In Brazil we don't find information about HMI lights and portable power sources, so i came here to ask you folks, about how to build a HMI lighting set for Photography and video, with 4 light sources (or more), all the cables, bulbs, ballasts and other accessories, as well as portable power source (generator or others).(The less expensive, the better).
Fernando Weberich said:
We're thinking about what HMI's we will need. We were planning to get 2-2500watts and 2-1200 watts…. What do you think? Used HMIs… would be awesome.
In order to maximize the number of lights you can run on the generator it is important to use an inverter generator and HMI ballasts with Power Factor Correction. As for what HMI fixtures to get, check out my post at
http://www.indietalk.com/showthread.php?t=20218. I would suggest you get at least one combination 4/2.5kw HMI Par so that you have a bigger light, that you can still run off the generator, for daylight fill.
It is going to be very hard to find Power Factor Correction in used HMIs. While it is true that all major manufacturers include PFC circuitry in HMI ballasts in the 6-18kw range - they do so by necessity. Because of the added cost, weight, and complexity of PFC circuitry, ballast manufacturers in the US have offered PFC circuitry only as an option in medium-sized 2.5-4kw ballasts. And, until very recently manufacturers did not offer PFC circuitry in HMI ballasts smaller than 2.5kw in the US (in the EU PFC circuitry in mandatory in all HMI ballasts sold.) Except for one notable exception, when manufacturers do offer PFC circuitry in smaller ballasts it is at a premium, adding as much as a $1000 to the cost of a 1200W ballast for instance. The new ballast manufacturer Power-2-Light, on the other hand, is including PFC circuitry in their ballasts at the same price point as other manufacturer’s non-PFC ballasts. But where Power-2- Light is still very new to the market, it is still the case that almost every 575 - 1200 W electronic ballast that you will find in North America will be a non-PFC.
There is a popular misconception that you should only use electronic ballasts with portable generators. Where that is true with conventional generators without crystal governors, it is not true of inverter generators like the Honda EU series. Magnetic ballasts will operate reliably on the Honda EU series generators because Honda's sine-wave inverter technology provides much higher quality power than conventional (non-inverter) generators. With a waveform distortion factor of less than 2.5%, the power generated by Honda’s EU series of generators is quite often better than what you get out of the wall outlet. The power these machines generate is rock solid with a frequency variance of only hundredths of a cycle - which eliminates the need for costly crystal governors. The Honda EU series generators provide true sine wave power with low enough distortion, and frequency stability, to power HMI's with magnetic ballasts without problems. As long as you shoot at one of the many safe frame rates, magnetic ballasts are also “flicker free” (where the topic of safe frame rates for magnetic ballasts is discussed extensively elsewhere in this forum I won’t get into it here.) Besides the extra bulk and weight of magnetic ballasts, the smaller magnetic ballasts (575-2500W) offer the distinct advantage of being less expensive and drawing less power (once they have come up to speed) than the commonly available non-PFC electronic equivalents. So if you don’t have access to the newest PFC electronic ballasts, you are better served by using the older magnetic ballasts on an inverter generator like the Honda EU 6500is over non-PFC electronic ballasts. I know this is contrary to the conventional wisdom, so I will quickly summarize why.
When electronic square wave HMI ballasts came on the market, they were at first thought to be the solution to all the problems inherent in running HMI lights on small portable generators. By eliminating the flicker problem associated with magnetic ballasts, they also eliminated the need for the expensive and ultimately unreliable AC governors required for flicker free filming with magnetic HMI ballasts and portable gas generators. Electronic square wave ballasts eliminate the potential for flicker by squaring off the curves of the AC sine wave supplying the globe. Squared off, the changeover period between cycles is so brief that the light no longer pulsates but is virtually continuous. Even if the AC Frequency of the power were to vary, a frame of film or video scan, would receive the same exposure because the light intensity is now not pulsating but nearly constant. Electronic square wave HMI ballasts allow you to film at any frame rate and even at a changing frame rate.
Since they are not frequency dependent, it was thought at first that electronic square wave ballasts would operate HMI more reliably on small portable generators – even those without frequency governors. For this reason, as soon as electronic square wave ballasts appeared on the market, many lighting rental houses replaced the more expensive crystal governed portable generators with less expensive non-synchronous portable generators. The theory was that an electronic square wave ballast would operate reliably on a non governed generator and allow filming at any frame rate, where as a magnetic HMI ballast operating on an unreliably AC governed generator allowed filming only at permitted frame rates.
In practice, electronic square wave ballasts turned out to be a mixed blessing. Part of the problem with operating electronic HMI ballasts on portable gas generators in the past has to do with the purity of the power waveform they generate. With an applied voltage waveform distortion of upwards of 19.5%, conventional generators do not interact well with the leading power factor (current leads voltage) of the capacitive reactance created by electronic square wave HMI ballasts. The net result is harmonic currents are thrown back into the power stream, which results in a further degradation of the voltage waveform and ultimately to equipment failure or damage.
The oscilloscope shots of the power waveforms below is from an article I wrote for our company newsletter and is typical of what results from the operation of a 1200W HMI with non-power factor corrected ballast on grid power (left), on a conventional generator (middle), and inverter generator (right.) The adverse effects of the harmonic noise generated by non-PFC electronic ballasts and exhibited here in the middle shot, can take the form of overheating and failing equipment, circuit breaker trips, excessive current on the neutral wire, and instability of the generator’s voltage and frequency. Harmonic noise of this magnitude can also damage HD digital cinema production equipment, create ground loops, and possibly create radio frequency (RF) interference.
Left: Grid Power w/ 1.2Kw Arri non-PFC Elec. Ballast. Center: Conventional AVR Power w/ 1.2Kw Arri non-PFC Elec. Ballast. Right: Inverter Power w/ 1.2Kw Arri non-PFC Elec. Ballast.
As is evident in the oscilloscope shots below of a 1200W magnetic HMI ballasts on grid power, on power generated by a conventional Generator (Honda EX5500), and power generated by an inverter generator (Honda EU6500is), the lagging power factor caused by the inductive reactance of magnetic ballasts has by comparison only a moderately adverse effect on the power waveform. Outside of causing a voltage spike in the inverter power, magnetic ballasts actually show a positive effect on the already distorted power waveform of the Honda EX5500 conventional generator.
Left: Grid Power w/ 1.2Kw Arri Magnetic Ballast. Center: Conventional AVR Power w/ 1.2Kw Arri Magnetic Ballast. Right: Inverter Power w/ 1.2Kw Arri Magnetic Ballast.
These oscilloscope shots confirm that if you don’t have access to the newest PFC electronic ballasts, the older magnetic ballasts are in fact cleaner running on portable gas generators than non-PFC electronic ballasts. And, where inverter generators like the Honda EU6500is do not require crystal governors to run at precisely 60Hz, you can operate magnetic HMI ballasts reliably on them. In addition, the smaller magnetic ballasts (575-2500W) offer the distinct advantage of being less expensive and draw less power (once they have come up to speed) than the commonly available non-PFC electronic equivalents (13.5A versus 19A for a 1.2kw.)
Of course there are downsides to using magnetic ballasts. One down side is that you are restricted to using only the safe frame rates and shutter angles. But when you consider that every film made before the early 1990s was made this way, you realize it is not such a limitation. Another downside to magnetic ballasts is that you can’t load the generator to full capacity because you must leave “head room” for their higher front end striking load. When choosing HMIs to run off portable generators, bear in mind that a magnetic ballasts draws more current during the striking phase and then they “settle down” and require less power to maintain the HMI Arc. By contrast, an electronic ballasts “ramps up”. That is, its’ current draw gradually builds until it “tops off.”
For example, even though a 2.5kw magnetic ballast draws approximately 26 amps you will not be able to run it reliably on the 30A/120V twist-lock receptacle on a 6500W generator’s power panel. As mentioned above, magnetic ballasts have a high front end striking load. For this reason, you must always leave “head room” on the generator for the strike. But, even though the twist-lock receptacle is rated for 30 Amps conventional 6500W generators are only capable of sustaining a peak load of 27.5 Amps per leg for a short period of time. Their continuous load capacity (more than 30 minutes) is 23 Amps per leg. And if there is any line loss from a long cable run the draw of a 2.5kw magnetic ballast will climb to upward of 30 Amps. To make matters worse, the lagging power factor caused by the inductive reactance of the magnetic ballast kicking harmonic currents back into the power stream causes spikes in the supply voltage that can cause erratic tripping of the breakers on the generator or ballast. For a more detailed explanation of why that is I suggest you read my newsletter article. The article is available at
www.screenlightandgrip.com/html/emailnewsletter_generators.html. In my experience the load of a 2.5kw magnetic ballast is too near the operating threshold of a 6500W generator for it to operate reliably.
The only sure way to power a 120V 2.5kw (or even a 4kw) HMI magnetic ballast on a portable gas generator is from its 240V circuit through a 240v-to-120v step down transformer like the one we manufacture for our modified Honda EU6500is. Our 60A Full Power Transformer/Distro steps down the 240V output of the generator to a single 60A 120V circuit that is capable of accommodating the high front end striking load, and even the voltage spikes, of either a 2.5kw or 4kw magnetic ballast at 120V. And, by splitting the large front end striking load of 2.5/4kw HMIs evenly over the two legs of the 240V circuit of the generator, the transformer reduces the impact on the generator when you first switch on the light. The same holds true when you switch on large tungsten lights like 6000W Molepar Six Lights or 5ks. And since, magnetic HMI ballasts will operate flicker free at all standard frame rates on an inverter generator (without the need for a crystal governor), our 60A Full Power Transformer/Distro gives new production life to older 2.5kw & 4kw HMIs with 120V magnetic ballasts. It provides an affordable way of powering more affordable HMIs.
Guy Holt, Gaffer, Boston