Christie Boxer 30 Service Manual Download Page 90

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6. With a flathead screwdriver, adjust the plunger until the motor assembly is free.
7. Disconnect the harness to the affected motor.
8. Replace the affected motor.
9. To install the offset module, repeat these steps in reverse order.

Lens mount components

Boxer 4K Service Guide

020-101699-04 Rev. 1 (02-2018)

Summary of Contents for Boxer 30

Page 1: ...Service Guide 020 101699 04 Boxer 4K...

Page 2: ...ms or damage caused by use of a product on a motion platform or other movable device where such product has not been designed modified or approved by Christie for such use i Problems or damage caused...

Page 3: ...ral hazards 16 Mandatory action 17 Electrical labels 17 Additional hazard labels 17 Service setups 18 Turning the projector on 18 Turning the projector off 18 Adjusting boresight 18 Adjusting the fold...

Page 4: ...12 44 Replacing the radiator fans 13 14 15 and 16 45 Replacing the HIP blower fans 17 and 18 46 Replacing the side intake duct 47 Replacing the side intake fans 19 and 20 47 Replacing the lamp driver...

Page 5: ...integrator front plate assembly 80 Replacing the integrator zoom and focus module 82 Replacing the relay optics housing 83 Cleaning or replacing fold mirror 1 84 Cleaning or replacing fold mirror 2 8...

Page 6: ...05 Replacing the housekeeping board HKBA 105 Replacing the status LED board SLB 106 Replacing the dual temperature sensor module DTSM 107 Replacing the lens connector board projector 107 Replacing the...

Page 7: ...Provides specifications for the operating environment Ambient temperature operating 5 to 40 C 41 to 104 F up to 1500 ft Humidity non condensing 10 to 80 Operating altitude 10 000 ft maximum at 5 to 2...

Page 8: ...y panel Displays the projector menus and status E Keypad interface Controls the projector F Christie TAP Enables Android devices to communicate with the projector using near field communication G Elec...

Page 9: ...full power Use this IEC 309 inlet to connect to an appropriately rated power cord component S provided for your region For use in full power mode U Power cord limited power Connects the provided powe...

Page 10: ...ratio dialog C Turns off the light source and puts the projector in standby D Selects an active or inactive input on any slot E Not supported Introduction Boxer 4K Service Guide 10 020 101699 04 Rev 1...

Page 11: ...closes the shutter R Not supported S Initiates a custom action when a number is selected T Selects a projector in multi projector installations U Returns to the previous menu level or exits menus if a...

Page 12: ...uded Part numbers are subject to change Line drawings provide projector dimensions and sizes for installation To download the latest interconnect diagram or line drawings visit www christiedigital com...

Page 13: ...amage EXTREME BRIGHTNESS When accessing a restricted access location for product service or maintenance avoid exposure to the product beam path by turning the product power off and disconnecting the p...

Page 14: ...ARD All harnessing must be properly routed and secured as originally installed especially in high voltage areas FIRE HAZARD Do not use a power cord harness or cable that appears damaged Light intensit...

Page 15: ...a minimum of 2 5 meters D Vertical distance to hazard zone The hazard zone must be no lower than 3 0 meters above the floor E Represents the top view of the projector F Represents the side view of th...

Page 16: ...disconnect all power sources before performing maintenance or service Electrocution hazard To avoid personal injury always disconnect all power sources before performing maintenance or service procedu...

Page 17: ...vice procedures Consult the service manual Electrical labels Indicates the presence of a protective earth ground Indicates the presence of an earth ground Additional hazard labels Risk Group 3 warning...

Page 18: ...sing the projector keypad press and hold the power button until you hear a beep To turn on the light source using the remote press and hold the ON button until you hear a beep Turning the projector of...

Page 19: ...sight for the three focus points 5 To focus the bottom boresight guide adjust the blue boresight screw Adjust the screw 1 4 inch If you get to the end further unlock the corresponding stabilization sc...

Page 20: ...t touches the base Repeat for the other two stabilization screws Continue to adjust the locking screws until they are tight Adjusting the fold mirror Fold mirror adjustment must be completed by traine...

Page 21: ...le knob labeled Vertical 6 Lock the fold mirror screw to lock the adjustment knobs Optimizing the integrator zoom and focus 1 From the Test Pattern menu select the Integrator Rod test pattern The Inte...

Page 22: ...ce problem occurs when one or more projected colors red green and blue appears misaligned when examined with a convergence test pattern The three colors should overlap to form pure white lines through...

Page 23: ...using one hand turn the left knob a quarter rotation and then the right knob a quarter rotation and so on Adjusting a single knob for vertical or rotational adjustment to an extreme before adjusting...

Page 24: ...reservoir fill port 5 Allow the system to vent for 10 seconds so captured pressures in the water blocks can begin to normalize 6 Wipe any coolant that may have bubbled out when removing the fill port...

Page 25: ...the inner locking ring of the female side of the fitting can become stuck in an open position 12 Wipe up any leaked coolant detected that did not get captured Service setups Boxer 4K Service Guide 25...

Page 26: ...modules on page 27 When re connecting harnesses see the interconnect drawings on www christiedigital com Tools required for service Before servicing the projector ensure the following tools are avail...

Page 27: ...r fan 21 22 003 111699 XX Green red fan 23 24 003 112555 XX Blue fan 25 003 112556 XX LAD blower 26 27 003 111697 XX Lamp duct housing fan 28 29 001 112559 XX Card cage fan 30 31 003 112557 XX Power s...

Page 28: ...PCB and holder 003 111635 XX Near field communication reader NFCR 003 105356 XX IR sensor board 003 100221 XX Housekeeping board HKBA 003 112350 XX Status LED board SLB 003 112245 XX Dual temperature...

Page 29: ...03 005837 XX Integrated keypad board to CLBs and NFCT harnesses 003 005836 XX Lamp driver to HKBA harnesses 003 005832 XX Lamp driver to inline harness 003 112511 XX HIP to light engine PCBs harnesses...

Page 30: ...9101 XX Lens 0 72 1 HB Fixed 144 110103 XX Lens 0 9 1 Fixed 144 111014 XX Twin HDMI input card 108 311101 XX Dual Link DVI input card 108 312101 XX Dual 3G HD SD SDI input card 108 313101 XX DMX512 in...

Page 31: ...curing the filter door 2 Pull out the filter door 3 Repeat steps 1 and 2 for the other filter door 4 If required replace one or both filter doors 5 To install the filter doors repeat these steps in re...

Page 32: ...ce a new washer on top of a 7mm socket nut driver with the convex side inside the socket hole 4 Position the new screw above the washer Projector covers and feet Boxer 4K Service Guide 32 020 101699 0...

Page 33: ...emoving the front cover The front cover provides access to the lens assembly and front sensors Estimated replacement time 3 5 minutes Projector covers and feet Boxer 4K Service Guide 33 020 101699 04...

Page 34: ...ecuring the front cover Removing the top cover The top cover provides access to the light engine HKBA board and various other components Estimated replacement time 1 minute 1 Loosen the six captive sc...

Page 35: ...over repeat these steps in reverse order Removing the optics side cover The optics side cover provides access to liquid cooling module integrator focus module zoom focus module NFC readers and other c...

Page 36: ...e cover 4 To install the electronics side cover repeat these steps in reverse order The chassis serial should match the electronics side cover when installing the cover Removing the bottom cover The b...

Page 37: ...mated replacement time 3 minutes for servicing a single foot 1 Ensure the projector is in a secure position Christie does not recommend having the projector overhang when replacing the feet unless the...

Page 38: ...eplacing the front air filters The front air filters are located on either side of the projection lens one of the electronics side and the other on the lamp side Estimated replacement time 1 5 minutes...

Page 39: ...ilter door Replacing the user interface air filter The user interface air filter is located next to the side panel display Estimated replacement time 1 5 minutes 1 To open the filter door loosen the c...

Page 40: ...ter door Replacing the laminar airflow device filter The laminar airflow device LAD filter is located beside the light engine compartment Estimated replacement time 10 25 minutes Filtration Boxer 4K S...

Page 41: ...ull the LAD filter towards the electronics assembly in the projector to clear the tabs 6 Rotate the LAD filter towards the user interface opening and pull it out 7 Remove the used filter 8 Install the...

Page 42: ...correct orientation of the fan also ensures that the fan harness reaches the connector Replacing the lamp blower fans 1 2 3 Each lamp cartridge has six fans cooling the lamp modules The blower fans 1...

Page 43: ...e lamp A blower fan 1 Remove the top cover on page 34 2 Remove the optics side cover on page 35 3 Disconnect the inline connector for the affected fan 4 Remove the two screws securing the fan and slid...

Page 44: ...ed fan and release it 7 Remove the one screw from the affected fan and release it 8 Replace the fan 9 To re install follow these steps in reverse order Replacing the lamp fans 8 10 12 Each lamp cartri...

Page 45: ...or fans 13 14 15 and 16 The four radiator fans are mounted in a fan pack that can be easily removed The fans provide the primary cooling for the radiator Estimated replacement time 5 25 minutes for re...

Page 46: ...for servicing a single blower fan 1 Remove the top cover on page 34 2 Remove the electronics side cover on page 36 3 Remove the card cage on page 59 4 Remove the user interface module on page 60 5 Di...

Page 47: ...minum duct to the fans 5 Remove the aluminum duct 6 Replace the aluminum duct 7 To install the side intake duct repeat these steps in reverse order Replacing the side intake fans 19 and 20 The side in...

Page 48: ...the affected fan and remove the fan 7 Replace the fan 8 To install the user interface intake fans repeat these steps in reverse order Replacing the lamp driver intake fan 21 The lamp driver intake fan...

Page 49: ...an 9 To re install complete these steps in reverse order When replacing the harness make sure to watch for any pinch points and tuck the fan harness under the front bracket Replacing the lamp driver e...

Page 50: ...the inline fan connector 6 Remove the two screws securing the fan and remove the fan 7 Replace the fan 8 To install the fan repeat these steps in reverse order Ensure you route the harnessing properl...

Page 51: ...the fan to the bracket 10 To remove the fan bracket remove the screw 11 Replace the fan and bracket if required 12 To install the red blower fan A or B repeat the steps specific to that fan design in...

Page 52: ...t time 14 minutes for servicing a single LAD blower fan 1 Remove the top cover on page 34 2 Remove the user interface module on page 60 3 Remove the LAD blower on page 56 4 Remove the two screws secur...

Page 53: ...move the optics side cover 3 Remove the rear cover 4 Loosen the two captive screws 5 Remove fan 28 and replace if required 6 Loosen the two captive screws Ventilation and cooling Boxer 4K Service Guid...

Page 54: ...ring the AC input module 3 Swing the AC input module door out to access the required fan 4 Disconnect the inline fan connector 5 Remove the four screws securing the connected fan 6 Remove the fan 7 Tr...

Page 55: ...r supply fan 1 Turn the projector on its side 2 Remove the power supply module on page 66 3 Disconnect the inline fan connector 4 Release the four rubber inserts securing the fan 5 Replace the fan 6 T...

Page 56: ...ing assembly 5 Release the one screw holding the blower to the light engine LAD assembly 6 Disconnect the two inline fan connections 7 Pull out the LAD blower module towards the inside of the projecto...

Page 57: ...ive screws securing the LCM 8 Slide the LCM out and disconnect the LCM harness 9 Replace the LCM 10 To re install follow these steps in reverse order Replacing the radiator The radiator provides the s...

Page 58: ...radiator hoses 6 Vent the liquid cooling module 7 Disconnect the two inline hose connections going to the radiator 8 Remove the two screws securing the fan bracket to the radiator 9 Slide the radiator...

Page 59: ...red green and blue mini SAS harnesses 6 Disconnect the four harnesses CLB and P3 P26 and P5 on the Core4 backplane board located on the top of the card cage 7 Loosen the four captive screws from the...

Page 60: ...terface module The user interface module mounts to the electronics side of the projector Using the side panel display the user can view and control input and output activities on the projector The nea...

Page 61: ...y 9 Remove the two air intake fans from the back of the assembly on page 47 10 Remove the filter door on page 31 11 Remove the filter on page 39 12 Keep the fans filter door and filter to replace on t...

Page 62: ...he rear cover on page 35 2 Remove the top cover on page 34 3 Remove the optics side cover on page 35 4 Remove the four screws to release the rear electronics bracket 5 Release the two harnesses from t...

Page 63: ...order Replacing the lamp door interlock Design B The lamp door interlock prevents the projector from operating when the lamp door is open Estimated replacement time 5 minutes 1 Remove the rear cover...

Page 64: ...t the rear of the projector 6 Remove the three screws securing the lamp driver access cover 7 Open the access cover 8 Remove the four screws securing the A and B lamp driver brackets 9 Disconnect the...

Page 65: ...e four connections to the lamp driver J70 J78 the lamp driver power inline and the lamp cartridge inline 4 Loosen the four captive screws from the top of the lamp driver module 5 Pull the lamp driver...

Page 66: ...e lamp driver module comes out as a stack 13 Remove the failed lamp driver 14 Install the new lamp driver 15 To reassemble the projector follow these steps in reverse order Replacing the power supply...

Page 67: ...following could result in death or serious injury To ensure proper grounding of the product insert the primary AC Input 1 and Input 2 connectors until you hear a click to indicate they are properly s...

Page 68: ...lead to the AC Input 2 ground post b Attach the second test lead to the projector s metal foot post c To confirm the ground integrity verify the ohmmeter reading is below 1 ohm to ensure the primary...

Page 69: ...lamp door loosen the two captive screws and open the door 3 Loosen the captive screw from the lamp cartridge containing the lamp module you want to replace 4 Use the handle to pull out the lamp cartr...

Page 70: ...4 Loosen the four lamp module mounting captive screws and remove the module 5 Install the new lamp module and fasten with the four captive screws 6 Slide the new cartridge back in until you feel the c...

Page 71: ...f the lens is pointing out when you remove the lens 10 Replace the lens 11 Replace the lens mounting bracket making sure the bracket tabs are pointing up 12 Tighten the four screws on the lens mountin...

Page 72: ...and remove 3 Loosen the captive screw securing the light dump 4 Remove the light dump 5 If required replace the light dump 6 To re install follow these steps in reverse order Replacing the shutter Th...

Page 73: ...ess 7 Connect the new shutter harness labeled shutter to the shutter J Switch to P Switch on the shutter assembly 8 Connect J85 end of the shutter harness to P85 connector on the housekeeping HKBA boa...

Page 74: ...ini SAS bracket 8 Disconnect the three mini SAS harnesses from the card cage 9 Disconnect the harnesses to the housekeeping HKBA board The J92 J30 J117 J77 J87 J88 and J5 harnesses run across the mini...

Page 75: ...n the two captive screws from the convergence interface plate 15 Loosen the three captive screws from the light engine base plate Optics Boxer 4K Service Guide 75 020 101699 04 Rev 1 02 2018 Copyright...

Page 76: ...able the red formatter board 17 Place the light engine on the shipping base plate 18 To secure the light engine to the shipping base plate tighten the two screws 19 Put the light engine and base plate...

Page 77: ...e is positioned between the two lamp cartridges and captures light from up to six lamps and combines it into a uniform rectangular light source for the light engine Estimated replacement time 16 minut...

Page 78: ...ring the rear top support bracket 4 Open the lamp door 5 Remove the rear cover on page 35 6 Remove the two lamp cartridges on page 70 7 Loosen the two captive screws to release the lamp cartridges 8 U...

Page 79: ...oute free from the harness clips 16 Disconnect the J72 NFCR harness A side 17 To release the top lamp duct module remove the three screws 18 To remove the outside lamp duct loosen the three captive sc...

Page 80: ...move the four screws from the front of the integrator focus module connecting it to the zoom and focus module 25 Slide the integrator module out the side of the projector 26 Replace the integrator mod...

Page 81: ...ator 4 Remove the five screws securing the lamp harness connector brackets to the front plate 5 Remove the two lamp harness connector brackets Optics Boxer 4K Service Guide 81 020 101699 04 Rev 1 02 2...

Page 82: ...Replacing the integrator zoom and focus module The integrator zoom and focus module allows the user to adjust the magnification and focus of the light directed onto the DMDs Estimated replacement time...

Page 83: ...order Replacing the relay optics housing The relay optics housing contains optical lens elements that move the light from the integrator zoom and focus module and folds it back into the light engine E...

Page 84: ...ll follow these steps in reverse order Cleaning or replacing fold mirror 1 Fold mirror 1 is located below the LiteLOC sensor and provides the first light bend to getting the light directed towards the...

Page 85: ...r 1 out of the fold mirror 1 adjust module 9 Clean or replace fold mirror 1 as required 10 To re install follow these steps in reverse order 11 After replacing fold mirror 1 power on the lamp in singl...

Page 86: ...he two bracket assemblies while securing fold mirror 2 4 Remove fold mirror 2 5 Clean or replace fold mirror 2 as required 6 To re install follow these steps in reverse order Optics Boxer 4K Service G...

Page 87: ...page 33 2 Remove the two screws securing the lens contact board 3 Disconnect the harness 4 Remove the lens contact board 5 To release the boresight indicator brackets and lens boot remove eight screw...

Page 88: ...offset sensors 5 Disconnect the vertical and horizontal offset motors 6 Release the harnesses from the five clips 7 Remove the three boresight safety screws 8 Remove the three boresight screws and th...

Page 89: ...default state Replacing the offset motor The offset motor provides a means of adjusting the position of the projection lens using motorized controls It contains both the horizontal and vertical offset...

Page 90: ...Disconnect the harness to the affected motor 8 Replace the affected motor 9 To install the offset module repeat these steps in reverse order Lens mount components Boxer 4K Service Guide 90 020 101699...

Page 91: ...1 Remove the light engine on page 73 2 Disconnect the red green and blue mini SAS harnesses from the light engine 3 Replace the mini SAS harnesses 4 Reconnect the mini SAS harnesses Make sure the acce...

Page 92: ...ses apply the remaining two swivel clamps Replacing the NFCR harnesses The NFCR harnesses are located on the panel mount connector Estimated replacement time 10 minutes 1 Remove the top cover on page...

Page 93: ...der harness a Remove the lamp driver module on page 65 b Disconnect harness connections from NFCR B1 B2 and B3 c Disconnect harness J72 from HKBA d Release the harness from the three tension clamps e...

Page 94: ...emove the IKB harnesses 7 Replace the IKB harness 8 To install the new IKB harness repeat these steps in reverse order Replacing the HKB and SLB harnesses The HKB and SLB sensor light board harnesses...

Page 95: ...ness 4 Replace the SLB harness a Disconnect J1 from the SLB b Disconnect J5 from the Core4 backplane board c Release the SLB harness from the six tension clamps Harnesses Boxer 4K Service Guide 95 020...

Page 96: ...timated replacement time 18 minutes 1 Remove the integrator module on page 77 2 Disconnect the two lamp driver harnesses from the integrator lamp cartridge bracket 3 Remove the two tension clips aroun...

Page 97: ...Estimated replacement time 7 5 minutes 1 Raise the vertical offset before starting this procedure 2 Unplug the AC line cord to remove power from the projector 3 Remove the front cover on page 33 4 Di...

Page 98: ...mount harness 9 To install the main lens mount harness repeat these steps in reverse order Harnesses Boxer 4K Service Guide 98 020 101699 04 Rev 1 02 2018 Copyright 2018 Christie Digital Systems USA...

Page 99: ...r and the control systems Estimated replacement time 30 seconds 1 Loosen the two captive screws and pull out the IMXB board 2 Replace the IMXB board 3 To re install follow these steps in reverse order...

Page 100: ...re install follow these steps in reverse order When replacing the HIP make sure you place it appropriately and secure the inline connector Replacing the backplane board C4BP The backplane board C4BP p...

Page 101: ...in place on the new backplane board 9 To re install follow these steps in reverse order Ensure fan harness connectors do not get trapped behind the backplane board Replacing the rear convenience ligh...

Page 102: ...for servicing a single CLB 1 Remove the electronics side cover on page 36 2 Remove the two screws securing the CLB 3 Disconnect the one or two inline connectors depending on which CLB is being remove...

Page 103: ...35 b Disconnect the harness of the NFCT to be replaced c Pinch the sides of the reader on the tabs slide it down and pull out d Replace the NFCT 2 To replace the NFCTs on the inside lamp duct B module...

Page 104: ...trol the projector operation Estimated replacement time 1 25 minutes 1 Remove the rear cover on page 35 2 Remove the two screws securing the rear IR sensor board to the bracket 3 Disconnect the rear I...

Page 105: ...acing the housekeeping board HKBA The housekeeping HKBA board acts as an interface board with the majority of the control devices feeding into it including most of the fans convenience light board IR...

Page 106: ...ual about the operational state of the projector Estimated replacement time 2 minutes 1 Remove the rear cover on page 35 2 Remove the two screws securing the board 3 Disconnect the harness and pull ou...

Page 107: ...teps in reverse order Replacing the lens connector board projector The lens connector board projector LCBP located on the projector lens mount provides the physical contact control between the lens an...

Page 108: ...cover from its lip to access the LSM and pull it out 7 Disconnect the harness from the LSM 8 Replace the LSM 9 To re install follow these steps in reverse order The LSM must be properly aligned and c...

Page 109: ...t on page 87 2 Remove the lens mount barrel on page 87 3 Remove the two screws securing the manual focus sensor 4 Route the harness from the clip 5 Cut the cable ties to remove the harness 6 Disconnec...

Page 110: ...To re install follow these steps in reverse order Replacing the vertical and horizontal offset adjust sensor The vertical and horizontal focus adjust sensors detect any vertical or horizontal offset a...

Page 111: ...ppropriate cable tie to the affected sensor 5 Remove and replace the affected sensor 6 If required repeat steps 1 to 5 for the other sensor 7 To re install follow these steps in reverse order Printed...

Page 112: ...ic of South Africa ph 27 0 11 510 0094 Korea Seoul ph 82 2 702 1601 Japan Tokyo ph 81 3 3599 7481 India ph 91 080 6708 9999 Germany ph 49 2161 664540 France ph 33 0 1 41 21 44 04 Russian Federation an...

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