There are 4 major parts to an illuminator module.
1.)First is the fan, which has a speed control system including 3 speed sensors and a microprocessor. This is to minimize thermal shocking of the bulb due to fan speed variations caused by voltage fluctuations, which in the US are +6% -10%.
This is enough to thermal shock the bulb and shorten its life.
The fan system wears out at a similar point to the bulb.
2.) Second is the circuit board which contains several other components which have finite lives, and
3.) Third is the reflector. This needs to be made of solid aluminum for heat transfer reasons as well as reflectivity. This reflector cannot be coated due to the extreme heat produced by the bulb. Without coating, the reflector starts to lose reflectivity over time.
4.) Lastly is the bulb. It is set into the reflector here at Syris using ceramic material and it is located within .001" of the optimum position within the reflector in order to avoid dark spots in the illumination. With the ceramic, this bulb is non-removable.
The normal life of the type of bulb we use is 40-100 hours. Through careful engineering, we stretch this to 400-525 hours, resulting in a cost of operation of $.86 - $1.07per hour.