be able to tell much with a multimeter. As the wire heats, its resistance will rise further.


What kinda wire you using?
Jay

Originally posted by 85runnerAZ


Thanks for the link. Bought 2. One for the Hellas and one for the rock lights. :bounce: :bounce2:

you could run one relay for each light that way when one fails you still have the other light, this also makes its 30Amps ratign per light not shared...


With one relay you have your lights in parell?
Parell is the correct way, if you put htem in series they will be dimmer, neitehr should b e hotter.

Do a direct ground and use fatter wire... 10aug-8aug are good for 30amp rating DC. Get the most strands int eh wire you can find, you so it will flex well.

Oh and keep them off the radiator they will get hot... :D

Originally posted by ashmanjeepXJ
you could run one relay for each light that way when one fails you still have the other light, this also makes its 30Amps ratign per light not shared...

Thing is the lights are quite a bit less reliable than the relays ;)


With one relay you have your lights in parell?
Parell is the correct way, if you put htem in series they will be dimmer, neitehr should b e hotter.

Could have 'em wired either way with one relay. Yes, parallel is what you want. Series would actually be cooler as it would only be pulling half the current....not what you want though.

Do a direct ground and use fatter wire... 10aug-8aug are good for 30amp rating DC. Get the most strands int eh wire you can find, you so it will flex well.

Good points....I like using 10 gauge for driving lights.
Jay

Originally posted by ROKTOY

Series would actually be cooler .


Yea it would be... :rolleyes: :D

Originally posted by ashmanjeepXJ



With one relay you have your lights in parell?
Parell is the correct way, if you put htem in series they will be dimmer, neitehr should b e hotter.



I'm using the relay that has 2 power terminal coming off of it for the lights....so I guess they are neither parallel or series..