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Old 02-14-2010, 12:49 PM
FireRanger FireRanger is offline
Blinded by the light
Join Date: Sep 2009
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Default HID controller crapped out. Made a new one :)

Back in the fall, the hi/lo controller for my HID's kicked the bucket. I had to cut the controller out of the circuit completely and hotwire the ballasts so I had only low beams. The hi/lo servos on the lamps use polarity reversal to switch up and down. Rather than buying an new HID kit for $50, I made a new controller myself for $15 in parts from radio shack.

The truck's low and high wires come in on the left and go through the two diodes. This applies power to the high current relay coil to power the ballast in high or low beam and prevents the two from backfeeding eachother.

The high beam input is also split off to that small board mounted DPDT relay to energize its coil when I switch to high beam. The relays two common terminals go to the lamp hi/lo servos. The NO and NC terminals are wired opposite of one another, creating the polarity reversal needed to operate the hi/lo lamp servos.

Place the board and the high current relay in a nice box with a strain relief on the wires and voila! Let there be light!

End result, when I turn on the low beams, the ballast relay energizes and the relay's NC contacts place the lamp servos in low beam. When I switch to high beam, the ballast relay stays on, and the NO contacts reverse polarity and switch the lamp servos to high beam. Its a wonderful thing.
Attached Images
File Type: jpg hi-lo-schematic.jpg (44.5 KB, 12 views)
File Type: jpg hi-lo-board.jpg (85.8 KB, 17 views)
File Type: jpg hi-lo-box.jpg (67.0 KB, 14 views)
2003 Edge 4.0 4wd

How to: Aux light wiring, relays, & fuses
Info: 300+ intake threads here on FRF
Info: HID Projectors
How To: NO HEAT Troubleshooting Guide
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