G19 - Spark when connecting reducer for headlights.

beech_house_G19 · 12-09-2018, 08:11 PM

I recently installed new headlights and taillights, along with a 48v to 12v reducer. The reducer has four, labeled wires and a fuse on the red “input” wire. Whenever I touch the ground wire to the battery terminal for the final connection, it results in a spark. What could I be missing?

trentofdestiny · 12-09-2018, 08:20 PM

Is it a big spark? A little spark is normal, the reducer uses power whenever it is connected.

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beech_house_G19 · 12-09-2018, 08:30 PM

It’s big enough to make me flinch and pull away. Lol

trentofdestiny · 12-09-2018, 08:31 PM

How many amps is the reducer rated for? A large spark could simply mean that the capacitors in the unit are initially charging up.

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beech_house_G19 · 12-09-2018, 08:43 PM

I believe it’s rated at 30 amps. Do you think I should just firmly attach it, despite the spark?

trentofdestiny · 12-09-2018, 08:47 PM

You need to install a 30 amp switch or smaller switch and 30 amp relay on the input side. You should not connect it directly to the battery without a switch on the input side because it will run the batteries dead.

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beech_house_G19 · 12-09-2018, 09:22 PM

Thanks for your help. I’ll give that a shot.

trentofdestiny · 12-09-2018, 09:24 PM

You're welcome. It may be hard to find a 30 amp rated switch. I recommend a 30 amp or higher rated relay to wire into the key switch so that the lights will only work with the key on. Obviously the relay must have a 48v coil not 12v. This makes it harder to find, but not impossible.

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cgtech · 12-09-2018, 10:22 PM

A 30a DC converter doesn't by any stretch of the imagination require a 30a switch on the input. A 30a/48v DC converter operating at 100% efficiency would only draw 7.5a input at full load 30a output. Of course 100% efficiency is an unobtainable goal, 85% efficiency is more like it. So, 7.5a plus 15% for efficiency losses equals a total load of 8.625a at full load assuming 85% conversion efficiency. I would use a good quality switch, but one capable of 30a is clearly unnecessary for input power.

trentofdestiny · 12-09-2018, 10:24 PM

Yeah you are correct, I forgot a converter listed as 30A means 30A @ 12V output and not 30A @ 48V input. Regardless, if he's wiring it to the key switch, should use a relay.

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12-09-2018, 08:11 PM	#1
beech_house_G19 Not Yet Wild Join Date: Dec 2018 Location: Harrisburg, PA Posts: 4	G19 - Spark when connecting reducer for headlights. I recently installed new headlights and taillights, along with a 48v to 12v reducer. The reducer has four, labeled wires and a fuse on the red “input” wire. Whenever I touch the ground wire to the battery terminal for the final connection, it results in a spark. What could I be missing?

12-09-2018, 08:20 PM	#2
trentofdestiny Gone Wild Join Date: Oct 2017 Location: Harrisburg, PA Posts: 380	Re: G19 - Spark when connecting reducer for headlights. Is it a big spark? A little spark is normal, the reducer uses power whenever it is connected. Sent from my iPhone using Tapatalk

12-09-2018, 08:30 PM	#3
beech_house_G19 Not Yet Wild Join Date: Dec 2018 Location: Harrisburg, PA Posts: 4	Re: G19 - Spark when connecting reducer for headlights. It’s big enough to make me flinch and pull away. Lol

12-09-2018, 08:31 PM	#4
trentofdestiny Gone Wild Join Date: Oct 2017 Location: Harrisburg, PA Posts: 380	Re: G19 - Spark when connecting reducer for headlights. How many amps is the reducer rated for? A large spark could simply mean that the capacitors in the unit are initially charging up. Sent from my iPhone using Tapatalk

12-09-2018, 08:43 PM	#5
beech_house_G19 Not Yet Wild Join Date: Dec 2018 Location: Harrisburg, PA Posts: 4	Re: G19 - Spark when connecting reducer for headlights. I believe it’s rated at 30 amps. Do you think I should just firmly attach it, despite the spark?

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12-09-2018, 08:47 PM	#6
trentofdestiny Gone Wild Join Date: Oct 2017 Location: Harrisburg, PA Posts: 380	Re: G19 - Spark when connecting reducer for headlights. You need to install a 30 amp switch or smaller switch and 30 amp relay on the input side. You should not connect it directly to the battery without a switch on the input side because it will run the batteries dead. Sent from my iPhone using Tapatalk

12-09-2018, 09:22 PM	#7
beech_house_G19 Not Yet Wild Join Date: Dec 2018 Location: Harrisburg, PA Posts: 4	Re: G19 - Spark when connecting reducer for headlights. Thanks for your help. I’ll give that a shot.

12-09-2018, 09:24 PM	#8
trentofdestiny Gone Wild Join Date: Oct 2017 Location: Harrisburg, PA Posts: 380	Re: G19 - Spark when connecting reducer for headlights. You're welcome. It may be hard to find a 30 amp rated switch. I recommend a 30 amp or higher rated relay to wire into the key switch so that the lights will only work with the key on. Obviously the relay must have a 48v coil not 12v. This makes it harder to find, but not impossible. Sent from my iPhone using Tapatalk

12-09-2018, 10:22 PM	#9
cgtech Over This Interview Is... Join Date: Jun 2012 Location: AZ Posts: 17,449	Re: G19 - Spark when connecting reducer for headlights. A 30a DC converter doesn't by any stretch of the imagination require a 30a switch on the input. A 30a/48v DC converter operating at 100% efficiency would only draw 7.5a input at full load 30a output. Of course 100% efficiency is an unobtainable goal, 85% efficiency is more like it. So, 7.5a plus 15% for efficiency losses equals a total load of 8.625a at full load assuming 85% conversion efficiency. I would use a good quality switch, but one capable of 30a is clearly unnecessary for input power.

12-09-2018, 10:24 PM	#10
trentofdestiny Gone Wild Join Date: Oct 2017 Location: Harrisburg, PA Posts: 380	Re: G19 - Spark when connecting reducer for headlights. Yeah you are correct, I forgot a converter listed as 30A means 30A @ 12V output and not 30A @ 48V input. Regardless, if he's wiring it to the key switch, should use a relay. Sent from my iPhone using Tapatalk

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