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Old 01-10-2020, 06:19 PM #1
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Light bar wiring harness

I just bought a 540w light bar and need a harness. I canít find anything that goes much over 300w. I found a mictuning 600w but I think itís for 2 300w connections. I am afraid the 12 awg wiring per light might not be sufficient for the bar I have.
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Old 01-10-2020, 07:06 PM #2
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Do you have any more information, perhaps a link to the bar itself?

I seriously doubt your lightbar actually uses that much juice. 540 watts at 12 volts is 45 amps of current. Thatís a ton of power for a light bar, even a good one.

I recommend you try and measure the actual current draw. Just as an example, this is a ď120 wattĒ light bar, which uses no more than 50 watts in operation.

12.30 x 4.01 = 49.32 watts



Generally speaking, I have found a 12 AWG wiring harness with a 30 amp relay to be more than adequate for almost all lighting solutions I have seen. Unless you are running something really special here, I would not be too concerned. That said, none of this means anything until you actually measure your load.
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Old 01-10-2020, 10:05 PM #3
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Here is the bar.

https://www.amazon.com/Nilight-18025.../dp/B07X9LB9G9

Here is the harness they just recommended

https://www.amazon.com/Nilight-Wirin.../dp/B074GYNJ85
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Old 01-13-2020, 07:04 PM #4
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I don't know if its posted wrong on Amazon but that thing is 30V.......

Not gonna work unless you got more to your set up.

*Edit
Well I scrolled down more and it says 9V to 30V. Amazing how Amazon has more product information than their own damn website.

12AWG should be good assuming you putting it upfront.
ampacity.jpg Photo by skylark462 | Photobucket
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Old 01-13-2020, 07:41 PM #5
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Most lighting I have come across works on 12v and 24v systems, so 30v would be the top end of a 24v systems input voltage.

While I too use those ampacity charts, that one is a bit aggressive in its selections… 3 feet of 12 AWG has a 8% voltage drop with 100A going through it. That conductor would be smoking hot. I try and keep my voltage drop to no more than 2% to 3% ideally… 5% max.

I generally limit my 12 AWG conducts to no more than 30-40 amps depending on the application. Even if the conductor can handle it, the contact resistance of other connectors, like the spades connecting to the relay, would soon become the limiting factor and main generator of heat. Insulation temp ratings also play a very large role, meaning use quality wire.

The website specs don’t tell us much of anything. I would venture to GUESS, than the actual consumed power is 50% of what they advertise, meaning you might see a 20-25 amp load, making a 12 AWG wiring harness sufficient. Again, without measuring the actual consumption this is all speculation / best guess.

Last edited by Bumbo; 01-13-2020 at 07:46 PM.
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Old 01-13-2020, 08:06 PM #6
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I just jacked the chat from the first google link I found.

I always measure mine for real world draw before wiring it up.
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Old 01-16-2020, 10:51 PM #7
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I think as long as you use 12-10 gauge wire with a good quality relay you'll be ok, between mine, (light bar, large round bumper lights, ditch lights, another set of led bumper lights ) no hot wires even when everything is on. Just relay each light or set that you hook up.
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