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Old 10-08-2015, 09:43 AM
 
Location: Denver
3,150 posts, read 7,384,759 times
Reputation: 2950

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I am using a 5K linear pot in my car. I want to use it to vary the voltage that goes to headlight leveling motors. I used this thread for the idea. DIY: Headlight manual level adjuster. Cars with factory HID's - AudiWorld Forums


The voltage range for the motors are 3.3V to 10.3V. The higher the voltage the higher the lights point.
I bench tested the pot with the leveling system and it worked great.

Now that I am getting ready to install the pot into my car I wanted to bench test it again to be sure it is good to go. But this time I used the car's battery to supply the power for testing. I had a 5 amp fuse in-line with the car battery.

I hooked up the ground to the pot and as soon as I hooked up the signal voltage from the car battery the pot fried and the fuse blew. I double checked that I had the correct pin for ground and that checked out.

I don't understand why this happened. It worked fine when I bench tested it on the leveling system. My only guess is that using the battery provided to much voltage and current for the pot to handle frying it.

I am now a little apprehensive to hook it up to the car's leveling motors because frying that system would be costly.

Any advice?
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Old 10-08-2015, 10:03 AM
 
Location: Portland, OR
1,029 posts, read 1,831,210 times
Reputation: 1392
You must have hooked it up wrong. 5KOhms and 14V is 39mw of power. I suspect you connected the wiper to one side of the battery and one of the two ends to the other side of the battery. That would short it out when the wiper approaches the end connected to the other side of the battery. It is also possible (actually likely) that the motor input is high power and that is also shorting out the pot. Normally HID/LED aiming systems are driven by stepper motors, which run on a phased input. You might have a servo circuit that converts a DC voltage into a position but if not, you have a lot of work ahead of you....
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Old 10-08-2015, 11:23 AM
 
Location: God's Gift to Mankind for flying anything
5,370 posts, read 11,275,577 times
Reputation: 4202
Quote:
Originally Posted by wankel7 View Post
I bench tested the pot with the leveling system and it worked great.
Can you draw the schematic of how you bench tested *your* system ?
Also on how you hooked up the actual *in car* test.
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