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Shutting down for maintenance

Always perform these steps before beginning any inspection or maintenance procedures on the

projector.

1. If the projector is operating, turn it off and allow it to cool for a minimum of 10 minutes.
2. Set the projector breaker switch to the off position.
3. Set the lamp power supply’s three breaker switches to the off positions.
4. Disconnect the projector from AC power.

Projector covers

Learn how to remove the covers and touch panel controller (TPC) of the projector.

Removing the touch panel controller

The touch panel controller (TPC) is a touch-sensitive screen used to control the projector, manage

sources, adjust the display, and view status information.
Estimated replacement time: 2 minutes

1. Remove the TPC tether (if installed) by removing the two screws from the ball joint on the

TPC and the ball joint on the projector which the tether is fastened to.

2. Disconnect the TPC harness from the connector on the projector’s back cover.

Disconnecting the TPC harness resets the TPC.

3. Loosen the TPC mounting arm slightly to remove the TPC assembly from the ball mount at

the back of the projector.

Parts and module replacement

Roadie 4K35 and 4K45 Service Manual

39

020-101694-03 Rev. 1 (01-2016)

Copyright

©

2016 Christie Digital Systems USA Inc. All rights reserved.

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Summary of Contents for Roadie 4K35

Page 1: ...Service Manual 020 101694 03 Roadie 4K35 and 4K45 ...

Page 2: ... such product has not been designed modified or approved by Christie for such use i Problems or damage caused by use of a projector in the presence of an oil based fog machine or laser based lighting that is unrelated to the projector j For LCD projectors the warranty period specified in the warranty applies only where the LCD projector is in normal use which means the LCD projector is not used mo...

Page 3: ...eaning the lamp blower 16 Inspecting and cleaning the fan extrator 17 Inspecting and filling the coolant reservoir 17 Inspecting the rear exhaust assembly 18 Filtration 18 Inspecting the light engine air filter 18 Inspecting the laminar airflow device filter 18 Inspecting and cleaning lamps 18 Removing dust from the lamp 19 Removing fingerprints smudges or oil from the lamp 19 Inspecting and clean...

Page 4: ...of image 33 Cannot communicate with the projector 33 Inaccurate display colors 34 Display is not rectangular 34 Display has suddenly frozen 34 Display is jittery or unstable 34 Parts and module replacement 35 Maintenance prerequisites 35 Tools required for service 35 Index of parts and modules 36 Shutting down for maintenance 39 Projector covers 39 Removing the touch panel controller 39 Removing t...

Page 5: ...4 52 Replacing the IMCB fan fan 18 52 Removing the main AC blower 53 Replacing the extractor fan 53 Removing the starter capacitor 54 Removing the liquid cooling reservoir 54 Removing the radiator 56 Replacing the main AC blower vane switch 57 Replacing the remote temperature sensor module 58 Removing the low profile extractor 58 Replacing the red FPGA blower fan 19 59 Replacing the firewall fan f...

Page 6: ...reaker switch 75 Replacing the AC relay 76 Replacing the low voltage power supply 77 Replacing the standby power supply 78 Lenses 79 Removing the projection lens 79 Replacing the lens mount 79 Replacing the anode yoke 80 Replacing the douser motor 81 Replacing the ceramic douser plate 81 Replacing the reflector and heat dump 82 Testing ground continuity and dielectric strength 82 Required test equ...

Page 7: ...95 F Minimum ambient temperature operating 10 C 50 F Power connection Learn the requirements for permanently wired installations or power cord connections Single phase 10A IEC320C14 lamp power supply to projector head or Single phase 15A North America 10A all other regions power cord projector head to AC mains The latter cord is provided for installations where the projector head is remotely lcoat...

Page 8: ...rtment and must remain closed and locked for normal operation Lamp replacement should only be performed by qualified technicians See Accessories E Low profile extractor Extracts heated air from the lamp compartment out the back of the projector The Roadie Ducted Exhaust kit not shown P N 113 107109 xx is available to duct hot air away from the projector See Accessories F Radiator access door panel...

Page 9: ...ojector AC power outlet Powers the projector head Do not use this outlet to power other devices B Main LPS breaker Acts as a power switch protecting the lamp power supply LPS against over current conditions of 40A or more C Projector Interlock and communication connections Provides communication between the projector and the LPS D DC cable connectors Locking connectors for DC cables These connecto...

Page 10: ...cs against over current conditions of 15 A or more H Power phase indicator lights Indicates the power on each of the three phases I LPS power inlet Supplies power to the LPS This connection must be wired by an electrician according to local regulations Introduction Roadie 4K35 and 4K45 Service Manual 10 020 101694 03 Rev 1 01 2016 Copyright 2016 Christie Digital Systems USA Inc All rights reserved...

Page 11: ...lustrates the path of electrical connections between modules Manufacturer s part numbers are included 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 Replacing modules To ensure you have the correct module and the projector module is replaced correctly...

Page 12: ...es but is not limited to protective electrically insulated footwear safety glasses and gloves rated for the working voltage of the equipment you are servicing Safety and warning guidelines Read all safety and warning guidelines before installing or operating the projector This projector must be operated in an environment that meets the operating range specification Use only the attachments and or ...

Page 13: ...rate the projector at the recommended voltage Danger Failure to comply with the following results in death or serious injury Disconnect projector from AC before opening any enclosure Warning Failure to comply with the following could result in death or serious injury FIRE AND SHOCK HAZARD Do not attempt operation unless the power cord power socket and power plug meet the appropriate local rating s...

Page 14: ... projector to cool down for a minimum of 10 minutes before performing maintenance or service procedures Indicates the presence of an electrical shock hazard To avoid personal injury always disconnect all power sources before performing maintenance or service procedures Indicates the presence of an electrocution hazard To avoid personal injury always disconnect all power sources before performing m...

Page 15: ...ightness can cause permanent eye damage Indicates possible optical radiation emitted from the product Indicates thermal radiation emitted from the product may cause burns This label warns of a cross connection hazard when installing multiple projectors at once A fire hazard exists if a lamp power supply interlock cable is connected to a different projector than its lamp power cables For more infor...

Page 16: ...m 20 inches around the projector and never block or cover the vents When replacing fans ensure you confirm the fan direction for airflow The correct orientation of the fan will also ensure that the fan harness reaches the connector Inspecting and cleaning the airflow interlocks Inspect and clean the airflow interlocks to remove accumulated dust or dirt that could impede movement Check Every 6 mont...

Page 17: ... folds or creases Do not apply finger pressure Use the solution in the cloth to collect the dirt 7 To reinstall the fan extractor repeat steps 2 to 4 in reverse order Inspecting and filling the coolant reservoir The liquid cooling module LCM circulates coolant through the digital micromirror device DMD heat sinks The coolant level should remain above the minimum level indicator and free from parti...

Page 18: ...onment Inspecting the laminar airflow device filter The laminar airflow device LAD filter is attached to the light engine assembly handle in the light engine compartment Check Every 6 months Replace the LAD filter Inspecting and cleaning lamps Inspect and clean the lamps to ensure optimum brightness Every 60 days Danger Failure to comply with the following results in death or serious injury This p...

Page 19: ...er 2 If some dust remains leave it as some dust is inevitable Avoid unnecessary cleaning Removing fingerprints smudges or oil from the lamp Remove fingerprints smudge or oil from the lamp to ensure optimum image brightness 1 Brush most of the dust off with a camelhair brush or use a dust free blower 2 Fold a microfiber cloth and wipe the remaining dust particles off the lamp with the smooth portio...

Page 20: ...ue such as Lensx 90 tissue or Newport Optics cleaning tissue For the lens only lens cleaning solution and microgiber cloth For the reflector only Methanol Isopropyl Alcohol Reagent Grade ACS 99 9 Acetone Reagent Grade ACS Optical grade cotton swabs with wooden stems Sticklers Fiber Optic Cleaner can be used on all optical components A bright portable illumination device such as an LED flashlight R...

Page 21: ...ree blower 2 Wrap a lens tissue around a swab and soak it in lens cleaning solution The tissue should be damp but not dripping Do not use a cleaning solvent that contains ammonia Avoid lens contact with Xylene and Ether 3 Gently wipe the surface using a figure eight motion 4 Repeat until the blemish is removed Service guidelines Roadie 4K35 and 4K45 Service Manual 21 020 101694 03 Rev 1 01 2016 Co...

Page 22: ... hold the Power button until you hear a beep Turning the projector off When powering off in preparation for inspection or maintenance always disconnect from AC 1 To turn the lamps off press and hold the Power button until you hear a beep When powering off the projector allow the projector to complete its cool down cycle Do not immediately unplug the projector if this can be avoided 2 To turn off p...

Page 23: ...e lock screw A and the lens mount stabilization screw D to maintain the adjustments 9 Check the boresight again 10 Adjust vertical boresight if required 11 To calibrate the lens motors tap Menu Configuration Calibrate Lens Motors Adjusting vertical boresight Boresight adjustment balances the tilt of the lens mount to compensate for screen to projector tilt Warning Failure to comply with the follow...

Page 24: ...are both well focused 9 Re focus the center of the image The goal is for good focus at the center and on all sides 10 Tighten the lock screw A and the lens mount stabilization screw D to maintain the adjustments 11 Check the boresight again 12 Perform a lens calibration tap Menu Configuration Calibrate Lens Motors Adjusting the fold mirror The fold mirror is used to bend the optical path If a corn...

Page 25: ...ie approved protective safety clothing must be worn when performing optical adjustments or servicing the product Caution Failure to comply with the following could result in minor or moderate injury 1 Display a full white field 2 Loosen the integrator assembly so that it can be manually moved 3 Adjust the focus Corners should be equal in focus although they may appear slightly blurry As necessary ...

Page 26: ...zoom and centering is complete 2 Ensure horizontal and vertical boresight procedures have been completed 3 Once at the required power settings allow 15 minutes for the unit to reach normal operating temperature 4 Converge the image a Evaluate the image convergence on page 27 b Adjust the image convergence on page 28 Related information Aligning the integrator module on page 25 DMD convergence The ...

Page 27: ...ad it to the projector you are working on if not present 2 Zoom and focus the image to see the entire outer edge of the test pattern frame 3 Using the horizontal and vertical white lines judge the convergence issues Look at one color at a time and remember that you can see a possible seven colors to lead you to a valid conclusion To help use the stripe pattern boxes along the outer frames Service ...

Page 28: ...n The blue formatter board differs slightly in physical layout but the adjustment functions are the same Typically the blue image component can be used as the fixed reference so no adjustment is required However if needed you can adjust the blue image component but you must remove the side panel The recommended normal convergence adjustments are from green to blue and red to green Screw 1 Screw 3 ...

Page 29: ...tal screw for the red and green formatters 4 Optionally remove the light engine air filter and fan pack to access the blue convergence adjustment screws and adjust the lines following steps 2 and 3 5 Review the alignment changes to ensure the convergence is satisfactory on page 29 and repeat steps 2 to 4 as necessary Related information Projector components on page 8 Image convergence assessment c...

Page 30: ...t in the lower right corner only The other three corners appear normal To minimize the effect on the bottom of the screen twist the image slightly counter clockwise Keep the subtitle zone as converged as possible If the problem appears to be more than an extra 1 2 of a pixel out of uniformity you may need a new lens prism assembly Service setups Roadie 4K35 and 4K45 Service Manual 30 020 101694 03...

Page 31: ...at must be addressed Use the touch panel controller TPC status menu to troubleshoot further Lamp does not ignite The projector is powered on but the lamp does not ignite Resolution Make sure all three breakers on the lamp power supply LPS are set to their on positions Check and correct all interlock failures Check the lamp power supply communication connections and restart the projector Verify tha...

Page 32: ... A fire hazard exists if a lamp power supply interlock cable is connected to a different projector than its lamp power cables Flicker shadows or dimness Images are flickering on screen have shadows or dimness when projected Resolution Make sure the shutter is fully open Verify that a LampLOC calibration is not already in progress Perform a LampLOC calibration Increase the lamp power Lamps which ar...

Page 33: ...anel controller communication harness is connected securely Blank screen no display of image The projector is powered on but the screen is blank and no image is displayed Resolution Make sure both lens caps have been removed from the projection lens Make sure the lamp is on Make sure that all power connections are good Make sure the shutter is fully open Make sure that any test pattern other than ...

Page 34: ...offset of the lens mount Display has suddenly frozen The image on the screen has frozen Resolution If the source is frozen restart the source device If the source is not frozen restart the projector Display is jittery or unstable The projected image has become jittery or unstable Resolution Verify that the input device is connected properly If the input device is not connected properly the project...

Page 35: ...nterconnect drawings on www christiedigital com Tools required for service Before servicing the projector ensure the following tools are available Keys for security locks Convergence Tool Set includes 2 5 mm driver with heat shrink tubing 2 0 inch and 6 5 inch lengths and an allen key convergence tool included for access to the red convergence mechanism Long and stubby neck magnetic tip ball drive...

Page 36: ...3 001515 XX knock out plate Touch panel controller TPC 003 105305 XX 003 111169 XX harness 003 003326 XX mount Light engine air filter 003 005010 XX Laminar airflow device LAD filter 03 001982 51P 3pk Card cage exhaust fans bottom fan 1 and 2 003 110827 XX Radiator fan Fan 3 003 112339 XX LAD fan fan 4 003 111697 XX Light engine fan pack fan 5 6 7 And 8 003 110827 XX Light engine fan fan 15 003 11...

Page 37: ...CDXL 70 Lamp Adaptor Kit CXL20 003 000598 XX 003 004251 XX 003 000599 XX 003 001165 XX 003 004252 XX 003 000600 XX 003 004253 XX 003 000601 XX 003 004254 XX 003 005087 XX 003 001728 XX Light engine 003 105277 XX 003 121330 XX water blocks 003 004672 XX MiniSAS cables Illumination optic system IOS 003 105488 XX Cold mirror 03 005027 52P Fold mirror 03 005028 51P Integrator snood Integrator assembly...

Page 38: ...03 120508 XX Standby power supply 003 120509 XX Lamp power supply LPS filter 003 000323 XX Projection lens Refer to the Specifications section in the User manual P N 020 101669 XX 020 101676 XX 020 101673 XX and 020 101678 XX Lens mount 003 105006 XX 003 003903 XX stepper motor 003 101194 XX focus motor 003 111069 XX center detector 003 101198 XX slide Anode yoke Douser motor 003 111976 XX Ceramic...

Page 39: ...nel controller TPC is a touch sensitive screen used to control the projector manage sources adjust the display and view status information Estimated replacement time 2 minutes 1 Remove the TPC tether if installed by removing the two screws from the ball joint on the TPC and the ball joint on the projector which the tether is fastened to 2 Disconnect the TPC harness from the connector on the projec...

Page 40: ...llations 1 Use finger pressure to push down on the shroud clips located at the top and bottom of the shroud as shown by the arrows 2 Carefully slide the shroud sideways and forward away from the lens mount and lens 3 Place the shroud covers on a clean surface to prevent scratches 4 To re install follow these steps in reverse order Removing the front top cover The front top cover provides access to...

Page 41: ...ure to comply with the following may result in property damage Christie products must be installed and serviced by Christie qualified technicians 1 Remove the front cover on page 40 2 Using the security key unlock the light engine cover 3 Lift up the cover and remove 4 To re install follow these steps in reverse order Parts and module replacement Roadie 4K35 and 4K45 Service Manual 41 020 101694 0...

Page 42: ...p side cover Estimated replacement time 1 minutes 1 Shut down the projector on page 22 2 Remove the shroud if installed on page 40 3 Loosen the three captive screws securing the cover 4 Pull the cover up to clear the bottom tabs and remove 5 To re install align the bottom tabs and follow these steps in reverse order Removing the lamp door Remove the lamp door to access the lamp compartment Estimat...

Page 43: ...ve the light engine air filter cover including filter on page 45 4 Remove the four screws securing the top of the cover to the chassis 5 Tilt the access panel frame a little to the front lift left side to clear the rear cover and remove 6 To re install align the bottom tabs and follow these steps in reverse order Related information Filtration on page 18 Removing the rear lens side cover The rear ...

Page 44: ...the back cover slightly for the bottom tabs to clear the frame and remove 5 To re install align the bottom tabs and follow these steps in reverse order Removing the front cover The front cover Estimated replacement time 35 minutes 10 minute calibration 1 Remove the front top cover on page 40 2 Remove the light engine cover on page 41 3 Remove the front lamp side cover on page 42 4 Remove the front...

Page 45: ...t and other foreign materials out of the projector Notice Failure to comply with the following may result in property damage Do not operate the product without the filter installed Use only high efficiency Christie approved filters Do not reuse an old air filter Removing the light engine air filter The light engine filter is located on the lens side of the projector behind the air filter cover Est...

Page 46: ... the fan will also ensure that the fan harness reaches the connector Replacing the card cage exhaust fans bottom fan 1 and 2 Fan 1 is located at the bottom of the card cage Estimated replacement time 18 minutes 1 Remove the front top cover on page 40 2 Remove the light engine cover on page 41 3 Remove the card cage assembly 4 Remove the two screws securing the fan compartment cover plate to the ba...

Page 47: ...ed information Filtration on page 18 Replacing the laminar airflow device fan fan 4 Estimated replacement time 5 minutes 1 Remove the front top cover on page 40 2 Remove the light engine cover on page 41 3 To remove the LAD fan housing from the light engine handle loosen the two captive screws Parts and module replacement Roadie 4K35 and 4K45 Service Manual 47 020 101694 03 Rev 1 01 2016 Copyright...

Page 48: ...causes overheating of the SFB FPGAs Estimated replacement time 8 minutes 1 Remove the front top cover on page 40 2 Remove the light engine cover on page 41 3 Remove the front lens side cover on page 43 4 Disconnect the three fan harnesses from the secondary EVB2 board 5 Loosen the two screws securing the right side of the fan pack to the frame 6 Loosen the thumbscrew securing the fan pack inside o...

Page 49: ...e label side faces into the projector and follow these steps in reverse order Replacing the light engine fan fan and15 Estimated replacement time 14 minutes 1 Remove the light engine fan pack fan 5 6 and 8 on page 48 2 Disconnect the required fan harnesses J39 from the secondary EVB board 3 Remove two screws securing the fan bracket Parts and module replacement Roadie 4K35 and 4K45 Service Manual ...

Page 50: ...e install follow these steps in reverse order Replacing the card cage intake fans top fan 10 11 and 12 Estimated replacement time 4 minutes per fan 1 Remove the front top cover on page 40 2 Remove the light engine cover on page 41 3 Disconnect the required fan harnesses from the primary EVB board 4 Disconnect the inline fan connector s and release the cables from the routing clip 5 Remove the four...

Page 51: ... the igniter fan and its safety cover 5 Replace the igniter fan 6 To re install the igniter fan follow these steps in reverse order Replacing the HIP fan fan 13 Estimated replacement time 16 minutes per fan 1 Remove the card cage 2 Disconnect the fan inline connector 3 Remove the four screws securing the fan Parts and module replacement Roadie 4K35 and 4K45 Service Manual 51 020 101694 03 Rev 1 01...

Page 52: ...ve the liquid cooling pump fan 5 Replace the liquid cooling pump fan 6 To secure the liquid cooling pump fan follow these steps in reverse order Replacing the IMCB fan fan 18 Estimated replacement time 5 minutes 1 Remove the touch panel controller on page 39 2 Remove the rear cover on page 44 3 Disconnect the fan connector 4 Remove the four screws securing the fan Parts and module replacement Road...

Page 53: ...screw and remove both foot extension rods if present 5 Disconnect the AC blower harness 6 Remove the three captive screws securing the blower 7 Remove the blower through the back of the projector Make sure the blower is removed on an angle to avoid contacting the AC blower vane interlock switch 8 Remove the four screws securing the blower to the mounting bracket 9 To complete the installation repe...

Page 54: ... time 5 minutes 10 minute lamp calibration 1 Remove the lamp 2 Remove the front top lid 3 Remove the rear top lid 4 Use an adjustable wrench to remove the locking nut for mounting the capacitor 5 Disconnect the two harness connections to the terminal block 6 Remove the starter capacitor 7 To install the starter capacitor repeat these steps in reverse order Removing the liquid cooling reservoir To ...

Page 55: ...ions harness from the coolant reservoir 5 Disconnect the coolant hoses from the coolant reservoir 6 Remove the three screws securing the reservoir bracket to the projector base plate Parts and module replacement Roadie 4K35 and 4K45 Service Manual 55 020 101694 03 Rev 1 01 2016 Copyright 2016 Christie Digital Systems USA Inc All rights reserved ...

Page 56: ...nd the filler cap 12 Check for proper flow from the liquid cooling module Removing the radiator Estimated replacement time 5 5 minutes 1 Remove the front top lid on page 40 2 Loosen the four screws securing the radiator to the frame 3 Disconnect the two disconnect hoses for the radiator Parts and module replacement Roadie 4K35 and 4K45 Service Manual 56 020 101694 03 Rev 1 01 2016 Copyright 2016 C...

Page 57: ...le the vane switch Do not attempt to operate the product with inadequate airflow which can result in dangerous overheating 1 Remove the main AC blower on page 53 2 Disconnect the two harnesses from the vane switch 3 Remove the three screws securing the bracket to the baseplate 4 Remove the two screws securing the switch to the bracket 5 Remove the vane switch 6 To install the main blower vane swit...

Page 58: ...sensor module remove the eight screws securing the exhaust blower cover 5 Remove the one screw securing the RTSM 6 To install the RTSM repeat these steps in reverse order Removing the low profile extractor Estimated replacement time 10 minutes 1 Remove the front top lid on page 40 2 Remove the rear top lid on page 42 3 Remove the eight screws 4 Release the brown blower L cable blue blower N cable ...

Page 59: ...ine area by exhausting hot air out of the projector 1 Remove the front top lid on page 40 2 Remove the light engine lid on page 41 3 Remove the front lens side cover on page 43 4 Remove the light engine fan pack on page 48 5 Remove the liquid cooling reservoir on page 54 6 Remove the firewall fan by pulling it away from the firewall and off the four rubber isolators 7 Replace the fan if required 8...

Page 60: ...necting it from AC and opening the lamp door Caution Failure to comply with the following could result in minor or moderate injury EXPLOSION HAZARD Handle a lamp by the cathode and anode end shafts only Do not handle the lamp by the glass Warning Failure to comply with the following could result in death or serious injury EXPLOSION HAZARD Lamps and bare bulbs even when packaged may explode if drop...

Page 61: ... lamp or bare bulb in any way EXPLOSION HAZARD Do not over tighten the lamp 1 Shut down the projector on page 22 2 Remove the new lamp from the protective case Before removing the lamp from the case loosen the cathode screw and remove the cathode nut from the lamp 3 If installing a lamp different than what was removed use the table below to determine the correct position of the anode yoke assembly...

Page 62: ... as the reflector plate or firewall 11 Re install the front lamp duct 12 Close and lock the lamp door 13 Connect the projector to AC power 14 Set the projector breaker switch to the on position 15 Record new lamp information a Tap Menu Lamp Change Lamp b Type the Lamp Type Serial Number and Hours Used c Tap Apply Lamp Change d Tap Continue 16 Perform a lamp calibration Replacing the light engine W...

Page 63: ...gine fan pack on page 48 6 Disconnect the two coolant hoses from the disconnects 7 Loosen the screw securing the bracket to the firewall 8 Remove the bracket 9 Loosen the screw securing the heat dump 10 Remove the heat dump Parts and module replacement Roadie 4K35 and 4K45 Service Manual 63 020 101694 03 Rev 1 01 2016 Copyright 2016 Christie Digital Systems USA Inc All rights reserved ...

Page 64: ... Replacing the illumination optic system Estimated replacement time 15 minutes 15 minute calibration Warning Failure to comply with the following could result in death or serious injury UV EXPOSURE Protective UV safety glasses with side shields and Christie approved protective safety clothing must be worn when performing optical adjustments or servicing the product 1 Remove the projection lens on ...

Page 65: ...al adjustments or servicing the product 1 Remove the front top lid on page 40 2 Remove the light sensor module on page 67 3 Remove the radiator and radiator fan on page 56 4 Remove one screw from each tab 5 Loosen the other screws from each tab 6 Wearing clean lint free gloves provided in the service kit carefully slide the cold mirror out 7 Place the cold mirror into the holder with its reflectiv...

Page 66: ... 2 Remove one screw from each tab 3 Loosen the other screws from each tab 4 Wearing the gloves provided with the service kit hold the mirror in place and swing the tabs out to the side 5 Carefully lower the mirror and remove 6 To install the fold mirror repeat these steps in reverse order 7 Before replacing the fold mirror cover adjust the fold mirror on page 24 Replacing the integrator snood Esti...

Page 67: ... assembly and set aside in a clean area where it cannot be damaged 5 To complete the installation repeat these steps in reverse order 6 Adjust the integrator on page 25 7 Adjust the fold mirror on page 24 Replacing the light sensor module Estimated Replacement Time 10 minutes 1 Remove the front top lid on page 40 2 Disconnect the light sensor module LSM harness from the inline connector 3 Remove t...

Page 68: ...ll the UV filter with the arrow marking on the side pointing towards the lamp 7 To complete the installation repeat these steps in reverse order 8 Perform a lamp calibration Electronics Learn how to replace the boards and cards in the projector Replacing the backplane Estimated replacement time 25 minutes 1 Remove the card cage 2 Remove the MCPU board on page 70 3 Remove the option cards on page 7...

Page 69: ... should have a software update done to them Replacing the high speed image processor Estimated replacement time 25 minutes 1 Remove the card cage 2 Remove the MCPU board on page 70 3 Remove the option cards on page 70 4 Remove the 10 screws from the rear of the card cage 5 Remove the rear cover on page 44 6 Remove the nine screws securing the high speed image processor board 7 Gently disconnect th...

Page 70: ... and slide out 4 To install the MCPU board repeat these steps in reverse order Related information Filtration on page 18 Replacing the option cards Estimated replacement time 1 5 minutes 1 Loosen the two captive screws securing the required card s to the card cage 2 Grip the two captive screws and slide out Parts and module replacement Roadie 4K35 and 4K45 Service Manual 70 020 101694 03 Rev 1 01 ...

Page 71: ...rew securing the EVB in place 6 Remove the EVB 7 To install the primary EVB repeat these steps in reverse order Replacing the secondary environmental board Estimated replacement time 8 minutes 1 Remove the front top lid on page 40 2 Remove the light engine lid on page 41 3 Disconnect the nine harnesses from the secondary environmental board EVB2 4 Loosen the thumbscrew securing the secondary EVB2 ...

Page 72: ...ion repeat these steps in reverse order 6 Perform a lamp calibration Replacing the lamp adjuster Estimated replacement time 15 minutes 10 minute calibration This procedure also includes removing the integrated motor control board IMCB 1 Remove the lamp if installed on page 60 2 Remove the rear cover on page 44 3 Disconnect P35 P36 and P94 from the IMCB 4 Remove the screw securing the cathode cable...

Page 73: ...ions P1 P3 a nd P4 3 Remove the four hex head screws securing the centrifugal fan interface board CFIB 4 Remove the CFIB 5 To install the CFIB repeat these steps in reverse order Power supplies Learn how to replace power related components Replacing the igniter Estimated replacement time 35 minutes 10 minute calibration When installing the positive and negative igniter harness leads to the igniter...

Page 74: ...move the bolt lock washer washer and cathode harness 12 With a 17 mm rachet remove the anode connection 13 With a 17 mm rachet and 6 inch adjustable wrench remove the cathode nut and bolt 14 Remove one screw from ignition wire 15 Disconnect igniter postive and negative harness connections 16 Remove two hex head screws securing the igniter assembly from the base 17 Remove the igniter assembly 18 Tr...

Page 75: ... To install the AC line filter repeat these steps in reverse order Replacing the AC breaker switch Estimated replacement time 4 5 minutes 1 Loosen the two screws securing the access plate on the underside of the projector baseplate Parts and module replacement Roadie 4K35 and 4K45 Service Manual 75 020 101694 03 Rev 1 01 2016 Copyright 2016 Christie Digital Systems USA Inc All rights reserved ...

Page 76: ... AC relay Estimated replacement time 10 minutes 1 Remove the rear lens side cover on page 43 2 Remove the screw closest to the blower and loosen the screw closest to the igniter shield 3 Lift the PVC shield to one side to gain access to the AC relay 4 Loosen the six screws securing the harnesses to the AC relay 5 Remove the eight harnesses Parts and module replacement Roadie 4K35 and 4K45 Service ...

Page 77: ...move the front top lid on page 40 2 Remove the rear lens side cover on page 43 3 Remove the rear top lid on page 42 4 Disconnect the four cables at the inline connection bracket 5 Release the 24V standby cable from the routing clip 6 Cut the cable tie if applicable 7 Release the blower vane switch cable from the routing clips 8 Disconnect the inline relay blue black harness 9 Disconnect the AC inl...

Page 78: ...in reverse order Replacing the standby power supply Estimated replacement time 12 minutes 1 Remove the low voltage power supply LVPS on page 77 2 Loosen the thumbscrew securing the standby power supply 3 Disconnect and remove the standby power supply 4 To install the standby power supply repeat these steps in reverse order Parts and module replacement Roadie 4K35 and 4K45 Service Manual 78 020 101...

Page 79: ... and the eyebolt The lens safety cable is provided with the Roadie 4K or Mirage 4K R lenses Only use this lens safety cable Warning Failure to comply with the following could result in death or serious injury The lens safety cable provided with the lens or service kit must be installed for overhead installations 8 To complete the installation repeat these steps in reverse order 9 Perform a lens ca...

Page 80: ...st remove the nut assembly on the other side of the front faceplate 7 Remove the main focus screw 8 Remove the lens mount assembly 9 To complete the installation repeat these steps in reverse order 10 Perform vertical on page 23 and horizontal on page 22 boresight alignments Replacing the anode yoke Estimated replacement time 7 minutes 10 minute calibration 1 Remove the lamp if installed on page 6...

Page 81: ...ve the motor 6 To install the douser motor orient the motor with the harness protruding from bottom 7 To complete the installation repeat these steps in reverse order 8 Perform a lamp calibration Replacing the ceramic douser plate Estimated Replacement Time 9 minutes 10 minute calibration 1 Remove the lamp if installed on page 60 2 Remove the rear cover on page 44 3 Remove the douser motor on page...

Page 82: ...r screws and retaining clips securing the heat dump 13 Wearing clean lint free gloves carefully slide the cold mirror out 14 Remove the four screws and retaining clips securing the inner reflector and remove it 15 Remove the four screws and retaining clips securing the outer reflector and remove it 16 To install the reflector and heat dump repeat these steps in reverse order 17 Perform a lamp cali...

Page 83: ... 2 Remove the side cover from the LPS a Loose the bottom three screws b Remove the top three screws c Lift and remove the side cover 3 Disconnect the two DC output cables from the LPS see E and F in the diagram A AC convenience outlet B AC convenience outlet C Three phase AC input opening D AC input terminal block E DC output cable opening F DC output cable opening Parts and module replacement Roa...

Page 84: ...ty test to verify a continuous conductive path exists for current to flow in the event of a fault 1 Attach one test lead into the lamp power supply LPS each ground post 2 Attach the second test lead into an LPS AC convenience outlet ground terminal 3 Verify the ground integrity 4 For the second AC convenience outlet repeat steps 2 and 3 5 If a pluggable three phase cord is used on the LPS complete...

Page 85: ...s Dwell Time s DC 2 12 7 1 0 4 6 2 Create a test cable a Acquire a AC female line cord b Strip the leads on the non plug end of the cable c Twist the line and the neutral black and white or blue and brown together to create a short 3 Attach the test high voltage HV lead to the lamp power supply LPS line and neutral shorted together terminals of an AC auxiliary outlet 4 Attach the test return lead ...

Page 86: ... down and that no leakage current is below 7 1 mA 9 If a line cord is not used complete the following a Attach the test return lead to the LPS earth ground post b Attach the test high voltage HV lead to the LPS L1 L2 L3 and N shorted together terminals of the AC input terminal block c Ensure no one is touching the EUT and perform the test as per the test equipment instructions d Verify there is no...

Page 87: ... 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 Eastern Europe and Russian Federation ph 36 0 1 47 48 100 China Shanghai ph 86 21 6278 7708 China Beijing ph 86 10 6561 0240 Brazil ph 55 11 2548 4753 Australia ph 61 0 7 3624 4888 Worldwide offices Italy ph 39 0 2 9902 1161 Consultant offices Canada Kitchener ph 5...

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