Morimoto XB35 / XB55 Ballasts - Testing

[TRSAndrew]

We're going to post up here with ways that we are putting a hurting on these new XB35/XB55 ballasts. We'll see where we went right, see where we need to improve, etc. After all info is uploaded, we'll unlock the thread and let the conversation begin!

We have begun distribution to beta testers that we trust well so that they can provide their feedback to us as well for the full production run which is scheduled to begin Nov 1st. At this time, only 100 examples have been produced so far.

Here is some background info on development and design of the ballasts: http://www.hidplanet.com/forums/show...-XB55-Ballasts.

Much has has changed between some of the original concepts & ideas that were posted and the way they ended up, but all for the better we believe!

Stay tuned!

Andrew @ TRS

[TRSAndrew]

Ice test

For these tests, we started by freezing five brand new Morimoto XB35 and XB55 ballasts in a tub of water. Here's us removing the bin from a night of freezing:

and then taking it to our test bench to test:

(see test notes regarding the picture below)



Now to remove them from the ice:







Immediately after that, we took them to the flame test!

Notes on test: As part of this testing, not all of them lit in the ice, and we found out why. Water got into the connectors and expanded when frozen, so the pins couldn't make contact for the ballast to work properly. Once the connectors were thawed and dried, the ballasts worked just fine.

We used some expanded seals, left the ballasts underwater again for another 6 hours, found no signs of moisture inside the igniter connector. Production ballasts will use a seal with a .3mm bigger diameter. Problem solved

[TRSAndrew]

EMI comparison to Denso Slim, Matsushita, Mitsubishi.

Please note: these are not to be taken as 100% iron-clad results. These are findings we have found ourselves and are just for reference purposes.

Overall averages:
Denso - 77
Matsushita - 40
Morimoto - 57
Mitsubishi - 112

Denso:







Matsushita:







Morimoto:







Mitsubishi:

[TRSAndrew]

Rapid-fire on/off test

For this test, we proceeded to fire each ballast after it was frozen and then toasted. Each was fired on and off for one minute.

Notes on test: The first video especially had misfires around 0:34 in. We have found this is due to the igniter capacitor being slightly smaller than the version used in the AMP igniter. These were built with a capacitance of .22uF, production models will have igniter capacitance of .47uF. Not that anybody should really sit there and turn their ballast on an off 100 times in a row for any reason, and not that the mis-fires were frequent, but it will be resolved anyways.

[TRSAndrew]

Flame test / heat test

For this test, we heated the casing of all ballasts to dry them off from the water / ice bucket challenge. One ballast we spent extra time on, taking the case surface to a high of 423F.

(this video and the picture below are simply showing the fun way we decided to dry the ballasts after their ice bath, why not? haha)

Final testing:

still drying the ballasts....



Now we'll pick one to really toast. Left it on the flame for about 2 minutes.



case temp was over 400F


Smokin!


Notes on test: We did see / hear bubbling of both the water inside the case as well as the paint on the case. The case was smoking once we finished blasting it with the torch.

[TRSAndrew]

Electrical draw / other figures and specifications vs. OEM ballasts test

Here, we tested out the wattage produced by three separate 50w ballasts (wattage is indicated in the bottom-left readout of the meter):







We also tested the 35w ballasts and had similar results--all right at 35w without much fluctuation.

Interestingly, the Denso ballasts started out at around 63w and then subsided down to about 35w after about a minute of operation. We suspect this has a lot to do with why Densos are so fast upon startup!

[TRSAndrew]

Alrightly ladies and gents. Content is being uploaded. I'll unlock this thread as soon as the rest is added. Enjoy in the interim!

[TRSAndrew]

Fully populated. Let us know what you think!

[blochead21]

So if the water got into the connectors, why not have waterproof connectors to prevent that?

[TRSAndrew]

So if the water got into the connectors, why not have waterproof connectors to prevent that?

Good question. They are definitely apt for being installed in a moist environment, however the water entered into the connectors by us unplugging the ballasts under water and plugging them back in--trapping the water to see what happens. The ballasts didn't have any hiccups being packed with water, just when it froze.

[blochead21]

So they are already water tight? Could you do another test leaving them in a bucket overnight (to allow water to seep in) and then test fire while still in the bucket?

[TRSAndrew]

So they are already water tight? Could you do another test leaving them in a bucket overnight (to allow water to seep in) and then test fire while still in the bucket?

We've done that already with zero hiccups, in fact! The same bucket was used before it was frozen, so the ballasts and all connections were submerged overnight (6pm-9am).

[shuaige]

Actually I want to point this out to you guys. Without having the new ballasts in hand, I can't comment on the quality of it being waterproof. But on some of the wiring harness/ projector solenoid harness connectors, etc, that you sold before (and may still do), the diameter of the hole in insulating rubber and the diameter of wire that goes through does not match, most times the wire diameter is smaller than the hole diameter in the insulating rubber and water/moisture can get through the hole in the rubber, this defeats the purpose of having the insulating rubber in the first place. If some of the wires or the insulating rubber can be properly sized to match, that would take care of some of the connectors rusting and/or shorting due to moisture issues.

[MilosB]

very nice.

[satrya]

Very interesting.

I like how the D2S version has a similar igniter configuration as the Matsushitas. @TRS: did you consider using the same connector on the ballast side as the Matsushitas as well?

With the nice igniter setup for the D2S, it makes the H1 / AMP version less attractive imho.