Projector Christie Roadie 25k User Manual

							Section 4 
Maintenance 
 
 Roadie 25K User’s Manual 4-1 
This projector is designed for safe and reliable operation. However safe operation is 
not assured by design alone; installers, service technicians, trained operators and all 
other users must maintain a safe environment at all times
. Please read through and 
understand all warnings and precautions before attempting to operate the projector. 
Observe and follow any warnings and instructions marked on the projector. 
The exclamation point within the equilateral triangle indicates related 
operating/maintenance instructions in the documentation accompanying 
the projector. 
The lightning flash and arrowhead symbol within the equilateral triangle 
indicates the presence of non-insulated dangerous voltage that may be 
of sufficient magnitude to constitute a risk of electric shock. 
Be aware of the following general precautions in all installations: 
 WARNING  
Never look directly into the projector lens or at the lamp. The 
extremely high brightness can cause permanent eye damage. 
 
 WARNING  
For protection from ultraviolet radiation, 
keep all projector housings intact during operation. 
Protective clothing and safety goggles are recommended. 
NOTES: 1) The American Conference of Governmental Industrial Hygienists 
(ACGIH) recommends occupational UV exposure for an 8-hour day to be less than 
0.1 microwatts per square centimeters of effective UV radiation. An evaluation of 
your workplace is advised to ensure employees are not exposed to cumulative 
radiation levels exceeding the government guidelines for your area. 2) Be aware that 
some medications are known to increase one’s sensitivity to UV radiation. 
 WARNING  
FIRE HAZARD. Keep hands, clothes, and all combustible material 
at least 1m away from the concentrated light beam of the lamp. 
 WARNING  
Position all cables where they cannot contact 
hot surfaces or be pulled or tripped over. 
4.1 Warnings and 
Guidelines 
  Labels and Markings  
 
 
 General Precautions 
 
 
 
 
 
 
  
						

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Roadie 25K User’s Manual  
This projector must be installed in an environment which meets the operating range 
specifications in Section 6, Specifications.  
 WARNING  
Opening or removing a projector cover 
requires a qualified service technician. 
  WARNING  
Do not attempt operation if the AC supply 
is not within the specified voltage range.  
Do not allow anything to rest on the power cords. Locate the projector where cords 
cannot be abused by persons walking on it or objects rolling over it. Never operate 
the projector if a power cable appears damaged in any way. 
Do not overload power outlets and extension cords as this can result in fire or shock 
hazards. 
Note that qualified service technicians only
 are permitted to open any enclosure on 
the product, and only if AC has been fully disconnected from the projection head 
and ballast. 
 WARNING  
SHOCK HAZARD. Disconnect projection head and 
ballast
 from AC before opening any enclosure. 
 Xenon arc lamps are under high pressure and must be handled with great care at all 
times. Lamps may explode if dropped or mishandled. 
Wear Protective Clothing 
Never open the lamp door unless you are wearing authorized protective clothing such 
as that included in a Christie Protective Clothing Safety Kit #598900-095
. 
Recommended protective clothing includes—but may not be limited to—protective 
gloves, latex lab gloves, double-layer 0.040” acetate face shield, and a quilted 
ballistic nylon jacket or a welder’s jacket. The shield is provided with the lamp. 
 WARNING  
EXPLOSION HAZARD —Wear authorized protective 
clothing whenever the lamp door is open! 
 WARNING  
Never attempt to remove the lamp directly after use. The lamp is 
under increased pressure when hot and may explode, causing 
personal injury and/or property damage. 
Allow to cool completely. 
NOTES: 1) Christie’s protective clothing recommendations are subject to change. 2) 
Any local or federal specifications take precedence over Christie recommendations.   
AC / Power Precautions 
 Lamp Precautions  
						

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Roadie 25K User’s Manual 4-3 
Cool the Lamp Completely 
The arc lamp operates at a very high pressure that increases with 
temperature. Failure to allow the lamp to sufficiently cool prior to 
handling increases the potential for an explosion causing personal 
injury and/or property damage. After turning the lamp off (powering 
down), it is crucial that you wait at least 10 minutes
 before turning off 
the breakers, disconnecting AC, and opening the lamp door. This 
provides enough time for the internal lamp cooling fans to properly cool the lamp. 
Cool completely
 before handling. Again, always wear Christie-approved protective 
clothing! 
 WARNING  
 Never attempt to access the lamp while it is on. 
 Wait at least 10 min. after lamp shut-off before powering 
down, disconnecting from AC, and opening the lamp door. 
 WARNING  
SHOCK HAZARD. Disconnect projection head and ballast from 
AC before opening the lamp door. 
For all other precautions critical for safe removal and replacement of the lamp, refer 
to 4.4. Replacing the Lamp & Filter. 
 
The high-intensity lamp and electronics rely on a variety of cooling components to 
reduce internal operating temperatures. Regular checking and maintenance of the 
entire cooling system is critical to prevent overheating and sudden projector failure, 
and helps to ensure reliable operation of all projector components over time. 
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. 
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 air flow, and can lead to 
overheating and failure of the projector. Check monthly.
 See 4.4, Replacing the 
Lamp & Filter for instructions. It is also recommended that you visually check the 
laminar airflow device (LAD) located nearby. The LAD should be nearly white or 
light grey in color. 
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 removing the igniter grille (rear side grille adjacent to the 
side input panel)—make sure 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: The cooler should require filling only upon projector 
installation. Fill with Christie’s 50/50 mix of distilled water and ethylene glycol. Top 
up as necessary, making sure not to over fill. 
 
 
4.2 Maintaining 
Proper Cooling 
 Ventilation 
 
  Air Filter 
 Liquid Cooler  
						

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Roadie 25K User’s Manual  
  IMPORTANT  
Whenever coolant has been added or replaced, check 
for a possible airlock upon the next projector power-up. 
After installation, check/maintain operation of both vane switches—one in the 
exhaust duct and one near the lamp fan—as follows: 
1. Turn projector 
ON (lamp is not needed). 
2.  Turn your extractor fan 
OFF. 
3.  Confirm that the LCD status display shows that the extractor fan vane switch 
has failed. Turn fan back 
ON to correct. 
4.  Block air intake at rear corner (input side) of projection head. 
5.  Confirm that the LCD status display shows that the lamp fan vane switch has 
failed. Clear air intake to correct. 
6.  Repeat all steps every 6 months in permanent installations. 
Maintain vane switches as described in 4.3, Maintenance and Cleaning. 
NOTE: If the exhaust duct becomes significantly blocked—or if a fan fails—the 
projector’s airflow sensor should trigger a shutdown before the projector becomes 
overheated or unsafe. Regardless, check the airflow periodically
.  
 
To help ensure optimized performance and reliability, check electrical, optical and 
other components regularly as described below. 
 WARNING  
SHOCK HAZARD. Disconnect projection head and ballast 
from AC at BOTH
 wall breakers. 
Do the following every 60 days or 500 hours of projector use (always disconnecting 
both the projection head and ballast from AC first): 

						

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Roadie 25K User’s Manual 4-5 
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—
make sure to wear protective clothing
 while inspecting or cleaning. Note that color 
on the reflector surface may vary—this is normal. 
Supplies 
For cleaning off dust and/or grease, you will need: 

						

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Roadie 25K User’s Manual  
apply pressure with your fingers—use the solution in the cloth to collect the 
dirt. 
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: 
LAMP FAN — A clogged lamp fan impeller or motor can reduce air flow, leading to 
possible overheating and failure of the lamp. Clean/treat the impeller as follows: 
1.  Vacuum loose dirt from the lamp fan impeller. 
2.  If necessary, use a brush with hot water and suitable detergent. 
 IMPORTANT  
Do not bend the impeller blades 
or loosen the balancing weights. 
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 duct 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 1) there are no obstructions or “kinks” within the ducting, 2) all air 
intake areas of the projection head and ballast are unobstructed, and 3) exhaust 
airflow at the top vent is 600 CFM. Make sure lamp wiring does not interfere with 
vane switch operation. See also 4.2, Maintaining Proper Cooling. 
LAMINAR AIRFLOW DEVICE (LAD) — Whenever checking/replacing the air filter on 
the side of the projector, also visually check the small square laminar airflow device 
(LAD) just beyond the filter opening. The LAD should be nearly white in color—if 
very dark (rare), it may have to be replaced by a qualified service technician. Contact 
Christie or your dealer. 
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. 
NOTE: For this procedure you will need a compatible Christie Xenon CDXL or CXL 
lamp as shown in Section 6, Specifications—never install a lamp intended for a 
different projector. 
 WARNING  
Make sure to use the correct wattage lamp supplied by Christie. 
 Other Components 
4.4 Replacing the 
Lamp & Filter 
 Lamp Replacement 
 Procedure  
						

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Roadie 25K User’s Manual 4-7 
 WARNING  
Lamp replacement is to be done by 
a qualified service technician only. 
 WARNING  
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. 
Turn off the projector 
Once off, allow the fans to run at least 10 minutes for cooling the lamp. 
 WARNING  
Never attempt to remove the lamp when it is hot. The 
lamp is under great pressure when hot and may explode, 
causing personal injury and/or property damage. 
Allow to cool completely. 
Set the ballast breaker (power switch) to OFF. 
Disconnect projection head
 and ballast from AC supply 
 WARNING  
SHOCK HAZARD. Disconnect both components from AC. 
Open the lamp door 
With protective clothing and shield on
, unlock the lamp door and open it. Refer back 
to Figure 2.19. If desired, release the tethered latch mechanism to remove the door 
entirely. 
Open lamp cooling compartment 
Turn knob to open the inner lamp cooling compartment and reveal the cathode end (–) 
of the lamp. Refer back to Figure 2.19. 
Remove the old lamp and inspect reflector 
6.1. Loosen set screws 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. 
6.2. Carefully
 slip the positive anode connector off the front of the lamp. 
6.3. 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. 
 WARNING  
Handle box with extreme caution—the lamp is hazardous 
even when packaged. Dispose of lamp box according to 
safety regulations for your area. 
 STEP 1 
 STEP 2 
 STEP 3 
 STEP 4 
 STEP 5 
 STEP 6  
						

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Roadie 25K User’s Manual  
6.4. With the lamp removed, visually inspect the reflector for dust. Clean if necessary 
as described in 4.3, Maintenance and Cleaning. 
Remove new lamp from protective cover 
7.1. Remove tape, knurled nut and locking star washer (if present) securing the lamp 
within its cover. 
7.2. 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. 
Install new lamp 
8.1. 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 (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. 
 
Figure 4.1.  Install Bulb 
8.2. 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. 
8.3. Tighten set screws in both negative and positive lamp connectors (Figure 4.2).   STEP 
7 
 STEP 8  
						

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Roadie 25K User’s Manual 4-9 
 
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.  
Check Leads 
Make sure that the anode (+) lead between lamp and igniter is well away from any 
projector metal such as the reflector or firewall. 
 WARNING  
Leads too close to metal parts will cause arcing during 
starting pulse. This is a SAFETY HAZARD
, 
and the lamp may not ignite. 
Close cooling compartment and lamp door 
The projector will not operate unless the louvered door is locked shut. 
Record the LAMP INSTALLED 
With a blue dot label or dry-erase pen, mark the lamp door’s 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.   STEP 9 

 STEP 10 
 STEP 11  
						

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Roadie 25K User’s Manual  
 
Figure 4.3. Always Mark the “Lamp Installed” Label 
(EXAMPLE) 
Re-connect to AC and turn breaker to ON 
Re-connect the projection head and the ballast to AC (see 2.1, Quick Setup), then set 
the ballast breaker to 
ON. 
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 under-powered nor over-driven upon power-up. 
 WARNING  
Do not attempt to ignite the lamp until its size (kW) is 
correctly defined in projector memory. 
1.  Refer back to Figure 3.29. Checking/Setting Lamp Size. Press Menu. The 
Status Display at the rear of the projector will show a “Lamp Size” of 2000, 
3000, 4500 or 6000 watts, depending on its last setting. Factory default=6000. 
2.  Enter either the Lamp Password shown in Figure 3.29, or the Christie service 
password. A password is required unless the “Enable Password” service 
option has been turned off. 
3. Use 
 to select which lamp is currently installed. Make sure the lamp 
type is also indicated on the lamp door label (see Figure 4.3). 
4.  When the Status Display shows the correct lamp type, the projector and lamp 
can be turned on. 
Power up & Ignite the Lamp 
Press 
 on any keypad. The projector will power up and the lamp will ignite. Wait 
approximately 10 minutes for the projector and lamp to warm up before continuing. 
Adjust lamp position 
Make sure the projector and lamp are warmed up. Then, from the Lamp menu, go to 
the LampLOC submenu and perform a “Do Auto” adjustment. It will take a minute or 
two as internal motors and sensors determine the ideal placement of the lamp. Proper   STEP 12 

 STEP 13 
 STEP 14 
 STEP 15