QUOTE(Marv's3.6six @ May 11 2016, 01:38 AM)
Here is the first draft of a new 2 relay circuit and individual fuses for operating the 4 fans and idiot light. Automotive DC power guys please comment.
Few thoughts.
- I don't think you need two relays. Those Bosch relays are good for 30A.
- If you do choose to split the circuit, I'd not feed the coil from Relay #2 from the controlled circuit of Relay #1. In that scenario, if you lose Relay #1 then neither will engage and no fans will run. 85s should home separately to main power.
- I suggest connecting the 86 terminals of both relay to a common ground terminal, then two separate wires from there, one each to the thermostat and the dash switch.
- I don't recommend an idiot light that fires up when the fans are running. That will become distracting as the fans cycle, and you'll eventually tune them out.
- If you want notification when you've manually enabled the fans, put an LED in series with the ground side of the dash switch.
- If you want notification of when the thermostat switch has closed but you're NOT getting power to the fans, then connect one side of the LED on the 87 circuit of the relay and the other side to the ground side of the thermostat. That should ground the LED through the fans and light it up. That will only alert you for failures in the controlled side of the relay; if the solenoid fails, you'll get no notification (but you have a temp gauge, right?
I'm all about KISS. So I'd go with a single relay running all four fans, switches and idiot lights as described above.