CP2220/CP4220 Theory of Operation

CP2220/CP4220 Theory of Operation

• Overview
• Introduce Lamp and Lens Suites
• Install, operate and service
CP2220/CP4220 Safely
• Troubleshoot Power and Lamp technical
issues
• Troubleshoot Optics and Light Engine
technical issues
• Troubleshoot Card Cage Electronics
Technical Issues
• Operate CP2220/CP4220
Overview

Operator Side

Non-operator Side
Lamp and Lens Suites

• Introduce Lamp Suite

• Introduce Lens Suite
• Introduce Motorized Auxiliary Lens
Mount and Auxiliary Lens
• Introduce Intelligent Lens System
(ILS)
Lamp Suite
CP2220/CP4220 Lamp Suite:
• CDXL-20 P/N 003-000598-xx
(Maximum Light output ~ 10K Lumens)
• CDXL-30 P/N 003-000599-xx
(Maximum Light output ~ 18K Lumens)
• CDXL-30SD P/N 003-001165-xx
(Maximum Light output ~ 23K Lumens)
• Superior Performance (SP) lamps are now
available
• CDXL-20SP / 003-004251-01
• CDXL-30SP / 003-004252-01 Note: Install the Lamp yoke at the
appropriate position for the lamp
Lens Suite
High Brightness Lenses High Contrast Lenses
Part Number 2K 4K Part Number Description 4K
Description Description Description
108-274101-01 1.25-1.45:1 1.13-1.31:1 38-809079-51 1.25-1.45:1 1.13-1.31:1

108-342100-01 1.25-1.83:1 1.13-1.66:1 108-400105-01 1.25-1.83:1 1.13-1.66:1

108-275101-01 1.45-1.8:1 1.31-1.62:1 38-809061-51 1.45-1.8:1 1.31-1.62:1

108-335102-01 1.45-2.05:1 1.31-1.85:1 108-401106-01 1.45-2.05:1 1.31-1.85:1

108-336103-01 1.6-2.4:1 1.45-2.17:1 108-402107-01 1.6-2.4:1 1.45-2.17:1

108-276101-01 1.8-2.4:1 1.63:2.16:1 38-809052-51 1.8-2.4:1 1.63:2.16:1

108-338105-01 2.15-3.6:1 1.95-3.26:1 108-404109-01 2.15-3.6:1 1.95-3.26:1

108-277101-01 2.2-3.0:1 1.98:2.71:1 38-809053-51 2.2-3.0:1 1.98:2.71:1

108-278101-01 3.0-4.3:1 2.71-3.89:1 38-809069-51 3.0-4.3:1 2.71-3.89:1

108-279101-01 4.3-6.0:1 3.89-5.43:1 38-809081-51 4.3-6.0:1 3.89-5.43:1

108-28 0101-01 5.5-8.5:1 4.98-7.69:1 38-809080-51 5.5-8.5:1 4.98-7.69:1

Notes:
• All lenses are 4K compatible
• It is about 10% reduction in throw ratio when the lens is used on 4K unit
Auxiliary Lens
Anamorphic Lens
Anamorphic lens is available for scope presentation (1.26 X –
Horizontal direction only). P/N 38-809054-XX
Wide Conversion Lens
Wide converter lens is available (1.26 X – Horizontal and Vertical).
P/N 108-281101-XX
Motorized Auxiliary Lens Mount (MALM)
Use of the Anamorphic or Wide Converter Lens requires the MALM
adapter. P/N 108-111102-XX

Note: Auxiliary lenses and the MALM are currently NOT available
from Christie
Intelligent Lens System (ILS)
• Horizontal and Vertical shift and • ILS connector has been added to
focus knobs are replaced by three simplify field installation.
motors.
• Operator can create lens files. A
• Fourth motor is mounted on the lens file will include lens mount
lens for motorized zoom. shift values as well as zoom and
focus values. You can then add the
• Integrated Motor Control Board lens file to a channel setting.
(IMCB) is installed to control the
four motors.
Kit Motor upgrade: P/N
127-102104-xx Note:
factory built CP4220 will
have ILS as a standard
feature.

ILS Connector ILS Operation

What did you learn?
You learned :
• CP2220/CP4220 Lamp Suite
• CP2220/CP4220 Lens Suite
• Optional Intelligent lens System (ILS) is available for CP4220.
• Factory built CP4220 will have ILS as a standard feature.
• ILS kit will NOT be included in the 4K upgrade kit (Upgrade
CP2220 to CP4220)
• Optional Motorized Auxiliary Lens Mount (MALM) is available
for CP2220/CP4220
CP2220/CP4220 Safety

• Protect yourself and the projector

from UV and IR exposure
• Use Extractor Fan as per Christie’s
Specifications
• Locate four safety Interlock
Switches
UV and IR Exposure
• Xenon arc lamps emit large amounts of UV and IR energy.
• Most of the UV and IR is contained in the lamp house of the
projector by using a Cold Mirror and UV Filter. Opening the lamp
door during operation can cause high UV exposure—which can
lead to permanent eye damage.

UV Filter
UV and IR Exposure
• There are minimal amounts of UV and IR in the light engine
compartment. However, detectable levels are still present.
Looking directly into the light path can cause permanent eye
damage from the intense light output.
Note: Always wear UV goggles while servicing the projector with the lamp on.

Reflective side Non-Reflective

faces the light side

Cold Mirror
Extractor Fan
• Exhaust Duct must be connected to
extractor fan with a minimum of 450 CFM

– CFM = Speed (ft/min) * 0.35

– CFM = Speed (m/min) * 1.15
• If ambient temperature is higher than 25
CO or the site elevation is more than 3000
ft, 600 CFM will be required for proper
cooling.
• Christie recommends that at least 10” of
rigid duct is used to connect the projector
exhaust to the site exhaust system
• Projector is specified to operate at
elevation lower than 2000 m (6000 ft)
and ambient temperature between 10 CO
and 35 CO.
Safe Operation
• CP2220/CP4220 are equipped with
four safety interlock switches:
– Lamp Door
– Lamp Fan
Lamp Door
– Extractor
– Fire Alarm (normally bypassed)
Lamp Fan

• All four switches are hardwired to

the Lamp Power Supply.
• Tampering any one of the four
switches results in stopping the DC
Extractor
output from the Lamp Power Supply
(LPS) to the lamp (i.e., lamp will turn
OFF). Fire Alarm Interlock
What did you learn?
• Protect yourself and the projector from UV and IR
exposure
• Use an Extractor Fan as per Christie specifications
• The CP2220 and CP4220 are equipped with four
interlock switches…do you remember the locations?
Note: It is very important that you read the Safety Statement
supplied with the projector prior to installing, operating or
servicing the projector.
Lamp/Power Compartment
• Connect AC Power to the Projector
• Introduce CP2220/CP4220
• Troubleshoot Standby Power Reflector
Supply failures
• Troubleshoot LampLOC™
• Troubleshoot Low Voltage Power assembly failures
Supply failures
• Troubleshoot Douser Drive failures
• Troubleshoot Lamp Power Supply
• Introduce Integrated Motor
failures
Control Board (IMCB)
• Troubleshoot Igniter failures
• Disassembly/assembly of all above
• Introduce Power Modes mentioned CP2220/CP4220
components
• Introduce Emergency Button
• Troubleshoot Lamp Fan failures
AC Power
• AC wiring must be completed by a certified electrician.
• Connect Ground First.
• Regional Electrical Code must be respected.
• Projector requires 200-240 VAC – Single phase connection rated at 30 A.
Standby Power Supply
• Rated Input range 100 – 240 VAC.
• Output 24 VDC.
• Standby Power Supply outputs 24 VDC
as long as the site breaker is ON.
• With reference to the
Interconnect Diagram, we can find the Standby Power Supply
component powered by Standby
Power Supply in standby mode. Device/Board Standby
24V
TPC 
Note: The Backplane does not receive 24V Backplane – EEPROM 
in Standby. Instead, it draws 3.3VDC from PI Board – Nios™ subsection
(Emergency Power On Switch,


the regulators on the PI Board. EEPROM and Reset CPLD)

IMCBs – holding current (routed 
through EVB)
Environmental Board – EEPROM 
only
Low Voltage Power Supply (LVPS)
• LVPS provides power to the projector in
full power mode, with the exception of
the TPC, which continues to be
powered by the Standby Power Supply.
• Input voltage: 100-240 V.
• Output voltage: 12 VDC and 24 VDC.
Each board regulates the voltages
required.
Low Voltage Power Supply
• You can connect both the LVPS and
Standby Power Supply to a UPS to keep
the electronics ON during brief power
outages.
• UPS output must be more than 1000
W/100 VAC.
LVPS…continued
• Full power mode is enabled by Power ON button on the TPC. When this
button is pressed, the LVPS receives an “enable signal” from the PI Board via
the backplane.
• The 12 VDC relay turns ON to supply 220 VAC to the Lamp Power Supply and
Lamp Blower. Note: The lamp remains OFF until the Lamp ON button is pressed.
• The PI Board enables serial communication with the Lamp Power Supply and
checks the status of the safety interlocks.
• With reference to the Interconnect Diagram, we can find the component
powered by the LVPS in full power mode.
Device/Board Standby LVPS LVPS
24V 12 V 24 V
TPC 
DLP 
Backplane  
PI Board – entire board 
Environmental Board (plus Fans and  
Temp Sensors)
IMCBs (routed through EVB) 
Lamp Power Supply
• 3.3kW low-ripple switch mode
lamp power supply. It has a
custom digital interface to
communicate with the PI Board
and allows electronic control of
lamp power.
• Sanrex and Ushio LPS are being
used interchangeably.
• CP2220/CP4220 lamp power
supply is located in the
lamp/power compartment.
• AC Input to the LPS is controlled
by the 12 VDC relay. I.e. LPS is OFF
in standby mode
Igniter
• An off-the-shelf Sanrex DC Xenon lamp igniter is located in the lamp
compartment.
• It connects in line with the lamp and Lamp Power Supply to provide ignition
power to the lamp.
• Sanrex igniter is compatible with both Sanrex and Ushio LPS.
What is the function of the igniter?

Ignite
r
Power Modes
• LVPS enables 12VDC relay when power is ON.
• AC power will be supplied to the Lamp Power Supply and AC Lamp Blower.
• Please refer to Interconnect Diagram.

Warm
Up

Lamp On

Lamp On
Warm
Up

Power On
Lamp On*
Power Off
Breaker Standby Full Power Lamp On
Power On Mode Mode Mode

Lamp Off
Cool
Down
Power
Power
On**
Off** Power
Off

Cool
Down
Legend
* Immediate Hot-strike of lamp Lamp On*

** Serial command only – not exposed in GUI

Power Modes…continued
Optional UPS
(100 VAC to 240 VAC)
Stdby PS TPC

LVPS BP

PIB EVB
IMCB Optional IMCB
Lamp LOC ILS

Relay
IMB & DLP
Electronics Lamp LEGEND
24 VDC
AC Blower LVPS enable
12 VDC
24 VDC
Site Panel Breaker
1-Ø 200 VAC
LPS Igniter 1-Ø200 VAC
High Current DC
cables
Emergency Start
• You cannot turn the Projector ON if the TPC fails.
• Emergency Start button on the PI Board provides limited projector
functionality.
• Usage of Emergency Start is logged on the PI Board.
Emergency
• When pressed: Start

– Power ON (PIB will strike the lamp at the last known power, Please
DO NOT replace the lamp then strike it using Emergency Start
especially when the new lamp power is different from the old one
– Lamp ON and Douser open
– Last functional channel is active
• When pressed and held (works even when the TPC is functional):
– Lamp OFF
– Douser closed
The following functions are unavailable in Emergency Start mode:
• Automation
• Lamp Power Change
• LiteLOC™ and ILS
Lamp Fan
• 220 VAC Blower
• Located right behind the lamp.
• Air flow to cool down the lamp and
the reflector.

Lamp fan (close up)

Lamp fan

Lamp Fan: side view

Reflector
• Glass honed.
• Reflector shield absorbs IR. Air flow between the shield and the reflector
cools the shield down.
• Spherical and elliptical sections to maximize light efficiency.
• Cast reflector mount.
• 11” Diameter

• UV filter is used to reduce the

amount of UV light in the light
engine compartment.
• The Reflector Mount has
notch for serviceability
improvements.
Lamp LOC™
• The lamp adjuster mounts the cathode
end of the lamp within the air duct and
allows it to be adjusted in 3 axis.
• Optimize the lamp position relative to the
reflector. All adjustments are motorized
using linear drive stepper motors
controlled by the Integrated Motor
Control Board (IMCB), which is mounted
in the proximity of the mechanism.
• The system measures the light
intensity in the light engine
compartment using a light sensor.
• The Light Sensor is connected to the
LampLOC’s IMCB.
Douser
• Douser Drive Motor is controlled by the LampLOC™ Integrated
Motor Control Board (IMCB).
• The projector will automatically reduce the Lamp Power to the
minimum if the douser is closed while the lamp is ON.

Douser Douser Drive Motor

Integrated Motor Control Board (IMCB)
• IMCB controls the douser drive motor as well as X, Y and Z axis
Lamp LOC motors.
• IMCB is a smart board running on its own microprocessor and
software. It requires only a trigger signal from the PI Board.
• Intelligent lens System uses the same IMCB to control Zoom,
Focus, Horizontal and Vertical shifts.

Integrated Motor Control Board (IMCB)

Disassembly/Assembly
1. Remove the lamp.
2. Locate CP2220 / CP4220 Lamp
compartment components.
3. Remove LVPS/Standby Power Supply.
4. Identify UPS power routing/AC power
route.
5. Remove lamp power supply/igniter
(don’t forget to remove the lens first).
6. Remove Lamp Fan/Yoke/Reflector.
7. Remove Lamp Loc assembly.
Notes:
8. Locate the LEDs blind connector. The arrow on the side of the UV filter points
towards the light source.
Refer to the Service Manual for detailed disass
embly /assembly instructions
What did you learn?
• To troubleshoot technical issues connected with
– AC Power connections
– Standby Power Supply
– Low Voltage Power Supply
– Lamp Power
– Lamp Fan
– Reflector
– LampLOC™ assembly
– Douser
– Integrated Motor Control Board (IMCB)
• Use Emergency Start Button to start a show even though the TPC has failed
• Disassemble/Assemble all these components
Optics and Light Engine

• Introduce and Adjust Illumination

Optics System (IOS™)
• Troubleshoot Light Engine Failures
• Maintain Liquid Cooling System
• Introduce Environmental Board
• Emphasize Light Engine Serviceability
• Disassembly/Assembly of all the
components listed
IOS Theory of Operation

• Overview
• Adjust Integrator Rod
• Introduce IOS Lenses
• Install Cold Mirror
• Adjust Fold Mirror
• Introduce Yellow Notch Filter
Overview
• IOS shapes, sizes and focuses the light on the DMD.

Note: CP2220 and CP4220 are using two different Integrator Rods because of the
different geometry of the DMDs.
Integrator Rod
How it works: The reflector projects the lamp’s light onto an integrator, which
homogenizes and shapes the light beam that falls on the DMDs to ensure
uniform illumination and minimal waste.

Note: CP2220 and CP4220 use a different Integrator Rod

Integrator Rod
• Internal silica rod distributes the
slightly irregular intensity of the light ent
n m
beam equally across a rectangular i g
Al Silver end
field, then passes this light to the first towards lamp

lens in the IOS.

• A special coated entrance aperture on
the integrator reflects maximized light F
collection while reducing o
temperature. c
u
• The Integrator rod has two s
adjustments:
– Horizontal movement (focus)
– Rotational movement (alignment)
Lens
• Integrator Rod aperture size is different from the DMD size.
• Light may diverge and dim by the time it hits the DMDs.
• 5 lens are used in conjunction to relay
the light to end up at the specified size
& focus to slightly overspill the active
DMD area.
• Each lens has its own f#’s (focal
distance).
• The Image at the end of the integrator
is what is focused onto the DMDs by
these lenses. That is why any dust or Close up of lens
damage to the exit aperture shows up
in the final focused image on-screen.
Lens…continued
Lens system includes:
• Lens 1
• Vignetting Aperture
• f/# (focal distance) Aperture. An optional aperture package is
available.
Note: Different sizes (smaller than the standard aperture) may be
used to improve contrast but a smaller aperture will decrease
brightness.

• Lens 2 to 4
• Lens 5 (angles incoming light path on to the DMDs)
Lens…continued
• In rare cases, adjustment to
the Lens 5 position may be
required to slightly change
the angle at which the light
strikes the DMDs (possibly
gaining a small improvement
in brightness while forfeiting
some contrast).
• Adjacent to the lens opening,
turn the slider lens Note: This adjustment is made at the factory.
adjustment screw as desired This slide is provided for informational purpose
only.
for the current installation.
Cold Mirror
Dichroic filter called a Cold Mirror, reflects visible wavelengths of
light while transmitting light. Thereby rejecting infrared and UV
wavelengths.
Note: We cannot see infrared light but we feel it as heat.
Fold Mirror
• Located on the bottom side of the IOS.
• Directs light from the integrator fully and precisely onto the DMD
pixels.
• After moving or replacing the Fold Mirror, check for consistent light
over-spill around the perimeter of a full white or black field.
Yellow Notch Filter (YNF)
• Xenon lamp light output is close to
the natural light.
• Adding a yellow notch filter makes
the light output closer to the
natural light.
• The end result is wider color gamut.

G’

G Y

R’
R

B
YNF…continued
• The angle at which light passes through the yellow notch filter affects
the final color of light reaching the light engine, which in turn affects
color accuracy in projected images.
• Precise green color coordinates
that are crucial for producing
accurate colors on the final
display can be obtained by
carefully adjusting the yellow
notch filter angle
• Adjust the yellow notch filter
whenever it is moved or
replaced, or when a new
Illumination Optics System (IOS) Note: This adjustment is made at
is installed. the factory. This slide is provided
for informational purpose only.
What did you learn?

You learned to:

• Adjust the Integrator Rod
• See how the IOS lenses function
• Install a Cold Mirror correctly
• Adjust a Fold Mirror
• See how the Yellow Notch Filter functions
Light Engine Theory of Operation

• Overview
• Introduce Prism theory of operation
• Introduce Digital Micromirror Devices™
(DMDs) theory of operation
• Introduce Satellite Formatter Boards
theory of operation
• Introduce Light Engine Quick
Disconnect Board (LEQD Board)
• Introduce Laminar Airflow Device (LAD)
System Overview
Light Engine Module
• This is the heart of the imaging system
and contains the color
splitting/combining 6-element prism and
the 3 DC2K DLP CinemaTM DMDs
(CP2220) or 3 DC4K DLP CinemaTM DMDs
(CP4220).
4K Light Engine
• The mechanical panel mounting system
is a fly-in-place system with fine
adjustment for near perfect mechanical
convergence.
• This assembly includes three Satellite
Formatter boards. There are two
designs: Red/Green and Blue made by
Christie from DLP reference designs. 2K Light Engine
Prism

TIR Prism

Green DMD

Xenon lamp source after

integrating rod
Prism…continued
• 6 Element Total Internal Reflection (TIR) prism.
• Dichroic coatings in the prism split incoming white light into its red,
green and blue color components.
• Light can either be reflected to
the next prism (the color
splitting prism) or transmitted
through the projection lens,
depending on the light’s angle
of incidence.
• When light enters the TIR prism
via the IOS, the angle of
TIR Prism
incidence ensures that all light
is reflected and sent to the
color splitting prism.
Digital Micromirror Device (DMD)
• A digital projector based on DLP
Cinema® technology transfers the
digitized image file onto three
optical semiconductors known as
Digital Micromirror Devices or
DMDs.
• Each chip is dedicated to one
primary color: red, green, or blue.
• Native resolution – 2048 x 1080 /
4096x2160.
• Native aspect ratio – 1.89.
• 1024 Shades of gray per DMD.
Digital Micromirror Device (DMD)
• Each mirror is mounted on a hinge hidden underneath,
allowing it to flip to either side at a 90 degree angle.
• DMDs are true digital devices since each mirror only has
two possible states while operating. Either tilted 10 or 12
degrees perpendicular in one direction (ON) or tilted the
same degree in the opposite direction (OFF).
• Reflected light will be absorbed by a black sheet of metal
called the light dump.
Satellite Formatter Boards
• Each of the three DMDs are mounted with physical and direct electrical contacts to a
Satellite Formatter Board.
• Generates the bias control voltage for each of the tiny micromirrors based on the
image information provided from the Integrated Cinema Processor Board (ICP).
• The direct electrical connection is required to guarantee no signal loss and to
accommodate the high frame rates used in 3D imagery.
• Each Satellite Formatter Board has its own processing engine and firmware.

Notes:
• All three boards use the same
version of TI main release package.
(Firmware is actually stored on the
ICP and loads on the Satellite
Formatter Board at Power-up)

• 2K Satellite Formatter Boards (SFBs)

are different from 4K SFBs
Light Engine Quick Disconnect Board (LEQD)
• Light Engine Quick Disconnect Board (LEQD) is used to
provide a quick disconnect method for flat cables (signal
and power) to the Light Engine from the backplane.
• LEQD is inserted in the backplane.

LEQD
Board
LEQD Board…continued
To isolate the optical issues from the electronics issues:
1. Change Image Orientation
2. Memorize the additive colour system

Additive Colors
Laminar Air Flow Device (LAD)
• Consists of a small fan and filter mounted in a plastic frame and secured
to the Light Engine Handle.
• Contains an approximate 1”x1” HEPA like filter that filters air blowing
over the 3 DMDs. This prevents dust and some small debris from
settling on the DMD glass cover or the prism.
• LAD system cools the surface of the DMDs
What did you learn?
• You learned the theory of operation of the:
– Prism
– Digital Micromirror Devices (DMDs)
– Satellite Formatter Boards
– Light Engine Quick Disconnect (LEQD Board)
– Laminar Airflow Device (LAD)
• Replace LAD Filter
Liquid Cooling System
• The Liquid Cooling System consists of a gold-
plated copper heat exchanger block bolted to
Liquid Coolant Reservoir
each DMD and daisy chained via UV resistant
PVC tubing as part of the Light Engine (LE)
assembly.
• Dripless, quick disconnects are used for
serviceability improvements (easier removal of
Light Engine).
• Pump and Heat Exchanger are located at the
Non-operator side.
Liquid Coolant tubes

• The Liquid Cooling pump is connected to the Note: Use only Jeff Cool P/N 000-100813-
Environmental Board (EVB). 01 to fill the liquid cooling system.

• Cooling pump is an intelligent device that does

not require speed control. EVB monitors the
pump speed.
Environmental Board
• The Environmental Board (EVB) is responsible for fans and temperature monitoring.
• EVB monitors the cooling pump speed and reports this information back to the PI
Board.

• One RS-422 connector from the EVB to the

Backplane for serviceability improvement.
• EVB and IMCBs parameters are controlled
by the PI Board via the RS-422 interface.
• EVB acts as a power and communication
pass-through for two IMCB boards that
control the ILS and LampLOC™.
• Reacts to DMD over temperature condition EVB Board
and toggles a logic to shut down the lamp
using the PIB.
Serviceability
• Cooling hoses connected using dripless quick disconnect.
• LEQD inserted in backplane.
• Temperature sensor harness connected to EVB.
• Light Engine (LE) handle is permanently attached to the LE.

• LAD system is permanently

attached to the LE.
• LE service assembly includes
LEQD Board.
• LE mounting screws are
Captive screws.

Light Engine
Serviceability…continued
• All temperature sensors are connected to an easy-access
EVB.
• LAD is attached to the Light Engine (also included in the
LE service assembly). The LAD:
– Reduces the LE replacement time.
– Reduces contamination from disconnecting air hoses
during LE replacement.
– Reduces critical convergence accuracy due to
torques applied to the DMD removing and
reattaching hoses during LE replacement.
• LE mounting screw service access window.
• 3mm Allan Key is included with each projector.
• Easy to replace intake filters—without breaking Security
Blocks and no tools required.
• Easy board swap (no IP address change required).
• No DC voltage adjustment is required after replacing the
LVPS. 3mm Allan Key Included
Disassembly/Assembly
With reference to Disassembly/Assembly instructions remove:
• Integrator Rod
• Liquid Cooling System
• Light Engine
• Environmental Board
What did you learn?
You learned to maintain and troubleshoot the components of the
Light Engine Compartment including:
• IOS
• Light Engine
• Liquid Cooling System
• Environmental Board
Card Cage Electronics

• Troubleshoot Card Cage Electronics

• Upgrade 2K projectors to 4K
• Maintain other controls such as fans
and filters
• Disassemble/assemble the listed
components
Card Cage
• Card Cage Overview
• Troubleshoot PI Board failures
• Use Faceplate Status LED to troubleshoot CP2220/CP4220 failures
• Link Decryptor Board (Daughter Board to the PI Board) Responsible for
Data Security and Marriage (see the introduction to Solaria Series
presentation)
• Integrated Media Block (IMB). Manufactured
and supplied by server manufacturers. It is
responsible for generating the video data
• Troubleshoot Integrated Cinema Processor
(ICP) failures
• Introduce Backplane
• Decipher Status LEDs condition Card Cage
Card Cage Overview
• All Solaria Series projectors
(CP2210, CP2215, CP2220,
CP2230, CP4220 and CP4230) use
the same Card Cage electronics.
Projector ID (part of Factory
Information) is programmed to
the PIB, Backplane, TPC and EVB
at the factory.
• 16 MB ICP is compatible with all Card Cage
models while 8MB ICP is
The Card Cage contains the following PCBs:
compatible with 2K models only • Backplane
• Projector Intelligence Board (PI Board)
• Projector ID and LPS ID must • Link Decryptor (LD) Board
•
match to enable the projector to IMB will attach to the backplane via a PCIe
connector
strike the Lamp • Integrated Cinema Processor (ICP)
Projector Intelligence Board (PI Board)
• The PI Board is controlled by a
Nios™ processor.
• PI Board runs a simple,
dedicated processing loop to
control functions within the
projector.
• PIB3G supports 3G-SDI (2
ports)
• 3G-SDI option card is available
for PIB3G.
PI Board
Projector Intelligence Board…continued
• Uploads new Firmware upgrade packages to EVB and IMCB and downloads logs.
• Remembers system configuration settings in Flash.
• Controls the Lamp Power Supply enable signal and relays commands to and
responses from the Lamp Power Supply.
• Provides Emergency Start capability. +24V
STBY LVPS

The projector is powered and the Supply

+24V STBY
lamp is struck, even in the absence

+12 V
+24 V
of the TPC. +24 V

+24V STBY
+24 V

+24V STBY IMCB #1

(LampLOC™)
+12 V RS-422

• Relays commands to and responses

`
PIB EVB
RS-422 +24 V

from the EVB and IMCBs. +24V STBY IMCB #2

(ILS)
RS-422

• Reacts to the EVB status that

requires actions, especially turning
Note: The control, including lamp strikes, is actually
the Lamp OFF if the DMDs are over done in the TPC except in the case of an Emergency
heated. Start and DMD overheat conditions.
Projector Intelligence Board…continued
• PI Board components include a built-in router and built-in switch.
• One IP address is assigned to the Internal Router WAN setting Via the TPC.
• The internal Router intelligence will direct each message to its destination using
port forwarding technique. Brimstone Electronics

PI Board
Projector

Non-Bimstone Electronics

•
IMCB #1

This architecture improves

RS422
LampLOC™
Ethernet
“RS232 PIB” port NIOS
RS232 / Serial RS232 RS422 EVB
On Faceplate (192.168.254.244)

serviceability because it RS422

Note: The Ethernet connection

RS422
IMCB #2
ILS

simplifies the ICP, LD and TPC between the Switch and the NIOS is
present, but not used.

Serial
swap between projectors. TPC
192.168.254.242
Switch

• TPC receives messages over Router

192.168.254.241

the Ethernet port only. Serial

Media Block
ICP LD
(IMB)
192.168.254.243 192.168.254.245
WAN 192.168.254.246
IP address on theatre
WAN

communication between
network

Nios™/PI Board serial port “Ethernet” jack

On Faceplate
“RS232 ICP” port
On Faceplate

gets translated to Ethernet Module

Projector Router (on PIB)
IP Address
192.168.254.241
TPC 192.168.254.242
using the built-in Router. ICP
Nios™ Processor (on PIB)
192.168.254.243
192.168.254.244
Link Decryptor Board 192.168.254.245
IMB 192.168.254.246
Projector Intelligence Board…continued
• PI Board connects to the Auxiliary I/O panel using a Ribbon cable.
Ports mounted on the Main board:
– HD-SDI A & HD-SDI B
– DVI- A & DVI- B
– Ethernet (100 Mb/s)
– GPIO

Ports mounted on the Auxiliary board:

– Status LEDs
– SCCI
– RS232 PIB & RS232 ICP
– 3D Connector
– Marriage button
– Emergency Start button
– Reset button
Projector Intelligence Board…continued
The Reset button on the PI Board will:
• Remember what state it was in (Full
Power or Standby mode).
• Reset all boards: PI Board, EVB, IMCBs.
• Drop LVPS enable which will cause ICP
and Satellite Formatter boards to reboot.
• Put the projector in the same power
mode before reset was pressed (Standby
or Full Power mode) after a reboot.
Notes: The system will not automatically re-
strike the lamp after rebooting. Also, the TPC
will not reset.
Faceplate Status LEDs
LED State Description State Description
STBY OFF No Power “Breaker OFF”, or ICP Red Communication error or board still
standby supply failure. starting up (45 seconds)
Green Standby Power, system will be
fully responsive with the Green ICP Board detected and working
exception of ICP/LD/IMB and the properly
light engine.
LD Board OFF Main power off or LD is disabled in
PWR OFF No LVPS power. Projector is in the UI – when using IMB.
Standby Mode or there is a LVPS
or harnessing failure. Check Red Board still starting up (30 seconds
Interrogator for ACOK/DCOK after main power on
events. If fans are running, it’s Communication error – LD may be
likely a harness failure. present but tampered, or absent
from the system.
Green Full Power, IMB and TI
electronics are powered. Lamp Green LD Board detected and working
may be struck. properly
Run OFF Projector function properly IMB OFF Main power off
Blinking Yellow PIB lost communication with TPC TPC-supported IMB not installed +
enabled in the TPC UI.
Blinking Green PIB and TPC communication is Red Communication error only on IMBs
established supported directly by the TPC UI.
PIB OFF PIB software not yet started or
software damaged. Green TPC-supported IMB Board detected
and working properly
Green PIB software not running yet (at
startup), or software damaged. Marriage OFF Main power off
Button
Blinking Green PI Board detected and working
properly Green Married
ICP OFF Main power off. Flashing Marriage initiated
Green

Red Not married

Faceplate Status LEDs…continued

Faceplate Status LEDs

Status is also displayed on the TPC main window

Integrated Cinema Processor (ICP)
• ICP provides image processing electronics.
• The ICP board plugs into the backplane.
• ICP receives video data from
• The PI Board after the LD board decrypts the Cinema content OR
• The Integrated Media Block (if installed)
• ICP creates the required signals to drive the three satellite formatter boards.

• ICP is contained inside SPB2 boundary.

• DLP files such as MCGD, TCGD and Screen
files are stored on the ICP board.
• ICP must be married to LD or IMB to
process cinema content.
ICP
ICP…continued
ICP Troubleshooting
• Menu >> Diagnostic >> DLP management
ICP…continued
ICP Troubleshooting
• Check the test results
ICP…continued
• ICP Faceplate uses a number of LEDs as well as two USB ports.

Note: USB ports are

NOT functioning.

LED Status Description

Regen OFF Main power off, LVPS or harness problem. – The PIB never drives the
“power down” signal that would disable the regulators.

ON Main Power on.

SOFST OFF / Red / Green Main ICP software application crashed, or failed to start
Blinking Green Software is working properly if this LED blinks about once a second.

OSST OFF / Red / Yellow Operating system failed to load completely

Green Software is working properly
FMTST Red Unable to configure Formatter FPGA with main or boot application

Yellow Boot application

Green Main application
ICPST Red Unable to configure ICP FPGA with main or boot application
Yellow Boot application, functionality is limited to upgrading software
Green Main application, full functionality
Port A/ B OFF Normal operation, these LEDs aren’t implemented
Backplane
• Backplane is a passive (does not
process signals) board which routes
signals and power from their source
to a destination.
• Backplane EEPROM contains factory
information and lamp information.
• ICP, PI Board, IMB and LEQD Board
are connected into the Backplane.
• Lamp Power Supply, Security Lid,
Security Ring, EVB and LED Status
Indicators are connected to the
backplane via exposed connectors.
• Please refer to the
Interconnect Diagram for details.
4K Upgradeability
• Solaria Series Electronics is 4K ready. 4K projectors are now
available from the factory.
• CP2220 and CP2230 have an optional field upgrade to 4K (CP2220U
and CP2230U).
Note: The model number and serial number of 2K units won’t change as part of
the upgrade; ONLY the functionality will change.
• CP2210 (0.98” DMD) will not be available at 4K resolution.
Please refer to attached compatibility matrix

DMD type Pixels DMD nominal size DMD actual size Pitch size
(wxh) (inches) (inches) (μm)

2K 2048x1080 1.2” 1.24699” 13.68

4K 4096x2160 1.38” 1.37825” 7.56
 4K Upgradeability…continued
LEGEND Integrator rod
Green Text: Essential for 4K - Larger to accommodate
Included in Upgrade Kit larger light path

Light Engine
- 3 DMDs and 3 SFBs
EMC Countermeasures -
- LVPS Compartment Grill 4K Optical prism
- Thermal Management
- IOS Compartment Grill
- New LEQD (LEQD2)
- 4230 LPS Ferrite
- New Convergence
- 4220 Harness
Motorized Lens Mount
- Factory installed
Projector Intelligence Board (PIB3G)
- (2) 3G SDI inputs Industrial Design
- Option Card physical interface - Black Skins
- Existing PIB can be used interchangeably - Front Shroud

Link Decryptor
- Not part of 4K projector
- 4K customers can order as Backplane
- I2C Capable
an accessory
- Rolled into Production in Q4
Image Media Block (IMB) 16 MB Integrated Cinema Processor (ICP)
- 3rd Party designed and supplied - New firmware
- IMB is coupled with External Media Storage - Larger flash memory
- Rolled into Production in Sept
4K Upgradeability…continued
• You must replace the 8 MB ICP board with the 16 MB ICP board. (2K units
manufactured after Sep 2009 have 16 MB ICP installed at the Factory).
• Satellite Formatter Boards (SFBs) software is stored on the ICP board and
loads to the SFBs at power-up.
• When you upgrade a 2K projector to 4K, a software upgrade is required after
installing the 4K light engine (you must install the 4K SFB software on the ICP).

• If the projector is already

running the latest software
revision at the time of the
upgrade, ICP software MUST
be reloaded to load the
correct SFB software on the
ICP.
4K Upgradeability…continued
• Light Engine and Integrator Rod replacements will be required for a 4K field
upgrade.
• 4K Integrator Rod has a 4K stamp on the Integrator Rod enclosure.
• Do NOT use a 4K Integrator Rod with a 2K light engine to prevent DMD
damage.
4K Upgradeability…continued
• 2K and 4K projectors use the same lens suite (lenses throw ratio will be
different due to the difference in the DMD size).
2K Throw Ratio 4K Throw Ratio

1.25-1.45:1 1.13-1.31:1

1.25-1.83:1 1.13-1.66:1

Throw Distance
1.45-1.8:1 1.31-1.62:1

1.45-2.05:1 1.31-1.85:1

1.6-2.4:1 1.45-2.17:1

1.8-2.4:1 1.63:2.17:1

2.15-3.6:1 1.95-3.26:1

2.2-3.0:1 1.98:2.71:1

3.0-4.3:1 2.71-3.89:1

4.3-6.0:1 3.89-5.43:1 Screen Width

5.5-8.5:1 4.98-7.69:1
4K 2K
4K Upgradeability…continued
• 4K SFBs report FPGA
temperatures to the LEQD via
I2C link which is implemented
on LEQD2 P/N 003-102056-01.
• LEQD2 requires Backplane P/N
003-111469-01 to report the
SFBs’ FPGA temperatures. This
backplane will be available
from the factory only. For
example, Field upgraded 4K
projectors may NOT report
SFBs FPGA temperatures.
LEQD2 Board
Status LEDs
There are LED Status Indicators on the back of the projector:
• Two sets of three color-coded LED status indicators affixed to Status LEDs

the top, rear corners of the projector. One set per corner.
• The LEDs are mounted on two LED Boards (LEDB).
• Cabling from each LEDB joins together at a blind-mate
connector on the rear skin for easy service.
LED State Description
Solid Green Lamp On Power is On, Lamp is On
Green Blip Power On Power is On, Lamp is Off

Solid Yellow Standby Mode Power is Off, Lamp is Off

Power saving mode
Yellow Blip Warming Up Transitioning to Power On
mode
Yellow Blip Green Blip Cooling Down Transitioning to Standby
Mode.
Flashing Red New Critical Alarm or New Critical Alarm or
Warning Warning has not been
acknowledged by operator
Solid Red Critical Alarm or Critical Alarm or Warning
Warning exists, but has been
acknowledged by operator
What did you learn?
You learned to:
• Troubleshoot the PI Board and see how it functions
• Use the Faceplate Status LEDs to troubleshoot CP2220/
CP4220 failures
• Troubleshoot the Integrated Cinema Processor (ICP) and
see how it functions
• Troubleshoot the Backplane and see how it functions
• Decipher Status LEDs conditions
Other systems and controls

• Use LiteLOC™ to maintain brightness on

the screen
• Use CP2220/CP4220 Temperature
Sensors to monitor environmental
condition
• Locate CP2220/CP4220 Fans
• Locate/Replace CP2220/CP4220 Filters
Light Output Control (LiteLOC™)
• LiteLOC ™ maintains a chosen light No LiteLOC LiteLOC
level over time.
• Closed loop lamp brightness control
system.
• Illumination feedback control
system continuously monitors lamp Natural Lamp Brightness

brightness. As brightness drops over

BRIGHTNESS
time, power to the lamp increases
to maintain constant brightness. Constant Regulated Brightness

• Light sensor is located on top of the

IOS. It sends brightness information Lamp Power

to the IMCB.
TIME
• LampLOC™ is different. It optimizes
lamp alignment.
Temperature Sensors
• Eight temperature sensors are used
for the following:
– Red, Green and Blue DMDs
– Prism
– Integrator
– Filtered air intake
– Card Cage Exhaust
– Lamp Exhaust
• All temperature sensors are
connected to the EVB and
monitored by the TPC.
• The TPC displays all warning or Temperature Sensor

error messages.
Temperature Sensors…continued
• If one of the DMD temperature reaches 63 CO, a warning
message will be displayed on the TPC.
• The Projector turns the Lamp OFF if one of the DMD
temperature reaches 68 CO and stays at this temperature
or higher for 1 minute.
• A warning message is displayed if the DMD temperature
drops to -1 CO and a alarm is triggered at -2 CO .
• A warning message is displayed if the Integrator Rod
temperature reaches 110 CO and a critical alarm will be
displayed if the temperature reaches 120 CO .
Fans
Fan # CP2230/CP4230
Fan 1 Card Cage Exhaust (Operator side)
Fan 2 Card Cage Exhaust (Non-Operator side)
Fan 3 Radiator
Fan 4 LAD fan
Fan 5 Intake Fanpack (top left)
Fan 6 Intake Fanpack (top right)
Fan 7 Intake Fanpack (bottom left)
Fans 1 and 2 Fan 3
Fan 8 Intake Fanpack (bottom right)
Fan 9 Optional Card Cage Fanpack (top left)
Fan 10 Card Cage Fanpack (top right)
Fan 11 Optional Card Cage Fanpack (bottom
left)
Fan 12 Card Cage Fanpack (bottom right)

Note: Fan 9 and 11 are standard on CP4220 and are available

as service assembly P/N 003-111709-XX for CP2220
Fan 4

Fans 5 to 8

Fans 10 and 12
Filters
CP2220/CP4220 uses three filters:

Main Air Intake Filter Radiator Filter

LAD Filter
What did you learn?
You learned to:
• Use LiteLOC™ to maintain brightness level
• Locate the Temperature Sensors
• Locate the Fans
• Locate and replace the Filters
Disassembly/Assembly
With reference to Disassembly/Assembly instructions remove:
• PI Board
• ICP Board
• LD Board
• IMB (If installed)
• Card Cage
• Backplane
• Card Cage exhaust fans
What did you learn?
You learned to maintain and troubleshoot the components of the Light
Engine Compartment including:
• Card Cage
• Fans, Filters, Temperature sensors
• LiteLOC™ system
Projector Operation

• Connect to the TPC using VNC

• Operate CP2220/CP4220 using the TPC
VNC
• Web based VNC is running on the TPC all the time.
• To access the Web based VNC:
1. Run Web Browser
2. Enter the Projector IP address and Port Number 5800 in the search bar (
http://Projector IP:5800)
3. Password: cdsclub
Notes:
• Free Access only affects port
5000.
• Port 5800 requires password
regardless of the Free Access
setting.
• Java must be enabled

• VNC Viewer software can be

used. In this case use port 5900
TPC Tour
With reference to the CP2220 User’s Guide or
CP4220 User’s Guide, familiarize yourself with the
following:
• Login using different access levels
• Break Marriage; then perform Marriage
• Check projector status
• Add and remove users Security
Level
Marriage
Role
Description Pages Available

Status None Default level for Serial Communication sessions or None

• Change network setting remote Desktop Launcher sessions that have not logged
in.
Not exposed in UI.

• Enter lamp information SNMP

Operator
None
None
SNMP v3 login.
No login required from TPC launcher.
None
Main, Status &
About pages

• Run Lamp LOC™ Advanced None Can change lamps and do channel setup. Above + Advanced
Setup, Channel
Setup pages

• Setup time zone

Admin None Can perform all administrative functions except perform Above +
marriage. Administrator Setup
pages

• Setup screen saver timer

Service None Can perform all administrative functions except perform All except marriage
marriage.
Marriage Yes Can perform all administrative functions in addition to All including
marriage. marriage
• Setup ACT
TPC Tour
With reference to CP2220 User’s Manual,
familiarize your self with the following:
• Calibrate ILS
• Calibrate Foot Lambert
• Create Lamp File and Lens File
• Navigate Channel setup screens
• Customize preferred channel list and
preferred test pattern list
• MCGD, TCGD, and Screen files are
discussed in the Installation--Adjustments
training.
Did you use the TPC help?
• Connect an External USB Keyboard and
Mouse (not required).
What did you learn?
You learned to:
• Connect to the TPC remotely using VNC
• Operate the CP2220/CP4220 using the TPC
What did you learn overall?
You learned about the CP2220/CP4220 theory of operation.
You learned how to:
• Differentiate the available lamp and lens suites
• Install, operate and service CP2220/CP4220 safely
• Disassemble/assemble and troubleshoot components
included in the Power and Lamp Compartment
• Disassemble/assemble and troubleshoot components
included in the Light Engine compartment and the Card
Cage.
• Operate CP2220/CP4220 using TPC and VNC