Christie Projector Roadie HD+35K User Manual

							Section 4: Maintenance
Roadie HD+35K User Manual4-3020-100340-02 Rev. 1  (01-2010)
4.2.1 Ventilation 
Vents and louvers in the projector covers provide ventilation, both for intake and exhaust. Never block or cover 
these openings. Do not install the projector near a radiator or heat register, or within an enclosure.
4.2.2 Air Filter 
It is recommended that you replace the air filter (located on the lamp side of the projection head) whenever you 
replace the lamp, or sooner, in dusty or dirty environments. A clogged filter reduces airflow, and can lead to 
overheating and failure of the projector. Check monthly. Refer to Section 4.4.2 Filter Replacement Procedure
 
for instructions.
4.2.3 Liquid Cooler 
The liquid cooler system circulates liquid to and from the DMDs in the projection head, reducing their 
operating temperature to an acceptable level. Periodically check the coolant level visible by opening the Igniter 
compartment door. The reservoir is approximately ½ full.
NOTE: A failure of the liquid cooling system will trigger an over-temperature alarm condition, clearly indicated 
with status displays/lights at the rear of the projector.
Filling the Cooler
Fill approximately 1/2 full. Fill with Christies 50/50 mix of distilled water and ethylene glycol. Top up as 
necessary, making sure not to over fill.
 IMPORTANT!  Whenever coolant has been added or replaced, check for a possible airlock at the next
projector power-up.
4.3 Maintenance and Cleaning
To help ensure optimized performance and reliability, check electrical, optical and other components regularly 
as described below.
  Shock Hazard. Disconnect projection head and ballast from AC at BOTH wall breakers.
4.3.1 Electrical
Do the following every 60 days or 500 hours of projector use (always disconnecting both the projection head 
and ballast from AC first):
• Check the contact surfaces of positive (anode) and cathode (negative) connections for cleanliness. Clean 
electrical contact surfaces as necessary to prevent contact resistance from scorching connectors.
• Verify that all electrical and lamp connections are tight.
4.3.2 Optical
Unnecessary cleaning of optics can be more harmful than helpful, increasing the risk of degrading delicate 
coatings and surfaces. In this projector, check only the lens and lamp reflector. Maintenance of other optical 
components requires a 
Christie accredited service technician. Check these components periodically in a clean, 
dust-free environment using a high-intensity light source or flashlight. Clean them only when dust, dirt, oil or 
other marks are obvious. Never touch an optical surface with your bare hand-always wear latex lab gloves. 
						

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Section 4: Maintenance
When to Check the Lens
A small amount of dust or dirt on the lens has minimal effect on image quality-to avoid the risk of scratching 
the lens, clean the lens only if absolutely required. See below.
When to Check the Lamp Reflector
Inspect the mirror surface (reflector) for cleanliness only during a lamp replacement, when the lamp is out. If 
necessary, clean as described below, and ensure that you wear protective clothing while inspecting or cleaning. 
NOTE: It is normal that the color on the reflector surface may vary.
Supplies
For cleaning off dust and/or grease, you will need:
• Soft camel-hair brush
• Dust-free blower-filtered dry nitrogen blown through an anti-static nozzle.
• Dust-free lens tissue such as Melles Griot Kodak tissues (18LAB020), Optowipes (18LAB022) or Kim 
Wipes or equivalent
• Lens cleaning solution such as Melles Griot Optics Cleaning Fluid 18LAB011 or equivalent. For lens only.
• Methanol. For reflector only.
• Cotton swabs with wooden stems only
• Lens cleaning cloth/microfibre such as Melles Griot 18LAB024 or equivalent.
Cleaning the Lens
If Dusty:
1. Brush most of the dust off with a camelhair brush and/or blow dust away with compressed air.
2. Fold a microfibre cloth smooth and gently wipe remaining dust particles off the lens. Make sure to wipe 
evenly with the smooth portion of the cloth that has no folds or creases. Do not apply pressure with your 
fingers. Instead, use the tension in the folded cloth itself to collect the dust.
3. If significant dust is still bound to the surface, dampen a clean microfibre cloth with lens cleaning solution 
(damp, not dripping). Wipe gently until clean.
If Fingerprints, Smudges, Oil:
1. Brush most of the dust off with a camelhair brush and/or blow dust away with compressed air.
2. Roll a lens tissue around a swab and soak in lens cleaning solution. Tissue should be damp but not 
dripping.
3. Gently wipe the surface using a figure 8 motion. Repeat until blemish is removed.
Cleaning the Reflector
If Dusty:
1. Brush most of the dust off with a camelhair brush and/or blow dust away with compressed air.
2. If some dust remains, just leave as is-air circulating at the lamp is unfiltered, so some dust is inevitable. 
Avoid unnecessary cleaning. 
						

							Section 4: Maintenance
Roadie HD+35K User Manual4-5020-100340-02 Rev. 1  (01-2010)
If Fingerprints, Smudges, Oil: 
1. First brush dust off with a camelhair brush and/or blow dust away with compressed air.
2. Fold a clean microfibre cloth and dampen with methanol. Make sure to wipe evenly with the smooth 
portion of the cloth that has no folds or creases. Do not apply pressure with your fingers. Instead, use the 
tension in the folded cloth itself to collect the dust.
4.3.3 Other Components
In a normal operating environment check, clean and treat the following components every 6 months or so to 
help ensure proper lamp and projector function:
Igniter
Clean the high voltage terminal and insulator to remove accumulated dust or dirt.
Air Flow Interlocks
The lamp fan vane switch is located within the lamp-cooling compartment. The extractor vane switch is 
located just inside the top duct on the projector lid. Check and, if necessary, clean the switches to remove 
accumulated dust or dirt that could impede movement. Within the exhaust hood connected at the top of the 
projector, adequate airflow must be maintained and routed away from the operating area surrounding the 
projector (or any nearby projectors). Inspect regularly and confirm that all air intake areas of the projection 
head and ballast are unobstructed. 
4.4 Replacing the Lamp & Filter
The high brightness of your projector is provided by a Xenon lamp mounted at two ends within a reflector and 
housed in the locked lamp compartment of the projection head. When the lamp approaches the end of its life, it 
must be replaced-do not exceed warranted lamp life by more than 20%, as an old lamp becomes increasingly 
and dangerously fragile, resulting in possible explosion.
To determine the age of your current lamp, consult the Status menu or Lamp menu.
It is recommended that you replace the air filter with every lamp replacement, or sooner in dusty or dirty 
environments. Check its condition monthly in all projectors.
4.4.1 Lamp Replacement Procedure
NOTE: For this procedure, you need a compatible Christie Xenon CDXL or CXL lamp as shown in Section 6 
Specifications. NEVER install a lamp intended for a different projector.
 Make sure to use the correct wattage lamp supplied by Christie.
Lamp replacement is to be done by a Christie accredited service technician only.
 Explosion Hazard. Wear authorized protective clothing whenever the lamp door is open! 
Never apply a twisting or bending force to the quartz lamp body. 
Read and follow all other general lamp precautions in 4.1, Warnings and Guidelines
.
1. By pressing and holding the 
POWER button (any remote or keypad), turn OFF the projector. 
2. Once OFF, allow the fans to run at least 10 minutes for cooling the lamp. 
						

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Section 4: Maintenance
Never attempt to remove the lamp when it is hot. The lamp is under high pressure when hot 
and may explode, causing personal injury and/or property damage.
3. Set the ballast breaker/switch to OFF.
4. Disconnect projection head and ballast from AC power supply.
 Shock Hazard. Disconnect both components from AC.
Wearing protective clothing and face shield, unlock the lamp door and open it. Refer to Figure 4-2
. If 
desired, release the tethered latch mechanism to remove the door entirely.
Unscrew the knob on the lamp cooling compartment door, and remove the door to reveal the cathode end  
(-) of the lamp. Refer to
 Figure 4-2.
5. Remove the old lamp and inspect the reflector as follows:
a. Loosen setscrews from negative/cathode (rear, 7/64) and positive/anode (front, 3/16) lamp 
connectors. These screws are shown in Figure 4-2
. Make sure to apply minimal torque and DO NOT 
STRESS the quartz tube.
b. Carefully slip the positive anode connector off the front of the lamp.
c. Handling by the cathode end only, unscrew the lamp from the rear connector and carefully remove 
from the projector. Immediately place the lamp inside the protective cover (saved from previous 
installation) and then seal it in a heavy carton on the floor where it cannot fall or be bumped.
Handle box with extreme caution-the lamp is hazardous even when packaged. Dispose of 
lamp box according to safety regulations for your area.
d. With the lamp removed, visually inspect the reflector for dust. Clean if necessary as described in 
Section 4.3 Maintenance and Cleaning
.
6. Remove the new lamp from it’s protective cover as follows:
a. Remove tape, knurled nut and locking star washer (if present) securing the lamp within its cover.
b. Handling at the ends only, extract the lamp from the cover. Set aside the protective cover for re-use in 
your next lamp disposal or for warranty return of an expired lamp.
7. Install the new lamp as follows:
a. With protective clothing and face shield on, insert the threaded cathode (-) end of the lamp into the 
negative lamp connector nut located in the rear of the lamp compartment and screw in fully (refer to 
Figure 4-1
, left portion). Hand-tighten only.
IMPORTANT! Handle by the cathode/anode end shafts only, never the glass. Do not over-tighten. Do not
stress the glass. 
						

							Section 4: Maintenance
Roadie HD+35K User Manual4-7020-100340-02 Rev. 1  (01-2010)
 Figure 4-1 Install Bulb
b. Rest the anode (+) end of the lamp on the lamp cradle as shown in Figure 4-1, right, and slip the 
positive lamp connector over the bulb end.
c. Tighten setscrews in both negative and positive lamp connectors as shown in Figure 4-2
.
 Figure 4-2 Secure Bulb at Cathode (-) and Anode (+) Connectors
IMPORTANT! Proper electrical contact prevents resistance in the lamp connectors. If you accidentally touch
the quartz body of the lamp with your bare hands, clean the surface as described in 
4.3,
Maintenance and Cleaning.  
						

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Section 4: Maintenance
8. Make sure that the anode (+) lead between lamp and Igniter is well away from any projector metal, such as 
the reflector or firewall.
 Leads too close to metal parts will cause arcing during starting pulse. This is 
a  Safety Hazard, and the lamp may not ignite.
9. Re-install the cooling compartment door and close the lamp compartment door.
NOTE: The projector will not operate unless the louvered lamp compartment door is locked shut.
10. With a blue dot label or dry-erase pen, mark the lamp doors LAMP INSTALLED label to indicate the size of 
the newly installed lamp - 2.0, 3.0, 4.5, or 6.0 kW. A supply of blue dot labels is secured inside the front 
cover of this manual.
 Figure 4-3  Always Mark the "Lamp Installed" Label (EXAMPLE)
11. Re-connect the projection head and the ballast to AC (refer to Section 2.1 Projector Quick Setup and 
Installation), and then set the breaker/power switch to ON.
12. Set proper Lamp Type (
MENU).
NOTE: Not required if your new lamp is the same Lamp Size (in kilowatts) as the previous lamp.
If your new lamp is rated higher or lower than the old lamp, record the new Lamp Size (2.0, 3.0, 4.5 or 6.0 
kW) in projector memory as described below. This setting establishes the proper range of power available 
for the installed lamp, ensuring that the new lamp is neither underpowered nor over-driven upon power-up.
Do not attempt to ignite the lamp until its size (kW) is correctly defined in 
projector memory.
Refer back to Figure 3-33
. 
a. Press 
MENU. The Sta tus  D is pla y at the rear of the projector shows a Lamp Size of 2000, 3000, 4500, 
or 6000 (Factory default) watts, depending on its last setting. 
b. Enter either the Lamp Password shown in Figure 3-34
, or the Christie service password. A password 
is required unless the Enable Password service option has been turned off.
c. Use the 
RIGHT and LEFT Arrow keys to locate and select which lamp is currently installed. Make sure 
the lamp type is also indicated on the lamp door label as shown in Figure 4-3
.
d. When the Sta tus Display shows the correct lamp type, the projector and lamp can be turned on.
13. Press 
POWER on any keypad/remote to power up the projector and ignite the lamp. Wait approximately 10 
minutes for the projector and lamp to warm up before continuing. 
						

							Section 4: Maintenance
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14. Adjust lamp position.
From the Lamp menu, go to the LampLOC secondary menu and perform a Do Auto adjustment. It takes 
a minute or two as internal motors and sensors determine the ideal placement of the lamp. Proper 
LampLOC ensures maximum brightness, with the lamp well-centered in the reflector and distanced 
correctly from the rest of the illumination system. Refer to Section 3.10.6 Adjusting Lamp Position 
(LampLOC™) for details.
15. Record the serial number of the new lamp, as follows:
a. In the Lamp menu, select Change Lamp.
b. In the Lamp S/N text box, enter the serial number.
c. Press 
ENTER on either keypad to record the number and to reset the lamp timer. The timer now begins 
to log time for the new lamp.
4.4.2 Filter Replacement Procedure
Replace the air filter whenever the lamp module is replaced, or more frequently if operating the projector in a 
dusty or dirty environment. Check monthly in all cases. The filter is located on the lamp side of the projection 
head, near the front.
Removing the Air Filter
Switch OFF the projector and disconnect the AC power cord.
1. By pressing and holding the POWER button (any remote or keypad), turn OFF the projector. 
2. Once OFF, allow the fans to run at least 10 minutes for cooling the lamp.
3. Set the breaker/power switch to OFF.
4. To open/remove the filter compartment door, loosen 2 corner screws using a flat screwdriver, and lift off 
door. 
						

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Section 4: Maintenance
5. Remove the air filter as follows:
Using your fingers, pull out top of filter to remove, as shown.
 Only use Christie filters. Never operate the projector without the filter installed.
Replace/Install New Air Filter
1. To replace or install a new filter, place the top of the air filter inside the air filter compartment and slide all 
the way up behind the tabs, then push the bottom of the air filter in.
2. With the filter in place, insert the bottom tabs of the filter door into the corresponding slots, close the filter 
door, and secure again with the 2 screws.
4.5 Replacing a Lens
A variety of lenses can accommodate different throw distances and specific types of installations. Refer to the 
Christie website for throw distance calculations. 
To replace or change a lens:
1. Unclip the lens safety tether from the handles or FredFrame .
2. Release the lens-locking lever (UP position). 
						

							Section 4: Maintenance
Roadie HD+35K User Manual4-11020-100340-02 Rev. 1  (01-2010)
3. Pull out lens and replace as described in Section 2.4.1 Lens Installation. Insert all the way back, following 
UP label on lens.
NOTE: Ensure that the Zoom connector is fully engaged.
In the event a lens is dropped, the lens tether and clamp assembly may become 
stressed, and therefore must be replaced before continuing its use. Failure to do so 
could result in injury or death.
Lens calibration must be performed each time a new lens is inserted or after 
performing manual lens mount adjustments. This is critical to the projector 
functioning properly. Failure to do so could result in damage to the lens mount, the 
projector, or the projection lens.
Make sure to secure with lens locking lever (UP position) and safety tether: Refer to Figure 2-23.
NOTES: 1) Make sure the lens UP label faces up, otherwise boresight may need readjustment. 2) Keep the lens 
safety tether attached to the projector ‘s handle or FredFrame™ for use with any lens ring clamp. This 
cable MUST be used with a flown projector.