P500 LED lightbar Question?

[joey400ex]

I recently installed a epistar 42in LED light bar on my P500. I ran the wiring harness straight to the battery with a relay switch and fuse (lampuz cruiser off road switch). While out hunting the wires near the battery caught fire and I was able to extinguish the fire rather quickly preventing major damage. I do not have great knowledge with electrical equipment but would like advice on whether this light should work with my system. The light bar is 240 watts, operating voltage is 9-32V DC, amp draw 10.5a/12v or 5.25/24v. Did it overheat because it's drawing too much power or did a wire ground out causing the issues? I had the lightbar only for a week and this happened after 15 minutes of use. I thought the P500 is a 12v battery system. Any help would be great, thanks. http://www.amazon.com/LAMPHUS-CRUIZER-Light-Wiring-Harness/dp/B00D1CQVIY/?tag=sxsweb24-20
http://www.amazon.com/SHANREN-Curved-Light-Flood-Combo/dp/B00LQHR9GE/?tag=sxsweb24-20

 

[Admin]

 

[scott]

I think using a bigger gauge wire will fix it. If it was wired right,,, that's the only thing it could of been i think.

 

[joey400ex]

I think I will use a thicker gauge wire again with a simple toggle switch without getting the relay and accessory wires. I have a feeling the wires were rubbing the metal on the ground wire and made contact with the hot wire. I will place a fuse near the battery terminal this time, I think I had too much wire between the fuse and terminal and the hot wire grounded out. Unless someone else thinks the system is drawing to many amps in addition to what is already being drawn during normal use.

 

[bobbyhill]

Welcome to the Club @joey400ex !! well fire is not good, I am glad that you had Min. Damage. I think that a bigger gage will work and I would also use some plastic wire wrap and tape it up.

 

[SBuckJ]

I agree with Joey....the wire must meet the amperage draw on the light...

http://www.offroaders.com/tech/12-volt-wire-gauge-amps.htm

 

[ohanacreek]

The wires they use are too small for that bar.
The ones that came with my 42" were, but I never used them, I made my own.

 

[ohanacreek]

I'd use a relay, few switches are rated for 20+amps.

 

[Code54]

Correct - sounds like the wire was undersized. Make sure you use a relay in the circuit and have it on a fuse. As Ohanacreek mentioned most switcher are not rated high enough for a constant draw where the relay will avoid that entire issue.
Good luck and if you have questions ask

 

[joey400ex]

Thanks for the replies, I will try another switch again with thicker gauge wire. I see it draws 10.5 amps with a 12 volts system, how many amp does the P500 typically draw while running with the lights on? I saw the charging amp were about 13.5 while running.

 

[ohanacreek]

240w at 12v is 20amps

Probably more realistically closer to 12.5-13.5v when running so maybe a bit lower draw.

Think the 500s charging system output is 450w like the 700.

 

[jak9922]

for 10amps use 14ga wire and always always always fuse the circuit as close to the batt as possible btw ive been a union electrician for 14 years now

 

[jak9922]

20a is 10ga wire you could use 12ga but play it safe go 10ga

 

[ohanacreek]

20a is 10ga wire you could use 12ga but play it safe go 10ga

I have 10ga on mine going to the relay it's only a 4' trip down the A-Pillar to the fuse/relay block. When in doubt or if it's close go a gauge larger. I have a book full of formulas at the office but I'm not there right now. There are numerous wire size calcs on the Internet, and some on the App Store, it's where I go when I'm not at the office to look it up.

 

[joey400ex]

I was thinking 10 ga wire, with the fuse as close to the positive battery terminal as possible to prevent another melt down. I will order another rely, any suggestions on what kind or company I should go with? What size fuse should I go with also, the last one was 30 amps.

 

[jak9922]

you fuse to the size of the wire if u use a 30a fuse and your wire is only good for 5a lol well what do you think is going to melt first!!!!! 10ga is good for 30a so you will be good there

 

[jak9922]

good rule of thumb is 15a is 14ga 20a is 12ga and 30a is 10ga but I personal never use 14ga the price between 12 and 14 is nothing compaired to peace of mind

 

[jak9922]

and another thing is make sure ALL!!!!! connections are tight loose connections cause heat and possible sparking which arnt good lol

 

[joey400ex]

Thanks for the help, I will give it another shot and see what happens.

 

[jak9922]

when in doubt just ask bro we are all here to help each other

 

[joey400ex]

Used 12 gauge wire with a 30 amp fuse, ran it for 30 minutes with the led light bar on. Wires did not get hot and no fire this time, lol. Went without the relay, hopefully it works out. Will keep y'all posted. Thanks for all the help!