Christie D4K35 Service Manual
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Christie D4K35 Service Manual

Christie d4k35 4k resolution for superior 3-chip dlp displays
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D4K35
S e r v i c e M a n u a l
020-100817-01

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Summary of Contents for Christie D4K35

  • Page 1 D4K35 S e r v i c e M a n u a l 020-100817-01...
  • Page 3 D4K35 S E R V I C E M A N U A L 020-100817-01...
  • Page 4 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.

  • Page 5: Table Of Contents

    Cool the Lamp Completely ....................2-4 2.7 Cooling ............................2-4 2.7.1 Ventilation ...........................2-4 2.7.2 Light Engine Air Filter ......................2-4 2.7.3 Liquid Cooling (Radiator) Air Filter ...................2-5 2.7.4 Liquid Cooling System ......................2-5 2.7.5 Filling the Coolant Reservoir....................2-5 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)
  • Page 6 4.2.3 Flicker, Shadows Or Dimness....................4-3 4.2.4 LampLOC™ Does Not Seem to Work ................4-3 4.2.5 LiteLOC™ Does Not Seem to Work ...................4-3 4.3 TPC ..............................4-4 4.4 Ethernet ............................4-4 4.4.1 Trouble Establishing Communication with Projector............4-4 4.5 Displays ............................4-4 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)
  • Page 7 5.6.2 Light Engine Fan Pack (4 fans) ...................5-13 5.6.3 Cardcage Intake Fans - Top (2 fans)..................5-14 5.6.4 Cardcage Exhaust Fans - Bottom (2 fans) ................5-14 5.7 Feet ..............................5-15 5.8 Illumination Optics and Liquid Cooling Compartment...............5-15 5.8.1 Cold Mirror ..........................5-15 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)
  • Page 8 5.13.1 Exhaust Duct Vane Switch ....................5-42 5.13.2 High Security Interlock Switch..................5-42 5.13.3 Lamp Door Interlock......................5-43 5.14 Primary Lens Mount ........................5-43 5.15 Lamp Power Supply (LPS) ......................5-44 5.15.1 Line Filter..........................5-44 6: Interconnections 7: Serial API 7.1 Function Codes ...........................7-1 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)
  • Page 9 8.9.2 Electro-Magnetic Compatibility ..................8-8 Emissions ..........................8-8 Immunity ..........................8-9 Environmental ........................8-9 8.10 Environment ..........................8-9 8.10.1 Operating Environment......................8-9 8.10.2 Non-Operating Environment .....................8-9 8.11 Accessories ..........................8-9 8.11.1 Standard (Included with product) ..................8-9 8.11.2 Accessories (sold separately)....................8-10 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)
  • Page 10 Table of Contents A: Exploded Views A.1 Exploded View - Internal......................A-1 A.2 Exploded View - External......................A-2 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 11: Labels And Marking

    Disclaimer: Every effort has been made to ensure the information in this manual 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. Labels and Marking Observe and follow any warnings and instructions marked on the projector.

  • Page 12: Control

    For sites in which the fourth interlock is not used, it is jumpered closed. The LPS communication/control cables each route to their own 9-pin connector located on the operator's side of the LPS. D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 13: Cooling

    Power and Lamp Requirements The universal lamp power supply (LPS) in the D4K35 offers adjustable lamp power to suit the size of lamp currently in use. Software allows each lamp to be over-driven by approximately 10% of its maximum rating.

  • Page 14: 7Kw Lamp Power Supply (Lps)

    LiteLOC feature to maintain constant light output. The connection can be disconnected during servicing, allowing the lamp power supply to be operated and interrogated by a service person using a laptop. For more information, refer to the D4K35 User Manual (P/N: 020-100773-xx). 1.4.3 Low Voltage Power Supply The LVPS provides all of the power to the projector in full power mode, with the exception of the TPC which is powered by the standby power supply.

  • Page 15: Interlocks

    Only a severe over-temperature reading on the DMDs will result in an automatic shutdown. Pump If the pump speed falls below a preset threshold the TPC will report a warning. D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 16: Lamp

    High temperature black paint on the inside of the shield absorbs the IR and UV light passed through by the reflector. Holes in the reflector mount allow cooling air to pass through to the inside of the front reflector and on to the lamp anode. D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 17: Lenses

    Good boresight ensures alignment of the primary lens to the light engine and prism. Refer to the D4K35 User Manual (P/N: 020-100773-xx) for all other primary lens installation details, the boresight adjustment procedure at the screen, and lens specifications.

  • Page 19: 2: Service Guidelines

    Christie Protective Clothing Safety Kit (P/N: 598900-095). DANGER! NEVER strike the lamp or run the lamp with the lamp door removed.

  • Page 20: Security Roles

    Section 2: Service Guidelines Security Roles Only Christie authorized service technicians should perform field repair and service to the unit. Site personnel may only perform diagnostic functions, such as running Interrogator. Safety Warnings and Guidelines 2.6.1 Labels and Markings • Observe and follow any warnings and instructions marked on the projector.

  • Page 21: Ac/Power Precautions

    EXPLOSION HAZARD! Wear authorized protective safety gear whenever the lamp door is open! Any lamp used in the D4K35 is under high pressure and must be handled with great care at all times. Lamps may explode if dropped or mishandled.

  • Page 22: Cool The Lamp Completely

    Cooling The D4K35 high-intensity lamp and electronics rely on a variety of cooling components to reduce internal operating temperatures. Regular inspection and maintenance of the entire cooling system is critical to prevent overheating and sudden projector failure and helps to ensure reliable operation of all projector components over time.

  • Page 23: Liquid Cooling (Radiator) Air Filter

    2.7.4 Liquid Cooling System Check: Every 6 months The liquid cooling system circulates liquid to and from the DMD heatsinks in the D4K35 reducing the DMD operating temperature to an acceptable level. Check the coolant level every six months, by removing the top projector lid.

  • Page 24: Exhaust Duct And Lamp Fan Interlocks

    • Check the contact surfaces of anode (positive) and cathode (negative) connections for cleanliness. • Clean electrical contact surfaces as necessary to prevent contact resistance from scorching connectors. Use appropriate contact cleaner. • Verify that all electrical and lamp connections are tight. D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 25: Optical

    In this projector, check only the lens and lamp reflector. Maintenance of other optical components requires a Christie authorized service technician. Check these components periodically in a clean, dust-free environment using a high-intensity light source or flashlight. Clean them only when dust, dirt, oil, fingerprints or other marks are obvious.

  • Page 26: Cleaning The Lamp Reflector

    Clean the high voltage terminal and insulator to remove accumulated dust or dirt. Airflow Interlocks The D4K35 uses two airflow interlocks; a lamp blower vane switch and an extractor vane switch. The lamp blower vane switch is located within the lamp cooling compartment. The extractor vane switch is located just inside the top duct on the projector lid.

  • Page 27: Laminar Airflow Device (Lad)

    The LAD filter is located in the light engine compartment. It is secured to the light engine assembly handle. The LAD filter should be nearly white in color. If it appears a dark gray color (rare) it will require replacement by a Christie authorized service technician. Contact Christie or your dealer. Cleaning ELECTRICAL SHOCK HAZARD! DISCONNECT FROM AC WHEN SERVICING.
  • Page 28 If the lenses must be cleaned, use a DRY soft cotton cloth. Rub gently in a cir- cular motion. 2-10 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 29: 3: Service Setups

    Reflectors, 12" Glass • Adjust LampLOC ™ UV Filter • Adjust LampLOC ™ Vane Switch (Exhaust) • Adjust LampLOC ™ Yellow Notch Filter • Adjust YNF screw for accurate green coordinates • Recalibrate color D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 30: Fold Mirror Alignment

    DMDs. 1. Display a full white field. 2. Loosen integrator assembly so that it can be freely moved by hand. D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 31: Adjusting Lamp Position (Lamploc™)

    • The lamp must be ON and the douser (shutter) is OPEN during adjustment. A 10-minute warm-up is recom- mended. • Display a white test pattern. This is recommended to allow you to view LampLOC progress on-screen. ™ D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 32: Automatically Adjusting The Lamp Position Using Lamploc

    You can improve on-screen uniformity after running LampLOC™ by manually adjusting the z-axis motor. However, brightness will be decreased by a very small amount when this is done. Figure 3-4 Adjust Lamp Position D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 33: Manually Adjusting The Lamp Position

    3. Measure the green coordinates. 4. Locate the adjustment screw on the center of the YNF frame and adjust until the following coordinates are reached: X = 0.265 (+/-0.02), Y = 0.690 (+/- 0.02) D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 34: Dmd Convergence Procedure

    To ensure the most accurate color representation across the whole image it is essential the three panels are perfectly aligned so that all pixels line up. The following convergence procedure outlines how to achieve this. Only Christie authorized service technicians should perform the following procedure. Read this entire section before adjusting convergence.

  • Page 35: Before Performing Convergence

    3-2. • Ensure boresight procedures have been completed before performing convergence. For details, refer to the D4K35 User Manual (P/N: 020-100773-xx). • Use only a prime lens when performing convergence. DO NOT use an anamorphic or Wide Converter Lens (WCL) lens.

  • Page 36: Evaluating Convergence

    7 colors to lead you to a valid conclusion. (Figure 3-8) The stripe pattern boxes along the outer frames can be very helpful as well. Figure 3-8 Seven Color Possibilities D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)
  • Page 37 Figure 3-9 is an example of a projector with two problems; Red is twisted counter-clockwise and Blue is high and to the left with no apparent twist. Figure 3-9 Poor Convergence Example (pattern simplified) D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 38: Red/Green/Blue Formatter Convergence Adjustment Description

    • The vertical adjustment screw and twist adjustment screw interact with each other such that if one is turned in the opposite direction of the other, the twist is affected. 3-10 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)
  • Page 39 It is a good idea to locate the shorter blade 2.5mm driver on adjusting screw #2 (especially on the red), and use the longer blade 2.5mm driver for screw#1 and horizontal (screw #3). Figure 3-11 Red/Green/Blue Formatter Twist and Vertical Adjustments D4K35 Service Manual 3-11 020-100817-01 Rev. 1 (04-2012)
  • Page 40 • A second driver can be inserted and removed to adjust the horizontal/twist adjustment screw or the vertical adjustment screw. Figure 3-12 Red/Green/Blue Formatter Horizontal Adjustments 3-12 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 41: Final Convergence Assessment

    If the problem appears to be more than an extra 1/2 of a pixel out of uniformity, a new lens/prism assembly may be the only solution. D4K35 Service Manual 3-13 020-100817-01 Rev. 1 (04-2012)

  • Page 42: Upgrading Main Software

    OK button. At this point, the TPC will reboot in order to install the TPC user interface software. The TPC will shut down, reboot, and display an install progress window as the user interface is installed. Once complete, tap the Finish button to return to the Main panel. 3-14 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 43: Upgrade: File Selection Window

    (greyed) if no upgrade file is selected. The Next button proceeds with the upgrade process by moving to the Extraction window. Next This button is disabled (greyed) if no upgrade file is selected. D4K35 Service Manual 3-15 020-100817-01 Rev. 1 (04-2012)

  • Page 44: Upgrade: Package Details Window

    This selection instructs the upgrade system to clear all configurations and upgrade Force Defaults Install all components on the system. This is equivalent to the projector when it’s released from the factory. 3-16 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 45: Upgrade: Installation Window

    Current state can be one of the following: idle, transferring, programming, aborted, failed, and done. Once the installation is complete (regardless if the installation was success or not) the Finish Finish button becomes enabled. D4K35 Service Manual 3-17 020-100817-01 Rev. 1 (04-2012)

  • Page 46: Hardware Change

    PIB3G and TPC serial numbers do not match. Figure 3-17 Hardware Change Window 3-18 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 47: Troubleshooting

    For more information on troubleshooting a displayed image, refer to the User Manual (P/N: 020-100773-xx). The D4K35 offers a comprehensive system of diagnostics, tracking a wide range of conditions and alerting the operator to a potential problem by display specific status information at the Touch Panel Controller (TPC) or by the available internal or external LEDs.

  • Page 48: Lamp

    Lamp). Alternatively, if you hear a brief “click”, but no light appears, the lamp likely needs replacement. If you do not hear anything, it may indicate a problem with the LPS (Christie-trained service required). 4.2.2 Lamp Suddenly Goes OFF 1. Check the lamp power in the Advanced Setup: Lamp Power / LiteLOC Setup window. Try increasing the lamp power.

  • Page 49: Flicker, Shadows Or Dimness

    Try to increase lamp power, if possible. Lamps which are near end of life may not operate reliably at lowest power range. 6. Fold mirror misalignment (Christie service required). 7. Integrator rod misalignment (Christie service required).

  • Page 50: Tpc

    The color, tint, color space and/or color temperature settings may require adjustment at your input source or in the Channel Setup: Config 2 window. Ensure the correct PCF, TCGD and Color Space file for the source are used. D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 51: Display Is Not Rectangular

    Add the anamorphic lens to regain image width. Cropping could also be due to the screen file selected that has cropping configured. In both scenarios, refer to the D4K35 User Manual (P/N: 020-100773-xx) for more information.

  • Page 52: The Display Is Jittery Or Unstable

    4.5.12 Portions of the Display are Cut OFF or Warped to the Opposite Edge Resizing may need adjustment. Adjust until entire image is visible and centered. For more information, refer to the D4K35 User Manual (P/N: 020-100773-xx). 4.5.13 Display Appears Compressed (Vertically Stretched) 1.

  • Page 53: Index Of Parts And Modules

    INDEX OF PARTS AND MODULES All replacement parts and accessories for D4K35 projectors can be found in the following tables. Each table contains a description of the part, and the service kit part number. An exploded view has been provided in Appendix B which can be used as a reference for identifying various projector parts.
  • Page 54 Section 5: Parts and Module Replacement Table 5.4 PCB Assemblies Part Name/Description Christie Service Kit Part # Backplane PCB 003-111469-01 Environmental Board (EVB) 003-111059-02 ICP PCB 003-101342-04 Integrated Motor Control Board (IMCB) 003-111426-01 Light Engine Quick Disconnect PCB (LEQD2) 003-102056-XX...
  • Page 55 Section 5: Parts and Module Replacement Table 5.7 Optional Lenses High Brightness Prime Zoom Lenses Christie Service Kit Part # Lens 1.25-1.45:1 129-104106-01 Lens 1.45-1.8:1 129-105107-01 Lens 1.8-2.4:1 129-106108-01 Lens 2.2-3.0:1 129-107109-01 Lens 3.0-4.3:1 129-108100-01 Lens 4.3-6.0:1 129-109101-01 Lens 5.5-8.5:1...

  • Page 56: General Safety Warnings And Guidelines

    GENERAL SAFETY WARNINGS AND GUIDELINES HIGH VOLTAGES! Always power down and disconnect power sources prior to servicing. All module replacement procedures must be performed by Christie authorized service technicians. Once the projector is powered down, allow the cooling fans to automatically turn OFF before disconnecting from AC and opening the projector.

  • Page 57: Removing Projector Covers

    (Estimated Replacement Time: 2 minutes) 1. Unlock front top lid using the low security key provided. (Figure 5-2) 2. Lift the lid up and remove. Figure 5-2 Front Top Lid D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 58: High Security Lid

    5.4.3 High Security Lid Remove the high security lid to access components in the light engine and cardcage compartments. NOTICE! Only Christie authorized service technicians should open the high security lid. (Estimated Replacement Time: 2 minutes) 1. Remove front top lid. Refer to 5.4.2 Front Top...

  • Page 59: Touch Panel Controller (Tpc)

    3. Tilt and lift the back cover just enough for the bottom tabs to clear the frame and remove. 4. When reinstalling, align the bottom tabs and reverse the above instructions. Figure 5-5 Remove Back Cover D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 60: Left Access Cover

    3. To release the door, slide the locking pin (accessible through the cutout located on the right side of the door) towards the inside of the door. Figure 5-7 Open Lamp Door D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 61: Lvps/Lps Cover

    3. When installing the cover, insert the tabbed end first then lift the cover until the top tab clips into place. Figure 5-9 PIB3G/ICP Cover D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 62: Access Panel Frame

    5.12.5 Lamp Replacement. 5. Remove the rear right skin. Refer to 5.4.9 LVPS/ Cover. 6. Remove the two screws securing the rear lid to the chassis. (Figure 5-11) Figure 5-11 Rear Lid 5-10 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 63: Air Filters

    3. Slide the air filter out from the back of the cover and discard. 4. When replacing, insert the new air filter with the airflow indicator facing into the projector. Figure 5-13 Radiator Air Filter Cover D4K35 Service Manual 5-11 020-100817-01 Rev. 1 (04-2012)

  • Page 64: Lad Filter

    Figure 5-15 Remove LAD Fan Assem out of the LAD hoses, but not onto the DMDs. 8. Re-connect the three LAD hoses. 5-12 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 65: Light Engine Fan Pack (4 Fans)

    10. Replace the fan(s) required by removing the rubber isolators from each fan. (Figure 5-17) NOTE: Install a fan with the label side facing into the projector,. Figure 5-17 Remove Light Engine Fan Pack D4K35 Service Manual 5-13 020-100817-01 Rev. 1 (04-2012)

  • Page 66: Cardcage Intake Fans - Top (2 Fans)

    7. Pull the fans off the bottom cover’s rubber isolators. Figure 5-19 Cardcage Exhaust Fans 8. Reverse instructions to re- install the bottom cardcage fans. Use needle-nose pliers to pull the rubber isolators through the fan mounting holes. 5-14 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 67: Feet

    (Figure 5-21) 7. After installation, LampLOC alignment and Measured Color Gamut Data (MCGD) calibration is ™ required. D4K35 Service Manual 5-15 020-100817-01 Rev. 1 (04-2012)

  • Page 68: Fold Mirror

    4. Holding the mirror in place, swing the tabs out to the side. 5. Carefully lower the mirror and remove. 6. When installing, repeat instructions in reverse. Adjust the fold mirror as needed. For details, refer to Fold Mirror Alignment. 5-16 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 69: Illumination Optic System (Ios)

    7. Using a 5mm hex key, remove the four screws securing the IOS to the base plate. 8. Remove the IOS. 9. When installing the IOS, repeat instructions in reverse. Reshoot MCGD files, align the aperture and adjust convergence. For details, refer to Section 3 Service Setups. D4K35 Service Manual 5-17 020-100817-01 Rev. 1 (04-2012)

  • Page 70: Snood (Integrator)

    5. When re-installing, repeat instructions in reverse. After powering up the projector, adjust the integrator and fold mirror as required for proper aperture alignment. For details, refer to Section 3 Service Setups. Figure 5-27 Integrator Assembly 5-18 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 71: Light Sensor Module

    (Figure 5-28) 6. Disconnect the two quick disconnect hoses. (Figure 5-28) 7. Disconnect the pump inline and radiator fan inline connectors. Figure 5-28 Liquid Cooling Assembly 8. Remove liquid cooling assembly. D4K35 Service Manual 5-19 020-100817-01 Rev. 1 (04-2012)

  • Page 72: Yellow Notch Filter (Ynf)

    Figure 5-30 Remove YNF 6. Carefully, pull the YNF out of the IOS. 7. When installing, repeat above instructions in reverse. Calibrate green primary and MCGD. For details, refer to Section 3 Service Setups. 5-20 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 73: Projector Pcb's

    5-9. 4. Release the security ring by pressing down on the latch located on the inside of the cardcage. (Figure 5-31) NOTES: Only Christie authorized service technicians should remove the security ring. Figure 5-31 Spring Latch for Security Ring 5. Remove the security ring by pressing down on the latch on the right-side of the cardcage. (Figure 5-32)
  • Page 74 10. Slide the cardcage back slightly, then pull it up and out to remove. 11. At this point, you can replace the entire cardcage assembly by repeating the above instructions in reverse or replace individual boards. 12. When installing, repeat the above instructions in reverse. 5-22 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 75: Backplane Pcb

    , remove the 15 screws securing the Backplane to the cardcage. (Figure 5-35) ™ 13. Slide the Backplane out of the cardcage. 14. When installing, repeat the above instructions in reverse. Figure 5-35 Cardcage with Backplan D4K35 Service Manual 5-23 020-100817-01 Rev. 1 (04-2012)

  • Page 76: Integrated Processor (Icp)

    Figure 5-37 PIB3G and PIB3G Faceplate 1. Remove the front lid. Refer to5.4.2 Front Top Lid. 2. Remove the high security lid. Refer to 5.4.3 High Security Lid. 3. Remove PIB3G/ICP cover. Refer to 5.4.10 PIB3G/ICP Cover. 5-24 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 77: Light Engine Quick Disconnect (Leqd)

    6. Pull the PIB3G assembly out of the cardcage. (Figure 5-37) 7. When installing, repeat the above instructions in reverse. Verify the software version installed. For details, refer to the D4K35 User Manual (P/N: 020-100773-xx). 5.9.5 Light Engine Quick Disconnect (LEQD) The LEQD is part of the light engine assembly.

  • Page 78: Integrated Motor Control Board (Imcb)

    5.4.3 High Security Lid. 3. Remove the PIB3G/ICP cover. 4. Remove the projection lens. Refer to the D4K35 User Manual (P/N: 020-100773-xx). 5. Disconnect the two coolant hoses from the quick disconnects. Then loosen the thumbscrew located on the bracket next to the disconnects.

  • Page 79: Power Supplies

    Reshoot MCGD files, align the aperture and adjust convergence. For details, refer to Section 3 Service Setups. Figure 5-42 Top View of Light Engine 5.11 Power Supplies Figure 5-43 LVPS Compartment D4K35 Service Manual 5-27 020-100817-01 Rev. 1 (04-2012)

  • Page 80: Ac Line Filter

    AC line filter is secured to, which is secured to the firewall. (Figure 5-44) 6. Disconnect the two harnesses from the AC line filter. Figure 5-44 Remove AC Line Filter 7. Remove the AC line filter. 5-28 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 81: Ac Relay

    7. Tilt the AC relay and use a #2 Phillips ™ loosen the six screws securing the harnesses. 8. Disconnect the eight harnesses. 9. Remove the AC relay. Figure 5-45 Remove AC Relay D4K35 Service Manual 5-29 020-100817-01 Rev. 1 (04-2012)

  • Page 82: Ac Terminal Block

    The LVPS is located in the igniter/blower compartment of the projector. It is held in place by a bracket above the igniter. The LVPS slides in and out along two guide rails at the top of the bracket. (Estimated Replacement Time: 15 minutes) 5-30 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 83: Lamp Compartment

    2. Remove the lamp (if installed). Refer to 5.12.5 Lamp Replacement. 3. Using a 5mm hex key, remove the two screws and lock washers from the yoke base. (Figure 5-49) Figure 5-49 Front of Lamp Compartment D4K35 Service Manual 5-31 020-100817-01 Rev. 1 (04-2012)

  • Page 84: Douser Motor

    ™ ceramic plate to the douser blade. (Figure 5-51) 4. When installing, repeat instructions in reverse. Once installed, perform LampLOC alignment. See 3.3 Adjusting ™ Lamp Position (LampLOC™). Figure 5-51 Ceramic Plate 5-32 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 85: Igniter

    LPS to the base plate. d. Using a 3mm hex key, remove the screw securing the ground to the base plate. e. Remove the igniter. Figure 5-52 D4K35 Igniter D4K35 Service Manual 5-33 020-100817-01 Rev. 1 (04-2012)

  • Page 86: Lamp Replacement

    EXPLOSION HAZARD! Wear authorized protective clothing whenever the lamp door is open and when handling the lamp. Never twist or bend the quartz lamp body. Use the correct wattage lamp supplied by Christie. Ensure those within the vicinity of the projector are also wearing protective safety gear.
  • Page 87 3. Install new lamp. a. Remove the protective cover from the new lamp by removing the tape, knurled nut and locking star washer securing it to its cover. D4K35 Service Manual 5-35 020-100817-01 Rev. 1 (04-2012)
  • Page 88 2) Check leads. Make sure the anode (+) lead between the lamp and igniter is well away from any projector metal, such as the reflector or fire- wall. f. Re-install the front lamp duct. 5-36 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)
  • Page 89 Advanced Setup: LampLOC window. By adjusting lamp position, you can achieve optimized light output by centering the lamp with the reflector and obtaining correct distancing from the center of the illumination system. Figure 5-57 Add Lamp Window D4K35 Service Manual 5-37 020-100817-01 Rev. 1 (04-2012)

  • Page 90: Lamp Adjust Assembly (Including Imcb)

    Ensure the blower is removed on an angle to avoid contacting the interlock switch. Figure 5-59 Main AC Blower 8. When installing, repeat instructions in reverse. Perform LiteLOC . For details, refer to Section 3 Service Setups. ™ 5-38 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 91: Main Blower Vane Switch

    4. Remove the switch from the bracket. 5. When installing, repeat instructions in reverse. Once installed, perform LampLOC alignment. For details, ™ refer to 3.3 Adjusting Lamp Position (LampLOC™). Figure 5-60 Blower Switch Leads D4K35 Service Manual 5-39 020-100817-01 Rev. 1 (04-2012)

  • Page 92: Reflectors (Including Heat Dump)

    7. Use a 3mm hex key to remove the six other screws on the duct. (Figure 5-62) Figure 5-62 Remove Screws Securing Duct 8. Remove the douser assembly. Refer to 5.12.4 Igniter, on page 5-33. 5-40 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 93: Uv Filter

    7. Once the UV filter is in position, repeat instructions in reverse to secure it in place. Once installed, perform LampLOC alignment. ™ For details, refer to 3.3 Adjusting Lamp Position (LampLOC™). Figure 5-64 UV Filter D4K35 Service Manual 5-41 020-100817-01 Rev. 1 (04-2012)

  • Page 94: Interlocks And Switches

    ™ switch. (Figure 5-66) 4. Disconnect the harness from the switch. 5. Remove the two 5.5mm nuts from the switch. 6. Remove the interlock switch. Figure 5-66 High Security Interlock 5-42 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 95: Lamp Door Interlock

    5. Remove the main focus screw (5mm hex). 6. Remove the primary lens mount. 7. When replacing, repeat instructions in reverse. Once the lens mount is installed, perform Boresight Alignment. For details, refer to the D4K35 User Manual (P/N: 020-100773-xx). D4K35 Service Manual 5-43...

  • Page 96: Lamp Power Supply (Lps)

    5.15 Lamp Power Supply (LPS) 5.15.1 Line Filter The line filter is the only accessible assembly that can be serviced by a Christie authorized service technician. If the LPS itself is not functioning correctly the entire unit would be replaced.
  • Page 97 6 Interconnections The D4K35 Interconnect Diagram illustrates the path of electrical connections between modules. Manufacturer’s part numbers are included. NOTE: Part numbers are subject to change. D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)
  • Page 99 D4K35 Interconnect Drawing NOTE: All part numbers subject to change IMCB enclosure mounted to lens mount J53 J99 P53 P99 GPIO 001-111172-xx Zoom Motor Focus Motor Removable Lenses 001-111171-xx (Focus, Zoom) 001-100646-xx GPIO Focus Motor 001-111172-xx Stepper Integrated Motor Zoom...
  • Page 100 D4K35 Interconnect Drawing NOTE: All part numbers subject to change Remote Lamp Power Supply Box Lamp Power Supply 002-100083-xx (NOTE: Not available separately) 016-100026 Breaker / Switch ON - OFF 1O 200-240V, 7A (x2) 001-111393-xx NOTE: Intended to power Head and Extractor Accessory...

  • Page 101: 7: Serial Api

    (ASD+C108?) Get the current status of Automatic Scan Type Detection on the provided channel. (ASD+C108 1) Use Automatic Scan Type Detection on channel 108. (ASD+C108 0) Do not use Automatic Scan Type Detection on channel 108. D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)
  • Page 102 Select color space for the current channel NONE EXAMPLES: (CSP+C108 “RGB Unity”) Use file “RGB Unity” on channel 108 (CSP+C108?) Get color space file name on channel 108 (CSP?L) List all entries of color space control D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)
  • Page 103 “SYS” (system), “ALL”. EXAMPLES: (DLG “20091108” “20091110” “ALL”) (DLG+EXLG!”Log data extracted to filename ‘logextract.txt’ on FTP root”) (DLG 2) Set current logging level to 2 (DLG?) Get current logging level. Response is (LDG!00002 “Info”) D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)
  • Page 104 Motor backlash in positive direction. Read-only. BACP Calibrate travel range and backlash on specified. Only valid parameter for this command is 1. SET only CALB command. Replace Cxxx with the channel number. Valid range is 101-164. Cxxx D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)
  • Page 105 Select gamma for the current channel. NONE EXAMPLES: (GAM+C108 “gamma 2.6”) Use file “gamma 2.6” on channel 108 (GAM+C108?) Get gamma file name on channel 108 (GAM?L) List all entries of gamma control D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)
  • Page 106 Adds or Copies an ICP file from the TPC’s ftproot directory to the appropriate directory on the ICP. Will FSET not overwrite an existing file with the same name. Not supported. FGET Deletes a file from the ICP. The filename parameter is case sensitive. FDEL D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)
  • Page 107 Calibrate travel range and backlash on specified. Only valid parameter for this command is 5. SET only CALB command. Motor calibration status (0-100%) CSTS Sets ILS to installed INST Enable/Disable the Intelligent Lens System for each channel. (1/0) NONE D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)
  • Page 108 (ITP+STUP “DC2K Framing Green, DC2K Framing Red”) Add these two test patterns to the user list (ITP+STUP 1 3) Add these two test patterns indexed in the ITP list to the user list D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)
  • Page 109 Lamp Intensity Calibration (LEN) Define model and serial number for primary installed lens and auxiliary lens. SUBCODE DESCRIPTION OF USE Auxiliary lens model AMOD Auxiliary lens serial number ASER Main lens model MMOD D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)
  • Page 110 (LHO+RSET 1) Reset the horizontal axis (LHO+STRT 1) Starts motor moving in positive direction (LHO+STOP) Stops motor (LHO+MOVR -100) Move motor 100 steps in negative direction (LHO+MOVR 200) Move motor 200 steps in positive direction 7-10 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)
  • Page 111 <lhodir>, <lvodir>, <zomdir>, and <fcsdir> represent the horizontal, vertical, zoom, and focus position information. Valid values for direction are 1 and -1. EXAMPLES: (LMV 1000 1500 500 -500 -1 -1 1 1) D4K35 Service Manual 7-11 020-100817-01 Rev. 1 (04-2012)
  • Page 112 SUBCODE DESCRIPTION OF USE Set or get the current lamp file for a specific channel Cxxx Set lamp file for current channel NONE 7-12 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)
  • Page 113 Set lamp intensity for the current channel. NONE EXAMPLES: (LPI 4500) Set lamp intensity to 4500 for current channel (LPI+C103 4000) Set the lamp intensity to 4000 for channel 3 (LPI?) Get lamp intensity for the active channel D4K35 Service Manual 7-13 020-100817-01 Rev. 1 (04-2012)
  • Page 114 Changing the lamp power for the current channel will change the lamp power for any channel using the same lamp file. SUBCODE DESCRIPTION OF USE Replace Cxxx with the channel number. Valid range is 101-164. Cxxx 7-14 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)
  • Page 115 (LVO+RSET 1) Reset the vertical axis (LVO+STRT 1) Starts motor moving in positive direction (LVO+STOP) Stops motor (LVO+MOVR -100) Move motor 100 steps in negative direction (LVO+MOVR 200) Move motor 200 steps in positive direction D4K35 Service Manual 7-15 020-100817-01 Rev. 1 (04-2012)
  • Page 116 Replace xxx with the channel number. Valid range is 101 - 164. Cxxx Select channel name for the current channel. NONE EXAMPLES: (NAM+C108 “Scope 2.39”) Set channel name for channel 108 (NAM+C108?) Get channel name for channel 108 7-16 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)
  • Page 117 (PCF+C108 “SCOPE 2.39”) Use PCF file “Scope 2.39” on channel 108. File used when PIU is on (PCF?L) List all entries of PCF control PCF In Use (PIU) Select whether to use the PCF file or not. SUBCODE DESCRIPTION OF USE D4K35 Service Manual 7-17 020-100817-01 Rev. 1 (04-2012)
  • Page 118 CPU is returned here. The return parameters are: Type, Major, Minor, and Beta. The beta value is optional meaning it is an engineering build and has not been validated. NOTE: List of devices: 40 = ACT, 46 = D4K35 48 = MCB/IMCB, 49 = EVB SUBCODE DESCRIPTION OF USE...
  • Page 119 (SC+POND “”) Set the power on event to no time - no event will be scheduled, if one was scheduled before it is removed. (SC+BPOF?) Query the current setting for bypass power off events. Screen Format (SCF) elect Screen format file which describes the geometry for the output image. SUBCODE DESCRIPTION OF USE D4K35 Service Manual 7-19 020-100817-01 Rev. 1 (04-2012)
  • Page 120 (SIN?L) Show entries on the list (SIN 1) Set current input port to entry with index 1 (SIN+C101 ?) Get input port on channel 101 (SIN+C101 1) Set input on channel 101 7-20 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)
  • Page 121 Select source format for the current channel. NONE EXAMPLES: (SRF+C108 “XXX”) Use file “XXX” on channel 108 (SRF+C108?) Get source file name on channel 108 (SRF?L) List all entries of source control (SRF+RFSH 1) Refresh TI file list D4K35 Service Manual 7-21 020-100817-01 Rev. 1 (04-2012)
  • Page 122 DESCRIPTION OF USE 0 - restart DLP communications; NONE 1 - stop DLP communications. EXAMPLES: (STP 0) Restart DLP communication (STP 1) Stop DLP communication (STP?) Request current state. Example response is (STP!000) 7-22 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)
  • Page 123 Replace xxx with the channel number. Valid range is 101 - 164. Cxxx Select 3D enable for the current channel NONE EXAMPLES: (TDC+C108 1) Enable 3D on channel 108 (TDC+C108?) Get 3D setting on channel 108 (TDC?) Get current 3D status D4K35 Service Manual 7-23 020-100817-01 Rev. 1 (04-2012)
  • Page 124 (TDR+C101?) Get L/R display reference on channel 101 Output Reference Delay (time) (TDT) Set output reference delay time for 3D control. This command controls how much delay between the input and out- put reference timing. SUBCODE DESCRIPTION OF USE 7-24 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)
  • Page 125 (TFR+C101?) Get frame rate multiple on channel 101 Get Certificates (TIG) Gets the ICP certificate. SUBCODE DESCRIPTION OF USE Retrieve ICP Certificate ICPC EXAMPLES: (TIG+ENGC?) Gets the LD certificate (TIG+ICPC?) Gets the ICP certificate D4K35 Service Manual 7-25 020-100817-01 Rev. 1 (04-2012)
  • Page 126 Replace xxx with the channel number. Valid range is 101-164. Cxxx Select output reference polarity for the current channel. NONE EXAMPLES: (TOP+C101 1) Set Output Reference Polarity to 1 on channel 101 (TOP+C101?) Get Output Reference Polarity on channel 101 7-26 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)
  • Page 127 (ZOM + RSET 1) Reset the zoom (ZOM+STRT 1) Starts motor moving in positive direction (ZOM+STOP) Stops motor (ZOM+MOVR -100) Move motor 100 steps in negative direction (ZOM+MOVR 200) Move motor 200 steps in positive direction. D4K35 Service Manual 7-27 020-100817-01 Rev. 1 (04-2012)

  • Page 129: Display

    45 bits total linear, 15 bits per RGB component 8.1.5 White Point Nominal White y = 0.351 ± 0.002 (full white, after calibration to Telecine mode) x = 0.314 ± 0.002 8.1.6 Gamma Nominal 2.6 ± 5% D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 130: Source Signal Compatibility

    1920 x 1080 8/10/12 4:4:4 59.94/60 Hz 1440 x 576 8/10/12 4:4:4 50 Hz 1920 x 1080 8/10/12 4:4:4 23.98/24 Hz 1920 x 1080 8/10/12 4:4:4 25 Hz 1920 x 1080 8/10/12 4:4:4 29.97/30 Hz D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 131: Control Signal Compatibility

    4:2:2 10bits Progressive 1. Currently there is no known 3rd party test pattern generator to test these formats. Control Signal Compatibility 8.3.1 Ethernet Port Interface 10Base-T/100-Base-TX Connector Female RJ-45 Bit Rate 100 Mbps D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 132: Rs232-Pib3G

    Input 3 - Douser Open Input 4 - Douser Closed Output 1 - Projector Health (high = health ok) Input Current 5mA nominal, 50mA maximum Input forward voltage drop 1.1V nominal, 1.4V maximum (@5mA) D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 133: Port

    195 mm x 148 mm x 44.4 mm Integrated Operating System Microsoft Windows® XPe Communication Interface with Projector 10/100BaseT Ethernet Power Requirement 1.02 A maximum at 24VDC ± 10% Interface Connector 12-pin Circular connector (push-pull) D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 134: Touch Panel Controller (650H)

    Low line: 180-253 VAC High line: 342-456 VAC Number of Phases Line Frequency 50-60Hz nominal Inrush current 120 A max. Current per Phase Low line: 35 A max. High line: 23 A max. D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 135: Lamp Power Supply Output To Projection Head

    2) The maximum power of the lamp power supply is restricted to 7000W ± 100W. Average Life: CDXL-203500 hours CDXL-302500 hours CDXL-45900 hours D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 136: Physical Specifications

    UL 60950-1, 2nd Edition IEC 60950-1:2005, 2nd Edition EN60950:2006+A11:2009 8.9.2 Electro-Magnetic Compatibility Emissions FCC CFR47, Part 15, Subpart B, Class A - Unintentional Radiators CISPR 22:2008-09/EN 55022:2006+A1:2007, Class A - Information Technology Equipment D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 137: Immunity

    8.11.1 Standard (Included with product) Touch Panel Controller (TPC) with interface cable User Manual and Setup Guide Interconnect Diagram Lens Mount Cover Motors and Zoom kit for motorized lens mount Light Engine removal tool Convergence tool D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 138: Accessories (Sold Separately)

    • 003-003082-01 Liquid Cooling Radiator Filter • 03-001982-51P LAD Filter (3-pack) • Firmware Installation Program • Liquid Cooling Kit (003-001837-xx) • TPC Remote Cable (003-111169-01) • Lamp Adaptor Kit for CXL-20 (003-001728-01) 8-10 D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)
  • Page 139 Appendix A: Exploded Views The following exploded views have been provided to assist in identifying the various serviceable parts in the projector. Table A.1 D4K35 Exploded View Index EXPLODED PART NAME/DESCRIPTION VIEW LABEL Lens Lens Mount Manual Knockout Plate Front Faceplate...
  • Page 140 Rear Lid Cover - Left Access Radiator Air Filter Cover Lamp Door Shroud Touch Panel Controller (TPC) Back Panel Cover - LVPS/LPS Access Panel Frame Cover - PIB3G/ICP Cover - Light Engine Air Filter D4K35 Service Manual 020-100817-01 Rev. 1 (04-2012)

  • Page 141: A.1 Exploded View - Internal

    Appendix A: Exploded Views A.1 Exploded View - Internal Figure A-1 Exploded View - Internal D4K35 Service Manual 020-100817-01 Rev.1 (04-2012)

  • Page 142: A.2 Exploded View - External

    Appendix A: Exploded Views A.2 Exploded View - External Figure A-2 Exploded View - External D4K35 Service Manual 020-100817-01 Rev.1 (04-2012)
  • Page 144 Corporate offi ces Worldwide offi ces USA – Cypress United Kingdom Eastern Europe Singapore Japan ph: 714-236-8610 ph: +44 118 977 8000 ph: +36 (0) 1 47 48 100 ph: +65 6877-8737 ph: 81-3-3599-7481 Canada – Kitchener France Middle East Beijing South Korea ph: 519-744-8005...

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