Headlight positive getting insanely hot after new converter.

[jabber82]

Installed a new 48-12v converter, old one went bad. After wiring it back up, the positive going from the headlight switch to the headlights got really hot to the touch but only when the headlights were turned off. Disconnected immediately. With the headlight switched turned on and I connected it, the wire stayed cool. The inline 15 amp fuse never popped. Switch works properly so my positive lines are not reversed. When testing with a multimeter, the line coming out of the headlight switch to headlights is showing 13.2V.

Here is how the whole system is wired.
1) 12v out of converter to headlight switch (load)
2) 12v out of switch to headlights (this is the one getting hot)
3) headlight switch ground straight to a battery.
4) ground from converter to headlights ground wire.

FYI, I am running 16ga wiring.

I am thoroughly confused as to why it would only get hot when the headlight switch is off. Thoughts?

Originally Posted by jabber82

Installed a new 48-12v converter, old one went bad. After wiring it back up, the positive going from the headlight switch to the headlights got really hot to the touch but only when the headlights were turned off. Disconnected immediately. With the headlight switched turned on and I connected it, the wire stayed cool. The inline 15 amp fuse never popped. Switch works properly so my positive lines are not reversed. When testing with a multimeter, the line coming out of the headlight switch to headlights is showing 13.2V.

Here is how the whole system is wired.
1) 12v out of converter to headlight switch (load)
2) 12v out of switch to headlights (this is the one getting hot)
3) headlight switch ground straight to a battery. no
4) ground from converter to headlights ground wire.

FYI, I am running 16ga wiring.

I am thoroughly confused as to why it would only get hot when the headlight switch is off. Thoughts?

there should be no ground to switch

[jabber82]

sorry, it is not the factory switch. I switched it out with a lighted LED rocker style switch. Ground is needed for the lighted part.

how many terminals ?

[jabber82]

3 terminals on the switch. Ground, load, supply.

https://www.amazon.com/Waterproof-Ma...+rocker+switch

[jabber82]

right after I typed my response... I think I am have switched the supply and load lines. Would that explain why the wire would get hot when switch is off and normal when on?

I figured the supply being the 12v in, the load being the accessory, and ground is ground. Was I backwards on my thinking?

Originally Posted by jabber82

right after I typed my response... I think I am have switched the supply and load lines. Would that explain why the wire would get hot when switch is off and normal when on?

I figured the supply being the 12v in, the load being the accessory, and ground is ground. Was I backwards on my thinking?

CORRECT

[jabber82]

gawd. I R an idiot...

Thanks for your help!

Have a great memorial day! May your steaks be cooked to perfection!

Originally Posted by jabber82

gawd. I R an idiot...

Thanks for your help!

Have a great memorial day! May your steaks be cooked to perfection!

hotdogs


like the diagram shows use reducer ground not a battery ground