Christie CP2420-Xe User manual

Service Guide
020-103566-02
CP2420-Xe and CP4420-Xe

NOTICES
COPYRIGHT AND TRADEMARKS
Copyright © 2022 Christie Digital Systems USA Inc. All rights reserved.
All brand names and product names are trademarks, registered trademarks or trade names of their respective holders.
GENERAL
Every effort has been made to ensure accuracy, however in some cases changes in the products or availability could occur which may not be reflected in this
document. Christie reserves the right to make changes to specifications at any time without notice. Performance specifications are typical, but may vary
depending on conditions beyond Christie's control such as maintenance of the product in proper working conditions. Performance specifications are based on
information available at the time of printing. Christie makes no warranty of any kind with regard to this material, including, but not limited to, implied
warranties of fitness for a particular purpose. Christie will not be liable for errors contained herein or for incidental or consequential damages in connection
with the performance or use of this material. Our centers of excellence for manufacturing in Kitchener, Ontario, Canada and in Shenzhen, China are ISO
9001:2015 Quality Management System-certified.
For the most current technical documentation and office contact information, visit http://www.christiedigital.com.
Warranty
Products are warranted under Christie’s standard limited warranty, the details of which are available at https://www.christiedigital.com/help-center/
warranties/ or by contacting your Christie dealer or Christie.
PREVENTATIVE MAINTENANCE
Preventative maintenance is an important part of the continued and proper operation of your product. Failure to perform maintenance as required, and in
accordance with the maintenance schedule specified by Christie, will void the warranty.
ENVIRONMENTAL
The product is designed and manufactured with high-quality materials and components that can be recycled and reused. This symbol means that electrical
and electronic equipment, at their end-of-life, should be disposed of separately from regular waste. Please dispose of the product appropriately and according
to local regulations. In the European Union, there are separate collection systems for used electrical and electronic products.
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Please help us to conserve the environment we live in!

Content
Introduction...................................................... 7
Product documentation................................................7
Related documentation..............................................
7
Site requirements...................................................8
Projector components.................................................8
Security roles......................................................9
Technical support................................................... 9
Service guidelines.................................................10
Ordering parts.................................................... 10
Replacing modules..................................................10
Observing original lead dressing......................................... 10
Interconnection and line drawings........................................10
Safety precautions..................................................11
General safety precautions...........................................11
Lamp safety precautions............................................12
Light intensity hazard distance........................................12
Servicing live equipment..............................................13
Service setups................................................... 15
Turning the projector on or off.......................................... 15
Adjusting offset by using an ILS .........................................15
Adjusting the left and right boresight ......................................16
Adjusting the top and bottom boresight ....................................18
Adjusting the fold mirror..............................................20
Aligning the integrator module.......................................... 20
Adjusting the lamp position with LampLOC...................................21
Adjusting the lamp position manually......................................21
Aligning the yellow notch filter (YNF)...................................... 22
Adjusting DMD convergence for CP2420-Xe.................................. 22
Adjusting DMD convergence for CP4420-Xe.................................. 25
Electronically adjusting convergence.......................................26
Activating marriage.................................................28
Maintenance and cleaning.......................................... 29
CP2420-Xe and CP4420-Xe Service Guide 3
020-103566-02 Rev. 1 (07-2022)
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Adjusting the offset.................................................29
Cooling.........................................................30
Replacing modules..................................................30
Filling the coolant reservoir............................................ 31
Replacing the light engine air filter........................................31
Replacing the radiator air filter.......................................... 32
Inspecting the ventilation............................................. 33
Inspecting the lamp.................................................33
Inspecting and cleaning the optics........................................33
Cleaning projector optics..............................................34
Tools required for cleaning optics.......................................34
Cleaning methods................................................34
Cleaning the light engine prism..........................................35
Cleaning the UV filter................................................35
Cleaning the projection lens............................................36
Cleaning the reflector................................................37
Cleaning the integrator...............................................38
Cleaning the lamp blower .............................................38
Rotating the lamp.................................................. 39
Replacing the lamp................................................. 39
Replacing the lens..................................................43
Parts and module replacement.......................................45
Service prerequisites................................................ 45
Disposing of replaced components and packaging.............................. 45
Tools required for service..............................................46
Index of parts and modules............................................46
Accessories.................................................... 48
Projector covers and feet...........................................50
Front-top cover....................................................50
High-security cover................................................. 51
Rear cover.......................................................51
Left access cover...................................................52
Lamp door.......................................................53
LVPS/LPS cover....................................................53
Communications panel cover........................................... 54
Light engine air filter cover............................................ 54
Access panel frame................................................. 55
Content
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Rear top cover.................................................... 55
Feet...........................................................57
Interlocks and switches............................................ 58
Lamp door interlock.................................................58
Exhaust duct vane switch............................................. 59
High-security interlock switch...........................................60
Main blower vane switch..............................................61
Lens mount components........................................... 63
Projection lens.................................................... 63
Lens mount......................................................63
Ventilation and cooling.............................................67
Light engine fan pack................................................67
Card cage bottom exhaust fans..........................................68
Red and green FPGA cooling blowers for CP4420-Xe.............................70
Liquid cooling module with pump module....................................70
Radiator module...................................................72
Lamp compartment................................................74
Lamp..........................................................74
Anode yoke......................................................78
Ceramic plate on the douser blade........................................78
Douser motor.....................................................79
Igniter......................................................... 80
Lamp adjuster module............................................... 82
Main AC blower....................................................83
Reflectors and heat dump............................................. 84
UV filter........................................................ 86
Electronics......................................................88
Card cage.......................................................88
AC line filter......................................................91
AC relay........................................................91
AC terminal block.................................................. 92
Lamp power supply (LPS)............................................. 92
Low voltage power supply (LVPS)........................................ 94
Optics..........................................................96
Content
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2K Light engine....................................................96
4K Light engine....................................................98
Cold mirror......................................................100
Fold mirror......................................................102
Integrator assembly................................................103
Illumination optic system (IOS).........................................104
Yellow notch filter (YNF)..............................................105
Printed circuit boards and sensors...................................107
Housekeeping board (HKBG)...........................................107
Status light board (SLB)............................................. 108
Formatter interface conversion board (FICB) for CP2420-Xe....................... 108
Light sensor board.................................................109
Content
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Introduction
This document provides technical information for assisting Christie-qualified technicians in the
servicing of the CP2420-Xe and CP4420-Xe projector.
Every effort has been made to make sure the information in this document is accurate and complete.
However, due to continuing research, all information is subject to change without notice. Christie
assumes no responsibility for omissions or inaccuracies.
The illustrations in this document are for representation only and may not depict your projector model
exactly.
Product documentation
For installation, setup, and user information, see the product documentation available on the Christie
website. Read all instructions before using or servicing this product.
To access the documentation from the Christie website:
• Go to this URL: https://bit.ly/3vxrm4Y or
https://www.christiedigital.com/products/cinema/projection/cinelife-plus-series/.
• Scan the QR code using a QR code reader app on a smartphone or tablet.
• On the product page, select the model and switch to the Downloads tab.
Related documentation
Additional information on this product is available in the following documents.
•CP2420-Xe and CP4420-Xe Product Safety Guide (P/N: 020-103564-XX)
•CP2420-Xe and CP4420-Xe Installation and Setup Guide (P/N: 020-103555-XX)
•CineLife+ User Guide (P/N: 020-103073-XX)
•CineLife+ Serial Commands Guide (P/N: 020-103075-XX)
CP2420-Xe and CP4420-Xe Service Guide 7
020-103566-02 Rev. 1 (07-2022)
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Site requirements
To safely install and operate the CP2420-Xe and CP4420-Xe, the installation location must meet these
minimum requirements.
Physical operating environment
• Ambient temperature (operating) 10 to 35°C (50 to 95°F)
• Humidity (non-condensing) 10% to 80%
• Operating altitude 0 to 3000 meters (0 to 9843 feet)
External exhaust ducting
Sufficient ventilation is required around the projector to regulate the temperature of the internal laser
module. If necessary, air intake and exhaust HVAC ducts can be installed.
The installation site must provide an airflow 450 cubic feet per minute (CFM) at 1 to 1000 meters
(3280.8 feet) elevation, and must accommodate a heat load of 4 kW.
600 CFM is required in projection rooms with ambient temperatures above 25°C (77°F) or at
elevations greater than 914.4 meters (3000 feet).
Projector components
Learn about the projector components.
N
O
B
C
A
F
DE
MJK
G
L
H
I
ID Component Description
A Projection lens A variety of lenses can be used with this cinema projector.
B Lens mount Optional motorized lens mount.
C Front top cover Provides access to internal components.
D Exhaust duct Extracts heated air from the lamp compartment.
E Vane switch Monitors the amount of airflow.
F Rear top cover Provides access to internal components.
G Back cover Provides access to internal components.
Introduction
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ID Component Description
H LED status indicators
(x2)
Provide information about the status of the projector.
I Light engine air filter
cover
Provides access to the air filter, which removes particles from the intake air
before it circulates in the front compartment to cool the main electronics.
J Communication panel
cover
Provides access to Input connections.
K LVPS/LPS access panel Provides access to the lamp power supply (LPS) connections, AC relay, and
LVPS.
L Adjustable feet (x4) Adjust the tilt of the projector.
M Security locks Prevent unauthorized access to projector components.
N Lamp door Provides access to the lamp. The lamp door must remain closed and locked for
normal operation. Lamp replacement must be performed only by qualified
technicians.
O Left access cover Provides access to the air filter.
Security roles
Only Christie authorized service technicians should perform field repair
, marriage setup, and service to
the unit.
Theater personnel should only perform diagnostic functions, such as running the projector
interrogator. After performing a procedure mandating the use of the high-security key, theater
personnel must ensure the security of the system is reestablished.
Technical support
Technical support for Christie Cinema products is available at:
•[email protected]
• [phone]
• Christie Professional Services: [phone] or [email protected]
Introduction
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Service guidelines
Review safety guidelines and information required for replacing modules.
Ordering parts
When ordering replacement parts, quote the part numbers of the items required. Quote the projector
model number, serial number, and date of manufacture, as indicated on the license label.
Not all parts are available separately. In addition, some parts stocked as inventory are available only
while the current supply lasts.
All part numbers are subject to change.
Replacing modules
To ensure you have the correct module, check the module markings and parts lists. To ensure you
replace the projector module correctly, check the relevant disassembly and replacement procedures.
Replace components with exact equivalents or Christie-approved replacement parts. Failure to do so
may result in unsafe operation.
Observing original lead dressing
Before servicing, always carefully observe the original lead dress. Take extra precautions to secure all
harnessing properly, especially in the high voltage circuitry areas. Replace any wire that appears to
have damaged insulation.
Interconnection and line drawings
The interconnect diagram illustrates the path of electrical connections between modules.
Manufacturer’s part numbers are included. Part numbers are subject to change.
Line drawings provide projector dimensions and sizes for installation.
To download the latest interconnect diagram or line drawings, visit www.christiedigital.com.
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Safety precautions
Learn about the safety precautions related to the Christie CP2420-Xe and CP4420-Xe projectors. This
projector is intended for use in a cinema environment.
General safety precautions
Read all safety and warning guidelines before installing or operating the projector.
Warning! If not avoided, the following could result in death or serious injury.
• TRIP OR FIRE HAZARD! Position all cables where they cannot contact hot surfaces, be pulled, be
tripped over, or damaged by persons walking on or objects rolling over the cables.
• This product must be installed within a restricted access location not accessible by the general
public.
• Only personnel who are trained on the precautions for the restricted access location can be
granted entry to the area.
• Install the product so users and the audience cannot enter the restricted area at eye level.
• ELECTRICAL and BURN HAZARD! Use caution when accessing internal components.
• High leakage current present when connected to IT power systems.
• FIRE AND SHOCK HAZARD! Use only the attachments, accessories, tools, and replacement parts
specified by Christie.
• FIRE HAZARD! Do not use a power cord, harness, or cable that appears damaged.
• A minimum of four people or appropriately rated lift equipment is required to safely lift, install,
or move the product.
• Do not install or operate the projector in any position that does not meet the stated product
specifications for alignment and orientation.
Caution! If not avoided, the following could result in minor or moderate injury.
• Only Christie qualified technicians are permitted to open product enclosures.
Service guidelines
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Lamp safety precautions
Read all safety and warning guidelines before installing the projector lamp.
Warning! If not avoided, the following could result in death or serious injury.
• This procedure must be performed by Christie qualified technicians.
• EXPLOSION HAZARD! Always wear manufacturer approved protective safety clothing (gloves,
jacket, face shield) whenever the lamp door is open or when handling the lamp. Any local or
federal specifications take precedence over Christie's protective clothing recommendations.
• Do not open the lamp door while the lamp is on.
• EXPLOSION HAZARD! Allow sufficient time for the lamp to cool down before powering down the
product, disconnecting it from AC, and opening the lamp door.
• EXPLOSION HAZARD! Do not stress the glass of a lamp or bare bulb in any way.
• EXPLOSION HAZARD! Lamps and bare bulbs, even when packaged, may explode if dropped or
mishandled.
• EXPLOSION HAZARD! Handle a lamp by the cathode and anode end shafts only. Do not handle
the lamp by the glass.
• EXPLOSION HAZARD! Do not over-tighten the lamp.
• Do not look directly into the lens when the light source is on. The extremely high brightness can
cause permanent eye damage.
• FIRE HAZARD! Keep hands, clothes, and all combustible material away from the concentrated
light beam of the projector.
Caution! If not avoided, the following could result in minor or moderate injury.
• Improper installation of the lamp can damage the projector.
• Incorrect lamp power supply and igniter connections can damage the product.
Light intensity hazard distance
This projector has been classified as Risk Group 3 as per the IEC 62471-5:2015 standard due to
possible hazardous optical and thermal radiation being emitted.
Warning! If not avoided, the following could result in serious injury.
• PERMANENT/TEMPORARY BLINDNESS HAZARD! No direct exposure to the beam must be
permitted.
• PERMANENT/TEMPORARY BLINDNESS HAZARD! Operators must control access to the beam
within the hazard distance or install the product at the height that prevents exposure of
spectators' eyes within the hazard distance. The hazard zone must be no lower than 2.5 meters
(US installations) or 2.0 meters (global installations) above any surface upon which any persons
are permitted to stand and the horizontal clearance to the hazard zone must be a minimum 1.0
meters.
• EXTREME BRIGHTNESS! Do not place reflective objects in the product light path.
The following show the zones for ocular and skin hazard distances.
Service guidelines
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• A—Hazard zone. The region of space where the projection light from the projector is above
emission limits for Risk Group 2. The light intensity may cause eye damage after a momentary
or brief exposure (before a person can avert his or her eyes away from the light source). The
light may cause skin burns to occur.
• B—Hazard distance. Operators must control access to the beam within the hazard distance or
install the product preventing potential exposure of the spectators' eyes from being in the
hazard distance.
• C—No access zone. Horizontal clearance of the no access zone must be a minimum of 1.0
meters.
• D—Vertical distance to hazard zone. The hazard zone must be no lower than 2.5 meters (US
installations) or 2.0 meters (global installations) above any surface upon which any persons
are permitted to stand.
If the vertical distance to hazard zone requirement (Zone D) is satisfied, the horizontal
clearance distance (Zone C) is not needed.
• E—Represents the top view of the projector.
• F—Represents the side view of the projector.
For information detailing the hazard distance for each lens, refer to the CP2420-Xe and CP4420-Xe
Installation and Setup Guide (P/N: 020-103555-XX).
Servicing live equipment
Only Christie accredited technicians who are knowledgeable about the hazards associated with
hazardous voltage and high temperatures are authorized to assemble, install, and service Christie
equipment.
To make sure you remain safe when servicing energized (live) Christie equipment:
• Locate the main AC power shut off prior to servicing the equipment. This will allow you to turn
the power off quickly in an emergency.
• Disconnect the projector from the communication and management network so it cannot
receive commands to turn the light source on, open the shutter, and move the lens.
Service guidelines
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• Familiarize yourself with all potential safety hazards prior to servicing the equipment. This
includes, but is not limited to, the location and accessibility of hazardous voltages.
• Read and understand all written procedures prior to commencing a service procedure.
• Understand and follow all local safety codes and requirements when servicing energized (live)
equipment.
• Perform equipment service in a location free of obstructions and other hazards. For example,
you must have an unobstructed view of the area being serviced.
Wear personal protective equipment (PPE) clothing appropriate to the service you are performing. This
includes, but is not limited to, protective (electrically insulated) footwear, safety glasses, and gloves
rated for the working voltage of the equipment you are servicing.
Service guidelines
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Service setups
Understand the special internal hardware and software adjustments and related details that may
require the attention of a qualified service technician, whether done periodically or after a specific
module replacement.
Optical adjustments are not considered maintenance. The lamps are turned on during optical
adjustments and UV emissions are present.
Turning the projector on or off
Turn on the projector to display content or turn off the projector to conserve energy or service the
projector.
To operate the projector, the circuit breakers must be in the ON position. If servicing the projector or
removing the protective covers, ensure the MAIN and UPS circuit breakers are in the OFF position.
In the right toolbar, select and hold Power.
If the light source is on when turning off the projector, the light source automatically enters a
ten-minute cool-down period.
Adjusting offset by using an ILS
Learn how to adjust the offset by using an ILS (Intelligent Lens System).
Always adjust the offset before adjusting boresight.
As boresight is adjusted, the lens offset may require additional minor adjustments.
1. Project an image with the primary lens.
2. Ensure lens calibration is completed before creating the ILS file.
3. Select Test Patterns and select a framing test pattern.
4. In the left navigation menu, select Image Settings > ILS File Setup.
5. Select the directional arrows in the Offset area.
For best optical performance, make sure to minimize keystone error by using the offset more
than aiming to center the image in an off-axis installation. Avoid extreme tilts or offsets.
Corner vignettes on a white test pattern indicates extreme offset that should be corrected by
using mechanical alignment.
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Adjusting the left and right boresight
Learn how to adjust the left and right boresight.
Warning! If not avoided, the following could result in death or serious injury.
• This procedure must be performed by Christie qualified technicians.
Caution! If not avoided, the following could result in minor or moderate injury.
• Do not look directly into the lens when the light source is on. The extremely high brightness can
cause permanent eye damage.
When performing boresight adjustments, the goal is to balance the tilt of the lens mount to
compensate for screen-to-projector tilt but also to precisely maintain the original factory settings of
the lens mount axial position.
1. Loosen the lock screws highlighted in the image below.
2. Extend the lens focus completely.
3. Adjust the Focus using the focus knob to retract the lens.
Watch the image at the left edge of the screen until it comes into focus. If the entire screen is
in focus, proceed to step 7.
Service setups
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4. Continue retracting the lens.
a) If the right edge of the image comes into focus before the lens is completely retracted,
adjust the horizontal boresight screw to direct or aim the lens mount towards the left of
the screen to balance out the left and right edges.
b) If the left edge of the image is not in focus, adjust the horizontal boresight screw to direct
or aim the lens mount toward the right side of the screen.
Service setups
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5. When both sides appear equally blurry, adjust the horizontal or vertical offset to re-center the
image.
6. Repeat steps 1 to 5 until both sides of the image are focused.
7. Tighten the horizontal hold screw to maintain the adjustments.
8. Check the boresight again.
Adjusting the top and bottom boresight
Learn how to adjust the top and bottom boresight.
Warning! If not avoided, the following could result in death or serious injury.
• This procedure must be performed by Christie qualified technicians.
Caution! If not avoided, the following could result in minor or moderate injury.
• Do not look directly into the lens when the light source is on. The extremely high brightness can
cause permanent eye damage.
1. Focus the image at the top edge of the screen.
2. Loosen the lock screws highlighted in the image below.
3. Extend the lens focus completely.
4. Adjust the focus knob to retract the lens.
Watch the image at the top edge of the screen until it comes into focus. If the entire screen is
in focus, proceed to step 8.
Service setups
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5. Continue retracting the lens.
a) If the bottom edge of the image comes into focus before the lens is completely retracted,
adjust the vertical boresight screw to direct or aim the lens mount up towards the top of
the screen to balance out the top and bottom edges.
b) If the top edge of the image is not in focus, adjust the vertical boresight screw to direct or
aim the lens mount toward the bottom of the screen.
Service setups
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6. When both sides appear equally blurry, adjust the horizontal and/or vertical offset to re-center
the image on the screen.
7. Repeat Steps 2 to 5 until the top and bottom of the screen are both focused.
8. Re-focus the center of the image.
The image should be focused at the center and on all sides.
9. Tighten the vertical hold screw to maintain the adjustments.
10. Check the boresight again.
Adjusting the fold mirror
When properly aligned, the fold mirror directs light from the integrator fully and precisely onto the
DMD pixels. If a corner or edge of an image is missing, the fold mirror might be misaligned with the
optical system.
After moving or replacing the fold mirror, check for consistent light over-spill around the perimeter of a
full white or black field—if the shadows vary or disappear completely along any edge or corner, the
fold mirror is cropping light from the DMDs and must be realigned. When corrected, the shadows cast
by the integrator edges form an even perimeter around the full active display area without interfering
with the image and all of the image is displayed.
1. To raise or lower the image, adjust the screw closest to the right side on the base of the
projector.
2. To move the image left or right, adjust the screw farthest from the right side.
Aligning the integrator module
The integrator module is located early in the light path, between the UV filter and cold mirror.
The main component of the integrator module, the internal solid silica pipe, efficiently converts the
initial round light beam supplied from the lamp into a uniform rectangle that passes through the
remainder of the optical system and eventually illuminates the three DMDs at the opposite end of the
light path. Therefore, when the integrator module is moved or replaced, its end-to-end position and its
rotation must be correct for proper focus and full illumination of the three DMDs.
Service setups
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