Hydrargyrum Medium-arc Iodide Lamp - Ballast Operation

Ballast Operation

To power an HMI bulb, special ballasts act as an ignitor to start the arc, and then regulate it by acting as a choke. Two types of ballasts exist: magnetic and electronic (square-wave or flicker-free). Magnetic ballasts are generally much heavier and bulkier than electronic ballasts, as they consist primarily of a network of large inductors. They are usually cheaper than electronic ballasts. Since the magnetic type of ballast does not maintain the discharge continuously, the lamp actually extinguishes at zero-crossings of the mains waveform; unless the camera is locked to the mains waveform, the difference in frequency between the lamp and the shutter will produce a beat frequency that is visible in the resulting recording. This is why TV standards typically use the power grid frequency as their basic frame rate. Magnetic ballasts are simple devices compared to electronic ballasts. Essentially, a magnetic ballast is a large, heavy transformer coil that uses a simple principle to generate the high startup voltages needed to create an arc in a cold lamp. Input power is routed to a choke coil connected between the main input and the lamp. The coil may be tapped in several places to provide for various input voltages (120 V or 240 V) and a high start-up voltage. Capacitors are also included to compensate for the inductance of the coil and improve the power factor. Because of the high amount of current through the ballast, a low humming sound is often heard due to magnetostriction of the ballast iron laminations. Some magnetic ballasts have insulation around the coil for silent operation.

Within the last ten years, electronic flicker-free (or Square-Wave) ballasts have become increasingly popular and affordable as an alternative to magnetic ballasts by eliminating most of the problems associated with HMI flicker. Unfortunately, their operation is not as simple as a magnetic ballast. Electronic ballasts can be thought of as operating in three stages—a DC intermediate converter, a power module, and an AC inverter. Power initially flows through the main breakers into an RF mains filter that prevents the flow of noise back onto the incoming power line. Then, rectifiers and capacitors charge and discharge to invert the negative half of the AC cycle and convert the line to positive DC voltage. This is called the DC intermediate. In the second stage, a buck converter draws from the DC intermediate and regulates current to the final power electronics via an electronic control board. This control board carefully adjusts the high frequency duty cycle of its transistors to maintain optimum color and light output as the lamp ages. Finally, the regulated current is inverted by an LF-converter board that uses four Insulated Gate Bipolar Transistors (IGBTs) to switch the DC at precisely 60 Hz into a square wave AC (unlike the sinusoidal pattern of line AC). Leaders in this field include Power Gems Corp, B&S, & Mytronic.

By using a square-wave output that is not referenced to the line cycle rate, a flicker-free output can be produced. Since the IGBTs switch on and off at a regulated cycle rate, a generator can be slightly off-speed and the lamp will still be flicker-free, which is not the case with a standard magnetic ballast. The square wave nature of the output results in a straight-line power output from the lamp. The time where cathodes aren't emitting electrons of high enough energy is very short, meaning that safe (flicker-free) filming can occur at camera framerates up to 10,000 frame/s on most electronic ballasts.

Unfortunately, this very sharp switching on and off inherent to the square-waveform causes extremely high frequency vibrations in the lamp. A square wave can be thought of as an infinite sum of odd-numbered harmonics, which will include frequencies at the resonant frequency of the bulb, causing it to vibrate at that frequency like a bell or whistle. The lamp housing does not help this, acting as a resonating chamber that amplifies the noise and presents a problem for sync-sound recording for film and video. To correct this, most electronic ballasts are equipped with a silent mode that eliminates the higher frequencies, but rounds off the voltage transition, causing the same flicker issue with magnetics, though to a lesser extent. This mode provides safe, flicker-free filming at framerates up to 24 frame/s on most electronic ballasts.

In addition to solving the problems of flicker, electronic ballasts also provide other advantages over magnetic ballasts. With a square wave voltage, the cathodes spend much more time emitting electrons and exciting the plasma, creating a gain of 5–10% in lumen output. The square-wave nature of the power flow allows lamp life to be extended by as much as 20%. Most modern ballasts are now also equipped with a dimmer, which uses pulse-width modulation to dim the lamp up to 50%, or as much as one stop of light. Unlike a tungsten-based light, which has a negative color temperature shift with a drop in power, the mercury emission spectra takes over with a drop in power (approximately 200 K bluer at 50% output).