the_fbi
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| posted on 7/10/06 at 11:08 AM |
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Headlight Dip and Main Wiring
Apologies for the really poor "picture" but this is how I've wired up my side/head/main and for some reason its not working.
The switch on the right (square) is a proper light switch, 3 positions, 1st being off, 2nd just sidelights, 3rd both side and headlights.
Switch on the left (round) is purely a off/on switch with the 3rd connection for the grounding of the internal light (blue) to show that main beam is
on.
For some reason only sidelights work, although when on main beam the blue light on the switch does light up. But the relay is buzzing and neither dip
or main beam is on.
The fact that the headlights aren't working means its a rather large cockup I fear, but i can't see where.
Thoughts please 
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MartinDB
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| posted on 7/10/06 at 11:45 AM |
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Aren't you missing a relay and putting (or trying to) all the power for the headlights through the switch?
The side/main light switch should energise a relay to feed the headlights, then the relay you have should switch between main and dipped.
Martin.
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the_fbi
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| posted on 7/10/06 at 12:02 PM |
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quote:
Originally posted by MartinDB
Aren't you missing a relay and putting (or trying to) all the power for the headlights through the switch?
The side/main light switch should energise a relay to feed the headlights, then the relay you have should switch between main and dipped.
Martin.
Thats just how Westfield do it and its a heavy loom because of it 
Not ideal but thats the way it is, the only relay they expect you to use as standard is the flasher one!
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RazMan
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| posted on 7/10/06 at 12:22 PM |
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I would definitely do as Martin says and put an extra relay in circuit. One for dip & the other for main. imho you risk burning the switch
contacts out by putting all the power through them.
If the relay is buzzing you may have the wrong connection to the coil.
[Edited on 7-10-06 by RazMan]
Cheers,
Raz
When thinking outside the box doesn't work any more, it's time to build a new box
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the_fbi
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| posted on 7/10/06 at 03:54 PM |
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quote:
Originally posted by RazMan
If the relay is buzzing you may have the wrong connection to the coil.
[Edited on 7-10-06 by RazMan]
I never thought to check, is the coil polarity dependant then?
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RazMan
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| posted on 7/10/06 at 04:08 PM |
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No, its not polarity sensitive. I was thinking maybe the power & switch connections have been swapped.
If you put 12v across the coil (85 & 86) it should give a reassuring click.
Try disconnecting the switch connections (30,87,87a) and see if the relay clicks in.
[Edited on 7-10-06 by RazMan]
Cheers,
Raz
When thinking outside the box doesn't work any more, it's time to build a new box
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flak monkey
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| posted on 7/10/06 at 04:31 PM |
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Depending on the switch you are using you might be able to get rid of the relay all together. Headlights dont draw that much current (about 10.8amps
for two 65W bulbs). The standard wire used through most looms is 1mm^2 thinwall which will handle 16amps continuous, in older looms it will be 2mm^2
standard cable which handle 17.5amp continuous.
My lights are wired up with 2 toggles switches, one off-on-on/on and one on-on switch to change between dip and main. Theres no relay in the circuit
(there never was in the mk2 escort infact...)
If you are using column switches forget it, but otherwise, get some heavier duty switches and do away with the relay. K.I.S.S....
David
Sera
http://www.motosera.com
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Peteff
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| posted on 7/10/06 at 04:48 PM |
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Where did you get the relay from?
It looks like one of the dim dip relays with a resistor built in to dim the headlamps for sidelights purposes. Apart from that it seems you are
running the dip and main from the same relay so they will all be on at the same time all the time including the main beam warning light.
yours, Pete
I went into the RSPCA office the other day. It was so small you could hardly swing a cat in there.
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the_fbi
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| posted on 7/10/06 at 04:55 PM |
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quote:
Originally posted by Peteff
It looks like one of the dim dip relays with a resistor built in to dim the headlamps for sidelights purposes. Apart from that it seems you are
running the dip and main from the same relay so they will all be on at the same time all the time including the main beam warning light.
Either you've totally missinterpreted my diagram or my diagram is totally wrong.
The whole point of the relay is to turn off the headlight (dip) when then main beam is on.
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the_fbi
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| posted on 7/10/06 at 04:56 PM |
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David: The switches can handle it, I just want the dip off when main beam is on, and the main beam switch I got was off/on not on/on
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flak monkey
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| posted on 7/10/06 at 05:41 PM |
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Well, an on/on switch is only about £2...so maybe its not worth the effort with the relay... lol. Depends how much its worth to you to get it working
with a relay
David
Sera
http://www.motosera.com
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RazMan
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| posted on 7/10/06 at 06:58 PM |
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Pete, the diagram is sound but the connections possibly aren't  It should work perfectly well as long as the switches are man enough for the
current involved.
Cheers,
Raz
When thinking outside the box doesn't work any more, it's time to build a new box
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JoelP
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| posted on 7/10/06 at 07:13 PM |
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assuming the innards of the relay are as they appear in the picture, it should all work IMHO. Id replace the relay as a start, in case its knackered.
Try temporarily wiring it up without the relay to see if any lights work at all.
Is it possible that you have a voltage drop caused by the main beam current drain, causing the relay to open and close rapidly? It shouldnt be
buzzing...
[Edited on 7/10/06 by JoelP]
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the_fbi
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| posted on 8/10/06 at 10:16 AM |
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Relay works fine on its own and wires all work fine on their own.
Relay is also new so should be OK.
I must admit the battery hasn't been charged for ages but does light the main beam very well when the relay is bypassed.
Its going to be something stupid the way Westfield expect the loom to be installed which is causing it, I just can't see where.
Not exactly the easiest piece of loom to work with either, given its supposed to be used with their dash/switches so all the cables are a certain
length and thats not where I've got the switches
I've got a SPST I can wire up in its place and see if it puts main beam on and no headlight I guess...
I can also try putting a direct feed from a spare +ve straight onto the 85 without coming off the headlight feed in case it is VD from using the same
feed into 85 and 30.
Thanks.
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the_fbi
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| posted on 8/10/06 at 11:49 AM |
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Don't know how I'd managed to do what I did, but I'd got a wire on wrong.
All sorted now and working fine
Thanks guys.
Chris
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RazMan
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| posted on 8/10/06 at 11:57 AM |
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So I was right then? Blimey, that's a first!
Cheers,
Raz
When thinking outside the box doesn't work any more, it's time to build a new box
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Peteff
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| posted on 8/10/06 at 11:59 AM |
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Either you've totally missinterpreted my diagram or my diagram is totally wrong.
It looks like the relays for dim/dip, I read it wrong. I thought the main beam warning light would come off the wire from the 87 terminal.
yours, Pete
I went into the RSPCA office the other day. It was so small you could hardly swing a cat in there.
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