Bushranger Night Hawk VLI Series Wiring System: 4WD Auxiliary Light Wiring & Control Guide

Testing statement: Firebusters has not personally tested this wiring system. This guide is based on current Bushranger specifications, published manuals and current Australian product listings. Vehicle fitment and product details can change, so confirm the latest documentation before installation.

Bushranger Night Hawk VLI Wiring System

The Bushranger Night Hawk VLI Series Wiring System, part number NHW20VLI, is designed specifically to control Bushranger Night Hawk VLI auxiliary driving lights and light bars.

Unlike a traditional driving-light wiring loom, it does not use a conventional automotive relay to switch the main light load.

Instead, Bushranger uses electronic transistor switching within the VLI system while each compatible light receives its main power directly from the vehicle battery.

Verified Specifications

Product Card

How the VLI System Differs from a Traditional Relay Harness

A conventional auxiliary-light harness normally uses an automotive relay to switch the higher-current lighting circuit.

The Night Hawk VLI system works differently.

Bushranger states that conventional relay switching is replaced by electronic transistor switching incorporated into the VLI light and control system.

Each compatible VLI light receives its primary power directly from the vehicle battery, while the controller and control leads provide the operating signals.

This is why the VLI controller itself should not be treated as a traditional high-current relay box.

No Published Per-Light Wattage Limit

Bushranger states that the NHW20VLI works with all Night Hawk VLI Series lights without a limitation on the power rating of each light.

That statement applies to compatible Bushranger VLI products and the way their direct battery power architecture is designed.

It should not be interpreted as permission to connect unrelated high-current lamps to the control system.

Two Lights Standard, Four Maximum

The standard kit controls up to two VLI lights.

It can control up to four VLI lights simultaneously when the required additional control leads and lights are added.

Bushranger states that VLI models and sizes can be combined within the system, provided they are compatible Night Hawk VLI products.

Seven Brightness Levels Plus Off

There are two ways Bushranger describes the controller:

• 7 brightness settings
• 8 control positions from 0% to 100%

These descriptions refer to the same basic arrangement: seven active brightness positions plus an OFF position.

The rotary control lets the driver reduce or increase VLI light intensity rather than operating the lamps only at maximum output.

PWM Brightness Control

The system uses Pulse Width Modulation, or PWM, to control compatible VLI lamp brightness.

PWM electronically changes the amount of time the light receives its operating signal rather than simply inserting a resistor into the circuit to waste power as heat.

The system is designed as a complete VLI architecture, so this control method should not be assumed compatible with non-VLI lighting.

Soft Start

Bushranger’s Soft Start feature gradually increases light intensity during approximately the first second after activation.

The manufacturer says this reduces sudden glare and reduces electrical shock loading on the LEDs and electronics.

It is a comfort and electronic-control feature, not a substitute for correct road use of high beam and auxiliary driving lights.

Automatic Polarity Detection

Modern vehicles do not all switch high beam in the same way.

Some systems use positive switching while others use negative switching.

The NHW20VLI uses automatic polarity detection to simplify integration with either arrangement.

However, that does not mean every vehicle can be connected without additional hardware.

Vehicle-Specific Adaptors May Still Be Required

Bushranger offers separate:

• headlight adaptors
• fuse taps
• additional control leads
• vehicle-specific high-beam integration parts

The manufacturer also publishes specific fitment notes for some:

• Ford Ranger models
• Volkswagen Amarok models
• Jeep Wrangler models

This is a good reason not to describe the NHW20VLI as universally plug-and-play on every vehicle.

The VLI-to-light connections are modular, but the vehicle’s high-beam trigger arrangement still needs to be identified correctly.

What Comes in the Kit?

Current distributor information lists the NHW20VLI kit as including:

• 1 × brightness control module with mounting cradle
• 1 × control-module adaptor
• 1 × 4m trigger wire with mini blade fuse
• 1 × 3m control lead
• 2 × 1.5m control leads
• 1 × four-way distribution lead
• 1 × control-module sticker
• 1 × 3M adhesive pad
• 2 × wire taps
• 1 × spare mini blade fuse
• 2 × mounting screws
• 5 × cable ties
• fitting instructions

Check the current package contents before ordering because kit inclusions can change.

Fuse Protection

The draft version of this guide previously stated that fuse provision was unknown.

Current distributor information confirms that the supplied trigger wire includes a mini blade fuse and that a spare mini blade fuse is also included.

Remember that the VLI lights themselves obtain their main power directly from the battery using the appropriate light power wiring.

Any battery-connected circuit should be installed exactly as the Bushranger manual specifies, with correct conductor routing and protection.

Is There a Relay?

No conventional 12V automotive switching relay is used in the NHW20VLI control architecture.

Bushranger describes it as a relay-free electronic switching system.

Do not add a traditional relay into the control wiring unless specifically required by an approved installation arrangement.

10–30V Operating Range

The published system voltage range is 10–30V DC.

This allows the controller to operate across compatible 12V and 24V vehicle electrical environments.

That voltage range does not automatically mean every VLI lamp or accessory can be installed on every 24V vehicle. Check the rating of each individual component.

20mA Standby Current

The Bushranger manual lists approximately 20mA standby current draw.

This is relatively small, but it is still worth considering on vehicles that remain parked for very long periods, particularly where the battery is already marginal or multiple permanent accessories are installed.

Installation

The manufacturer manual gives an approximate fitting time of 45 minutes.

That should be treated as an indicative figure rather than a promise.

Actual installation time may increase where:

• firewall access is difficult
• a vehicle-specific high-beam adaptor is required
• the battery is remotely located
• multiple lights are installed
• the vehicle uses complex headlight electronics
• additional cable protection or mounting work is necessary

Routing Wiring Through the Vehicle

Vehicle wiring should be routed so that it is protected from:

• exhaust heat
• sharp panel edges
• moving steering or suspension components
• fan belts and pulleys
• crush points
• abrasion
• water traps

Where wiring passes through a firewall or metal panel, use an appropriate existing grommet or properly protected penetration rather than passing bare cable across a sharp edge.

Professional Installation

The modular VLI system is designed to simplify installation, but that does not mean every owner should modify vehicle wiring themselves.

Consider a qualified auto electrician where:

• you are uncertain about positive or negative high-beam switching
• the vehicle has LED or electronically controlled headlights
• a vehicle-specific adaptor is required
• the vehicle is still under manufacturer warranty
• you are unfamiliar with battery isolation and circuit protection

Road-Lighting Rules Matter

Australian Design Rule 13/00 deals with the installation of lighting and signalling devices on many road vehicles.

For driving lamps, the ADR requires them to be electrically arranged so they can only illuminate when the vehicle’s main-beam headlamp switch is in the ON position.

The VLI system’s high-beam trigger architecture is designed around this type of operation, but the installer remains responsible for the complete vehicle installation.

What Does UNECE R10 Mean?

The Bushranger manual lists UNECE R10 compliance for the control system.

UNECE R10 relates primarily to electromagnetic compatibility of vehicle electrical and electronic equipment.

It should not be interpreted as a blanket approval for:

• lamp mounting position
• beam aim
• number of driving lamps
• all vehicle applications
• every state or territory road-use requirement

Maintenance

Periodically inspect:

• battery terminals and power connections
• control plugs
• firewall wiring
• cable ties and protective sleeving
• connectors for corrosion or water ingress
• control-module mounting
• high-beam trigger connection
• lamp power leads

Investigate intermittent operation, heat damage, damaged insulation or loose connections rather than continuing to use the system.

Warranty Information

Warranty information currently published for the NHW20VLI is inconsistent between sources.

Some current retail listings describe a 1-year warranty, while Bushranger VLI manuals and brochures have published a 5-year warranty.

For that reason, Firebusters recommends confirming the warranty that applies to the specific item and seller at the time of purchase.

Who Is This System Best Suited To?

The NHW20VLI makes the most sense for:

• owners using Bushranger Night Hawk VLI lights
• installations where cabin brightness adjustment is wanted
• vehicles requiring positive- or negative-switched high-beam detection
• users planning two lights now with possible expansion later
• installations using multiple VLI lamp sizes

Who May Be Better With Another Harness?

A conventional auxiliary-light wiring harness may be more appropriate where:

• you are using non-VLI lights
• you only need simple ON/OFF driving-light control
• you are mixing unrelated lamp brands
• the selected lamps already include their own approved harness

Buyer Checklist

• Confirm your lights are Bushranger Night Hawk VLI models.
• Check whether you are installing two or four lights.
• Check whether additional control leads are needed.
• Identify your vehicle’s high-beam switching arrangement.
• Check Bushranger’s vehicle-specific fitment notes.
• Confirm whether a headlight adaptor or fuse tap is required.
• Plan firewall cable routing before installation.
• Confirm the complete lighting installation meets applicable road rules.
• Check the current warranty with your chosen seller.

Frequently Asked Questions

How many lights does the standard kit control?

Up to two compatible Night Hawk VLI lights.

Can it control four lights?

Yes. Up to four compatible VLI lights can be controlled using additional control leads.

Does it use a relay?

No conventional automotive relay is used in the VLI switching architecture. Bushranger uses transistor-based electronic switching.

What voltage does it support?

The controller is rated for 10–30V DC.

How much current does it draw when idle?

The published standby current is approximately 20mA.

How many brightness settings are there?

Seven active brightness settings plus an OFF position — eight rotary positions in total.

Does it work with negative-switched high beam?

Yes. Bushranger specifies automatic polarity detection for positive- and negative-switched high-beam circuits.

Does the kit include a fuse?

Current kit information lists a 4m trigger wire with a mini blade fuse and a spare mini blade fuse.

Can I connect any driving light?

No. The system is specifically designed for Bushranger Night Hawk VLI Series lighting.

Does it fit every vehicle without extra parts?

No. Bushranger offers vehicle- and headlight-specific adaptors, and it publishes special fitment notes for some vehicles.

Is it road legal?

The controller itself does not determine whether the complete installation is road legal. Lamp selection, mounting, aiming, number of lamps and wiring operation must comply with the requirements that apply to the vehicle.

Final Assessment

The Bushranger Night Hawk NHW20VLI is more than a basic driving-light wiring loom.

It combines electronic relay-free switching, PWM brightness control, automatic polarity detection, soft-start programming and modular control wiring for compatible Night Hawk VLI lamps.

Its standard configuration controls two lights, with expansion to four using additional leads.

Firebusters recommendation: consider the NHW20VLI if you are committed to Bushranger Night Hawk VLI lighting and want the variable-brightness functions the lamps are designed to provide. For mixed-brand lighting or a simple fixed-output driving-light installation, a conventional correctly rated harness may be the more straightforward option.

Research Sources

• 
  Bushranger – Night Hawk VLI Series Wiring System
  
• 
  Current Affiliate Product Listing – NHW20VLI
  
• 
  Australian Design Rule 13/00 – Installation of Lighting and Light Signalling Devices
  

Specifications, vehicle fitment, accessory requirements and warranty information can change. Check the current Bushranger manual and vehicle-specific fitment documentation before installation.