Rigid Ditch Lights Blowing Fuse

Anyone out there have issues with installing Rigid DSSpro Ditch lights ?

I have mine mounted and wired. When I hit the switch the 15 amp wire harness fuse blows.
If I disconnect one light pod, the other lights up just fine and the fuse does not blow. This happens with either light connected / disconnected. I have checked the wiring instructions and the relay harness is installed as directed - all connections are tight.

My uncle is an electrical engineer and did the install.. I don't think he'll be able to sleep until we figure out the issue!

Truck is a 22 TRD Pro Hybrid

Thanks in advance for any suggestions.

 

How big is the relay? If it's a 30A and the wiring can support it, up the fuse size to match

 

Sounds like the trigger and power aren’t wired as they should be. These trucks also use a canbus system. So what are you using as your trigger source?

 

The lights came as a kit with hood mounting brackets and a wiring harness. The wiring harness has two keyed plugs for the lights (making it impossible for a reverse polarity connect), a switch for the cab and a relay. The power wires are black (ground) and red (positive post on the battery). All wired up and without the lights plugged in you can hear the relay actuate when the cab switch is flipped. Plug in one light, flip the switch and it lights. Disconnect that light and plug in the other light, flip the switch and it lights. Plug in both lights, flip the switch and the wiring harness fuse (15 amp) blows. The Rigid website shows current draw per pod to be around 4 amps so 2 lights operating together should be drawing well under 15 amps. I would suspect a bad light unit but either one lights up separately, runs for 15 minutes or more without heating up, smoking, etc.

 

Encountered a similar issue before, turns out I wired the switch wrong.

 

Update: The light pod specs say each light pod draws less than 4 amps. Just for grins I put a 5 amp (specs call for 15A) fuse in the wiring harness fuse holder.
With each light independently connected (right connected, left disconnected, then left connected and right disconnected) the connected light illuminates just fine. I would assume this demonstrates that each lamp is drawing their 3.7 amps when powered up. Yet when both lights are connected they pop a 15 amp fuse. Crazy, huh?

 

I'd replace whatever POS relay in the kit with a new POS relay (or a Hella), and see if that solves the issue...
(since it doesn't appear you have a short/etc elsewhere; unless that switch is mis-wired somehow, and plays a role)

 

Check the wiring down the line then...maybe a continuity test between power and ground...sounds like its the harness if it only blows with two lights hooked up. They might have messed up the connections at the relay if its just a single

 

I just wired in the Baja Designs Squadron ditch lights in my 25 Pro and wired it to the blank TOW IGR spot. No issues with a 10 amp fuse on there.

 

Do you have a separate set of lights to test your connection? If they work without blowing a fuse, then you know it has to be one of the new lights shorting out when connected together.