CP2000 Ballast - Replacing Thyristor Instruction Sheet
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1 CP2000 Ballast - Replacing Thyristor Instruction Sheet INTRODUCTION These instructions are for the CP2000 Ballast and explain how to: replace the existing 80 Amp Thyristor with a new 100 Amp Thyristor replace the Ballast cover with a new vented ballast lid replace the pedestal rear vent panel to accommodate the new Ballast lid calibrate the ballast to ensure the ripple current is set for 3-phase balancing. If only the Thyristor components are to be replaced these instructions must be followed in their entirety. If all the parts are to be replaced it is required that the lamp type and total lamp hours are recorded. It is also required that the thyristor components are saved and returned to Christie Digital Systems (Kitchener) as outlined in ISA These instructions should be used in conjunction with the video instructions located on sharepoint (ISA08-010). MATERIALS REQUIRED (2) 100A Thyristors (4) Thyristor Mounting Clips (1)Thyristor Lid (modified) (1) Vent Cover Thyristor (1) Pedestal Vent Ballast thyristor CP2000 Ballast - Replacing Thyristor Instruction Sheet 1 of 9
2 TOOLS REQUIRED Torque Driver (adjustable) Phillips Screwdriver - #2 Fluke test cables and True RMS Meter Flashlight Electrostatic Strap & Pad Kim Wipes Non-Latex Gloves Insulated Flat Screwdriver - 1/8 or narrower Fine Point Marker Tie Wrap Needle Nose Pliers Alcan Jointing Compound Low Security Key Nut Driver 5/16 Telescopic Magnet SAFETY WARNINGS AND GUIDELINES Always power down and disconnect ALL power sources to the projector before servicing or cleaning. Failure to comply could result in bodily harm. Read all instructions before proceeding with installation. personnel only. The following procedure must be performed by qualified projector service Wait approximately 5 minutes after powering down the projector to allow for the Thyristor plate to cool sufficiently before removing thyristor components. INSTRUCTIONS 1. Using a low security key, open the pedestal doors. 2. Using 5/16 nut driver, remove pedestal rear panel mounting nuts and rack shield mounting nuts. See Figure 1. Figure 1 Pedestal Rear Panel Mounting Nuts 3. Remove the pedestal rear panel. If you are replacing the rear panel, discard the old panel. 2 of 9 CP2000 Ballast - Replacing Thyristor Instruction Sheet
3 4. Using #2 Phillips screwdriver remove and retain the 6 screws of ballast lid. See Figure 2. Figure 2 Ballast Lid Screws 5. Remove the ballast lid. If you are replacing the ballast lid, discard the old lid. IMPORTANT: When replacing Thyristors, complete work on the first Thyristor before beginning work on the second. This will provide you with a visual reference should you encounter any difficulties. 6. Using a fine point marker, number both Thyristors 3-phase input and output wires and mark the color location of the gate wires on the aluminium plate. Gate wires are 1 colored and 1 white with the white wire always on the outer edge of the component. See Figure 4. NOTICES: 1) Prior to removal, observe the orientation of the numbers located on the top of the Thyristor. This will help with re-installation of the new Thyristor, identified in Figure 3. 2) Output wire number must correspond to the 3-phase input wire when being re-installed (Figure 4). Figure 3 - Thyristor CP2000 Ballast - Replacing Thyristor Instruction Sheet 3 of 9
4 Figure 4 CP2000 Ballast 7. Remove the 3-phase input screws (3). 8. Remove the 3-phase input wire and output wire. NOTE: Make note of the stacking position of the Control R /Control S wire on the centre terminal. See Figure 18 for details. 9. Use needle-nose pliers to disconnect the pre-marked gate wires. NOTE: The white gate wire must be twisted and connected to the outside of the Thyristor when reinstalled, as identified in Figure Remove mounting screws (2). See Figure Removed and save the Thyristor. 12. Using a Kim wipe, remove any residual Alcan jointing compound from the mounting plate. NOTE: All debris MUST be removed from the mounting plate. 13. Use a telescopic magnet to help slide (2) Thyristor mounting clips (supplied with the kit) onto the inside edge of the aluminum plate. See Figures 5 and 6. Figure 5 Using the Telescopic Magnet Figure 6 Sliding the Clip 4 of 9 CP2000 Ballast - Replacing Thyristor Instruction Sheet
5 14. Within 5 minutes of cleaning the aluminium plate, apply a thin layer of Alcan jointing compound (Figure 7) to a tie wrap as identified in Figure 8. NOTICES: 1) If 5 minutes has elapsed after cleaning, re-clean to avoid oxidation. 2) Only use Alcan jointing compound, no substitutions. 15. Evenly spread the Alcan jointing compound on the surface area of the Thyristor as identified in Figure 9. NOTICES: 1) Applying an excess of Alcan jointing compound to the Thyristor surface creates inaccurate positioning to the thermal coupling. 2) Not enough Alcan jointing compound, as identified in Figure 10, or compound not uniformly distributed, as identified in Figure 11, will produce oxidation. 3) Take your time to apply the Alcan jointing compound. Figure 7 Alcan Jointing Compound Right Figure 8 - Apply compound Figure 9 - Compound Uniformly Distributed Wrong Wrong Figure 10 - NOT enough compound Figure 11 - NOT uniformly distributed 16. Place and position the new Thyristor onto the ballast aluminum plate, aligning the two mounting holes over the aluminum plate screw holes. 17. Align the mounting clips with the aluminum plate screw holes for mounting the Thyristor. The alignment must be exact. See Figure 12 CP2000 Ballast - Replacing Thyristor Instruction Sheet 5 of 9
6 Thyristor Mounting Clip Aluminium Plate Figure 12 Aligning the Mounting Clip 18. Partially thread one of the mounting screws into the Thyristor, then do the same to the other. It is critical that the screw thread into both the aluminum plate and the mounting clips. To ensure this happens thread the screw until the split washer is partially compressed, see Figure 13. At this point the screw should engage both the aluminum plate and the mounting clip. Figure 13 Split Washer Partially Compressed 19. Verify that the screw has engaged the mounting clip. Attempt to rotate the clip from side to side then in and out. If the clip cannot move from side to side it is not properly engaged. If the clip can slide in and out, it is not properly engaged. See Figure 14. If the clip rotates from side to side but can not slide in and out, it is properly engaged. Figure 14 Verifying the Clip is Properly Engaged 6 of 9 CP2000 Ballast - Replacing Thyristor Instruction Sheet
7 Figure 15 The clip will bend when not properly installed 20. Use a torque driver to apply 2.5 to 3.0 Nm (22.1 to 26.7 in/lbs) to each mounting screw. Tighten each screw a little at a time, alternating between screws to ensure an even distribution of the compound. NOTE: DO NOT tighten the screws one at a time as this causes gaps resulting in an unreliable Thyristor. 21. NOTE: There is a risk that the thread in the Aluminum Plate may strip. Should this occur the Thyristor metal clip added earlier in this procedure will secure the screw. Aluminium Plate Mounting Clip Mounting Clip Figure 16 - Positioning Thyristor Figure Attach the 3-phase input, output and Control R or Control S wires to the top of the Thyristor. See Figure 18. NOTE: Initially position the 3-phase input (larger terminal) before the output (smaller terminal). Failure to do so will result in decreasing contact area, current flow and increase temperature. For locations 1 and 3 the Control R or Control S wire is not present however the order is the same with the 3-Phase input on the bottom. CP2000 Ballast - Replacing Thyristor Instruction Sheet 7 of 9
8 Figure 18 - Positioning 3-Phase Input & Output Wire (2nd terminal only) 23. Using a torque driver, apply Nm ( in-lbs) to the 3-phase input screws (3). NOTE: Applying an excessive amount of torque causes the Thyristors bottom plate to bend creating thermal gaps resulting in an unreliable Thyristor. 24. Attach the gate wires, white wire to the outside of the component, matching the colors recorded on the aluminium plate. 25. Confirm the correct wiring placement by comparing the replaced Thyristor to the other Thyristor. 26. Repeat steps 7 to 26 for the other Thyristor. 27. Install the new ballast lid by sliding into the pedestal through the opening left by the removed pedestal rear panel. - Be careful not to catch leading edge on any exposed wires within the Ballast. 28. Do not install the ballast lid screws. 29. Install the pedestal rear panel by lifting the ballast lid slightly to allow the top of the channel to slide between the bottom of the vent and the top lid. See Figure 19. Figure 19 Pedestal rear panel fitting between lid and vent 30. Fasten the rear panel and rack shields using the rear panel mounting nuts removed in step 2. 8 of 9 CP2000 Ballast - Replacing Thyristor Instruction Sheet
9 31. Fasten the modified lid using the 6 ballast lid screws removed in step 4. Remember to attach the wiring clips with 2 of the screws. See Figure 20. Figure 20 Location of Wiring Clips 32. Calibrate the ballast to verify the ripple current is set for 3-phase balancing. NOTE: Use fluke test cables identified in Figure 21. a. Attach meter leads to AC nuts. NOTE: Ensure the projector power is OFF. If the meter leads are connected to the ballast when power is ON, it could result in damaging the meter. b. Re-connect the main AC to the projector then power ON and strike the lamp. NOTE: Allow it to warm up for a minimum of 5 minutes. c. Set the multi-meter to AC scale and insert meter leads to meter. d. Use a flashlight to locate the two-phase control Figure 21 - Fluke Test Cables adjustment screws (potentiometers) recessed inside the ballast, near the rear corner. NOTE: Location is on the non-operator s side of the projector as identified in Figure 22. e. Direct the flashlight through one hole to locate the screw lying under the other hole. f. Simultaneously watch the meter and turn the phase adjustment screws until the ripple measurement is minimized. g. Go back and forth between the 2 screws as necessary to achieve the lowest possible meter reading. h. Adjust to minimum mv value that can be achieved. NOTE: The mv value MUST be below 500 mv and should be below 300 mv. 33. When calibrations are completed, remove all cables and Figure 22 - Adjusting Ballast Phases tools from the pedestal area. 34. Inspect the working area to ensure that all tools and unsecured parts are removed. 35. Close and lock the pedestal doors. 36. Record lamp type and total lamp hours as outlined in ISA CP2000 Ballast - Replacing Thyristor Instruction Sheet 9 of 9
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