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» Film-Tech Forum ARCHIVE   » Operations   » Film Handlers' Forum   » So What Do You Do When A Bulb Explodes? (Page 1)

 
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Author Topic: So What Do You Do When A Bulb Explodes?
Dustin Mitchell
Phenomenal Film Handler

Posts: 1865
From: Mondovi, WI, USA
Registered: Mar 2000


 - posted 02-27-2002 03:19 PM      Profile for Dustin Mitchell   Email Dustin Mitchell   Send New Private Message       Edit/Delete Post 
Is the answer to simply vacum out the lamphouse and install a new bulb?

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Jeff Taylor
Jedi Master Film Handler

Posts: 601
From: Chatham, NJ/East Hampton, NY
Registered: Apr 2000


 - posted 02-27-2002 03:21 PM      Profile for Jeff Taylor   Email Jeff Taylor   Send New Private Message       Edit/Delete Post 
That kinda depends on whether it took the mirror, douser, shutter, etc with it when it departed.

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Leo Enticknap
Film God

Posts: 7474
From: Loma Linda, CA
Registered: Jul 2000


 - posted 02-27-2002 03:30 PM      Profile for Leo Enticknap   Author's Homepage   Email Leo Enticknap   Send New Private Message       Edit/Delete Post 
No.

When a fuse blows in an electrical appliance, you don't (if you've got any sense) just replace it and carry on regardless. You attempt to identify why it blew, because 9 times out of 10 the fuse blowing is a symptom of an underlying problem (the tenth time it's an innocent power surge on the incoming supply, but never rely on that being the case). Replace the fuse without finding out what caused it to blow, and at the very least you'll get the same result again, but you also run the risk that next time the damage will be more severe.

The same applies to lamps - the main difference being that blowing up lamps all the time is pretty expensive compared to fuses. I'm assuming that your lamphouse mirror is still in one piece and that the igniter unit appears to be undamaged. In this case then at the very least inspect all circuit boards, connectors &c. visually for any obvious signs of damage. If you can't identify any obvious reason why it blew (e.g. the extract fan failed, or it's done about 30,000 hours), I'd suggest calling an engineer in.

The one exploding lamp I ever had when I was a projectionist was eventually traced to a faulty ammeter - basically, it was saying 60 amps when in reality and without knowing it, we were running it at 100-110. Needless to say this was not obvious when we cleared up the wreckage from the explosion, but if we hadn't kept investigating until we got to the bottom of the matter we'd have blown up another lamp.

So my advice would be, make every effort to find out what caused the explosion.


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John Pytlak
Film God

Posts: 9987
From: Rochester, NY 14650-1922
Registered: Jan 2000


 - posted 02-27-2002 03:34 PM      Profile for John Pytlak   Author's Homepage   Email John Pytlak   Send New Private Message       Edit/Delete Post 
One thing that's often neglected after a lamp explosion is trying to determine WHY it happened. Was the cooling adequate? Were the connections good? Was the lamp being run at excessive current? Is the ammeter properly calibrated? Is there excessive current ripple? Was the lamp well beyond it's warranteed life? What was the practice for shut-down/cool-down? Keeping a well-documented maintenance log is very important to these efforts.

------------------
John P. Pytlak, Senior Technical Specialist
Worldwide Technical Services, Entertainment Imaging
Research Labs, Building 69, Room 7525A
Rochester, New York, 14650-1922 USA
Tel: 585-477-5325 Cell: 585-781-4036 Fax: 585-722-7243
E-Mail: john.pytlak@kodak.com
Web site: http://www.kodak.com/go/motion


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Dustin Mitchell
Phenomenal Film Handler

Posts: 1865
From: Mondovi, WI, USA
Registered: Mar 2000


 - posted 02-27-2002 04:17 PM      Profile for Dustin Mitchell   Email Dustin Mitchell   Send New Private Message       Edit/Delete Post 
Leo, that's what I thought. But according to our tech service, 'that's not their job' and we should just 'vacum it out and put a new bulb in.'

Course these things always happen on my day off, so the bulb's already been replace. Apparantly the mirror was intact but the douser was toast. Oh well, geuss you really don't need that anyway, right?

Sometimes I don't even know why I try.

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Pete Naples
Phenomenal Film Handler

Posts: 1565
From: Dunfermline, Scotland
Registered: Feb 2001


 - posted 02-27-2002 04:38 PM      Profile for Pete Naples   Email Pete Naples   Send New Private Message       Edit/Delete Post 
I hear all these people tell me about bulbs exploding, and you know something, in 12 or so years I have had it happen to me once, while I was installing a new lamp in a new machine. I can only assume it had been dropped in transit to site. I've always thought that lamps exploding in operation was one of those projectionists 'old wives tales'. None of my service sites have ever told me of exploding lamps either. Must make one hell of a bang if one goes hot though!

I second Leo's comment, these things do not randomly explode, besides the obvious mechanical damage to the mirror etc, there's got to be some underlying cause.

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Will Kutler
Phenomenal Film Handler

Posts: 1506
From: Tucson, AZ, USA
Registered: Feb 2001


 - posted 02-27-2002 04:49 PM      Profile for Will Kutler   Email Will Kutler   Send New Private Message       Edit/Delete Post 
Dustin,

This topic has been discussed before. Leo and John are also correct.

To add to the list:

Bulbs should be inspected for damage or defects prior to installation. Also, applying excessive torque while installing may damage the quartz (bulb manufacturers talk about this)

Another possibility could be that the lamp house door was opened prior to the required cool down time.

I only had a bulb explode on me once. This is when I was lifting a brand new Perkin Elmer out of its box, it exploded in my had and made me jump a little . Thank God I was wearing the required safety gear and the bulb still had on it's protective wrapping!

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Dustin Mitchell
Phenomenal Film Handler

Posts: 1865
From: Mondovi, WI, USA
Registered: Mar 2000


 - posted 02-27-2002 04:57 PM      Profile for Dustin Mitchell   Email Dustin Mitchell   Send New Private Message       Edit/Delete Post 
Oh, I'm fairly certain I know why the lamp blew. One of two things, or possibly a combination of both:

1) The autostrike board in this lamphouse (Strong Super Lume-X) has been non-functional for quite some time, thus necessitating the operator to always manually ignite the lamp by depressing the strike button at the top of the lamphouse. If I understand things correctly this put stress on the bulb. The parts to fix this have been sitting at the theatre for quite some time, but our service company almost never comes out on regular service calls.

2) I suspect the ampmeter was defective-as was Leo's case. It reads 60 Amps no matter how high or low the power supply is turned up. I brought it up to my tech during the last service call, but he said it was fine.

*Stalks off muttering about how no one ever listens to him*

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Paul G. Thompson
The Weenie Man

Posts: 4718
From: Mount Vernon WA USA
Registered: Nov 2000


 - posted 02-27-2002 06:24 PM      Profile for Paul G. Thompson   Email Paul G. Thompson   Send New Private Message       Edit/Delete Post 
Dustin, as far as manual ignition is concerned, it would be stressful on the lamp if whoever was pressing the button gets a little carried away on how long it is held in.

The ammeter mis-calibration has merit. I have seen some that were as far off as 15 amps.

Most service techs will not sweep out the lamphouse. Nor will they change the bulb. Reason is, if the bulb blows up, there is just too much "finger pointing" on whose fault it was.

If MTS does your service work, it is their policy NOT to change xenon bulbs. I have to side with MTS on that one. Don't get angry with your tech. He is simply following orders.


Paul


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Gordon McLeod
Film God

Posts: 9532
From: Toronto Ontario Canada
Registered: Jun 99


 - posted 02-27-2002 07:06 PM      Profile for Gordon McLeod   Email Gordon McLeod   Send New Private Message       Edit/Delete Post 
Before changeing the lamp discharge the filter capacitors in the rectifier as they probably charged up to the full boost voltage when the lamp failed and produced an open circuit

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Peter Kerchinsky
Master Film Handler

Posts: 326
From: Seattle, WA, USA
Registered: Jan 2002


 - posted 02-27-2002 09:45 PM      Profile for Peter Kerchinsky   Email Peter Kerchinsky   Send New Private Message       Edit/Delete Post 
The person with the bulb that exploded never said how many hours of what size that bulb was.
I believe he has a Super Lumex lamp which is probably good for about 2500 to 3000 hours. For us, that's pushing a horizontal Christie CXL-20R. Anything above those hours usually causes problems.
That manual strike button on top of the lamphouse should be hit "gently" and not held down for any long period. We have found that also causes problems and try to keep the lamp in top shape to prevent using it.
Usually what I do when a bulb explodes is: 1. run like hell out of the booth. That;s got to be the loudest boom I've ever heard. 2. Change my pants then proceed back into the booth. (Just kidding)
Go Mariners!

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Gordon McLeod
Film God

Posts: 9532
From: Toronto Ontario Canada
Registered: Jun 99


 - posted 02-27-2002 09:53 PM      Profile for Gordon McLeod   Email Gordon McLeod   Send New Private Message       Edit/Delete Post 
THe manual ignitor on a strong is perfectly safe on the lamp as long as one releases it as soon as it ignites the same is true for any lamphouse as the Ignition voltage is the same
I have often felt that a longer pulse that actually lights the lamp is better than a row of short ones that don't

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Paul G. Thompson
The Weenie Man

Posts: 4718
From: Mount Vernon WA USA
Registered: Nov 2000


 - posted 02-27-2002 10:19 PM      Profile for Paul G. Thompson   Email Paul G. Thompson   Send New Private Message       Edit/Delete Post 
I have to completely agree with Gordon.


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Jerry Chase
Phenomenal Film Handler

Posts: 1068
From: Margate, FL, USA
Registered: Nov 2000


 - posted 02-27-2002 10:47 PM      Profile for Jerry Chase   Author's Homepage     Send New Private Message       Edit/Delete Post 
"I have often felt that a longer pulse that actually lights the lamp is better than a row of short ones that don't"

Why?


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Paul G. Thompson
The Weenie Man

Posts: 4718
From: Mount Vernon WA USA
Registered: Nov 2000


 - posted 02-28-2002 12:18 AM      Profile for Paul G. Thompson   Email Paul G. Thompson   Send New Private Message       Edit/Delete Post 
Jerry, somewhere I heard one ignition attempt is equivalent to 3/4 of an hour running time. How true it is, I really don't know. That's what I have been told, anyway.

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