BOXLIGHT CP-320t User manual

SERVICE MANUAL
ORIGINAL VERSION
REFERENCE NO. SM5110523-00
BOXLIGHT CP-320t
SERVICE MANUAL
Chassis No. MA3-CP-320t00
NOTE: Match the Chassis No. on the unit’s
back cover with the Chassis No. in the
Service Manual.
If the Original Version Service
Manual Chassis No. does not match
the unit’s, additional Service
Literature is required.You must refer to
“Notices” to the Original Service
Manual prior to servicing the unit.
PRODUCT CODE
1 122 157 04 (MA3E)

-2-
■Contents
■Safety Instructions ________________________________________________3
■Specifications ____________________________________________________4
■Adjustments after Parts Replacement ________________________________5
■Circuit Protections ________________________________________________6
● Thermal switch ____________________________________________6
●Interlock switch ____________________________________________6
●Fuse ____________________________________________________6
●Warning temperature and power failure protection __________________7
■Mechanical Disassemblies__________________________________________8
■Optical Parts Disassemblies ______________________________________14
■LCD Panel/Prism Ass’y Replacement ________________________________19
■Lamp Replacement ______________________________________________20
■Optical Adjustments ______________________________________________21
■Electrical Adjustments ____________________________________________25
●Service Adjustment Menu Operation____________________________25
●Circuit Adjustments ________________________________________26
●Test Points and Locations ____________________________________30
●Service Adjustment Data Table ________________________________31
■Chassis Block Diagrams __________________________________________34
Chassis over view ____________________________________________34
Inputs & video signal processing stage ____________________________35
LCD panel driving stage ______________________________________36
Audio signal processing circuit __________________________________37
Motor driving circuit __________________________________________38
System controls ______________________________________________39
Power supply & protection circuit ________________________________40
■Troubleshooting ________________________________________________42
No Power __________________________________________________42
No Picture __________________________________________________43
No Sound __________________________________________________45
Lens Motor Problems__________________________________________45
■Control Port Functions ____________________________________________46
● System Control & I/O Port Table ______________________________46
■Waveform ______________________________________________________48
■Cleaning ______________________________________________________49
■IC Block Diagrams ______________________________________________50
■Service Parts List ____________________________________________59-87
Electrical Parts List ________________________________________59-82
Mechanical Parts List ______________________________________83-89
Drawings & Diagrams
■Parts description and reading in schematic diagram ____________________ A2
■Schematic diagrams __________________________________________ A3-A9
■Printed wiring board diagrams ________________________________ A11-A15
■Pins description of ICs, transistors, diodes __________________________ A16

-3-
■Safety Instructions
WARNING:
The chassis of this projector is isolated (COLD) from AC line by using the converter transformer. Primary side of
the converter and lamp power supply unit circuit is connected to the AC line and it is hot, which hot circuit is iden-
tified with the line ( ) in the schematic diagram. For continued product safety and protection of personnel
injury, servicing should be made with qualified personnel.
The following precautions must be observed.
SAFETY PRECAUTIONS
1: An isolation transformer should be connected in the
power line between the projector and the AC line
before any service is performed on the projector.
2: Comply with all caution and safety-related notes pro-
vided on the cabinet back, cabinet bottom, inside the
cabinet or on the chassis.
3: When replacing a chassis in the cabinet, always be
certain that all the protective devices are installed
properly, such as, control knobs, adjustment covers
or shields, barriers, etc.
DO NOT OPERATE THIS PROJECTOR WITHOUT
THE PROTECTIVE SHIELD IN POSITION AND
PROPERLY SECURED.
4: Before replacing the cabinet cover, thoroughly
inspect the inside of the cabinet to see that no stray
parts or tools have been left inside.
Before returning any projector to the customer, the
service personnel must be sure it is completely safe to
operate without danger of electric shock.
SERVICE PERSONNEL WARNING
Eye damage may result from directly viewing the light produced by the Lamp used in this equipment. Always turn
off Lamp before opening cover. The Ultraviolet radiation eye protection required during this servicing.
Never turn the power on without the lamp to avoid electric-shock or damage of the devices since the stabilizer
generates high voltages(15kV - 25kV) at its starts.
Since the lamp is very high temperature during units operation replacement of the lamp should be done at least
45 minutes after the power has been turned off, to allow the lamp cool-off.
PRODUCT SAFETY NOTICE
Product safety should be considered when a component replacement is made in any area of the projector.
Components indicated by mark !in the parts list and the schematic diagram designate components in which
safety can be of special significance. It is, therefore, particularly recommended that the replacement of there parts
must be made by exactly the same parts.
DO NOT ATTEMPT TO SERVICING THE
REMOTE CONTROL UNIT.
Laser Beam may be leaked out when in disassemble
the Unit. As the Laser Beam used in this Remote con-
trol unit is harmful to the eyes.
LASER RADIATION
DO NOT STARE INTO BEAM
MAX. OUTPUT: 1mW
WAVE LENGTH: 650 ±20nm
CLASS II LASER PRODUCT
This product is complied with 21 CFR
part 1040.10
CAUTION LASER RADIATION
DO NOT STARE INTO BEAM
CLASS 2 LASER PRODUCT
LASER-STRAHLING
NICHT IN DEN STRAHL BLICKEN
LASER KLASSE 2
IEC60825-1, Am. 1 1997
MAX OUTPUT ( ) : 1 mW
WAVE LENGTH ( ) : 650±20nm

-4-
■Specifications
●The specifications are subject to change without notice.
This symbol on the nameplate means the product is Listed by Underwriters
Laboratories Inc. It is designed and manufactured to meet rigid U.L. safety stan-
dards against risk of fire, casualty and electrical hazards.
Projector Type Multi-media Projector
Dimensions (W x H x D) 13.11” x 3.52” x 9.96” (333mm x 89.5mm x 253mm)
Net Weight 9.5 lbs (4.3 kg)
LCD Panel System 0.8” TFT Active Matrix type, 3 panels
Panel Resolution 1024 x 768 dots
Number of Pixels 2,359,296 (1024 x 768 x 3 panels)
Color System 6 color system (PAL, SECAM, NTSC, NTSC4.43, PAL-M and PAL-N)
High Definition TV SIgnals 480i, 480p, 575i, 575p, 720p. 1035i and 1080i
Scanning Frequency H-sync. 15 ~ 100kHz, V-sync. 50 ~ 100Hz
Projection Image Size (diagonal) Adjustable from 36” to 260”
Projection Lens F 1.9 ~ 2.1 lens with f 21.3mm ~ 25.6mm with motor zoom and focus
Throw Distance 3.6’ ~ 22.6’ (1.1m ~ 6.9m)
Projection Lamp 180watts
AV Input Jacks RCA Type x 3 (Video/Y, Cb/Pb, Cr/Pr) and Mini DIN 4 pin x 1(S-Video)
AV Audio Input Jacks RCA Type x 2
Computer Input Jacks DVI-I Terminal (Digital/Analog)
Computer Input/Monitor Output Terminal (VGA) HDB15 Terminal x 1 (This terminal is switchable)
Computer Audio Input Jack Mini Jack (stereo)
Control Port Connector Mini DIN 8 pin x 1
USB Connector USB Series B receptacle x 1
Audio Output Jacks RCA Type x 2
Internal Audio Amp. 1.0watt RMS (monaural)
Built-in Speaker 1 speaker, 1.18” x 1.57” (30mm x 40mm)
Feet Adjustment 0˚ to 15.6˚
Voltage and AC 100 ~ 120V (3.0A Max. Ampere), 50/60Hz (The U.S.A and Canada)
Power Consumption AC 200 ~ 240V (1.5A Max. Ampere), 50/60Hz (Continental Europe)
Operating Temperature 41˚F ~ 95˚F (5˚C ~ 35˚C)
Storage Temperature 14˚F ~ 140˚F (-10˚C ~ 60˚C)
Remote Control Transmitters Wireless Remote Control, batteries AA, UM3 or R06 Type x 2

-5-
● :Adjustment necessary ❍ :Check necessary
■Adjustments after Parts Replacement
Contrast Adjustment
R-Contrast adjustment ●
G-Contrast adjustment ●
B-Contrast adjustment ●
Condenser lens adjustment ❍●
Condenser lens-out adjustment ❍●
Relay lens-out adjustment ❍●
Fan voltage adjustment ●
Signal center adjustment ●
PSIG adjustment ●
Gain adjustment [PC] ●
Gain adjustment [Video] ●
Gain adjustment [Component] ●
Gamma gain adjustment [PC] ●
Gamma gain adjustment [AV] ●
Common center adjustment ● ●
Signal offset adjustment [PC] ●
Signal offset adjustment [AV] ●
White balance adjustment ❍ ❍
Disassembly / Replaced Parts
LCD/
Prism
Ass’y
Condenser
Lens
Polarized glass
RGB
Optical Adjustments
Electrical Adjustments
P. F.
Board
Main
Board
Condenser
Lens-Out
Relay
Lens-Out
Power
Board

This projector provides the following circuit protections to operate in safety. If the abnormality occurs inside the pro-
jector, it will automatically turn off by operating one of the following protection circuits.
●Fuse
The fuse is located inside of the projector. When either the LAMP
indicator or the READY indicator is not illuminated, fuse may be
opened. Check the fuse as following steps.
It should be used the specified fuse as follows;
How to replace the fuse
1. Remove the cabinet top following to “Mechanical
Disassemblies”.
2. Remove the fuse from fuse holder.
To install the fuse, take reversed step in the above.
Fuse Part No.: 423 022 2102
TYPE T4.0AH 250V FUSE
LITTLE FUSE INC. TYPE 215004
-6-
●Interlock switch
The interlock switch (SW904) cuts off the AC mains power supply
when the lamp cover is removed. After opening the lamp cover for
replacing the lamp ass’y, place the lamp cover correctly otherwise
the projector can not turn on.
●Thermal switch
There is the thermal switch (SW902) inside of the projector to
prevent the internal temperature rising abnormally. When the
internal temperature reaches near 100˚C, turn off the AC main
power supply automatically.
The thermal switch is not reset to normal automatically even if the
internal temperature becomes normal. Reset the thermal switch
following procedure.
Check the resistance between terminals of thermal switch by
using the tester. If it has high impedance, thermal switch may be
in operative.
How to reset the thermal switch
1. Remove cabinet top following to the “Mechanical
Disassemblies”.
2. Press the reset button on the thermal switch.
CAUTION:
Before press the reset button, make sure that the AC cord must
be disconnected from the AC outlet.
■Circuit Protections
Thermal switch (SW902)
Reset Button
Line Filter Board
Fuse

-7-
Circuit Protections
●Warning temperature and power failure protection
The projector will be automatically turned off when the internal temperature of the projector exceeds the normal oper-
ating temperature, or the cooling fans stop, or the power supplies in the projector are failed.
- If the TEMP WARNING indicator (red) is flashing, it may detect the abnormal temperature inside the projector.
Check the following possible causes and wait until the WARNING TEMP indicator flashing stops, and then try to
turn on the projector.
- If both of the TEMP WARNING (red) and READY (green) indicators are flashing at the same time, It may defect the
cooling fans and power supply circuits. Check fan operation and power supply lines referring to the chapter “Power
supply & protection circuit” in the Chassis Block Diagram section.
Possible causes
- Air filter is clogged with dust particles. Remove dust from the air filter by following instructions in the “Air filter
care and cleaning” below.
- Ventilation slots of the projector are blocked. In such an event, reposition the projector so that ventilation slots are
not obstructed.
- Check if projector is used at higher temperature place (Normal operating temperature is 5 to 35 ˚C or 41 to 95˚F)
Air filter care and cleaning
The removable air filter prevents dust from accumulation on the surface of the projection lens and projection mirror.
Should the air filter become clogged with dust particles, it will reduce the cooling fan’s effectiveness and may result
in internal heat build up and reduce the life of the projector.
To clean up the air filters, follow the cleaning procedure
below:
1. Turn the power off, and disconnect the AC power cord
from the AC outlet.
2. Turn the projector up side down and remove air filter by
pulling the latches of it upward.
3. Clean the air filter with brush or wash out the dust and
particles.
4. Replace the air filter properly. Make sure that the air fil-
ter is fully inserted.
CAUTION:
Do not operate the projector with the air filter removed. The
dust is stuck on the LCD panel and the mirror, and it may
spoil the fine picture image.
Do not put the small parts into the air intake vents. It may
result in the malfunction of the projector. The air filters are
small parts. Take care that children don’t eat or swallow it.
RECOMMENDATION
We recommend not to use the projector in dusty, smoky places. Using it in dusty place may cause the poor picture
quality.
When using under the dusty or smoky conditions, dust may accumulate on the LCD panel and lens inside it, and
may resultantly be projected on the screen together with the picture.
When the above symptoms are noticed, please clean up the LCD panel and lens following to the “Cleaning
Method”.
Air filter

1Remove 4 screws A(M3x6) to take the Cabinet Top Ass’y upward off.
2Remove the Control Panel off from the Cabinet Top by lifting the edge of
control panel.
Fig.1
1Remove 8 screws (M3x6) to take the Main Board upward off.
Fig.2
zCabinet Top and Control Panel removal
xMain Board removal
A
A
A
A
Main Board
Control panel
Cabinet top
-8-
■Mechanical Disassemblies
Mechanical disassemble should be made following procedures in numerical order.
Following steps show the basic procedures, therefore unnecessary step may be ignored.
Caution:
The parts and screws should be placed exactly the same position as the original otherwise it may cause loss of
performance and product safety.
Screws Expression
(Type Diameter x Length) mm
T type M Type

-9-
Mechanical Disassemblies
1Remove 1 screw A(M4x8) to release grounding wires.
2 Pull the Rear Panel ass’y upward.
3Remove 4 screws B(T3x6) and remove the AV Board.
4Remove 4 screws C(T3x6) and remove the DVI Board.
5Remove 4 screws D(T2.6x6) and remove the speaker.
6Remove 1 screws E(T3x8) and remove the Sensor Board.
Fig.3
Fig.4
1Remove 3 screws A (M3x4), 1 screw B (M3x8) and unhook 2 hooks Cat
the both of left and right side, and the take the Front Panel ass’y off.
2Remove 1 screw D (T3x8) to take the R/C Board off.
cAV, DVI, Temp Board and Speaker removal
vFront Panel and R/C Board removal
A
B
B
B
C
A
A
A
B
C
D
DVI board
AV board
Speaker
R/C board
B
C
C
D
D
E
Temp board

-10-
Mechanical Disassemblies
1Remove 1 screw A(M3x4) and remove SW902, and then remove 1 screw
B(M3x6) and disconnect the Lamp Socket.
2Remove 2 screws C(M3x6) to take the Lamp Ballast ass’y upward off.
3Remove 2 screws D(T2x6) to take the isolation sheet off.
4Remove 4 screws E(T3x6) to take the lamp ballast board off.
Fig.5
1Remove 3 screws A(M3x6) and pull the Filter Board ass’y upward.
2Remove 1 screw B(M4x8) to take the grounding lead from the cabinet bottom.
3Remove 4 screws C(T3x8) to take the Filter Board off.
Fig.6
bLamp Ballast Unit removal
nFilter Board removal
B
Lamp ballast board
C
C
E
E
E
E
A
A
A
B
C
C
C
C
Filter board
D
D
Isolation sheet
A
Lamp ballast socket
SW902