Suspected failing ICP in NC1200 - thoughts appreciated

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  • Leo Enticknap
    Film God
    • Jan 2020
    • 3572
    • Loma Linda, CA

    #1

    Suspected failing ICP in NC1200 - thoughts appreciated

    This is a difficult one, because the theater is in a small town a remote, rural area, and there is no tech (that I know of) that could get there without several hours of drive time and a hotel bill. It's also a nonprofit theater that doesn't have money to throw around (or, more accurately, even less money to throw around than the for profit theater industry, which itself isn't in great shape). The owner is a smart guy, who is able to do planned maintenance, including lamp and SX-3000 battery swaps, and other relatively straightforward repairs. But he doesn't want to take on disemboweling an NEC, even a relatively easy NEC to disembowel, which the 1200 is.

    The problem reported this morning was errors 140 and 141 - DLP CommR and CommE fails. Poking around via the remote PC, I found the ICP to be in boot mode:

    image.png​

    I rebooted the ICP via the ICP app, which appeared to clear it...

    image.png​

    ...but those errors on the projector side had not gone away, and didn't go away, even after rebooting the projector.

    I advised the owner to contact clean and reseat the ICP, which he did. I talked him through clearing the service door tamper on the phone afterwards, and then attempted the remarriage via the GDC UI, which didn't work - "IMB Divorced" remained after a timeout.

    I then looked in the ICP app again, and in the Load/Install tab, saw that both slots A and B showed nothing there, and that the running image was boot mode. I uploaded the ICP version 4.5.454 from the NEC Series 2 4.3.20 package, rebooted the ICP, and then the ICP reported that it was happy:

    image.png​

    However, the projector side is showing that it has no communication with the ICP (note the grayed out "Cinema Board" section):

    image.png​

    At this point, I asked the owner to try playing both DCP and alternative content (DVI in through the NEC board): he reported that both played OK and looked good on the screen. I advised him to leave the projector powered on with the lamp off when not in use (his usual practice is to shut it down completely, including the mains breakers) until we can figure out what to do next, for fear that if the ICP loses power, it might not boot up again into a functional state.

    According to the online error code lookup on Sharp's site, the underlying problem could be a dying ICP, a dying motherboard in the card cage, or dodgy connections between them. Replacing all of those parts, plus the cost of getting me there to do it (10-12 hours of drive time each way) is going to be so expensive that I've suggested that they contemplate replacing the projector, which he's receptive to discussing with the nonprofit's board. Another argument in favor of that would be that the retired projector could then serve as a parts donor for another of the same model in their other screen.

    My question is this: has anyone else seen this specific symptom (projector is functional, but DCC cannot pull status information from the ICP), and can shed light on whether it's a minor issue that can safely be ignored, or an indication of a serious can that cannot be kicked down the road much further? My gut feeling is the latter, but would appreciate any feedback that anyone has to offer. The fact that this is a difficult and expensive site to get to makes this all the more tricky.
  • Steve Guttag
    Film God
    • Jan 2020
    • 3777
    • Annapolis, MD

    #2
    I have not. My Barco bias has me thinking signal backplane (Mother PWB). But, if he hasn't done so already, I would have him use D5 DeOxit on the Legacy Board, ICP and CPU boards. Sometimes, these sorts of problems show up in a place that didn't cause the problem. So, if there is noise on one of the communication lines, the CPU board may report no communication with ICP because with all of the noise on the line, it couldn't talk to the ICP when it was being checked on boot up or other communication. Reseating all of those boards could alleviate that (as well as DeOxit). Even the power rails can be suspect, which can include the PJDIV (or its various connectors as that one touches most everything).

    Comment

    • Leo Enticknap
      Film God
      • Jan 2020
      • 3572
      • Loma Linda, CA

      #3
      Thanks. He already cleaned and reseated the ICP. I guess I should have asked him to do the NEC input board as well. Getting to the motherboard/backplane, CPU and PJDIV boards would involve a level of internal surgery that I don't think he'd feel comfortable with.

      Something fundamentally irrational is going on. If the CPU board cannot communicate with the ICP at all, then the projector should not be able to command the ICP to change inputs between the SX-3000 and the NEC input board, but we know that it can. Given that the ICP seems to be OK when looking at it via the ICP and Enigma app, but DCC cannot see it at all, I'm also wondering about the projector's internal router card.

      It all comes down to the same problem: to ensure a one and done reliable repair, I'd need to drive up there with a bunch of pricey parts (including an ICP), which would be a huge expense for the customer. As of now the projector seems to be working, even though it is reporting itself to be in a condition in which it should not be working. As long as it stays fully powered up from now on, I'm hoping that we've bought enough time to plan the permanent solution on a cost effective rather than an emergency footing.

      Comment

      • Carsten Kurz
        Film God
        • Jan 2020
        • 1481
        • Germany

        #4
        Isn't the router a classic issue in NECs? And relatively easy and cheap to replace?

        Comment

        • Fraser Falconer
          Film Handler
          • Jan 2020
          • 57
          • Gore, New Zealand

          #5
          Hi Leo,
          A projector log can give you a good look at what the projector thinks about the ICP. What were the LED's on the ICP doing when the projector was faulting? As they can tell you where the ICP is at. My past experience a DLP 140 error usually isn't good from the health point of view of the ICP. DLP 140 coupled with DLP CommE or DLP CommR are reasonably common, a Full AC off usually sorts it or a reseat of all the PWB connected to the back plane if it's still not happy, will sort those issues. The ICP to 4.5 may have saved it,by writing the firmware etc. The real question is where is the Cert Battery voltage at?

          Cheers Fraser

          Comment

          • Steve Guttag
            Film God
            • Jan 2020
            • 3777
            • Annapolis, MD

            #6
            The CPU board is the top board and has the ICP fan mounted in the middle of it to blow down onto the ICP heat sink. If the can reseat the other boards, he can reseat the top one too.

            Comment

            • Marcel Birgelen
              Film God
              • Jan 2020
              • 3619
              • Maastricht, NL

              #7
              I have a hunch Carsten is onto something... simply because the CPU cannot manage the ICP, which otherwise still seems to be working fine, as it's capable of playing encrypted DCI content.

              Comment

              • Leo Enticknap
                Film God
                • Jan 2020
                • 3572
                • Loma Linda, CA

                #8
                Originally posted by Fraser Falconer
                What were the LED's on the ICP doing when the projector was faulting? As they can tell you where the ICP is at.
                I can't tell you, because I wasn't on site and the owner wasn't in the booth when I was working on the projector remotely. The log just showed everything normal until the 140 and 141 errors appeared at the conclusion of a boot sequence.

                Originally posted by Fraser Falconer
                The real question is where is the Cert Battery voltage at?
                Not a good place, most likely. The projector was installed in 2012, the theater is only operational for 3-4 evenings a week, and the projector was totally powered down when not in use, until a couple of days ago. This is another argument in favor of a new projector, and for leaving this one powered up until it's time to power it down for the last time, that I made to the owner. That ICP can't have long to go.

                We've presented two options: attempt a repair by means of replacing the parts that could be causing the fault, starting with the cheapest and working up to the most pricey, at the end of which any unused parts can be returned unopened for credit; or replace the projector. Waiting to hear from the customer. If they opt for the repair, I'll also ask Sharp for their input, in case they've seen this pattern of symptoms before and have a clear idea of how to achieve a permanent fix.

                Thanks for everyone's responses; more news when I have it.
                Last edited by Leo Enticknap; 01-08-2026, 05:05 PM.

                Comment

                • Mark Gulbrandsen
                  Film God
                  • Jan 2020
                  • 3093
                  • Nashville, TN

                  #9
                  I only had two ICP,s actually fail in NEC's and one was because the Drive In booth was hit by lightening. Treating the edge connectors with Deoxit and then re-seating them is certainly in order. I did have one that wouldn't boot properly in Cody, WY a number of years back. Re-seating that ICP cured it. It was after that happened when I started treating even new NEC's with Deoxit on install. The edge connectors in they are pretty crappy. The second failure was because the theater sat closed for several years before a new owner took over. So out of over 300 NEC installs, even the types of failures I had, one because of mother Nature and one because the gear wasn't powered up for years is pretty irrelevant. The Barco's and Christie's I installed were also 100% with no failures.

                  Comment

                  • Leo Enticknap
                    Film God
                    • Jan 2020
                    • 3572
                    • Loma Linda, CA

                    #10
                    Good news - they're going for the projector replacement option, and have placed an order for an SP2K-9S.

                    Comment

                    • Marcel Birgelen
                      Film God
                      • Jan 2020
                      • 3619
                      • Maastricht, NL

                      #11
                      I was wondering if Sharp/NEC did ever come back to you with a potential diagnosis of the issue at hand.

                      Comment

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