Is the return wire too close?

[dudemar]

Hi guys,

I was looking at my HID bulb and I noticed the return wire is slightly bent, about midway it looks too close to the bulb than it should be. Normally there's about 1 mm of space in between, but again halfway down it looks like there's only 0.5 mm. I did drop my light a few times, but I'm not sure if that would generate enough force to bend the wire. Generally I thought return wires were straight across the board, but I could be wrong. I was going to straighten it out with a pair of neddlenose pliers, but thought I should consult here first before I attempt anything drastic.

Thanks,

Dudemar

 

[Patriot]

All of my wires are bent looking. I thought about tweaking it but figured that my chances breaking it were too good. I also figured that it didn't matter if the wires weren't straight anyhow. I'm not sure why they all seem to be bent either but I'm not that knowledgeable about HID bulbs even though I uses them often.

 

[dudemar]

Well that's reassuring, I now know it's not something unusual. Like you, I don't want to risk a $120 bulb going down the drain. As long as the wire doesn't bend any further, everything should be fine.

Thanks,

Dudemar

 

[BVH]

I would not touch it. As long as it's not near any metal where it penetrates through into the reflector, then no-harm, no-foul. No need to risk breaking the wire, it's insulator if it has one or the glass envelope.

 

[dudemar]

No need to risk breaking the wire, it's insulator if it has one or the glass envelope.

That's exactly what I was thinking. It has no insulator on the wire, but even if the wire touched the glass it shouldn't short or anything.

 

[MikeLip]

If there is one thing I've learned in 30 years of electronics, it's this; If it's potentially fragile and expensive, and it's working, LEAVE IT ALONE!

 

[LED61]

Because of liability issues, the DOT required all HID bulbs in OEM car applications to have insulated return wires. If the uninsulated return wire hits metal and arcs ZAP!!, you risk your ballast down the drain.

For flashlights it creates an ugly shadow and flashlight manufacturers have decided on their own to do away with the insulator and bend the return wire inwards. Some would consider this risky but there really has not been an accident in flashlights. I've noticed though Dan at XeVision has decided to leave the HID capsules alone with their return wires.

 

[dudemar]

Thanks LED61,

That's a very interesting point! Now I know for sure nothing's wrong with my bulb.

Thanks a lot,

Dudemar

 

[LED61]

Yeah, don't worry about the return wire hitting the glass envelope, worry about it coming too close to the reflector that's the real danger and the reason they are bent inwards.