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Author Topic: Xenon Bulbs Exploding after about 1200 Hours Michael Gonzalez Jedi Master Film Handler Posts: 790 From: Grand Island , NE USA Registered: Sep 2000 posted 09-05-2003 11:33 AM                     Slightly off topic but I just received in 3 Xennon bulbs and one of them exploded inside the box in shipping. The interesting thing is that there is glass falling out of the sides of the unopened box (the bulb box not the shipping box)even though the bulbs are suppose to be in a plastic case to prevent this from happening. Even though I am really curious about it, I am smart enough to leave the box unopened so that they will KNOW that we got it in that condition.  |  IP: Logged Jeff Klump Film Handler Posts: 22 From: Austin, Texas, USA Registered: Aug 2003 posted 09-05-2003 04:40 PM                    We must be lucky to be receiving Christie and Osram bulbs because none of ours have ever been dead on delivery. 3 of our 16 lamphouses have damages from explosions after only about 800 hrs. One of which blew after only 250. All three were 4000w ORC bulbs. Ever since I've been a Osram/Christie fan.  |  IP: Logged John Pytlak Film God Posts: 9987 From: Rochester, NY 14650-1922 Registered: Jan 2000 posted 09-06-2003 06:09 AM                        quote: The weird thing is that the positive (anode?) end of the dead lamp almost looked burned--not melted. Not sure if this happened as a result of the explosion or if it caused it. There wasn't any visible damage or charring to other parts of the bulb, and all connections appeared to be tight. If the connection look "burned" or discolored, it's likely that a poor connection caused some localized heating, leading to the failure of the lamp.  |  IP: Logged Chris Hipp Phenomenal Film Handler Posts: 1462 From: Mesquite, Tx (east of Dallas) Registered: Jul 2003 posted 09-06-2003 03:05 PM                     Have you guys ever seen the way the Fed ex guys handle the Xenon bulbs? I don't think they have any idea what they are. As far as Osram, Usually Osram bulbs are great for a very long time, but lately I've been having problems with them. Two bulb explosions at low hours and a seal failure all in the past 6 months. Some other theatres nearby have been having the same problems with them. However, I still prefer Osram.  |  IP: Logged John Walsh Film God Posts: 2490 From: Connecticut, USA, Earth, Milky Way Registered: Oct 1999 posted 09-06-2003 03:53 PM                     The old Cinemation had photocells to detect if the lamp was on.  |  IP: Logged Travis Hubrig Expert Film Handler Posts: 175 From: Minot ND, USA Registered: May 2003 posted 09-06-2003 08:46 PM                     Scott, It seems that you are getting your money's worth out of your bulbs... What is the warranty life of those bulbs? One major mistake that I have made in the past is not tightening the bulbs good enough. After the intial installation the bulb should be checked again for tightness within the first few days. Burnt or discolored ends on the bulb is an indicator that maybe there is a loose connection... I went through three bulbs until I discovered that I had a bad positive DC cable to my bulb.  |  IP: Logged Paul G. Thompson The Weenie Man Posts: 4718 From: Mount Vernon WA USA Registered: Nov 2000 posted 09-07-2003 02:01 PM                     Are you overdriving the lamps?  |  IP: Logged Leo Enticknap Film God Posts: 7474 From: Loma Linda, CA Registered: Jul 2000 posted 09-08-2003 01:49 AM                        quote: The Soviets sold a lamp that would often explode prematurely. So that's how they're getting rid of all those unused SS-20s...  |  IP: Logged Ben Stephenson Film Handler Posts: 29 From: Manchester, England Registered: Jan 2001 posted 09-17-2003 08:01 PM                    Osram have just asked for all there 5K Xenons back in the UK, They are very quick to explode after very few hours. Just have a batch of 4K Osram Xenons that fail to strike, Good Job ......  |  IP: Logged Dennis M Dow Jr Expert Film Handler Posts: 141 From: Bloomfield NJ USA Registered: Oct 2003 posted 10-25-2003 08:59 PM                       We have been very lucky with our osrams... only one explosion (new bulb first showing) in 5 yrs of operation....  |  IP: Logged Jean-Michel Grin Expert Film Handler Posts: 222 From: Geneva & Lausanne, Switzerland Registered: Jul 2002 posted 10-25-2003 09:11 PM                        One day, a customer asked to the aprentice projectionist: Your picture is verry dark, do something ! An then the projectionist raised up the currrent at the rectifier... And of course the xenon lamp exploded  |  IP: Logged Michael Schaffer "Where is the Boardwalk Hotel?" Posts: 4143 From: Boston, MA Registered: Apr 2002 posted 10-25-2003 10:03 PM                        That leads me to a different but related questions: which face shield/mask really protects you from a xenon explosion? I never had a lamp blow up on me outside the projector, and I would tend to think that a sturdy plastic shield should be enough to protect you from a cold explosion, but...  |  IP: Logged Randy Stankey Film God Posts: 6539 From: Erie, Pennsylvania Registered: Jun 99 posted 10-25-2003 10:38 PM                     I have done a few science experiments in this department. I have dropped them from a second story balcony onto concrete. I have chucked them into dumpsters. I have shot them with a .22 cal. rifle. They shatter pretty nicely. They give a good loud, "POP!" sound when they break. Chunks of glass up to a couple-three inches in diameter will fly as far as 10 to 20 feet. Shards of glass ranging from a milimeter to several centimeters in size fly in all directions. Anything within 10 feet of the exploding lamp will definately suffer damage. I'd estimate the "kill zone" to be a good 20 to 25 feet in diameter. Glass particles can also ricochet off objects. If exploded inside the thin cardboard boxes like the Osrams come in (without the "clam shell" in place) some of the larger pieces may penetrate the box. If exploded in the same manner in a heavier box like the Christies come in pieces of glass may pierce the inner layer of the corrigated cardboard but none will penetrate. Obviously, a heavy leather welders apron and gloves should be worn when working with xenon lamps but I would also advise a good pair of safety goggles be worn underneath the face shield. No glass particles will penetrate the Lexan® face shield but, because of the possibility of ricocheting glass, some of the particles may get under the bottom of the shield and into your face. Hey, if you get a cut on your face from a riccochet it's no big deal. Cuts heal. You might end up with a scar on your face but when people ask you where you got the scar you can impress them by saying, "Oh, I got it in an explosion..." Not so with your eyes! A projectionist who can't see can't keep the picture in focus, can he? To be injured for life and permanently out of work is a really bad thing! Just wear the goggles, dammitt! I would say that goggles and gloves are manditory but you can save some money on the rest of the gear if you have a big, thick, heavy coat. Something like a Carhartt® coat should be sufficient. If you have an old, retired hunting jacket you could hang it up on a hook somewhere in your booth. Not only could you use it for lamp changing duty, you have something on hand to wear if you need to go outside in cold weather. The goggles, shield and gloves are still mandatory!  |  IP: Logged Gordon McLeod Film God Posts: 9532 From: Toronto Ontario Canada Registered: Jun 99 posted 10-26-2003 09:21 AM                     Often the anode in particular will oxidise after an explosion as it is red hot and look burnt  |  IP: Logged John Pytlak Film God Posts: 9987 From: Rochester, NY 14650-1922 Registered: Jan 2000 posted 10-27-2003 11:30 AM                        Randy's suggestion of using "double protection" of both safety goggles and a full face shield is a good one. Your eyes are irreplaceable, and the flying quartz shards from an exploding lamp are unpredictable, and could get around just a face shield. Protect your hands and wrists too, as well as your torso and neck.  |  IP: Logged

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