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Author Topic: Modifying Cooling on a Super Hightlight Jeremy Weigel Phenomenal Film Handler Posts: 1062 From: Edmond, OK, USA Registered: Mar 2007 posted 04-07-2007 03:07 PM                     Has anyone tried modifying the forced air lamp cooling system on a Super Highlight console? It just seems to me that the single air spout at the front of the bulb doesn't provide enough air flow over the bulb.  |  IP: Logged Mark Gulbrandsen Resident Trollmaster Posts: 16657 From: Music City Registered: Jun 99 posted 04-08-2007 09:20 AM                     You didn't say if it is a Highlite or Highlite 2, the 2 also has a front mounted blower below the schnood. If your exhaust was properly set up the normal internal cooling is usually adaquate for up to a 3kw lamp. The exhaust should be 900 plus cfm for a 2kw and 1500 plus for a 3-4 kw. These are minimum specs I reccomend. If there is very little air comming from the internal exhaust then check the small squirrel cage blower to see if the wheel vanes are clogged with dust, this happens and is common. Disnmantle an clean at least once a year, more often if you're in dusty conditions. also oil the motor while you're at it. A few drops of 30 weight non-detergent in each hole is good. Mark  |  IP: Logged Jeremy Weigel Phenomenal Film Handler Posts: 1062 From: Edmond, OK, USA Registered: Mar 2007 posted 04-08-2007 05:08 PM                     Hi Mark, Its a Super Highlight (1988). I was looking to modify the cooling to something like how Strong has them now with the whole back end of the reflector boxed in with the high velocity blower(s) to push air from back to front over the bulb. I am also looking into mounting higher velocity updraft blowers aswell.  |  IP: Logged Mark Gulbrandsen Resident Trollmaster Posts: 16657 From: Music City Registered: Jun 99 posted 04-08-2007 05:22 PM                     Could be done but it would cost$$. The more important aspect is thestack blower. That alone will increase lamp life drastically when its adaquate. Mark  |  IP: Logged Jeremy Weigel Phenomenal Film Handler Posts: 1062 From: Edmond, OK, USA Registered: Mar 2007 posted 04-08-2007 07:23 PM                     "Stack blower"? Are you refering to the updraft blower on the roof?  |  IP: Logged Mark Gulbrandsen Resident Trollmaster Posts: 16657 From: Music City Registered: Jun 99 posted 04-08-2007 08:43 PM                     Yes...  |  IP: Logged Jeremy Weigel Phenomenal Film Handler Posts: 1062 From: Edmond, OK, USA Registered: Mar 2007 posted 04-08-2007 08:46 PM                     Gotchya.  |  IP: Logged Jeremy Weigel Phenomenal Film Handler Posts: 1062 From: Edmond, OK, USA Registered: Mar 2007 posted 05-14-2007 03:31 PM                     quote: Mark Gulbrandsen The exhaust should be 900 plus cfm for a 2kw and 1500 plus for a 3-4 kw. Hey Mark, What size of air duct are you using to get 900+ cfm. My Super Hghlights (1988) have a 6" exhaust with flex transitioned to an 8" metal tube up to the mushroom blower. I had my HVAC tech take a look at the setup and he said it would very unlikely to move 900cfm (approx. 2 tons) through this size duct. He recommended transitioning from the 6" directly to to at least a 10" duct all the way up.  |  IP: Logged Gordon McLeod Film God Posts: 9532 From: Toronto Ontario Canada Registered: Jun 99 posted 05-15-2007 08:30 AM                     Every elbow foot of pipe piece of flex introduces static pressure on the system loading the fan and as such reducing total CFM It is virtualy impossible to move 900 CFm through a round 6" opening  |  IP: Logged Mark Gulbrandsen Resident Trollmaster Posts: 16657 From: Music City Registered: Jun 99 posted 05-15-2007 04:56 PM                     We always spec. in 8" or 10" duct depending on how long the run is and the lamphouse wattage. We prefer the blowers mounted inside because outside maintainance is ONLY NEEDED in the winter when its blowing 60mph. Mark  |  IP: Logged Louis Bornwasser Film God Posts: 4441 From: prospect ky usa Registered: Mar 2005 posted 05-15-2007 07:05 PM                        Yes, indeed. My theatres once had pitched roofs and outside exhausts. We learned quickly that INSIDE blowers are best. A pitched roof with 1/2 inch of ice is no thrill when you have to tie down the extension ladders that allow you up-the roof. (Note that failures occur ONLY in cold weather.) Louis  |  IP: Logged Jeremy Weigel Phenomenal Film Handler Posts: 1062 From: Edmond, OK, USA Registered: Mar 2007 posted 05-15-2007 11:36 PM                     What kind of inside blower do you use?  |  IP: Logged Mark Gulbrandsen Resident Trollmaster Posts: 16657 From: Music City Registered: Jun 99 posted 05-16-2007 07:09 AM                     Grainger 7C038 for up to 2kw... sized up with similar series blowers for up to 4kw and over that wattage the radial series bowers produce more air movement but are quite expensive. If you get just the 7C038 blower without motor Emerson makes a ball bearing motor that fits so you don't have to use the crappy Chineese bushing style motor Grainger supplies. The Chineese motor Grainger sells runs VERY hot! The Emerson makes this into a non-maintainance issue. Mark  |  IP: Logged John Walsh Film God Posts: 2490 From: Connecticut, USA, Earth, Milky Way Registered: Oct 1999 posted 05-16-2007 12:48 PM                     I was talking to an HVAC guy about xenon exhaust in a larger multiplex. He suggested that it might be better to design the system such that, say, half of the exhausts where ducted together and install a closet-sized air handler large enough. For some redundancy, half would be on one system, half on the other. When the cost of labor to frame out each hole in the roof, a buy and wire separate blowers for each projector, reduced maintaince etc. was added up, the idea did make some sense.  |  IP: Logged Richard Fowler Film God Posts: 2392 From: Ft. Lauderdale, FL, USA Registered: Jun 2001 posted 05-16-2007 01:05 PM                     I did the return air closet idea on a multiplex upgrade in an old structure. All the air handlers for the auditoriums where located on the projection floor so building extra exhaust closets for the lamphouses where cost effective. Dampers where used to balance the system and has been trouble free in the past 22 years with excellent bulb life. Every new or used Highlight we worked on where modified to eight inch prior to install. Older units with no reflector air chamber we would upgrade the wimpy muffin fan in the sheet metal support; end result better bulb life and less reflector pealing. We also had a $2.50 fix for the focus problem on the older units.  |  IP: Logged

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