Date: Sun, 7 Jun 2009 21:33:37 -0700
Reply-To: Michael Hart <mjhart853@YAHOO.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Michael Hart <mjhart853@YAHOO.COM>
Subject: Re: High Power Headlight Kit (SA): melting connector
In-Reply-To: <586a66170906072126q303a38ffjf715d2b614b86f3@mail.gmail.com>
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Bob,
I don't think this a grounding problem - the melting is only on the two relay block connectors transmitting the 400W from the positive supply to the wires going to the bulbs (the switched 'hot' supply). Since this is a CA van the grounds are clean and resistances are measured low. I haven't measured the actual total current flow (it should be ~35A based on the 12.2V I measured and spec'd bulb ratings); perhaps it might be even higher? I suspect the connectors are only rated to 20A or 30A?
Mike
'87 Westy
________________________________
From: Bob Stevens <mtbiker62@gmail.com>
To: Michael Hart <mjhart853@yahoo.com>
Cc: vanagon@gerry.vanagon.com
Sent: Sunday, June 7, 2009 9:26:59 PM
Subject: Re: High Power Headlight Kit (SA): melting connector
I've put relays and 80/100w bulbs in my system (OE vanagon lights). I've replaced the passenger side plug 2 times since this modification. I made new grounds with larger wires to both grounds and power, and that has (so far) eliminated my overheating problems. I ran short ground wires to the steel "firewall" directly behind the lights. I also have Hella 550 "high beam" lights on my bumper, which really turn night into day out in the desert night. They automatically come on with my high beam switch. It sounds to me like you have a lot of resistance in your system, which may be coming from poor grounds?
Bob
'87 Syncro Westy
On Sun, Jun 7, 2009 at 10:05 PM, Michael Hart <mjhart853@yahoo.com> wrote:
I the SA Grille with high pwer headlight kit installed in my '87 Westy [SA Grille, relays, lots of additional wiring & 80/100W bulbs (outer lights) & 100W bulbs (inners) (done approximately 2 years ago). I used the high power headlight kit from 'a well known on-line vendor'.
Whilst checking fuses today, I found that one of the relay connector blocks (high beam relay) had melted pretty badly and the wires were very discoloured. Running the high beams, the wires and connector block got very hot (& it was only 70F today) within a few minutes use. Just as well that I haven't used high beams all that much since I did the install!!
Apparently 400W of light (34A) is too much for these connectors. I also found that the wires leading into the inner high beam units also showed signs of too much heat (these wires are just a few inches long, after that I had installed major wiring back to the relays). I have put the original 55W bulbs into the inner high beam units, reducing the total load to 310W (26A) at which point wire & connector temperatures seem more reasonable (yet still quite warm).
I followed all the vendor instructions exactly, but it seems to me that perhaps 400W is over-rating the kit (of course, I do like the major improvement in lighting).
Has anyone else seen problems like this??
Thanks,
Mike,
87 Westy
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