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» Film-Tech Forum   » Operations   » Digital Cinema Forum   » Christie CP2220 lamp power supply repair

   
Author Topic: Christie CP2220 lamp power supply repair
Christian Hove
Film Handler

Posts: 31
From: Aalborg, Aalborg, Denmark
Registered: Jan 2012


 - posted 02-12-2018 07:59 AM      Profile for Christian Hove   Email Christian Hove   Send New Private Message       Edit/Delete Post 
Hi,
One of our Christie CP2220's is down with a "Ballast communication failed".
Having swapped the lamp power supply with another projector confirmed that the LPS is bad (the bad one is bad in both projectors and the good one is good in both projectors).
The first price quote we got for a new LPS is +6500USD which is a significant expense for a small art cinema.
So - Has anyone succeeded repairing such a LPS? (SanRex KSX-3001CDIRC1)

My findings so far is somewhat limited:
With the projector turned on, the LPS draw current from the mains (~170mA) and with a RS232 sniffer I can see that the projector sends commands to the LPS, but nothing is sent back from the LPS - I expect this causes the "Ballast Communication Fail" (I haven't logged the serial traffic on a healthy LPS yet though).

Thanks,
Christian

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Gordon McLeod
Film God

Posts: 9402
From: Toronto Ontario Canada
Registered: Jun 99


 - posted 02-12-2018 09:22 AM      Profile for Gordon McLeod   Email Gordon McLeod   Send New Private Message       Edit/Delete Post 
if it persists after rebooting the system try unplugging the RS232 cable and reconnecting
I have had contact issues in the past

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Adrian Avram
Film Handler

Posts: 27
From: Iasi, Romania
Registered: Oct 2013


 - posted 02-12-2018 10:03 AM      Profile for Adrian Avram   Email Adrian Avram   Send New Private Message       Edit/Delete Post 
Hi,
Are the two fans from the back of the rectifier spinning when the projector is powered on?

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Christian Hove
Film Handler

Posts: 31
From: Aalborg, Aalborg, Denmark
Registered: Jan 2012


 - posted 02-13-2018 02:29 AM      Profile for Christian Hove   Email Christian Hove   Send New Private Message       Edit/Delete Post 
The RS232 connector has been unpluggeg/plugged and cleaned several times (the LPS was tested bad in another projector as well)

The fans in the LPS are not moving when the projector is powered on.

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Marcel Birgelen
Film God

Posts: 2257
From: Maastricht, Limburg, Netherlands
Registered: Feb 2012


 - posted 02-13-2018 02:52 AM      Profile for Marcel Birgelen   Email Marcel Birgelen   Send New Private Message       Edit/Delete Post 
What it confirms is that either the controller in the LPS has gone bad or the low voltage power supply went bad and is no longer powering the controller or else you would at least see some return RS232 traffic. It's not the easiest component to diagnose or to repair.

If you've done electronics repair in the past or you know somebody who has, you might check for the obvious defects like a blown capacitor or simply a bad fuse.

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Adrian Avram
Film Handler

Posts: 27
From: Iasi, Romania
Registered: Oct 2013


 - posted 02-13-2018 02:56 AM      Profile for Adrian Avram   Email Adrian Avram   Send New Private Message       Edit/Delete Post 
I had a similar situation. I opened the LPS and after some checkings I found one 10 ohm power resistor on the AC input board, open circuit. This resistor is used like an inrush current limiter, and has a built in fuse. All the power electronics checked out fine, no short circuits detected.
After replacing it, the LPS powered up fine.

 -

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Christian Hove
Film Handler

Posts: 31
From: Aalborg, Aalborg, Denmark
Registered: Jan 2012


 - posted 02-13-2018 08:20 AM      Profile for Christian Hove   Email Christian Hove   Send New Private Message       Edit/Delete Post 
I'm sitting here with a big smile om my face [Big Grin]
I've just returned to my desk to google the infinite ohm power resistor I found in the LPS capacitor precharge circuit - And then I saw your post with a picture of the exact same part!

Anyway I have replaced the 10R thermofuse-power resistor with two 22R of the same type but with lower temperature rating in parallel and the LPS is up again.
Now I have spent some time trying to find an exact replacement part but have had no luck yet finding an dealer here in DK carrying that part.
I believe that the complete Micron part number is MEG05N100JU142.
I found a foreign dealer here http://www.bdent.com/meg05n100ju142-micron-radial-component.html
...but the part is out of stock.

Where did you find the replacement you used?

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Adrian Avram
Film Handler

Posts: 27
From: Iasi, Romania
Registered: Oct 2013


 - posted 02-13-2018 09:16 AM      Profile for Adrian Avram   Email Adrian Avram   Send New Private Message       Edit/Delete Post 
I could not find the exact replacement either. I inserted an identical shape, resistance and wattage ceramic resistor.
I believe the one from the link below, can be a more suitable match (although it looks different).

https://www.digikey.com/products/en?mpart=TA205PA10R0JE&v=273

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Marcel Birgelen
Film God

Posts: 2257
From: Maastricht, Limburg, Netherlands
Registered: Feb 2012


 - posted 02-13-2018 04:51 PM      Profile for Marcel Birgelen   Email Marcel Birgelen   Send New Private Message       Edit/Delete Post 
quote: Christian Hove
I believe that the complete Micron part number is MEG05N100JU142.
I found a foreign dealer here http://www.bdent.com/meg05n100ju142-micron-radial-component.html
...but the part is out of stock.

Where did you find the replacement you used?

The 151 °C version is in stock on the same site.

I doubt the extra 9 °C will introduce much of a fire hazard, it will at least be better than to replace the component with a resistor without a thermal fuse.

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Christian Hove
Film Handler

Posts: 31
From: Aalborg, Aalborg, Denmark
Registered: Jan 2012


 - posted 02-15-2018 06:22 AM      Profile for Christian Hove   Email Christian Hove   Send New Private Message       Edit/Delete Post 
Good point, I'll order a couple of them right away.

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Justin West
Master Film Handler

Posts: 265
From: Peoria, IL, USA
Registered: Jul 2001


 - posted 02-15-2018 05:23 PM      Profile for Justin West   Email Justin West   Send New Private Message       Edit/Delete Post 
Wow, it was nice to see how a non user-serviceable part just got serviced by a user! [thumbsup] With the support of others here on F-T! In this digital age, I heard horror stories about how some manufacturers make it very difficult to obtain information or support on their equipment...and, of course, IF THEY ARE EVEN AVAILABLE, replacement parts costs are outrageous...especially for a small operator. Nice going, guys! [Smile]

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Mark Gulbrandsen
Resident Trollmaster

Posts: 15894
From: Bountiful, Utah
Registered: Jun 99


 - posted 02-16-2018 01:20 PM      Profile for Mark Gulbrandsen   Email Mark Gulbrandsen   Send New Private Message       Edit/Delete Post 
Strong switchers have similar as a non user replaceable part and for a good reason. Its there first and foremost as a safety device so the rectifier doesn't catch fire. When I started servicing Strong switchers I got them all back together and it would run for a while and then crash again. Turned out the high voltage filter caps would short out randomly, but only when running at full load. You could actually hear a click in the capacitor when it shorted when tested at 300 volts on a bench supply, and there after all caps were removed and tested. I still do this to this day.
So if your resistor should fail again I'd highly suspect something behind is amuck. Also, you ought to have input surge suppression on this equipment, because surge could also take it out.The one shown is just an example of a whole panel suppressor, and they should be installed by a qualified electrician.

Surge Supresser

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Adrian Avram
Film Handler

Posts: 27
From: Iasi, Romania
Registered: Oct 2013


 - posted 02-16-2018 03:07 PM      Profile for Adrian Avram   Email Adrian Avram   Send New Private Message       Edit/Delete Post 
I do agree with Mark here. The LPS is not an item you want to toy with, unless you know what you are doing. In my case the unit is an emergency back-up (until a proper/identical replacement part will be sourced). Safety issue must not be disregarded here.

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Christian Hove
Film Handler

Posts: 31
From: Aalborg, Aalborg, Denmark
Registered: Jan 2012


 - posted 02-21-2018 07:38 AM      Profile for Christian Hove   Email Christian Hove   Send New Private Message       Edit/Delete Post 
Thank you all for your comments!
We have power suppressors as the first thing where the utility lines enters our power panel. I believe that they cover our complete installation.
The emergency repair I made is still working - I just got the 151C version of the part in the mail today - Now I just need to swap it in.
I thought about Marks shorted caps under full load - I don't believe that this is the case here - If i understood the circuit correctly, the precharge resistors are shorted by a relay when the ballast is up and running and hence no current are running through the resistors when the lamp is on.
I guess that one of the following happened:
- The resistor/thermofuse got bad over time.
- Malfunctioning relay, not shorting the precharge resistors correctly.
- Temporarily shorted cap during precharge.
- Heat build-up in the precharge resistors caused by turning on/off repeatedly.

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