Waverly Hills Sanatorium
In 2013, I was tasked with developing a projection mapping installation from the ground up. This included sourcing and purchasing all necessary equipment, designing and constructing the supporting infrastructure, and creating the show itself. The most challenging aspect was establishing the technical foundation—determining the equipment requirements, engineering the physical setup, and developing a reliable system capable of delivering the scale and complexity of the final production.
Projection Geometry and Projector Placement
The first step was determining the throw distance required to cover the building’s 90-foot-wide by 66-foot-tall projection surface using three 16,000-lumen Barco projectors. Each projector was equipped with a variable zoom lens offering a throw ratio of 1.25:1 to 2.5:1.
Throw ratio is calculated by dividing the distance from the projector lens to the projection surface by the width of the projected image. At a 1.25:1 throw ratio, a projector positioned 20 feet from the building produces an image approximately 16 feet wide and 9 feet tall.
To determine the required placement distance, I used the intended 68-foot height of building and a 9-foot reference dimension:
(68 ÷ (9x3)) × 16 (1.25)+4 = 54.37
This calculation produced an estimated placement distance of 54.37 feet from the building, including four feet allocated for the protective projector enclosure, but the stand will be in the middle of a pathed area. So we need to set the stand back to 83 feet to be clear of everything. (68 ÷ (9x3)) × 16 (x)+4 = 83. X=1.87:1. The lens offered considerable flexibility for the installation.
The projector tower was designed to elevate the equipment approximately 20 feet above ground level to reduce interference from objects and activity in the projection area. The projectors’ vertical lens-shift capability provided additional flexibility for aligning the images with the building. The original tower design incorporated three mounting levels spaced seven feet apart, with the overall structure reaching approximately 40 feet in height.
The final positioning of the projectors required coordinating throw distance, image overlap, vertical alignment, and mounting elevation to achieve the intended projection coverage across the building’s facade.
Power Distribution and Electrical Load Requirements
The next major challenge was designing a reliable power distribution system capable of supporting the three projectors, playback computer, audio system, and supporting electronics. Each component had specific voltage and power requirements, so I calculated the anticipated current draw to determine the necessary circuit capacity.
Projectors
Each Barco projector required 7,000 watts of power at 240 volts. Using a power factor of 0.85, I calculated the estimated current draw as follows:
7,000 W ÷ (240 V × 0.85) = 34.31 amps per projector
With three projectors operating simultaneously, the system required three dedicated circuits capable of supporting the projected load.
Audio System
The audio system was estimated to consume 1,000 watts at 120 volts. Using a power factor of 0.8, the calculated current draw was:
1,000 W ÷ (120 V × 0.85) = 9.8 amps
Playback Computer
The playback computer was estimated to consume 850 watts at 120 volts:
850 W ÷ (120 V × 0.85) = 8.33 amps
Mixer, Lighting, and Monitor
The remaining equipment—including the audio mixer, lighting, and monitor—was estimated to consume 280 watts at 120 volts:
280 W ÷ (120 V × 0.85) = 2.74 amps
Electrical Distribution Plan
Based on these estimates, I determined that the power distribution system needed to accommodate the following circuit configuration:
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Three 40-amp, 240-volt circuits dedicated to the projectors.
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Three 15-amp circuits allocated to the audio equipment.
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One 20-amp circuit dedicated to the playback computer and other supporting electronics.
This configuration provided a structured approach to distributing power across the projection and audio systems while separating major equipment loads onto dedicated circuits. Establishing these requirements early was essential to ensuring the installation could support the technical demands of the show reliably.
Technical Improvements and System Evolution
Over the years, we systematically upgraded the projection system to improve power efficiency, environmental protection, remote operation, and long-term reliability.
Projector Technology and Power Efficiency
We transitioned from traditional lamp-based projectors to laser projection systems. This upgrade reduced electrical demand, eliminated the need for frequent lamp replacements, and simplified maintenance. The newer projectors also reduced the overall maintenance burden associated with keeping the system operational throughout the season.
Climate-Controlled Projector Enclosures
We redesigned the projector enclosures to provide a controlled operating environment for sensitive electronics. The upgraded enclosures incorporated climate control to manage internal temperatures and help prevent overheating and condensation. We also improved protection against moisture and insects, reducing the risk of electrical issues, contamination, and equipment failure.
Remote Operation and Control
We modernized the system to support remote operation, integrating low-voltage control wiring, Bluetooth, and Wi-Fi connectivity. This allowed us to control and manage equipment without requiring direct access to each component. Remote connectivity reduced the need to physically access elevated projector platforms and made system adjustments and troubleshooting more efficient.
Troubleshooting and Reliability Improvements
The first year involved extensive troubleshooting as we worked through the challenges of operating a large-scale outdoor projection system. We identified problems, developed solutions, and refined the equipment and installation methods through repeated testing and real-world operation. Over time, these incremental improvements helped us create a more dependable system, streamline setup and maintenance, and reduce the operational challenges encountered during each show.The system's evolution was driven by practical experience: identifying limitations, implementing targeted upgrades, and continually improving the technology to meet the demands of a large-scale outdoor projection installation.