I just finished my whole battery box setup and then all of a sudden all this smoke came form under my hood. I unplug the battery real quick and freak out. The wiring harness on my haltech fried. The harness was not plugged into the haltech, thank god!! None of the wires going to the haltech were fried, just one wire going from one of the relays to the haltech big connection port, SO what the **** happened??? In order for that to occur one of the wires had to be touching ground, if the haltech wasn't plugged in WTF? I may try and salavge the harness, just rewire the relay and patch up the wires that it touched, I am really ******* pist right now.

God im about to shoot someone wtf happened! Can i buy a new wiring harness? Just the harness? All my sensors and everthing else is fine...

I think you can just buy the harness. but I don't know how much it is.. Now you will definately want to double and triple check everything cuz you don't want to fry the haltech..

yea no **** those things are expensive, like 1400.00 or so. dose that sound about right? i dunno i own a NA https://www.nopistons.com/forums/pub...IR#>/blush.png

Maybe a bad harness?

Thats what I am saving up for now.. and then the REPU will be complete..

That has gone through my mind, cuz how the **** would that happen unless some of the wires inside the harness were touching each other, I think what caused it is somehow one of the wires was grounded, and by grounding it completed the circuit of the battery and couldn't handle all the amps, cuz the wire was so small and then started friing, Cuz if the wire went from the battery to the relay to the haltech, and the haltech wasn't plugged in, how else would the wire ground? Yea im ticked, i think i am going to try and replace the burnt wires, but I want to know how the **** this happened, cuz ok i replace all the wires the same **** might happen again.

bummer man, sorry to hear it.



I powered mine up and got it online before installing it in the car, using a AT PC power supply for the +12VDC. You might want to try that first instead of going straight to the battery next time... the AT power supply won't put out the amps a car battery will, and is protected in the event of a short.



Let us know what you find was the cause, I'm very curious as I've been doing alot of tinkering with my E6K on the PC power supply with the harness scattered all over the living room while working on my lcd gauges. I would hate to have a short like that happen.

Well the wire the cooked was the one that went from the main power relay to the haltech port connection, I am going to email Haltech tonight, i can't figure out why it happened.

I can't really see what is going on in that pic



could you get more up close pics of the wire that fried and the connector to the main power relay showing which wires went in which holes on the relay connector? I can compare it to mine to see if they wired it incorrectly shorting it at the relay...

didnt you get the harness that you put your own ends on?

Does the harness come all wrapped or are the wires individual?

well the part that was fried was all wrapped up, so i had nothing do to with it.

I was only trying to eliminate the possibility of a problem in installation.\,

you said its a power wire, is it fused?

the actuall harness that goes to the motor is fine, except the part thats in the casing

apparently it's the black wire coming off the main relay, thats the wire which grounds the relay switch circuit... the haltech power is fused but this one probably is not.



there are 4 wires coming to the main power relay:



black: ground

grey: switched +12VDC



red: battery +Ve

yel/red: system +13.8VDC





the haltech was not installed, so assuming the connector for the relay is wired properly, the yel/red has infinite resistance (no continuity) the red would be hot, using battery as direct source...



Now since the black is the one that fried it either got some high amp current from the red or the grey, but the red, if my memory serves me correctly, goes through the haltech fuse block before going to the relay.. so that fuse would have blown.



It looks like all your juice came from your switched +12VDC source, which may or may not have been fused depending on what you used as a switched source...



It's possible the relay has an internal short... check the resistance across the terminals the grey and black wires go to. if it's 0 theres a short and it fried your wiring... but the switched source should have been fused, if it were it would have blown and the harness would be fine and dandy.

https://www.nopistons.com/forums/pub..._DIR#>/sad.png

Yea the +12v ign source wire I had plugged in was not burnt at all so that was not drawing juice, that would make sense if it was burnt to hell.

i had problems with the pins on the relays pulling out, they weren't crimped well at all



mike

Tommorrow I will lay the biatch out, rewire all the burnt wires, and test it outside of my car with a fuse on the power source going to the relay... That should do it.

Here is the ground wire that melted going to the relay, But the +12V ign switched source was not hot/or even hot when the ignition was turned on, verified that today with my digi multimeter..

You can't really see it that well but there are 4 open wires in there, wtf?

I checked the relays, they are good. This is what I believe happened; when the relay was given power, it grounded the power to complete the circuit as usual, and the ground wire was too small, 16awg, while the power wire was larger either 14-12awg. The ground wire couldn't handle all the juice and fried, along with all the wires it was next too. So why the hell did haltech make the ground wire so small? https://www.nopistons.com/forums/pub...R#>/unsure.png

good question. But if you got it all apart rewire it with larger ground

Well if Haltech doesn't compensate me, I will rewire it with a much larger wire, and I will rewire all grounds/power wires outstide the main harness and have inline fuses put in.

did you have it fused correctly?

I burnt out my plow headlights switch, melted it beyond recognition

first time I wired it all up because I used too heavy of a power wire and

had too big of a fuse. Sometimes bigger isnt better. But its always better to have

a heavy ground.

Yes. It had all the fuses on it, and none of them blew... https://www.nopistons.com/forums/pub..._DIR#>/sad.png

maybe the fuses are to big?

they came with the haltech, they are between 25-30amp I believe, Does anyone know off hand how many amps each size wire can handle? I need to know for reconstruction...

why would so many amps being traveling throught the wires anyhow? What determines how many amps is going through the circuit anyhow? Doesn't whatever is doing the pulling, ie: efan determine that? But what about in this case...

need a bigger audience.... https://www.nopistons.com/forums/pub..._DIR#>/dry.png

i really cant help much considering this is wiring for a haltec wich i know nothing about.

well the battery is capable of putting like 100+amps into anything it can find as a ground



mike

ok, thats what I was looking for... So if that was the only hot wire in the car, 100 amps would be trying to go through it? What if it wasn't, what if they are severl wires pulling, I mean does it matter how many things are pulling amps from it, in determined how many amps a grounded wire will pull?>

so a short would have cause this? What kind of wire would the ground need to touch? a +12v wire of something that pulls a lot of amps?

you got some dirty fingernails https://www.nopistons.com/forums/pub...DIR#>/wink.png

if your relay had a short in it, it would be similar to taking that thin black wire from the ground and touching it to the positive terminal on the battery...



if the wiring was wrong and there was a short due to wires going to the wrong places... it would be similar. It appears you have a number of things going to your positive terminal via some car audio type connector... I suspect some of those lines are not fused.... like if that grey wire is going to your fuel pump, is it fused?

Your poor car. https://www.nopistons.com/forums/pub...O_DIR#>/11.gif I hope you can get it together soon.

Well its either the relay was miswired and sent the power from the power wire to the ground, or the ground shorted out inside the pre-wired loom, or the grey +12v source completed the circuit and sent too much power through the ground, but I have not wired the chassis or the dash harness(which the grey wire was plugged into) and I checked it with a multimeter to confirm this, and they grey wire is still intact, no signs of overload. SO either the relay is miswired and cross completed the 2 circuits or the ground wire shorted out inside the harness. Still waiting for haltech to write back, hitman on the hand has been very helpful.

ouch sorry to hear/see that :(



are you going to elite for tuning? any idea of when?