Light bar switch gets hot!

[jhill15]

Hey everyone, I recently added a 20" 126w light bar to my Highlander.

After it's been on for a few minutes the switch gets hot, not so much that I can't touch it but enough to draw concern that something isn't right.

Here's my switch "3 point rocker"

I bought a 380w opt7 wiring harness and wired up correctly.

Does anyone know what could be going on?
Thanks everyone!


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[javajoe79]

Is it hot because it's a lighted switch?

 

[paranoid56]

thats a relay setup?

 

[rayra]

Almost certainly NOT a relay setup if his switch is getting hot. Muh Amps. 126W ~= 10.5A, if flowing thru that switch. I'd be looking at the switch rating BEFORE IT SETS YOUR DASH / TRUCK ON FIRE, the wire gauge and I'd be changing to a relay sw setup instead.

 

[Betarocker]

How do you know if you wired it correctly? What's your trigger source? Have you got a wiring diagram you can post and explain what you've done?

Should only be minimal current flowing through a switch like that as it only needs enough power to ignite the bulb and trigger the relay.

 

[Hilldweller]

Measure the amperage at the switch with a multimeter. It should be quite low.

http://www.wikihow.com/Measure-Amperage

If you read high amps, you've either wired it wrong or have a crappy relay.

 

[jhill15]

Sorry guys I'm just now getting back. My tapatalk didn't notify me that I had responses.

Is it hot because it's a lighted switch?

Yes it's a lighted switch

thats a relay setup?

Yup has a 40amp relay

Almost certainly NOT a relay setup if his switch is getting hot. Muh Amps. 126W ~= 10.5A, if flowing thru that switch. I'd be looking at the switch rating BEFORE IT SETS YOUR DASH / TRUCK ON FIRE, the wire gauge and I'd be changing to a relay sw setup instead.

Switch rating is 35amp

How do you know if you wired it correctly? What's your trigger source? Have you got a wiring diagram you can post and explain what you've done?

Should only be minimal current flowing through a switch like that as it only needs enough power to ignite the bulb and trigger the relay.

I've wired up several of these with the same wiring kit and never had an issue before. It's pretty simple.

That heat is just energy you paid good money for & its not making its way to your lightbulbs...

Anyway, I see that harness kit includes a relay, and appears to be semi assembled & idiotproof for installation.
You mention its connected correctly, Was it OEM assembled correctly?
Perhaps rocker is switching full power plus the relaycoil ??
Measure current thru the switch & compare that to 'specs of the switch and what its supposed to carry.

If wiring is correct, Either the switch is not up to scratch, perhaps poor connections.
Possibly its indicator lite is emitting the felt heat,
You might disconnect the indicator & see if it operates cooler.

Btw, Another observation (aka, grasping at straws...)
That rockerswitch is adjacent to your instrument dimmer.
Those dimmers are often just a rheostat, what restrict output voltage wasted as heat.
Perhaps you feeling heat from that dimmer ?

I will check my connections to make sure they are solid.

I thought about the dimmer as well and ran my finger across the switch panel, the light bar switch was the only thing hot.

Measure the amperage at the switch with a multimeter. It should be quite low.

http://www.wikihow.com/Measure-Amperage

If you read high amps, you've either wired it wrong or have a crappy relay.

I will check it with my multimeter to see how much it's pulling.


Thanks everyone for the responses.

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[RedF]

I am very skeptical about that rocker switch being rated at 35 amps.

I agree with checking how much current is actually being passed through that switch. To energize the coil in a relay should take a fraction of an amp.

 

[Hilldweller]

I am very skeptical about that rocker switch being rated at 35 amps.

I agree with checking how much current is actually being passed through that switch. To energize the coil in a relay should take a fraction of an amp.

I agree. It's a $.35 switch that's probably only rated for .35 amps. If the relay is bad or miswired and more amps are running through it, it will melt eventually.

 

[fike]

Did rocker come in the kit? Did you buy it from Amazon?

I have been getting some real crappy small and obscure parts from Amazon...I think some manufacturers are flooding the market with parts that didn't make the cut for their customer.

If no, then I would try another rocker bought separately--they are really cheap. It could be too much resistance somewhere in the small circuit.

 

[javajoe79]

I am guessing that one of the wires on the switch is to ground the light in the switch. Unhook that wire and see if it's still hot

 

[PhulesAU]

I agree. It's a $.35 switch that's probably only rated for .35 amps. If the relay is bad or miswired and more amps are running through it, it will melt eventually.

Would bet money on this.

 

[toyick]

Actually whats most likely wrong with it, is its not a true LED switch...that meaning is the little light inside the switch isnt an LED, and causing good ol heat....alot of those switchs from Amazon are not "led" switches...and have been reported to do the same thing....i would unplug the ground going to the actual rocker switch, that turns the indicator light on or off, and just run it that way and see if it still gets hot... I think two guys before me hinted at that...

 

[kojackJKU]

yep, I agree. I always set up my lights with just ground coming through the firewall. less chance of fire etc, and never use a light up switch.

 

[jhill15]

Tapatalk has been the worst to update me on this thread. Sorry about that guys!

The switch came with the kit, and I did purchase it on Amazon.
I'm pretty sure the neutral on the switch is the ground to the light inside of it.

Could be that the light inside the switch itself is not an led and getting hot.

I will unplug the ground coming to the switch and see what that does.

Thanks everyone!


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