 |
 |
 |
 |
 |
 |
"I LIVE in my tan!"
A1 Tanning Supply.com
A1 Tanning Supply.com
BALLASTS OVERVIEW
In today’s tanning industry there are three Ballast Systems used to operate
Low Pressure tanning lamps. All three will do the same functions: Provide the
proper voltage to the cathodes of the lamps which will start the process.
Provide the lamp with the proper voltage required to start the lamp. Limit the
electrical current which flows through the lamp.
Preheat Choke System
The most commonly used and generally powers lamps from 8 watts to over
200 watts.
Rapid Start Magnetic Systems
Used only by a few United States equipment manufacturers. Generally powers
to HO (100W) and VHO (160) lamp operation.
Rapid Start Electronic Systems
Used for powering HO (100W) lamps only. Used almost entirely for small
home-tanning units. Generally speaking, the most expensive operation and is
therefore not included in verbiage to follow.
Rapid Start Magnetic Systems
The Rapid Start Magnetic Ballast will quickly and smoothly start Rapid Start
lamps in general lighting applications. This system uses a separate winding
within the ballast which will them provide the lamp electrodes with a low
voltage that “heats” the electrodes. The lamp electrode (cathode), is similar to
the coil of an incandescent lamp. The heating reduces the starting
requirements of the Rapid Start Lamp and will generally start the lamp in
approximately 1 second. When the lamp is started the cathode heat that is
essential to the starting of the rapid start lamp becomes non-essential
following lamp ignition, it remains even when the lamp is operating. There are
“Special” Rapid Start Ballasts that disconnect the cathode heat after the lamp
has been started, these ballasts are very energy efficient but the high cost
makes them very impractical for operation in tanning equipment.
Preheat Choke System
A Preheat Choke System is generally a simple and inexpensive “choke”
transformer. It serves to provide the appropriate starting current and to also
“choke” the current to the lamp during operation. The choke ballast is used in
combination with a separate “starter”. The device also provides approximately
1 second of current flow to the lamp cathode to “preheat” them which then
causes the cathodes to emit electrons that aid the starting process. When the
cathode reach the preheat condition, the starter will automatically open to stop
the current flow. When this happens, full voltage is then applied between the
two cathodes of the lamp, the arc strikes and the lamp is operational. In
addition to the choke ballast and starter, many applications also use a third
component called a capacitor to provide power factor correction. With Preheat
Systems this capacitor is a separate component.
There are a few guidelines for operating both systems. Generally, a Preheat
System can operate both Rapid Start and Preheat Lamp types. Rapid Start
Ballasts are designed to operate only Rapid Start Lamps. Lamps which are
designed to exclusive operation on preheat circuits will not function reliably on
Rapid Start Ballasts. While these lamps might work under only the best
circumstances, under normal circumstances starting is generally unreliable. In
today’s market, tanning lamps are generally hybrids and are listed as
acceptable for both Preheat and Rapid Start Operation.
Advantages and Disadvantages of the Two Systems:
Advantage:
In order for the sun bed designers and salon owners to make educated
decisions as to which system is more worthy, it is necessary to compare
systems at many levels and from many perspectives.
Acceptance. Approximately 96% of the worldwide installed base of equipment
uses the Preheat Choke System. The reasons for this dominance will become
clear as we continue.
Preheat Choke Flexibility.
Preheat choke systems are commonly used to operate from 8watt to +200watt
L/P lamps. R/S magnetics are used almost exclusively with HO (100W) and
VHO (160W) lamps.
Preheat Choke Optical Design of Equipment.
The requirement that a continuous grounded strip be positioned within 1" of
the entire length of the lamps that are operated by R/S ballasts requires
numerous design compromises by equipment manufacturers. This often
results in a loss of optical efficiency. This does not apply to preheat
operation.
Preheat Choke Continuity of Service.
Preheat systems operate with one ballast and starter per lamp. Failure of the
lamp, ballast or starter means one lamp is inoperative. A Rapid Start magnetic
ballast operates 2 lamps in series. Failure of either lamp or the ballast means
two lamps are out.
Preheat Choke Weight/Dimensions.
A 2-Lamp R/S(100W) ballast weighs 10+ pounds. Two 100W chokes with
starters, starter sockets, and capacitor weigh slightly over 6 1/2 pounds. In a
40 lamp bed this translates to +/- 140 extra pounds to ship, lift, and move. Also,
2 chokes plus capacitor consume only about 40% of the space needed for a 2-
lamp R/S unit.
Preheat Choke Ease of Installation (by manufacturer).
The Rapid Start ballast is probably easier. All input and outputs are made via
color-coded leads integral to the ballast. When using a choke ballast and
components the bed maker usually uses a pre-assembled wire harness.
Rapid Start Magnetic Ease of Installation (Replacement by User).
Replacement of a failed R/S magnetic ballast by a service person or salon
operator involves the disconnect and reconnect of no fewer than 8 wires;
chokes have 2.
Preheat Choke Lamp Starting (functional).
Both systems are designed to start a lamp quickly while "minimizing the harm"
that occurs to the lamp during starting. A major proportion of R/S ballasts are
used to operate recessed double contact (RDC) based lamps, and the
connection between RDC lamps and an RDC socket are not as positive and
reliable as a bi/pin connection. R/S operation depends upon an almost perfect
connection between lamp and lamp holder Absent quality contact, the
cathodes fail to heat properly prior to the ballast initiating ignition which causes
"sputtering" of the cathode’s emissive coating from the cathode to the glass
wall of the lamp. The lamp will turn "black at the ends" quickly and the lamp
often fails early. Poor RDC connections are probably the greatest single cause
of premature lamp failure.
Preheat Choke System Maintenance (Total Cost).
The preheat system consists of two "wear" parts: lamp and starter. The Rapid
Start has only the lamp. Starters are often replaced when and if they fail, but
some salon owners "group" replace every 2nd, 3rd, or 4th change to assure
integrity of operation (+6,000 cycles are typical starter ratings!) The choke
ballast itself is almost bullet-proof; if installed and operated properly, +50,000
hours of operation can be expected. Rapid start ballasts perform close to this
specification. In reality, failure rates for both are minimal. But when a failure
occurs the similarity ends. In a preheat, 100W system the cost to the salon to
replace a failed starter may be somewhere between $1.50 and $1.75.
Replacement of a 100W choke ballast may run from $10.00 to $15.00. Any
failure of a single internal component of a magnetic R/S ballast (starting coil,
starting cap, etc.) dictates the replacement of the entire ballast. No low-cost
repairs can be made. Salons will pay in the range of $50.00 to $65.00 to
replace a two-lamp 100W magnetic ballast. Similar ratios pertain to the 160W
system.
Preheat Choke Troubleshooting.
With a R/S system all problems can be traced to either the lamp, lamp holder,
connection or ballast. With a preheat system, we must add the starter and
starter socket. This probably gives a slight edge to the R/S system.
Rapid Start Magnetic Adaptation of Equipment to Utility Provided Service.
When rapid start ballasts are used in tanning equipment, the choice is usually
for one with an input volt-age rating of 120V. This voltage is available on the
two most common utility systems in the U.S.: The 120/240V single phase, 3-
wire, and the 120/208V, three phase, 4-wire. Under normal conditions a rapid
start bed may be hooked directly to utility-provided power without the need for
conditioning. Choke powered equipment is different. While in most cases
these beds and booths may be directly connected to a single phase service,
the addition of a small "buck/boost" transformer is necessary for 120/208V
service connections. This assures reliable lamp starting and optimal lamp
performance. The "size" of this transformer may be anywhere from .25KVA to
1.0KVA (depending upon the KVA requirement of the bed) and acquisition cost
is from $69.00 to $212.00 (source of price data is Grainger catalog).
Rapid Start Magnetic Effects of Humidity and/or Dirt on Lamp Operation.
One of the critical elements of R/S operation is that the lamp must be "excited"
by means of external voltage which causes ionization of the lamp’s internal
gases. This external "excitation" is created by the potential that exists between
the lamp and a continuous ground that must run the entire length of the lamp.
The rapid start lamp itself must be coated with a clear (non-wetting) silicon
material. This is done to counteract the adverse effect that humidity has on R/S
lamp starting. Under high humidity conditions, lamps on R/S circuits may start
slowly or not at all. This is usually due to dirt on the lamps that is offsetting the
desired effect of the silicon coating. Unfortunately, tanning lamps have some
very rigorous cooling requirements, and movement or circulation of air is the
only practical method to accomplish this. With air circulation comes many
forms of air-borne contaminants, many of which are deposited on the surface
of the lamps. This dirt is particularly unfriendly to R/S systems. To complicate
the matter, many common "cleaners" will also strip the silicon coating from the
lamp, making it impossible to start the lamp at all. The preheat system is
virtually immune to these problems.
Preheat Choke Total Cost of Equipment
Most equipment manufacturers will quickly admit to moderately higher labor
costs when building a piece of equipment using preheat choke ballasts and
related components versus rapid start magnetic. These higher labor costs are
readily accepted because of the huge material savings that are realized. The
net result is that the preheat choke equipment will always have a total
manufacturing cost that is less than its rapid start magnetic counterpart. The
worldwide business for products and services thrives on the fact that
consumers are ready and willing to pay premiums for features or
enhancements that offer benefits such as: improved performance, lower cost
of ownership, ease of use, durability, etc. In the case of preheat choke vs. rapid
start magnetics, there are no features and benefits to offset the higher costs of
the rapid start system. In simple terms, these higher costs are unnecessary.
Higher manufacturing costs inevitably translate directly to higher consumer
prices. Ultimately, it is the lower cost of preheat choke systems, and the better
consumer value, that explain the dominant use of this system.
Preheat choke lamp Output (using Standard Components).
In today’s market, "Lamp Output" is probably the most important factor for
those purchasing new equipment. Which of the two competing systems
normally, readily, easily and inexpensively optimizes lamp output? In order to
make this comparison, we tested commonly available, off-the-shelf
components used in the every day production of tanning equipment. In all
comparisons, the exact same lamp was used to eliminate error caused by
normal lamp-to-lamp variations. In all cases, multiple measurements were
taken and averages used so that conclusions are not reached from a single
test. Other conditions such as ambient temperature and warm-up time were
consistent from test to test. Lamp irradiance was measured using an IL
1700UV meter. Tests were conducted and reported by Szekely Engineering
and are available on request.
Preheat Choke Energy Efficiency.
Today’s energy costs require that we also consider ballast efficiency. Both
systems take A/C input and convert it to UV output and heat. The most efficient
system will maximize UV and minimize heat. Excess heat is not only wasteful
in itself, but must be disposed of by the equipment maker and salon owner via
increased cooling capacity. At the same time we conducted output
measurements, we monitored and recorded energy consumption. The choke
system is inherently more efficient, due in great part to the wasteful cathode
heat energy that remains following lamp ignition on the rapid start system.
Preheat Choke Modification of Components.
The ability to modify or enhance lamp output when using the Preheat Choke
System is unsurpassed. Design adjustments to the wattage of a choke ballast
are quickly and easily made and carry small (if any) cost premiums. Small,
inexpensive buck/boost trans-formers on the service feed may be used to
correct (up or down) input voltage to the very precise value recommended by
the equipment manufacturer. Additionally, creative circuitry and use of
capacitors may further refine lamp output so that very exact lamp irradiance
objectives are met. This degree of flexibility and precision are not practically
obtainable with the R/S system.
In today’s tanning industry there are three Ballast Systems used to operate
Low Pressure tanning lamps. All three will do the same functions: Provide the
proper voltage to the cathodes of the lamps which will start the process.
Provide the lamp with the proper voltage required to start the lamp. Limit the
electrical current which flows through the lamp.
Preheat Choke System
The most commonly used and generally powers lamps from 8 watts to over
200 watts.
Rapid Start Magnetic Systems
Used only by a few United States equipment manufacturers. Generally powers
to HO (100W) and VHO (160) lamp operation.
Rapid Start Electronic Systems
Used for powering HO (100W) lamps only. Used almost entirely for small
home-tanning units. Generally speaking, the most expensive operation and is
therefore not included in verbiage to follow.
Rapid Start Magnetic Systems
The Rapid Start Magnetic Ballast will quickly and smoothly start Rapid Start
lamps in general lighting applications. This system uses a separate winding
within the ballast which will them provide the lamp electrodes with a low
voltage that “heats” the electrodes. The lamp electrode (cathode), is similar to
the coil of an incandescent lamp. The heating reduces the starting
requirements of the Rapid Start Lamp and will generally start the lamp in
approximately 1 second. When the lamp is started the cathode heat that is
essential to the starting of the rapid start lamp becomes non-essential
following lamp ignition, it remains even when the lamp is operating. There are
“Special” Rapid Start Ballasts that disconnect the cathode heat after the lamp
has been started, these ballasts are very energy efficient but the high cost
makes them very impractical for operation in tanning equipment.
Preheat Choke System
A Preheat Choke System is generally a simple and inexpensive “choke”
transformer. It serves to provide the appropriate starting current and to also
“choke” the current to the lamp during operation. The choke ballast is used in
combination with a separate “starter”. The device also provides approximately
1 second of current flow to the lamp cathode to “preheat” them which then
causes the cathodes to emit electrons that aid the starting process. When the
cathode reach the preheat condition, the starter will automatically open to stop
the current flow. When this happens, full voltage is then applied between the
two cathodes of the lamp, the arc strikes and the lamp is operational. In
addition to the choke ballast and starter, many applications also use a third
component called a capacitor to provide power factor correction. With Preheat
Systems this capacitor is a separate component.
There are a few guidelines for operating both systems. Generally, a Preheat
System can operate both Rapid Start and Preheat Lamp types. Rapid Start
Ballasts are designed to operate only Rapid Start Lamps. Lamps which are
designed to exclusive operation on preheat circuits will not function reliably on
Rapid Start Ballasts. While these lamps might work under only the best
circumstances, under normal circumstances starting is generally unreliable. In
today’s market, tanning lamps are generally hybrids and are listed as
acceptable for both Preheat and Rapid Start Operation.
Advantages and Disadvantages of the Two Systems:
Advantage:
In order for the sun bed designers and salon owners to make educated
decisions as to which system is more worthy, it is necessary to compare
systems at many levels and from many perspectives.
Acceptance. Approximately 96% of the worldwide installed base of equipment
uses the Preheat Choke System. The reasons for this dominance will become
clear as we continue.
Preheat Choke Flexibility.
Preheat choke systems are commonly used to operate from 8watt to +200watt
L/P lamps. R/S magnetics are used almost exclusively with HO (100W) and
VHO (160W) lamps.
Preheat Choke Optical Design of Equipment.
The requirement that a continuous grounded strip be positioned within 1" of
the entire length of the lamps that are operated by R/S ballasts requires
numerous design compromises by equipment manufacturers. This often
results in a loss of optical efficiency. This does not apply to preheat
operation.
Preheat Choke Continuity of Service.
Preheat systems operate with one ballast and starter per lamp. Failure of the
lamp, ballast or starter means one lamp is inoperative. A Rapid Start magnetic
ballast operates 2 lamps in series. Failure of either lamp or the ballast means
two lamps are out.
Preheat Choke Weight/Dimensions.
A 2-Lamp R/S(100W) ballast weighs 10+ pounds. Two 100W chokes with
starters, starter sockets, and capacitor weigh slightly over 6 1/2 pounds. In a
40 lamp bed this translates to +/- 140 extra pounds to ship, lift, and move. Also,
2 chokes plus capacitor consume only about 40% of the space needed for a 2-
lamp R/S unit.
Preheat Choke Ease of Installation (by manufacturer).
The Rapid Start ballast is probably easier. All input and outputs are made via
color-coded leads integral to the ballast. When using a choke ballast and
components the bed maker usually uses a pre-assembled wire harness.
Rapid Start Magnetic Ease of Installation (Replacement by User).
Replacement of a failed R/S magnetic ballast by a service person or salon
operator involves the disconnect and reconnect of no fewer than 8 wires;
chokes have 2.
Preheat Choke Lamp Starting (functional).
Both systems are designed to start a lamp quickly while "minimizing the harm"
that occurs to the lamp during starting. A major proportion of R/S ballasts are
used to operate recessed double contact (RDC) based lamps, and the
connection between RDC lamps and an RDC socket are not as positive and
reliable as a bi/pin connection. R/S operation depends upon an almost perfect
connection between lamp and lamp holder Absent quality contact, the
cathodes fail to heat properly prior to the ballast initiating ignition which causes
"sputtering" of the cathode’s emissive coating from the cathode to the glass
wall of the lamp. The lamp will turn "black at the ends" quickly and the lamp
often fails early. Poor RDC connections are probably the greatest single cause
of premature lamp failure.
Preheat Choke System Maintenance (Total Cost).
The preheat system consists of two "wear" parts: lamp and starter. The Rapid
Start has only the lamp. Starters are often replaced when and if they fail, but
some salon owners "group" replace every 2nd, 3rd, or 4th change to assure
integrity of operation (+6,000 cycles are typical starter ratings!) The choke
ballast itself is almost bullet-proof; if installed and operated properly, +50,000
hours of operation can be expected. Rapid start ballasts perform close to this
specification. In reality, failure rates for both are minimal. But when a failure
occurs the similarity ends. In a preheat, 100W system the cost to the salon to
replace a failed starter may be somewhere between $1.50 and $1.75.
Replacement of a 100W choke ballast may run from $10.00 to $15.00. Any
failure of a single internal component of a magnetic R/S ballast (starting coil,
starting cap, etc.) dictates the replacement of the entire ballast. No low-cost
repairs can be made. Salons will pay in the range of $50.00 to $65.00 to
replace a two-lamp 100W magnetic ballast. Similar ratios pertain to the 160W
system.
Preheat Choke Troubleshooting.
With a R/S system all problems can be traced to either the lamp, lamp holder,
connection or ballast. With a preheat system, we must add the starter and
starter socket. This probably gives a slight edge to the R/S system.
Rapid Start Magnetic Adaptation of Equipment to Utility Provided Service.
When rapid start ballasts are used in tanning equipment, the choice is usually
for one with an input volt-age rating of 120V. This voltage is available on the
two most common utility systems in the U.S.: The 120/240V single phase, 3-
wire, and the 120/208V, three phase, 4-wire. Under normal conditions a rapid
start bed may be hooked directly to utility-provided power without the need for
conditioning. Choke powered equipment is different. While in most cases
these beds and booths may be directly connected to a single phase service,
the addition of a small "buck/boost" transformer is necessary for 120/208V
service connections. This assures reliable lamp starting and optimal lamp
performance. The "size" of this transformer may be anywhere from .25KVA to
1.0KVA (depending upon the KVA requirement of the bed) and acquisition cost
is from $69.00 to $212.00 (source of price data is Grainger catalog).
Rapid Start Magnetic Effects of Humidity and/or Dirt on Lamp Operation.
One of the critical elements of R/S operation is that the lamp must be "excited"
by means of external voltage which causes ionization of the lamp’s internal
gases. This external "excitation" is created by the potential that exists between
the lamp and a continuous ground that must run the entire length of the lamp.
The rapid start lamp itself must be coated with a clear (non-wetting) silicon
material. This is done to counteract the adverse effect that humidity has on R/S
lamp starting. Under high humidity conditions, lamps on R/S circuits may start
slowly or not at all. This is usually due to dirt on the lamps that is offsetting the
desired effect of the silicon coating. Unfortunately, tanning lamps have some
very rigorous cooling requirements, and movement or circulation of air is the
only practical method to accomplish this. With air circulation comes many
forms of air-borne contaminants, many of which are deposited on the surface
of the lamps. This dirt is particularly unfriendly to R/S systems. To complicate
the matter, many common "cleaners" will also strip the silicon coating from the
lamp, making it impossible to start the lamp at all. The preheat system is
virtually immune to these problems.
Preheat Choke Total Cost of Equipment
Most equipment manufacturers will quickly admit to moderately higher labor
costs when building a piece of equipment using preheat choke ballasts and
related components versus rapid start magnetic. These higher labor costs are
readily accepted because of the huge material savings that are realized. The
net result is that the preheat choke equipment will always have a total
manufacturing cost that is less than its rapid start magnetic counterpart. The
worldwide business for products and services thrives on the fact that
consumers are ready and willing to pay premiums for features or
enhancements that offer benefits such as: improved performance, lower cost
of ownership, ease of use, durability, etc. In the case of preheat choke vs. rapid
start magnetics, there are no features and benefits to offset the higher costs of
the rapid start system. In simple terms, these higher costs are unnecessary.
Higher manufacturing costs inevitably translate directly to higher consumer
prices. Ultimately, it is the lower cost of preheat choke systems, and the better
consumer value, that explain the dominant use of this system.
Preheat choke lamp Output (using Standard Components).
In today’s market, "Lamp Output" is probably the most important factor for
those purchasing new equipment. Which of the two competing systems
normally, readily, easily and inexpensively optimizes lamp output? In order to
make this comparison, we tested commonly available, off-the-shelf
components used in the every day production of tanning equipment. In all
comparisons, the exact same lamp was used to eliminate error caused by
normal lamp-to-lamp variations. In all cases, multiple measurements were
taken and averages used so that conclusions are not reached from a single
test. Other conditions such as ambient temperature and warm-up time were
consistent from test to test. Lamp irradiance was measured using an IL
1700UV meter. Tests were conducted and reported by Szekely Engineering
and are available on request.
Preheat Choke Energy Efficiency.
Today’s energy costs require that we also consider ballast efficiency. Both
systems take A/C input and convert it to UV output and heat. The most efficient
system will maximize UV and minimize heat. Excess heat is not only wasteful
in itself, but must be disposed of by the equipment maker and salon owner via
increased cooling capacity. At the same time we conducted output
measurements, we monitored and recorded energy consumption. The choke
system is inherently more efficient, due in great part to the wasteful cathode
heat energy that remains following lamp ignition on the rapid start system.
Preheat Choke Modification of Components.
The ability to modify or enhance lamp output when using the Preheat Choke
System is unsurpassed. Design adjustments to the wattage of a choke ballast
are quickly and easily made and carry small (if any) cost premiums. Small,
inexpensive buck/boost trans-formers on the service feed may be used to
correct (up or down) input voltage to the very precise value recommended by
the equipment manufacturer. Additionally, creative circuitry and use of
capacitors may further refine lamp output so that very exact lamp irradiance
objectives are met. This degree of flexibility and precision are not practically
obtainable with the R/S system.