Clicking from solenoid

[Roy748]

With the battery connected up as normal, the lights turn on and off as normal. It's as the battery discharges it triggers the relay to turn the lights on permanently. Tempted to buy a new relay as it seems that once voltage drops it turns the lights on which does not seem normal.

[g8dhe]

The relay is what is called a Normally Open (NO) relay, when power isn't applied the contacts are Open i.e. turned off, only when power is applied to the relay coil does the magnetic field pull the contacts into the Closed position which means that the lights come on. To me it sounds like you have either a contact in the wiring loom or something very odd going on causing the relay to operate in an unexpected way. What ever its going to need probing around with a meter to find the actual fault or random changing of components in the hope that the problem disappears.

[Roy748]

That's what I thought, being ok at DIY gets me by but electrics is like finding a needle in a hay stack.. oh well fortunately the van is not required any time soon

[g8dhe]

I doubt that they have changed the wiring significantly on a 2001 version (but you never know!) but details here you will need Flash working

[Roy748]

Thanks for the diagram
I'm just puzzled as to why the relay triggers closed causing the lights to actually turn on as the voltage drops. In the past my battery drained slowly with age but never exhibited the lights turning on.
The van has been parked up for 2 weeks following its MOT so nothing has happened to disturb the electrics

[g8dhe]

That's what is causing me confusion as well! There is no obvious reason as to how that can be happening, no simple short or break is going to make that happen!!

Suggest if you haven't already take the rubber covers off the relays and swap them around, just wondering if water has got down into the connectors and causing problems but even that doesn't make a lot of sense but as one is tied up with the air con there might be something odd happening else where ....

[rita]

Is it possible for you to swap the relay with a known faultless unit ?

[Roy748]

Ok update
I have just tested the amperage draw using my meter. The battery was only receiving 0.02 pull, when parked, which I believe under 0.05 is normal. I then considered if the split charger was pulling amps when parked, no with this connected its 0.03..
I then started the van and all was well, lights turn on and off as they should. High beam etc work fine, no weird actions in between attempts, and with the van running no problems reappear.
Now with the van turned off I tested the voltage using my meter direct on the battery terminals, as I touched the terminals with the probes it triggered the fault.. even with the battery at 12.85v. It then stopped..
Then when I locked the van via the drivers door it triggered the lights on and sound again from the relay.
So have now disconnected the battery so as not to go off randomly this evening with the temperature drop.
Oh it's not the headlight relay but the side and tail lights, as your photo, 2nd relay away from the expansion unit. However when its triggered only the headlights turn on, not the tail lights.
I have only deducted it's the side light relay as when its triggered placing my hand on the relay its notably vibrating as opposed to the others
Very baffling as all was fine 4 days ago, and not been driven following MOT

[Roy748]

I guess my next best step is to order a new relay, would I be able to get a part number off the existing one? I will need to remove the leisure battery in order to remove the relay.

[g8dhe]

There are TWO relays on the frame, swap them over to test. The relays have a description on them Like
H270 -Style
12v 20A -Coil and contact rating
NO - Contact type
xxxxxx - Date code.

[Roy748]

Thank you. I will try that tomorrow and update.

[Roy748]

Update..
Well having removed the relay I think my problem is evident, corrosion I believe.
I think my best option is to replace this unit?

[Roy748]

Does not look like the bongo shop stocks them

[g8dhe]

You will have a problem replacing that loom, just clean up the connectors and a good squirt of contact cleaner before using WD40 before putting the relays back in.

[Roy748]

Hi. G8dhe
Will do, have just ordered both relays from bongo spares, I have some needle files which I can clean the loom connectors with, followed by contact cleaner.
Hopefully this was the cause of my problem