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Old 04-24-2009, 10:56 PM   #1
Jcrite8987
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Default Hella 500 wiring problem

Hey guys, I tried to search but i couldnt find an answere. I have 2 sets of hella 500 driving lamps on my STI. Each set has its own relay and it connects to a y type connection when it enters into the cabbin to the switch. I am running power off my parking lights also. Here is my problem. I keep blowing out the 15 amp fuse on one of the sets of lights. Its the same set each time. I can put a new fuse in and it will blow it right when i flip the light switch. What would be causing this to happen on just that one set of lights? A short maybe? What should i look for? Also i have a fuse running from the switch to the parking light wire inside the cabbin. I am not sure as to what the amp is but would i be wrong to assume that maybe its not enough to power both light sets and is blowing the fuse on that one set? Please help me out guys, its driving me crazy.
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Old 04-24-2009, 11:00 PM   #2
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Default Ps

.double post

Last edited by Jcrite8987; 04-24-2009 at 11:07 PM.
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Old 04-25-2009, 01:05 AM   #3
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anyone?
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Old 04-25-2009, 04:34 AM   #4
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You do indeed have a short after the relay connection to the lights. Look for a power wire that is touching ground somehow on the set of lights that don't work.
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Old 04-25-2009, 11:35 AM   #5
Jcrite8987
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Alright. I was thinking is was a short also. I'll take a look at the lights tonight. Im also gonna shorten up the wires a little so i'll double check everything on that part to.
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Old 04-25-2009, 12:43 PM   #6
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55w or 100w bulbs? Are you using one switch to turn both pairs on together?
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Old 04-25-2009, 03:57 PM   #7
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what do you mean when you said you're running power off your parking lights?? i thought for aux lights, the power should come straight from the battery
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Old 04-25-2009, 11:03 PM   #8
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55 w bulbs and i am running one switch together. I tapped into the parking lights for the constant 12v power suply on the switch instead of tapping into the high beams.
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Old 04-26-2009, 12:11 AM   #9
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Quote:
Originally Posted by Jcrite8987 View Post
55 w bulbs and i am running one switch together. I tapped into the parking lights for the constant 12v power suply on the switch instead of tapping into the high beams.
If I am understanding your post correctly, you are switching the relays on/off with the parking lamp circuit...or are you powering the lights (high current) from the parking light circuit...?
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Old 04-26-2009, 02:53 AM   #10
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Alright guys. Well me and my buddy tried to re wire everything using the high beams and it was no luck. We could still only get one set to work. Tomarrow im just going to ditch the second set of lights and only run one set of light instead of two bc im sick of fooling around with this.

This was the story for tonight.

First we checked all the connections and everything seemed fine. After trieng a few fuses and blowing them out my Defi Gauges started to not turn on when the head lights were on. I thought that was weird. Then when we tried to wire everything using the high beams we could not get the two sets to light only one set did. Then we decided to only use one set of lights. We wired it all up and it ate the 20 amp fuse that i had running from the battery. We decided to call it a night and start again tomarrow night.

Now when i went to start my car to park it in the gerage the car would not start. I then got pissed and hit the wall a few times and smoked a cigarette to calm down. Luckily I had a brand new battery at my house so I then procceded to cut all the lines for the Hella lights and we changed the battery. The car fired right up and ran like a champ considering the battery was negative terminal was unplugged the whole night.

That was the story for the night. Im going to draw up a wiring diagram for you guys to look at in a few minutes after i take care of a few emails for work.
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Old 04-26-2009, 03:10 AM   #11
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That is the diagram i am going to use.

I think you guys can tell what is what with it.

Let me know what you guys think of this. It should work bc i used it to get the one set to light up when i first attempted this a few days ago.
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Old 04-26-2009, 04:17 AM   #12
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The relay wiring looks ok to me but the ground connection on the toggle switch dosen't make sense to me. I am assuming the center connection of the switch is a common to the end ones. I think power needs to go to the place where ground is now tied to the switch to supply power to the relay coil.
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Old 04-26-2009, 01:53 PM   #13
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alright well I think I might have gotten the wires on the switch messed up on the diagram. I need to pull up the diagram from Hella and double check it. Anybody have any opinions on it?
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Old 04-26-2009, 03:17 PM   #14
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What are you trying to do with the switch? If the orange wire is just providing switched power to run the coil of the relay then you are fine. You just don't need the ground lead going to the switch, it is useless. You could also just use a simple on-off switch. You don't need a two pole switch but either one will do the job.
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Old 04-26-2009, 05:01 PM   #15
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yes the orange wire is just providing power for the relay coil. I was just following off the diagram that was given by hella. It said to have a ground on the switch. I'm goingto give it another shot tonight and see if I have any luck.
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Old 04-26-2009, 07:22 PM   #16
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Since they said have a good ground to the switch I assume their design was providing power to the coil first and the switch made the ground connection to complete the circuit. Your drawing shows switched power is provided to the coil with a fixed ground. Either way will work.
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Old 04-27-2009, 01:14 AM   #17
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Well guys you will be happy to know that i got the one set of light working. Im just going to run one set for now because I do not want to push my luck and go ahead and screw up the ones that work while trying to install a second set. I will leave that for a later date when im bored.

I ran into some problems while installing. I modified my diagram a little bit because like i stated above i got the switch wires mixed up. The wire with the 2 amp fuse on it went to the parking lights and not the actual relay. I then still could not get them to work and i noticed that my inline fuse that i had on the battery was not sparking at all which meant that i was not recieving any power to that. I was lucky enough to have another inline fuse holder that was 12g wire and not the small wire that Hella provided. I put in a 20 amp fuse also that i had in my mass amounts of fuses in my toolbox. I then flipped the switch and bam! lights came on and were bright as can be.

Im happy that it finally worked out for me. Im now going to go ahead and neatly organize the relay and the wires in the engine bay so it looks somewhat organized.

Thanks again guys for all your help.
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