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Thread: Mega 3515 ballast 5th wire?

  1. #1
    Flashaholic willieschmidt's Avatar
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    Default Mega 3515 ballast 5th wire?

    Have a 35w HID Titanium Innovation Mega 3515. Got my 55w ballast in the mail. Removed the Mega front cover & reflector. Unbolted the ballast and noticed 5 wires. Ran out of time to investigate. Two go to the bulb. Two are power wires. What is the extra yellow wire?

  2. #2
    BVH's Avatar
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    Default Re: Mega 3515 ballast 5th wire?

    Not 100% sure but it might be a circuit that won't allow the ballast to power up if the battery charging pin is inserted - to prevent the light from running off the wall wart. In any case, you can cut the wire at the PC board or otherwise not use it in your mod. You don't need to use it. I've done 5 of these with 5-wire ballasts.
    WWII 60" Anti Aircraft Carbon Arc (Sold), Short Arcs: 1.6KW NightSun, 1KW VSS-3A, .8KW TrakkaBeam, 600 Watt M-134 Gun Light, 500 Watt X-500-14s, 500 Watt Starbursts, 300 Watt Locators, Megaray, 150 Watt Set Beam & Communicator, Maxabeam Gen3, LarryK14@52V

  3. #3
    Flashaholic willieschmidt's Avatar
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    Default Re: Mega 3515 ballast 5th wire?

    Quote Originally Posted by BVH View Post
    Not 100% sure but it might be a circuit that won't allow the ballast to power up if the battery charging pin is inserted - to prevent the light from running off the wall wart. In any case, you can cut the wire at the PC board or otherwise not use it in your mod. You don't need to use it. I've done 5 of these with 5-wire ballasts.
    Will add note to 110v plug..... For charging only. Do NOT operate device while charging.
    BVH,
    Thanks for the quick reply. Hopefully life will allow time to finish the job tonight.
    Willie
    Last edited by willieschmidt; 05-31-2012 at 07:50 AM.

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    Flashaholic* bshanahan14rulz's Avatar
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    Default Re: Mega 3515 ballast 5th wire?

    Did you folks happen to notice if the stock 35W ballast circuitry is potted?

  5. #5
    Flashaholic willieschmidt's Avatar
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    Default Re: Mega 3515 ballast 5th wire?

    Quote Originally Posted by bshanahan14rulz View Post
    Did you folks happen to notice if the stock 35W ballast circuitry is potted?
    This ballast doesn't have the commercial metal case like the automotive type or the automotive power plug. The entire ballast is encased in black epoxy type compound with five wires. The bulb wires do have the standard HID plugs like the automotive type. The positive and negative have female blade conectors.

  6. #6

    Default Re: Mega 3515 ballast 5th wire?

    I'm pretty sure It is used to prevent you to turn on the ballast while it's charging. I had the same wire in my mozo hid spotlight, it will work without it


  7. #7
    Flashaholic* Lips's Avatar
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    Default Re: Mega 3515 ballast 5th wire?

    just curious, where does that extra wire suppose to connect to to shut ballast down?

  8. #8
    BVH's Avatar
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    Default Re: Mega 3515 ballast 5th wire?

    My guess is that maybe when the charging pin is inserted and current or Voltage are present, it might power an electronic switch within the ballast that opens the main + input circuit? Just a wild guess.
    WWII 60" Anti Aircraft Carbon Arc (Sold), Short Arcs: 1.6KW NightSun, 1KW VSS-3A, .8KW TrakkaBeam, 600 Watt M-134 Gun Light, 500 Watt X-500-14s, 500 Watt Starbursts, 300 Watt Locators, Megaray, 150 Watt Set Beam & Communicator, Maxabeam Gen3, LarryK14@52V

  9. #9
    Flashaholic* Lips's Avatar
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    Default Re: Mega 3515 ballast 5th wire?

    10-4 on that. I mean where do you put the other side. On the battery or on the charging pin?

  10. #10
    BVH's Avatar
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    Default Re: Mega 3515 ballast 5th wire?

    No, it went into/onto the small charging PCB and I never traced it out on the board. I just cut em off!
    WWII 60" Anti Aircraft Carbon Arc (Sold), Short Arcs: 1.6KW NightSun, 1KW VSS-3A, .8KW TrakkaBeam, 600 Watt M-134 Gun Light, 500 Watt X-500-14s, 500 Watt Starbursts, 300 Watt Locators, Megaray, 150 Watt Set Beam & Communicator, Maxabeam Gen3, LarryK14@52V

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