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We have 16 Mighty Scan fixtures that use 250 Watt MR-16 bulbs. We are loosing bulbs and bulb sockets are having issue ( wires are disconnecting or burning out )

I think it could be a cooling issue. One of the ideas I have is to upgrade to 80mm fans on the fixtures to something that is much higher RPM. Does anyone know what the stock Fans move in CFM? I have found some 80mm fans that run at 5000 RPM, but they are a little loud. Of course during club hours much is pretty loud so it wouldn't be an issue, but 20 of these might add up.

Also I noticed all our fans are configured to blow the hot air out instead of blowing cool air in. I would think it would be better to blow hot air in. What is everyone's opinion?
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Well, different brands of fans have different CFM ratings and db ratings. There are sleeve bearing and ball bearing. Depends who you talk to what is better. I've had both last a long time and fail, so I buy what's on sale. But at 200 fans, you're probably looking at $200 or so, give or take 10-12%.

SOMETIMES the fan state their CFM, but not always, so you might want to call tech support on this one. You might also need to change to the correct terminations, which may or may not be cheap. It won't be super costly, that's for sure.

As far as cooling issues/heat issues, that could be a problem. You might want to find some heat insulating wrap designed for electronics and wrap it around the fan wires, which will help. I can't see that costing much.

Most fans are configured to blow hot air OUT, or rather pull air through the fixture, across the item needing cooling, and the back out. That's what most computers do. I over-fan, so I have a filter on the front, and fans pulling air IN, and then additional fans pulling hot air OUT through the back, top and bottom.

You don't want to blow air in, as that will deifnately pull in way too much dust, and a cool blast could cause the glass on the bulb to shatter and there goes another bulb!

YOu also want to ensure the fans that come with the fixtures and youre replacements are of the same power rating, but at 12v DC, I think you're not going to have problems finding matches. Check your clearances though!

ADJ does sell long life bulbs for these fixtures, but at $25 each, well, can you say "ouch" for 20 of them? That's a $500 pop right there for a fresh set.

Also, since we're talking airflow, where are these mounted? Is this a mobile application or a club application? Maybe you need more clearance around the fixtures. Maybe if it's a fixed location, adding some small fans or a large fan to move the air around might help? Mabye a set of strategically placed ceiling fans?
Theses fans are mounted about 12 feet from the ground. Its in a club, so once they are mounted they are not taken down unless for maintenance. The Club keeps things relatively cool in there. I suspect that the latest batch of Devine Lighting house bulbs run hotter than OEM bulbs. The Stock fan is 12V although I am not sure as to the CFM rating of the fan. I will call tech support to try to get that info
While you're on the phone with tech support ask about those bulbs too.

Also though, how much space ABove and AROUND the lights are there?

I know when I put my Mackie SRM450's up on a pole and close to a low ceiling, they tend to run hotter based on how they use the passive heat sink to keep the amp units cool.

Even though the club keeps things cool in general, we both know heat rises, and so maybe around the lights, it's not so cool. That would make sense, you've got a 250-watt bulb going off in there!
I called tech support and they didn't have a clue. They can't be spinning that fast as they pretty quiet. I just bought 4 Panasonic NMB-MAT 80mm fans these have Hydro-wave bearings which are supposed to last for 50K hours and be relatively quiet. They move 46.9 CFM, and spin at about 3500 RPM. Noise is 38.2 dBA. They might be a little noisy, but I think these might solve my problems.

Another issue I am having is when the fixtures have been on for a while, and get hot they pull more amps then when they were initially turned on. This is causing them to overload our circuits. Hopefully these new fans will get the job done.

I will report back when I get these installed
I know its normal for electronics to pull more amps when their temperature goes up, this is the reason I am interested in upgrading the fans. I even considered cutting a larger opening in the Mighty Scans to make room for a 120mm fan. The Stock Fans you can feel a little heat coming from the fans, but in my opinion its not enough.

We have between 5-6 fixtures per circuit. The breakers snap at 20 Amps. Our lights consist of 10 HES TrackSpots, 16 Mighty Scans, 2 Accu Spot 300s and 8 LED PARs, 3 Scorpion Lasers.

Next time I am there I will use a Kill-a-Watt meter to find out how the power consumption changes as the fixture heats up.

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