Kinoton FP 30 D User Manual

FP 30 D

4 Operating Elements

4.1 Main Switch

The main switch is mounted in projector door (arrow, FP 30 D with 15x15 Matrix).

Main switch in position I:

Current is switched on. The switch lights up red.

Main switch in position 0:

Current is switched off. The switch is not lit up.

Figure 4-1 Main switch

Operating Manual 4-55

4.1.1 Operating Panel for FP 30 D

NOTE

Figure 4-2 Operating panel (example)

Operating panel buttons

projector stop (red)

projector go

film positioning

dowser open

dowser close

lens and aperture change to normal screen (option)

lens and aperture change to wide screen (option)

lens and aperture change to cinemascope (option)

reverse running (option)

AUTO

START

Starts automatic operation

selects aperture combination (only turret with two lenses)

The buttons

are optional.

, , and

4-56

NOTE

As soon as projector is switched on the buttons illuminate white or red.

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FP 30 D

4.2 External Operating Elements

4.2.1 Control Panel BWR

Figure 4-3 Control panel

NOTE

As soon as panel is activated (main switch is switched on) the buttons illuminate white or red.

Buttons

switch-on auditorium light bright

switch-on auditorium light for slight performance

stop auditorium light dimmer (red)

switch-off auditorium lights

switch-on stage lights bright

stop stage light dimmer (red)

switch-off stage lights

Operating Manual 4-57

BW1

BW2

select mask 1

select mask 2

select CS mask

stop masking movement (red)

change lens/aperture to format 1

change lens/aperture to format 2

change lens/aperture to CS format

open curtain

FWD

STOP

stop curtain movement (red)

AUTO

START

close curtain

focusing

framing

open dowser

close dowser

start projection running

stop projection running

start automatic operation

4-58

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FP 30 D

4.2.2 Auditorium Control Panel (option)

Figure 4-4 Auditorium control panel

NOTE

As soon as panel is activated (main switch is switched on) the buttons illuminate green or red.

Buttons

AUTO

START

AUTO STOP

switch-on auditorium light bright

stop auditorium light dimmer (red)

switch-off auditorium lights

switch-on auditorium light for slight performance

start automatic operation

stop automatic operation

switch-on stage lights bright

stop stage light dimmer (red)

switch-off stage lights

focusing

framing

loudness control When loudness control is activated, LED lights up.

Operating Manual 4-59

4-60

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FP 30 D

5 Operation and Troubleshooting

5.1 Operation

5.1.1 Switch-On / Switch-Off Switch-On

1. Switch-on external power supply in performance room.

2. Switch-on main switch

(position мIо).

3. Thread film and do all adjustments either manually or automatically by pushing

the corresponding buttons.

AUTO

4. Push the button

at operating panel or push the button

START

, the program

runs automatically.

- Projector is running.

- Xenon lamp is on.

- Ventilation is running.

Switch-Off

1. Push the button

at operating panel of projector or at control panel. The

projector stops.

2. Switch-off main switch

(position м0о) of projector. The light is off.

- Projectors stops.

- Xenon lamp gets off.

- Ventilation is running.

3. Switch-off external power supply.

NOTE

If you have an emergency, push the main switch

(position м0о).

Operating Manual 5-61

5.1.2 Start Program Threading for Operation

1. Put film reel on take-off shaft of projector or prepare non-rewind system (see operating manual ST 200 E / MT 600/2000).

2. Thread film in feed sprocket (film perforation onto sprocket teeth).

3. Thread film in film track and close film pressure skate.

4. Lead film via guide rollers to sound device and then to bottom sprocket.

5. Wind-up the film several times around the take-up reel or lead film to мtake-upо level of non-rewind system.

Figure 5-1 Threading instruction

5.1.3 End Program

1. Close gate shutter by push button panel.

at projector operating panel or at control

5-62

2. Due to the film break sensor the projector stops automatically, when the film is through.

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FP 30 D

5.2 Troubleshooting

5.2.1 General Hints

Currently technology and programming guarantee a perfect process of system, nevertheless there could be problems because of incorrect operation, poor maintenance, wrong procedures and other things. This chapter has information about possible problems and error messages and about solving these problems.

Basically the system distinguishes two types of errors: error type 1: projector stops immediately error type 2: errors which do not stop projector

5.2.2 Trouble Shooting Chart (error type 2)

Problem

noisy operation

intermittent movement is worn reels are curved friction shafts hit chains and/or gears are worn film is threaded wrong

rollers seize poor cleaning

no lubrication

oil leak oil too fluid / too much oil

oil line is blocked seals are defective

foam in oil gauge glass

film break when starting

wrong oil too little oil frictions are not adjusted correctly friction is too dry

exchange (service) repair or exchange exchange exchange thread correctly

(see chapter 5.2.1) clean regularly lubricate (see chapter 6.2.2) observe type of oil and quantity

(see chapter 6.2.2) clean oil line replace seal exchange fill oil adjust lubricate with Cardan oil

Operating Manual 5-63

Problem

picture moves vertically (jumps)

picture moves horizontally (weaves)

perforation damage in direction of travel

perforation damage against moving direction

skate pressure is not adjusted correctly intermittent sprocket hits film print defective skate is worn coupling bushing defective intermittent movement defective

ceramic rollers are blocked or worn lateral guide rollers are worn tension rollers are blocked take-off friction is too strong skate pressure is too strong intermittent sprocket or feed sprocket

teeth have worn take-up friction is too strong bottom sprocket teeth have worn

adjust

exchange (service) new print exchange exchange (service) exchange (service) move manually or exchange exchange move or exchange loose adjust exchange the worn sprocket

adjust exchange

perforation side damage

scratches on film

picture blurring

sprockets teeth are damaged film track position is not correct pad shoe is damaged emulsion particles on rollers rollers, skate, sound track and/or film

runner strips are defective or worn friction works unevenly film loop is too large shutter is not adjusted correctly pressure of skate too low

exchange adjust exchange clean exchange the worn or defective

one adjust thread film correctly adjust increase pressure

ATTENTION

If there are any serious other problems please call local service or head office of KINOTON, telephone 00 49 / 89 / 89 44 46-0.

5-64

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FP 30 D

6 Maintenance / Cleaning and Repair

6.1 General Hints

ATTENTION

Allow work on electric supply to be carried out by competent electricians only.

??

Make sure that nobody starts the projector while you are working on it.

??

You must disconnect projector from power supply (switch off main switch) before any maintenance and cleaning work.

All adjustments are to be carried out by experts.

??

Because KINOTON uses maintenance-free elements, the consumption of material and the expenditure of time for maintenance work and repair are reduced to a minimum.

The necessary maintenance and cleaning work must be carried out by the projectors operators. This work has to be carried out regularly and carefully. See the following cleaning and maintenance lists regarding this.

6.2 Cleaning and Maintenance

6.2.1 Cleaning After each film running

film track pad shoes film gate / aperture sprockets

Daily

projector Remove dust with a soft cloth. pad shoes Clean with a soft toothbrush. lens Clean with a badger bristle brush.

film track Clean with a soft tooth brush or cloth.

Blow out with air pressure or clean with a soft toothbrush.

Remove oil and finger prints with a lens tissue which is lightly moistened with alcohol.

ATTENTION

Never use sharp objects to remove hard particles out of film track.

Operating Manual 6-65

Weekly

projector Clean with a soft cloth. aperture changer Clean steel rod and brass tube with a cloth and the

Monthly

water cooling Clean air condenser with a brush.

6.2.2 Maintenance Weekly

water cooling Check whether all hose connections are tight. aperture changer After cleaning lubricate the threaded spindle with

threaded spindle with a brush.

Klёberplex BEM 43-132.

Do not lubricate the brass tube

!.

Monthly

guide rollers Lubricate the guide roller shafts with Esso universal oil.

NOTE

The guide rollers cannot replace each other.

reel shafts Lubricate the friction shafts with Esso universal oil.

Every three months

lens holder Lubricate the slides of lens holder with EL 4854. gear / worm shaft of

shutter / chains

Lubricate the gear, worm shaft of shutter and chains with Esso universal oil.

Yearly

sound device Lubricate the pressure roller and ball bearings with

Cardan oil, type 8657 and pressure roller shaft with Esso universal oil.

NOTE

To do this you must remove the roller arm (sound device standard) with its roller. Adjust the tension of the torsion spring to 350 to 400 g (measured at shaft).

6-66

water cooling Empty and clean heat exchanger.

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FP 30 D

After reconditioning

sound shaft / sound pressure roller

Lubricate the ball bearings of pressure roller with oil, type EL 4854.

water cooling Check whether pumps and refrigerating set are closed

and not defective.

6.2.2.1 Greasing the Intermittent Movement

Change oil (type 3672):

after 50 operating hours

??

after 100 operating hours

??

after 500 operating hours

??

after every 2000 operating hours or once in a year

??

Filling oil in intermittent movement

Fill oil, type 3672.

Fill oil through hose after removing the cover of the oil gauge. The oil level has

??

to be between the red and green ring. During filling, turn motor slowly by hand so that the air bubbles can escape and

??

turn frame twice. If necessary fill in more oil. Put cover on oil gauge and insert hose in clip again.

??

NOTE

The oil quantity is about 200 ml.

Operating Manual 6-67

6.3 Repair

6.3.1 Tensioning the Chains NOTE

The chains must not be taut, but must not flap during movement.

Adjust the tension of chains:

Upper chain

Loosen feed sprocket assembly (arrow) by the two hexagon socket screws and slide vertically until the chain is tensioned correctly.

Figure 6-1 Tension upper chain

Lower chain

Loosen the three screws at the bearing flange of the take-up friction (arrow).

Turn flange in 120° steps until the chain is tensioned correctly.

Fasten flange again.

Figure 6-2 Tension lower chain

6-68

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FP 30 D

6.3.2 Exchanging the Sprocket

Figure 6-3 Exchange sprocket

1. Loosen film stripper screws and remove film stripper .

2. Turn anticlockwise sprocket screw five to six turns (screw is not visible in figure, it is in the middle of the sprocket ).

sprocket film stripper pad shoe

3

1

2

3. Open pad shoe and pull sprocket from shaft.

NOTE

If the teeth of sprocket are worn on one side only, you can turn it and use the other side. Otherwise you have to replace the sprocket.

4. Install new sprocket on the shaft with slight counter-pressure on the chain wheel (inside of projector).

5. Tighten clamping screw.

NOTE

The end play of the sprocket may have a value between 0,01 and 0,03 mm.

6. Insert film stripper . Place two pieces of film between sprocket and film stripper. Lightly press stripper against the film, tighten stripper screws.

Operating Manual 6-69

6.3.3 Exchanging the Pad Shoe

pad shoe distance screw

1

pad shoe spring cage with adjusting screw

2

3

Figure 6-4 Exchange pad shoe

1. Loosen locking screw and adjusting screw с the spring will relax.

2. Pull pad shoe from its shaft.

3. Grease shaft with Cardan oil.

4. Install new pad shoe on shaft.

5. Place torsion spring in the hole of spring cage and place the whole assembly in pad shoe.

6. Adjust distance screw in a way that a play of three film thickness is between pad shoe and sprocket.

NOTE

Be sure that spring end is placed exactly in hole of pad shoe.

7. Adjust tension of spring by turning adjusting screw clockwise that pad shoe pressure is: 450 g

50 g open

?

150 g to 250 g closed (measured at pad shoe with spring scale).

8. Tighten hexagon socket screw.

6-70

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FP 30 D

6.3.4 Exchanging the Xenon Bulb

Figure 6-5 Xenon unit

DANGER

Wait ten minutes after switching off xenon lamp to open lamphouse.

??

mirror xenon bulb in protective coat bulb stay anode cable (+) hexagon socket screw to fix the

xenon bulb (not visible in figure)

The power of xenon lamp and rectifier must be switched off all-polo. Therefore

??

switch off main switch of projector and screw out fuse of lamphouse. You can suffer hurts when broken glass is flying around (xenon bulb has an

??

inner pressure of 8 to 10 bar in cold condition and about 30 bar in hot condition). Because of that you have to wear protective suit, protective gloves and face/neck protection during all works on open lamphouse.

Disassembly

1. Remove door of lamphouse.

2. Put protective coat around bulb.

3. Remove positive cable from connecting bolt in lamphouse.

4. Remove xenon bulb: Loosen hexagonal socket screw behind xenon lamp. At the same time hold bulb with the other hand.

5. Carefully pull bulb out of hole of mirror .

DANGER

Because of explosion danger the used xenon lamp room.

must not

lie in performance

If you want to use it again it is recommended to pack xenon bulb in original package and store it in a box. Give the packed xenon bulb back to your purveyor.

Operating Manual 6-71

Assembly

DANGER

Xenon bulbs are high-pressure glow-discharge lamps. Insert xenon bulb (without 7000 W bulb) in protective coat only. Do not insert with violence. Do not insert by touching the anode base. Wear protective cloves and a face / neck protection.

If you insert the 7000 W bulb you have to wear a protective suit because the protective coat must be removed before inserting it.

1. Remove cap of protective coat of xenon bulb up to 2000 W.

2. Thread xenon bulb in protective coat (wind solid cloth around 7000 W bulb) with cathode base in front through central hole of mirror .

3. Hold bulb with one hand and fasten it with your other hand. Tighten screw with an Allan key.

NOTE

Xenon lamps up to 2000 W are directly screwed in socket. With xenon lamps from 2000 W onwards you have to screw an adapter on bulb, the hexagonal socket screw will be screwed in adapter to fasten xenon bulb (see point 3).

4. Remove protective coat (up to 2000 W).

5. First adjust the screen illumination (see next chapter 6.3.5).

6. Lay anode base on bulb stay (bulbs with 2000 to 7000 W). Adjust bulb stay in height so that xenon bulb is lying in a horizontal level.

7. Fasten xenon bulb anode cable at connecting bolt in lamphouse.

8. Close door of lamphouse and tighten screws.

6-72

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FP 30 D

6.3.5 Adjusting (illumination of screen) the Xenon Bulb

6

7

1

5

4

2

3

Figure 6-6 Adjustments of xenon bulb

You can adjust the xenon bulb against mirror in three levels (horizontal , vertical and axial ).

xenon bulb bulb stay stabilising magnet horizontal

adjustment

axial adjustment vertical

adjustment

mirror

1. Open lamphouse and loosen the bulb stay .

2. Close lamphouse and start projector.

DANGER

Open lamphouse after a waiting period of 10 minutes only.

??

The current of lamp and rectifier must be switched off all-polo. Switch-off main

??

switch of projector and turn out fuse of lamphouse. Work at open lamphouse to be carried out has be done with protective suit,

??

cloves and face shield. You can seriously hurt yourself when xenon bulb explodes and broken glass is flying around.

3. Select CS format.

4. Do all adjustments through the openings in lamphouse.

5. Turning hexagon socket screw , the xenon lamp is adjusted as much along the optical axis until only a reduced round illuminated spot can be seen on screen.

6. By turning adjusting screws right с left (horizontally) and up с down (vertically) you have to bring this light spot precisely into the middle of the screen.

7. Fasten the bulb stay in the adjusted position.

Operating Manual 6-73

NOTE

Whenever in extreme special cases the described way to adjust is not possible, you can change the mirror position with the aid of the adjusting screws of mirror holder. The adjustment of light arc is to be done with the aid of the stabilization magnet . These adjustments are to be carried out by authorized experts or service men of KINOTON only. (see service chapter 9.3).

6.3.6 Exchanging the Mirror

adjusting screw above mirror adjusting screw below adjusting screw below adjusting screw other mirror mirror holder fixing screw

Figure 6-7 Mirror

ATTENTION

Open lamphouse after a waiting period of 10 minutes only.

??

The current of lamp and rectifier must be switched off all-polo. Switch-off main

??

switch of projector and turn out fuse. Work at open lamphouse to be carried out has be done with protective suit,

??

cloves and face shield. You can seriously hurt yourself when xenon bulb explodes and broken glass is flying around.

Disassembly

1. Remove door of lamphouse.

2. Remove xenon bulb as described in chapter 6.3.4, Disassembly.

6-74

3. Loosen fixing screw of mirror holder on the top ?.

4. Take out mirror carefully.

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FP 30 D

Assembly

ATTENTION

Do not touch the inner side of mirror (reflecting surface) with bare hands. If necessary, remove fingerprints with alcohol-soaked cloth.

1. Place mirror into lower holders and swing the upper one above the mirror and place it on the edge of the mirror.

2. Tighten fixing screw ?.

3. If necessary adjust adjusting screws , and .

ATTENTION

Care must be taken that the mirror is not firmly clamped, otherwise when heated during operation it would not be able to expand and would brake. The mirror should lie on the two lower holders only while it is pressed by the spring

, lightly against the front edge of the holder only.

4. Insert xenon bulb (see chapter 6.3.4, Assembly).

NOTE

The optical axis is factory-set. If adjustment is necessary, it is carried out by experts or service men of KINOTON only (see chapter 9.4).

Operating Manual 6-75

6.3.7 Exchanging the Heat Filter ATTENTION

The heat filter is a reflection filter, therefore you have to watch out for the

reflection side of filter to be directed to xenon lamp

You can see the edge of reflection coating when you look at the small side of

??

filter holding it against the light. The reflection side is slightly adhesive. Touch the filter on one edge with your

??

fingers - On the adhesive side you will see a fingerprint.

Lamphouse up to 2000 W

.

fixing bar heat filter holders

1. Loosen screws of fixing bar.

2. Lift up heat filter a little bit and sidely pull out.

Figure 6-8 Heat filter

3. Place the new heat filter by sidely shoving it in fixing bar at the top and inserting it into the holders at the bottom.

4. Tighten screws of fixing bar.

5. Remove protective foil.

Lamphouse 2000 to 7000 W

1. Pull out the old heat filter.

2. Remove protective foil from the new filter!

3. Put heat filter on the lower holders and press the filter against the spring (arrow) until it arrests at the end of the spring (clamping).

6-76

Figure 6-9 Heat filter

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7 Lists of Parts and Wearing Parts

7.1 Projection Parts

Part Figure Pos. Piece

film runner strips white 7-1/7-2 guide roller half

guide roller cap film cleaner 7-1 sprocket 16 tooth

sprocket shaft bearing

pad shoe nut spring

guide roller cap (small) guide roller (small) half

film pressure skate spring

knurled screw for runner strips 7-1/7-2 knurled screw for lens fastening 7-2 ceramic roller 7-2 fuse 6.3 AT 01 4822 253 30031

7-1/7-3

7-1

1 2

3 4

5

6

7

8 9

10

01 5322 463 10021 01

01 01 0040 060 0048X 01

01 01

01 01 01

01 01

01 5322 505 10192 01 5322 502 10336 01 5322 532 50362

Item No.

5322 525 60096 5322 462 70374

5322 522 30119 5322 522 30407 5322 520 10025

5322 525 30003 5322 462 50027 5322 492 40001

5322 462 70373 5322 525 60095

5322 463 10019 5322 492 60122

Operating Manual 7-77

7.2 Drive Parts

Part Figure Index No. Item No.

chain wheel shaft

upper chain 7-4 12 5322 358 50007 1-blade shutter 7-4 13 5322 515 20015 synchronous 220 V motor

asynchronous 220/110 V motor lower chain (friction 600 m)

lower chain (friction 1800 m) lower chain (friction 4000 m)

take-up chain wheel 74 teeth take-up chain wheel 30 teeth

spring 7-4/7-7 17 5322 492 50064 knurled nut 7-4/7-7 18 5322 505 10049 felt disk 7-6/7-7 19 5322 358 50028 oil hose 7-5 20 5322 530 20236 fibre gear 7-5 21 5322 522 30089 shutter shaft 7-5 22 5322 535 50009 aperture changer motor 7-8 23 1000 361 87010 focusing motor 7-6 24 1000 361 87013 lens turret motor 7-6 25 1000 361 87012 framing motor 7-6 26 1000 361 87015

7-4 11 5322 522 30088

5322 535 90485

7-4/7-5 14 5322 361 60057

5322 361 50003

7-4/7-5/7-7 15 5322 358 50009

5322 358 50011 1000 358 57008

7-4/7-7 16 5322 522 30105

5322 522 31091

7-78

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FP 30 D

8

7

6

1

2

3

5

Figure 7-1

Operating Manual 7-79

4

1

10

8

Figure 7-2

Figure 7-3

5

4

2

7-80

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FP 30 D

11

12

13

14

19 18

Figure 7-4

15

16

17

Operating Manual 7-81

22

21

20

14

Figure 7-5

15

24

25

7-82

Figure 7-6

26

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FP 30 D

15

16

17

Figure 7-7

19

18

23

Figure 7-8

Operating Manual 7-83

7.3 Parts for Reverse-Scan Sound Device

Part Figure Index No. Item No.

analog LED 7-9 digital LED 7-9 digital sound optics 7-9 analog sound optics 7-9 analog p. c. board 7-9 digital p. c. board 7-9 sensor (cue) 7-9 LEDs holder with

2 LEDs digital LED holder 7-9

34

27

30

7-9

31

27 28 29 30 31 32 33 34

35

0080 500 32063 0080 500 32063 1000 380 27005 1000 380 27005 0080 500 00655 0080 500 00654 1000 282 67001 1000 212 97001

1000 212 97002

33

35

Figure 7-9

28

29 32

7-84

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7.4 Lamphouse Parts

Part Figure Pos. Piece Item No.

dichroic mirror

?

300 mm f=60/540

?

340 mm f=55/825

FP 30 D

7-10

36

01 01

0040 180 00156 0040 180 00155

xenon bulbs 700 W / HSC 1000 W / HSC 1600 W / HSC 2000 W / SHDC 2000 W / HTP 2000 W / H 2000 W / HS 2500 W / HS 3000 W / H 3000 W / HTP 3000 W / HS 4000 W / HTP 4000 W / HS 4200 W / CA 5000 W / H 5000 W HBM 7000 W / HS 7000 W / HSH

adapter for 2000 W / H adapter for 2000 W / HS adapter for 3000 W / H adapter for 4000 W / HS

heat filter 20 x 20 7-10

7-10

37

38

01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01

01 01 01 01

01 0025 760 70213

0040 120 00101 0040 120 00102 0040 120 00103 0040 120 00104 0040 120 00150 0040 120 00094 0040 120 00098 0040 120 00095 0040 120 00096 0040 120 00154 0040 120 00155 0040 120 00151 0040 120 00097 0040 120 00156 0040 120 00157 0040 120 00170 0040 120 00152 0040 120 00159

1000 404 57017 1000 404 57018 1000 404 57019 1000 404 57020

36

37

38

Figure 7-10

Operating Manual 7-85

NOTE

If you need detailed information about parts please call your service company or KINOTON.

7.5 Addresses and Notes

7-86

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FP 30 D

8 Technical Data, Circuit Diagrams and Plans of Terminal

Connections

8.1 Projector Data

Name KINOTON Projector FP 30 D Type FP 30 D / FP 30 D-F / FP 30 D-A Serial No. See number plate on housing.

Connecting data

Power supply 110/120/230/240 V Frequency 50 or 60 Hz Supply fuse 10 A Power max. 500 W (without xenon lamp)

Power and operating data

Nominal motor speed 1500 rpm Motor power 100 W

Sizes and weights

Version / components Ratios or Sizes Weights

Projector FP 30 D 424 mm x 750 mm x 2340 mm 140 kg Frictions 600/1800/4000 m

2000/6000/12000 feet Friction shafts Lens turret / Lens holder Apertures 1:1.37 / 1:1.66 or 1:1.85 / 1:2.35 Framing

9 mm or ? 12.7 mm

?

70.6 mm

?

Ѕ picture manual or automatic

?

Operating Manual 8-87

8.2 Data of Reverse-Scan Sound Device

Connecting data

Power supply 115/230 V Frequency 50 or 60 Hz Power max. 6 W

Operating data

Frequency response

Wow and flutter

analog: 30 Hz с 16 kHz digital: 20 Hz с 20 kHz

≤ 0.1%

1 dB

?

0.5 dB

?

8-88

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FP 30 D

8.3 Plans of Terminal Connections

8.3.1 Terminal Connection on Control Board NOTE

The control board with terminal strip is mounted in projector door.

proj.start

lamphouse

FU

LA-pilot

proj.stop

FU

mag.lamp

109 109 122 122 60a 60b

res res

POS

E1 E2

106X

C\O C\O

LED ON

LED ON doswer

106Y

20 28 E1

28 20

ST1

ST2

ST3

re1

re1a

RE

re1c

RE

2

4 4a 4b

RE

3

RE RE

1 2

?

3 4 5

120

6 7 8 9 10 11 12

1 2 3 4 5 6 7 8 9 10 11 12

re1b

re4

0.1

120

?0.1

re1a

?0.1

120

re1b

re3re3

RERERE

1c1b1a1

re1

re2

re4

re4a

1 2 3 4 5 6

re4a

re4b

RE

5

re5

ST4

1 2

reserve

F-AUTOM.

PIN2

re6

3 4 5 6 7 8 9

re7

re6

RE

6

470 ?F

RE

7

100

Operating Manual 8-89

8.3.2 FP 30 D Terminal Connection

No. Connection (source) Colour Connection (target)

1

protect. conduct, ground (40) PE gn/ye mains connecting 230 V / 50 с 60 Hz

2

mains-phase (60) L bk mains connecting 230 V / 50 с 60 Hz

3

mains-zero (20) PN gr mains connecting 230 V / 50 с 60 Hz

4

+24 V control voltage of projector rd

5

-24 V control voltage of projector

6

C/O pk sound change-over enable

7

C/O pk sound change-over power supply

8

reserve operating contact RE 1 gn ST200 E 1

9

reserve operating contact RE 1 gn ST200 E 2

10

37C bl ST200 E 4

11

bridged or ST200 E 5

bridged

bridged bridged

12 13

reserve operating contact RE 1 pu

14

reserve operating contact RE 1 pu

15

mains-phase (60) L bk lamphouse 230 V

16

mains-zero (20) PN bl lamphouse 230 V

17

ST1 / 18 bn lamphouse 60A

18

ST1 / 19 bn lamphouse 60B

19

control rectifier 122A wt lamphouse 122A

20 21 22

control rectifier 122 wt lamphouse 122

23

protect. conduct, ground (40) PE gn/ye

24

+ 24 V ye magnet light shutter ye

25

- 24 V bl magnet light shutter bl

bl

8-90

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FP 30 D

8.3.3 FP 30 D-A Terminal Connection

No. Connection (source) Colour Connection (target)

1

protect. conduct, ground (40) PE gn/ye mains connecting 230 V / 50 с 60 Hz

2

mains-phase (60) L bk mains connecting 230 V / 50 с 60 Hz

3

mains-zero (20) PN gr mains connecting 230 V / 50 с 60 Hz

4

+24 V control voltage of projector rd

5

-24 V control voltage of projector

6

C/O pk sound change-over enable

7

C/O pk sound change-over power supply

8

37C pk holding contact STOP

9

37D bl holding contact COM

10

37E start forward wt Start

11

Start backward

12

UP wt/bl frame

13

com. bl frame

14

DOWN wt/gn frame

15

+ pk focus

16

com. bl focus

17

- pu focus

18

WS bn turret control

19

com. pu turret control

20

CS ye turret control

21

NS gr turret control

reserve

bridged bridged

22 23

ST 200 E pu Non-Rewind System control

24

ST 200 E pu Non-Rewind System control

25

106 X dowser OPEN ye change-over

26

105 com. gr change-over

27

106 dowser CLOSE or change-over

28

reserve trigger ST 200 E

29

reserve gn contact RE 1

30

reserve gn contact RE 1

31

mains-phase (60) L bk lamphouse 230 V

32

mains-zero (20) PN bl lamphouse 230 V

33

ST1 / 18 60A bn

34

ST2 / 19 60B bn

35

control rectifier 122A wt lamphouse 122A

36 37 38

control rectifier 122 wt lamphouse 122

39

protect. conduct, ground (40) PE gn/ye

40

+ 24 V ye magnet light shutter ye

41

- 24 V bl magnet light shutter bl

bl

Operating Manual 8-91

8.3.4 FP 30 D-F Terminal Connection

No. Connection (source) Colour Connection (target)

1 2 3 4 5 6 7 8

9 10 11 12 13

NC NC

slide slide

bridged bridged

14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55

0

0 56

protect. conduct, ground (40) PE gn/ye mains connecting 230 V / 50 с 60 Hz mains-phase (60) L bk mains connecting 230 V / 50 с 60 Hz mains-zero (20) PN gr mains connecting 230 V / 50 с 60 Hz +24 V control voltage of projector rt

-24 V control voltage of projector bl C/O pk closing contact for sound change-over C/O pk closing contact for sound change-over reserve working contact RE 1 reserve working contact RE 1 automatic START automatic START change-over tape change-over tape

UP frame com. frame DOWN frame + focus com. focus

- focus 106 X open dowser change-over 105 com. change-over 106 close dowser change-over 37C COM 37D STOP 37E start forward START WS turret control com. turret control CS turret control NS turret control NS masking

light auditorium light com. auditorium light dark auditorium light light stage light com. stage light dark stage light close curtain com. curtain open curtain WS masking com. masking CS masking

mains-phase (60) L bk lamphouse 230 V mains-zero (20) PN bl lamphouse 230 V 10 bn loudspeaker safety contact 11 bn aker safety contact control rectifier 122A wt lamphouse 122A

control rectifier 122 wt lamphouse 122 + lamphouse contact

- lamphouse contact protect. conduct, ground (40) PE gn/ye

8-92

Издание: , 2008 г. Kinomedia.net

®

FP 30 D

8.3.5 Connections of Operating Panel Connectors

Connection of 30 pole male receptacle

row A row B row C

0 0 Matrix RE 15 0 9 9 Matrix RE 15 9 8 8 8 tie lug film slide 7 pulse Matrix RE 12 7 pulse Matrix RE 12 7 pulse Matrix RE 12 6 109 AY 6 pulse Matrix RE 9 6 masking N 5 projector Y37E 5 projector Y37C 5 projector Y37D 4 masking com 4 masking B 4 masking CO 3 stage com 3 stage dark 3 stage light 2 auditorium light com 2 auditorium light dark 2 auditorium light light 1 curtain com 1 curtain opened 1 curtain closed

Connection of 30 pole female receptacle

row C row B row A

0 0 tape off 0 tape on 9 9 9 8 lens CO 8 lens WS 8 lens NS 7 projector 7 projsetcotpo r 7 projsetcatrot r 6 focus - 6 focus com 6 focus + 5 framing down 5 framing com 5 framing up 4 - 24 V 4 contact tape 4 contact tape 3 + 24 V 3 pulse start film 3 pulse start film 2 GND 2 pulse start slide 2 pulse start slide 1 106 Y 1 105 1 106 X

Operating Manual 8-93

Plan of connection to 30 pole connectors for control panel BWR

No. Connection / Description No. Connection / Description

1

auditorium light stop

2

auditorium light com.

3

auditorium light light

4

slide

5

auditorium light dark

6

stage light stop

7

stage light com.

8

stage light light

9

stage light dark

10

curtain stop

11

curtain com.

12

curtain close

13

curtain open

14

masking stop

15

masking com.

16

masking normal screen

17

masking wide screen

18

masking cinemascope

19

lens turret normal screen

20

lens turret normal screen

21

lens turret wide screen

22

lens turret wide screen

23

lens turret cinemascope

24

danger

25

danger

26

tape contact matrix

27

tie lug projector X

28

rewind projector X

29

projector X com.

30

projector X start/stop

31

tie lug projector Y

32

projector Y com.

33

projector Y start/stop

34

change-over 106 X

35

change-over 105

36

change-over 106 Y

37

pulse start slide

38

pulse start slide

39

autostart

40

autostart

41

tape start

42

tape com.

43

tape stop

44

not occupied

45

not occupied

46

not occupied

47

framing up

48

framing com.

49

framing down

50

focusing +

51

focusing com.

52

focusing -

53

-24 V

54

0 V

55

109 AY

56

Matrix RE 9

57

Matrix RE 9

58

Matrix RE 12

59

Matrix RE 12

60

PE Ground

8-94

Издание: , 2008 г. Kinomedia.net

®

8.4 Circuit Diagrams

8.4.1 FP 30 D-A (standard)

C/O

7

6

ST2/11

re4

com

13

12

14

ST2/10

print focus

FP 30 D

+

-

com

16

15

17

print

framing

N

21

print

lens turret

com

CI

WS

18

19

20

terminal connexion

ST3/1

24/s

LED ON

ST2/12

ST3/2

re4a

ST3/4

mag.lamp

/LED

/FRIKT. /FU

MATRIX

60

T1/04791

OV130V 110V

7 9

532

20

110V

6.3A

1SK

1

2

connexion

40

60

terminal

220V

re4a

PILOT-LA

DOWSER

ST1/12

M

re1c

re4b

12 1314151617

3

20

re4b

270

REFEKTION

SK

ST2/3

2

1

2A

18V 9V 24V

GL1

2200 ?F

3

20

ST2/1

32

31

29

60

20

ST1/1

re1c

ST1/8

re1a

ST2/2

ST1/7

30

33

60A

RESRE1 -

1000 ?F

8136

SK10

POS

24V

3.9K

4

LED

35

36

34

60B

122

PROJ.

2

3

RE

ST2/4

ST2/5

re1a

ST1/6

ST1/5

37

38

4

24V

122

122A

+

25/s

SK

ST1/11

re1b

re3

ST2/8

4polig

re1

re2

1b

1c

RE

5

9

24V

_

1a

RE

SK6

START

SK5

STOP

8

37D

PEL1 N

E2

FILTER

FU

ST1/9ST1/10 ST2/6

L

ST2/7

987

E4 E1

28 20

39

U V W

1

4b

RE

4a

RE

ST2/9

ST1/2

CLOSED

OPEN

26

25

10

37C

37E

106X

20

60

24V

_

106Y106Y

106X106X

5

proj.Yproj.X

2525

27

Change-over

5

27

24V

_

5

4

RE

re4

ST3/6

re5

SK8

SK7

27

105

106Y

out

3

1 GND

2

3

1

MONO

L

R out

out

+

-

+

GND

5

4

3

2

1

51

42

3

DOLBY

lamphouse

rectifier

lamphouse

stop-proj.

com-proj.

start-proj.

Operating Manual 8-95

8.4.2 FP 30 D-F (with PA automation system)

Start Projector

1

K4

RELAY F5/F4

Dowser open

Stage OFF

6

2

1

5

3

9

10

1

11

3

2

Terminal strip

R25 100

R26

270

24V

T5

1

8

Curtain open

1

K3

4

5

7

12

RELAIS F4/F3

4

D17

F4

Relay

3

+

11

7

FK5

C2

R28

BC337

50

C12

+

10k

T6

BC327

Start Sequence

GND

4

CS

321

WS

Masking

NS

1K

24V 24V

R30

M5M4

GND

432

CS

WS

Lens turret

NS

1

P4

R29

50

R32

2

1

M7

4K

R31

D21

RE14RE13RE12

D20D19

J1/1

J1/3

J1/5

House ON

Reserve

House OFF

6

2

3

5

1

9

5

4

7

10

11

7

6

8

Reserve

1

K2

5

1

5

12

9

RELAIS F2

9

1N4105

D18

470 ?F

1N4105

Stop2 Timer

F5

470 ?F

R11

Relay

50

24V

F1

Relay

FK2

25k

D9

Start button

J4

On=timer stop

24V

Jumper

Stop sequence

24V

T4

On=timer stop J3

F2

Relay

Jumper

3

R18

50

11

+

7

FK3

R33

BC337

100

C6

+

470 ?F

3K6

R19

P3

50K

2

1

Dowser closed

Projector Stop

Non Sync

6

2

3

4

5

7

12

10

11

10

12

Curtain closed

Stage ON

1

K1

2

1

5

9

RELAIS F1

14

13

Stop 1

F3

Relay

D4

1N4105

24V

RE6

24V

1

Reserve

Spare

6

3

7

10

11

16

15

D10

1N4105

Stop 2

/F1 F2

Relay

RE7

24V

1

M8

GND

24V

D9

1N4105

24V

+

-

1N4105

Relay

Dashed framed relays are the same.

C4

1000 ?F

D10

1N4105

F3

C5

stop

Connection

-

100 ?F

RL1

C3

FK1

Non Sync

100 ?F

+

REK=relay contact

M6

5

GND

41 2 3

J1/2

J1/4 J1/6

Sound formats

Bistabil

+

1

F5 Stop

24V

K2/NR12/Non Sync

Dolby SR

Dolby A

MONO

8-96

4

3

5

2

1

S1

RE8

24V

6

A

J1/9

1N4148

Start

24V

+

-

C7

100 ?F

10

9

8

11

7

B

D12

J1/7

RE9

24V

FK5 Start relay

12

24V

+

-

C10

100 ?F

Picture pulse

50

R8

R16

On=foil stop

On=timer stop

J2

Jumper

Stop pulse

RE10

24V

Sound pulse

4

3

2

5

1

S2

6

A

J1/10

1N4148

24V

Start

RE11

24V

+

C8

100 ?F

-

10

9

8

11

7

12

B

J1/8

D11

24V

+

C9

100 ?F

RL2

Bistabil

+

1

D9

1N4105 /F1 F2

see stop2

Relay

B

T1

50

BC327

R7

4K

1K

24V 24V

R2

R1

J1

Jumper

M3

Film break

1

2

BC337

24V

T3

+

100 ?F

C6

2K

R9

1K

P1

24V

RE4

24V

RE3

RE1

24V

RE5

T2

24V

RE2

BC337

+

1K

P2

2K

R10

Sensor1

24V

M1

Gnd bu

Ub+ bn

Sign bk

3

2

1

Sensor1

24V

M2

Ub+ bn

Sign bk

Gnd bu

123

RL3

Bistabil

+

+ +

C2

100 ?F

Relay switching

1N4148

No Trai. Mainp. 1 NS WS

2 NS CS

3 WS CS 4 WS NS 5 CS NS 6 CS WS

D1

Издание: , 2008 г. Kinomedia.net

LED u.R3,3K

RE1=>R5,D1,L1 RE2=>R4,D2,L2 RE3=>R6,D3,L3 RE4=>R12,D5,L4 RE5=>R13,D6,L5 RE8=>R21,D13,L8 RE9=>R22,D14,L9 RE10=>R23,D15,L10 RE11=>R24,D16,L11

No Trai. Mainp. 1 MONO Dolby A

2 Mono DolbySR

3 Dolby A DolbySR 4 Dolby A Mono 5 DolbySR Mono 6 DolbySR Dolby A

®

8.4.3 FP 30 D

FP 30 D

out

3

1 GND

2

+

-

COM

B5

A5

30polREMOTE

print focus

COM

B6

C5

A6

C6

framing

N

A8

COM

CI

WS

B8

C8

C9

A9

B9

C28

C14

A14

E14

print lens-turret

A16

MATRIX

SENSOR

A-START

B3

C2

2

3

1

MONO

L

R out

out

+

-

+

GND

5

4

3

2

1

51

42

3

DOLBY

C/OLED ON

ST2/10 ST2/11

ST2/12

ST3/2

re4a

ST3/4 ST3/1

mag.lamp

/LED

/FRIKT. /FU

MATRIX

20

60

T1/04791

OV130V 110V

12 1314151617

7 9

532

1

110V

18V 9V 24V

6.3A

1SK

1

terminal

40

15

3

2

20

60

re4re4a

24/s

25/s

SK

ST1/11

re1b

PILOT-LA

DOWSER

ST1/12

M

re1c

re4b

2A

20

16

20

re4b

270

REFEKTION

SK

ST2/3

2

GL1

2200 ?F

3

ST1/1

re1c

ST1/8

ST2/2

ST2/1

8

RES

re1a

ST1/7

17

9

60A

1000 ?F

8136

SK10

POS

24V

3.9K

4

LED

re1a

ST1/6

ST1/5

18

22

21

20

122

60B

122

122A

PROJ.

2

3

RE

ST2/5

ST2/4

C6

re2

E6

5

4

19

C3

24V

122A

24V

+

_

re1b

4polig

re1

1b

RE

1c

A6

re1

MATRIX

RE

START

STOP

C4

B7

37D

re3

ST2/8

re2

1

4b

RE

1a

RE

ST1/2

SK6

SK5

A7

C7

37C

37E

PEL1 N

E2

FILTER

FU

ST1/9ST1/10 S T2/6

L

ST2/7

987

E4 E1

28 20

39

U V W

4

RE

4a

RE

re4re5

ST2/9

SK8

CLOSED

SK7

OPEN

A1

B1

C1

106X

105

106Y

20

60

24V

_

106Y106Y

106X106X

C1C1

A1A1

C4C4

proj.Yproj.X

Change-over

24V

_

re17

5

ST3/6

re16

MATRIX

C24

E24

E22

30polREMOTE

220V

RE1 -

lamphouse

rectifier

Operating Manual 8-97

8.4.4 Lamphouse

8-98

Издание: , 2008 г. Kinomedia.net

®

FP 30 D

8.4.5 Reverse-Scan Sound Device

LED2-

K2-6

LED2+

K2-7

R5

1,8 ?

0.33uF

C13 C12

+

TantalTantal

L2

7uHy

C14

+

Tantal

C9 C8

+

L3

500uHy

50kHz/12Vss

Ubr eff = 0.5V

B40C1500

D2

2

Out

1

V+

LM2575T

IC1

0.1uF+47uF

C7, C5

820

R1

+

C17

+

10V~

Typ Roederstein 1113T

10uF

10?

P1

R6

5,6 ?

10uF

1uF

33uF

+

1000uF

C10

BYT03-200

4

Fb

3

GND

-ADJ

OFF

5

25V

4700uF

-

GB2

B with Low ESR rejection >76d

< 0.35mA eff

at 800 mA

through LED is Current ripple

equal to 70 dB

R4

470

(0..22kHz)

Capacitor

Switching-Noise

R3

1K

C18, C19

11

125

1/4 ISQ 202

6

IC6

B40C1500

K2-4

LED1+

K2-5

LED1-

1113TTyp Roederstein

R12

1,8 ?

0.33uF

C25 C24

10uF

10?

P2

+

L4

7uHy

C14

R13

5,6 ?

10uF

+

Tantal Tantal

1uF

C20C21

33uF

+

Tantal

+

1000uF

C22

L5

500uHy

D3

2

Out

1

-ADJ

V+

LM2575T

IC4

5

0.1uF+47uF

820

R9

+

C29

+

10V~

R11

470

BYT03-200

4

Fb

3

GND

R10

OFF

25V

4700uF

-

GB4

1K

13

14

1/4 ISQ 202

4

3

IC6

B40C1500

K2-1

+15V

K2-2

0V

C28

0.1uF

IC5

uA7815

C27

1uF

+

4

5

3

R15

3,3k

+

C23

+

15V~

1

IC7

BTS432E

2

R14

1K

9

10

470uF

40V

-

GB5

1/4 ISQ 202

8

7

IC6

B40C1500

J1

IC2

5

IC3

3

R8

3,3k

+

C1

+

15V~

-15V

K2-3

C16C15

0.1uF

uA7815

1uF

+

4

1

BTS432E

2

R7

1K

16

15

40V

470uF

-

GB3

1/4 ISQ 202

2

1

IC6

J2

0,8A T

SI2

20VA

2n2/250V~

C1

SI3

0,8A T

R2

1W

0.6A

10V~

X1

115

C2

0.1uF

250V~

18mHy

L1

C4

0.1uF/250V~

AC~

K1-1

K1-3

0.6A

10V~

15V~

115V~

0

115

X3

2n2/250V~

C3

15V~

0.12A

10V~

0.3A

+

B40C800

115V~

0

X2

?C

GB1

-

0 T

0.5A T

SI1

AC~

K1-2

GND/PE

230V~ AC

470

D1

1N4001

+

220uF/25V

C6

K2-8

En+

K2-9

Enable

En-

Operating Manual 8-99

8-100

Издание: , 2008 г. Kinomedia.net

®

FP 30 D

Contents

9 Service Work.........................................................................................................9-1

9.1 First Running............................................................................................................9-1

9.1.1 General Check.....................................................................................................9-1

9.1.2 Checking the Projector Running...........................................................................9-2

9.1.3 Checking the Xenon Lamp...................................................................................9-3

9.2 Adjusting the Projector............................................................................................9-4

9.2.1 Positioning the Projector to the Screen.................................................................9-4

9.2.2 Adjusting the Lenses in Lens Turret.....................................................................9-5

9.2.3 Filing of Apertures................................................................................................9-6

9.3 Xenon Lamp..............................................................................................................9-8

9.3.1 Basic Adjustment of Xenon Unit...........................................................................9-8

9.3.2 Fine Adjustment of Screen Illumination..............................................................9-10

9.3.3 Adjusting the Light Arc Stabilisation Magnet.......................................................9-12

9.4 Reverse-Scan Sound Device..................................................................................9-14

9.4.1 Adjustments........................................................................................................9-14

9.4.1.1 Pre-adjusting the Analog Sound Device......................................................................9-14

9.4.1.2 Adjusting the Digital Sound Device.............................................................................9-16

9.4.1.3 Fine-Adjusting the Analog Sound Device....................................................................9-18

9.4.1.4 Check Cross Talk........................................................................................................9-20

9.4.1.5 Final Check..................................................................................................................9-20

9.4.2 Exchanging Reverse-Scan Sound Device Parts.................................................9-21

9.4.2.1 Sound Optics...............................................................................................................9-21

9.4.2.2 Exchanging the p. c. Boards........................................................................................9-22

9.4.2.3 Exchanging the LEDs Holder......................................................................................9-22

Service Chapter i

9.5 Intermittent Movement (Maltese Cross)................................................................9-23

9.5.1 Disassembly of Intermittent Movement..............................................................9-23

9.5.1.1 Disassembly and Assembly of Gear and Chain Wheel Unit........................................9-25

9.5.2 Assembly of Intermittent Movement...................................................................9-26

9.5.2.1 Inserting the Film Track...............................................................................................9-26

9.5.2.2 Adjusting the Intermittent Sprocket Shaft....................................................................9-27

9.5.2.3 Adjusting the Intermittent Sprocket..............................................................................9-27

9.5.2.4 Inserting the Chain Wheel Unit....................................................................................9-27

9.5.2.5 Tensioning the Chains.................................................................................................9-28

9.5.2.6 Inserting the Runner Strips and Film Pressure Skate.................................................9-29

9.5.2.7 Assembly of Motor.......................................................................................................9-29

9.5.2.8 Rough Shutter Adjustment...........................................................................................9-30

9.5.2.9 Fine Shutter Adjustment..............................................................................................9-30

9.5.2.10 Filling in Oil..................................................................................................................9-31

9.5.3 Exchanging the Shaft Seal of a Maltese Cross Drive.........................................9-31

9.6 Intermittent Sprocket.............................................................................................9-36

9.6.1 Exchanging the Intermittent Sprocket................................................................9-36

9.6.2 Exchanging the Intermittent Sprocket Shaft with Seal Ring................................9-37

9.7 Adjusting the Frequency Inverter..........................................................................9-38

9.7.1 LCD Keypad.......................................................................................................9-39

9.7.2 Adjusting via Keypad..........................................................................................9-41

9.7.3 Code Table........................................................................................................9-42

9.8 Adjustments and Maintenance Work of Lens Turret and Aperture Changer.....9-43

9.8.1 Retool and Grease Aperture Changer................................................................9-43

9.8.1.1 Change the Attachment of the Linear Drive (aperture changer up to 09.99 only).....9-44

9.8.1.2 Work the Steel Rod and the Brass Tube (aperture changer up to 09.99 only)............9-44

9.8.1.3 Grease Threaded Spindle (aperture changer up to 09.99 only)..................................9-45

9.8.1.4 Function Check (all aperture changers)......................................................................9-45

9.8.2 Adjusting Brightness LED Position Sensors.......................................................9-45

9.8.3 Mechanical Check of Lens Turret.......................................................................9-46

9.8.3.1 Check Turret Rotation.................................................................................................9-46

9.8.3.2 Check Arresting Magnet..............................................................................................9-46

9.8.3.3 Check Toothed Belt.....................................................................................................9-47

9.8.4 Lens Turret / Aperture Changer Control Board...................................................9-48

9.8.5 Adjusting the Lens Turret Positions....................................................................9-49

9.8.5.1 Connection of a Measuring Adapter or/and a Multimeter............................................9-49

9.8.5.2 Checking and Adjusting the Sensor Board MSK 81-04...............................................9-50

9.8.5.3 Testing Board MSK 81-05...........................................................................................9-53

9.8.6 Clean Lens Turret..............................................................................................9-55

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9 Service Work

ATTENTION

The work described in this chapter are to be carried out by experts or

??

competent service men of KINOTON only. Make sure that nobody starts projector while you are working on it.

??

During all maintenance and cleaning work you must disconnect the projector from power supply (switch off main switch).

To ensure long-life and perfect running of projector the following checks must

??

be carried out exactly and carefully before the first running of the projector and its associated equipment.

9.1 First Running

FP 30 D

9.1.1 General Check

1. Check the electrical connections.

4. Check weather lamphouse exhaust is switched on.

5. Check for correct installation and connection of xenon lamphouse.

2. Check oil level of intermittent movement oil gauge glass. The oil level should be in the middle between the red and green oil level ring (arrows).

3. Check perfect and slight run of projector mechanism by manually turning the motor.

Service Chapter 9-1

9.1.2 Checking the Projector Running

1. Switch off xenon rectifier.

2. Switch on main switch

(position СIм). Lamp illuminates red.

3. Cover reflex film break sensor(s) (arrow) with a suitable cap or a piece of rolled film.

4. Move lever arm of Non-Rewind System (if installed) out of its zeroposition and hold it with a string in that position.

5. Push The projector should run.

6. Push

The projector should stop.

7. Only ST 200 or ST 200 E with film break relay: Push

and release the platterҐs lever arm.

The projector should stop after approx. 1 s when lever arm is in its zero-position.

8. During projector run check the following functions:

- gate shutter and exciter lamp or LEDs

- lens turret and aperture changer

- focusing and framing with opened gate shutter.

- RUN and xenon relay

9. During projector run remove cover on film break sensor The projector should stop after 1 s.

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9.1.3 Checking the Xenon Lamp

1. Check xenon lamp and mirror are installed correctly. Check lamphouse is connected properly.

2. Current regulator of rectifier has to be set correctly for the xenon lamp used.

3. Check fuse (4 A) on lamphouse.

4. Switch on projector,

Immediately

5.

check and adjust the current intensity of the lamp on ammeter of

in position мIо. Lamp illuminates red.

lamphouse:

Lamp power

[W]

Control value

[A]

Current max.

[A]

500 28 30

700 37 45 1000 50 55 1600 65 70 2000 70 85 2500 90 100 3000 100 110 4000 135 150 5000 140 150 7000 160 165

6. Insert aperture plate (CS) and lens or push the button control panel if you have an aperture changer.

at operating or

ATTENTION

The film pressure skate must be closed, due to the risk of burning the pressure skate.

7. Open dowser and roughly adjust the uniform picture illumination.

ATTENTION

Dowser must not be open for a long time, due to the risk of burning the film or lens.

NOTE

You will find description of fine adjustment in chapter 9.2.3, Filing of Apertures.

Service Chapter 9-3

9.2 Adjusting the Projector

9.2.1 Positioning the Projector to the Screen

CS format

lateral demarcation

format NS format WS

lateral demarcation

central point

format WS format NS

1. Insert the center hole aperture into the aperture changer.

2. Run a test film loop SMPTE or OPTRONIK.

3. Project test film in a way the central point of the test film appears on screen (if necessary adjust frame).

4. Mark this central point on the screen with adhesive tape.

ATTENTION

Do not use any very sticky adhesive tapes to mark screen. When tape is removed, no residue can remain on screen.

5. Remove centre hole aperture and insert the lens with the largest focal length (CS).

6. Position projector horizontally and vertically in a way that the projected rectangle is symmetrical within the provided masked picture area.

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9.2.2 Adjusting the Lenses in Lens Turret

CS format

lateral demarcation

format NS format WS

lateral demarcation

central point

format WS format NS

Do not move CS lens!

Adjust all other lenses in their body of the tubes in a way the projected picture on screen is in the marked central point. The demarcation arrows on the test film depending on the selected film format are to be seen half.

Service Chapter 9-5

9.2.3 Filing of Apertures ATTENTION

The finishing of apertures should only be made by projecting a test film, which contains the edge markings of all usual picture formats (SMPTE or Optronic).

1. Project and focus test film loop with all lenses.

2. Screw lens for CS projection (larger focal distance of used lenses) with

anamorphic lens and insert it into turret. Turn turret in position CS.

3. Set astigmatism adjusting ring in the front of anamorphic lens to the given

projection distance (projector с screen).

4. Project test film.

5. Turn the lens with anamorphic lens assembly in turret in a way that the two lines

are rectangular in the middle of the picture.

6. Perfectly adjust focus by turning astigmatism adjusting ring of anamorphic lens

while sliding the lens and anamorphic lens assembly.

7. Begin with any aperture.

hole for driving pin aperture 1:1.66 aperture 1:1.85

aperture CS

Aperture plates:

No. Name Type Aspect Ratio

1 N normal screen 1:1.37 2 CS cinemascope 1:2.35 3 WS wide screen 1:1.85 4 center hole aperture to position projector to the screen

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Aperture for aperture changer

undersize triple aperture

fullsize triple aperture

1:1.66 1:1.85 CS (1:2.35 / 1:1.37)

center hole aperture double/triple

hole

1. File edges of all aperture holes obliquely in a way that the small opening results from it points at film and that picture edges are much more sharply defined.

2. File the height of aperture hole м1.85о

in a way that the upper and the lower

edge of picture does not show any shadings on screen.

Service Chapter 9-7

9.3 Xenon Lamp

NOTE

Before installing the mirror you have to check and if necessary adjust the optical axis.

9.3.1 Basic Adjustment of Xenon Unit NOTE

The xenon unit is factory-set. If basic adjustment is changed because of

??

transport or modification, you have to adjust it with a setting gauge. Pay attention to an exact adjustment. Only then you can get a full screen

??

illumination.

Insert the setting gauge

The following drawing shows how the setting gauge is inserted in lamphouse and projector:

Issue: 09/2000 9-8

1. Insert disc (2) instead of the mirror.

2. Thread bar (1) through hole of disc and screw the bar in bulb socket.

3. Adjust bar with horizontal and vertical adjusting screws in a way that the bar is

exactly standing in the middle of the disc.

FP 30 D

4. Put platter (3) on bar (1) and tighten it.

5. Clamp bush (5) in lens holder.

6. Thread bar (6) through opening of the bush, then through film gate to lamphouse (open dowser manually).

NOTE

To prevent damages of film gate, remove shutter housing.

7. In lamphouse shove platter (4) on bar (6) and tighten it.

8. Put bar with platter until both platters touch each other.

Adjusting

1. Loosen fixing screws of xenon unit.

2. Move xenon unit or lay shims under frame of unit until the adjustment is correct.

NOTE

The xenon unit is exactly adjusted when both platters are standing parallel and coaxial (see first figure). The second and third figures show the incorrect adjustment.

Adjusted correctly:

optical axis is parallel to setting gauge.

3. Tighten fixing screws and remove setting gauge.

Now the mirror can be inserted, see chapter 2.4.1.1.

Service Chapter 9-9

9.3.2 Fine Adjustment of Screen Illumination

adjusting screw xenon bulb heat filter adjusting screws stabilising magnet axial adjustment horiz. adjustment vertical adjustment

1. Start Projector.

2. Select CS format. You can adjust the xenon bulb against mirror in three levels (horizontal , vertical

and axial ).

DANGER

??

Open lamphouse after a waiting period of 10 minutes.

??

The current of lamp and rectifier must be switched off all-polo. Switch-off main switch of projector and screw out fuse.

??

Work at open lamphouse to be carried out has to be done with protective suit, cloves and face shield. You can seriously hurt yourself when xenon bulb explodes and broken glass is flying around.

3. With the aid of the hexagon screw , the xenon lamp is adjusted as much along the optical axis until only a reduced round illuminated spot can be seen on screen.

4. By turning adjusting screws right с left (horizontally) and up с down (vertically) you have to bring this light spot precisely into the middle of the screen.

9-10

5. Turning the hexagon screw you have to draw up the spot until the screen illumination is even.

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Luminance B in centre of screen: 40 cd/m2 = 126 apostilb (min. 30 cd/m

The luminance of lateral measure points should not be less than 50%, better 68% of luminance of screen centre.

To determine the illuminance (Lux) you have to measure it. Multiplicate it with the degree of reflection or with the luminance factor (only with reflection screens):

2

= 95 apostilb)

You can measure the luminance with a spot meter also:

2

1°/cd pro m

or footlampert should be 50 to 65 cd/ m2

(1 cd x 0,292 = 1 footlampert)

NOTE

Always measure with the largest aperture (21,3 x 18,2).

NOTE

Whenever in extreme special cases the described way to adjust is not possible, you can change the mirror position with the aid of the adjusting screws

/ of

mirror holder.

Service Chapter 9-11

9.3.3 Adjusting the Light Arc Stabilisation Magnet

DANGER

This adjustment can only be done when lamphouse is open and xenon lamp is

??

ignited. Therefore be especially careful.

A magnet stabilises the light arc between cathode and anode of xenon bulb. Therefore no onesided electrode consumption can arise. The life of xenon lamp goes up. Furthermore the magnet constantly holds light arc in the centre of mirror (better optical efficiency).

Use a face shield with UV protective glasses (weld protective glasses).

??

All work at open lamphouse to be carried out has to be done with protective

??

suit, cloves and face shield. You can seriously hurt yourself when xenon bulb explodes and broken glass is flying around.

1. The mirror has a window. Insert mirror in a way you will horizontally see the light arc through this window.

2. Insert xenon bulb.

3. Ignite lamp and set the corresponding intensity of current at hand-wheel of rectifier.

4. Look at light arc.

Light arc is adjusted correctly.

9-12

Light arc is not adjusted correctly. A correct adjustment is necessary.

The stabilisation magnet is laying in an aluminium holder which is fastened at ignition unit base.

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Adjusting

space ignition unit base - magnet

??

for 1000 to 2000 W xenon unit: 79 to 81 mm

space ignition unit base - magnet

??

for 2000 to 7000 W xenon unit: 92 to 94 mm

1. Adjust magnet by lifting and lowering the aluminium holder until the light arc has the correct position.

2. Coat the screws after adjustment.

Service Chapter 9-13

9.4 Reverse-Scan Sound Device

9.4.1 Adjustments NOTE

The position of sound pressure roller has already been factory-adjusted to the right film gauge and should not be changed.

After mounting of sound device or its parts you have to do the following adjustments in the given order.

9.4.1.1 Pre-adjusting the Analog Sound Device

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mounting plate azimuth adjusting screws lateral position adjusting screw LEDs holder focus adjusting ring

1. Switch on sound. Check current at terminal of power supply. The range of current has to be 700 mA.

2. Connect the oscilloscope to the DOLBY processor pre-amplifier board (e.g. CP65 - CAT 240A).

3. Insert a measuring instrument between the mounting plate and lens holder.

NOTE

The distance between the p.c. board CAT 655 mounting plate and the lens holder should be 7.88 mm (average).

4. Thread a sound focus film (9 kHz) or a CAT 69T (1 kHz), and adjust the best signal focus (max. level) on oscilloscope by turning the ring of lens

.

5. Loosen LEDs holder and optimize illumination by shifting LEDs holder until you get maximum level on oscilloscope.

phase (azimuth) is not correct phase is correct

6. Adjust azimuth via XY mode on oscilloscope when turning adjusting screws.

Service Chapter 9-15

9.4.1.2 Adjusting the Digital Sound Device NOTE

The distance between the mounting plate and the lens holder should be 7.88 mm (average).

mounting plate azimuth adjusting screws lateral position adjusting screw LEDs holder focus adjusting ring

1. Connect oscilloscope to the video board of DOLBY digital processor (e. g.:

DA10, DA20, CP500) and/or connect a suitable PC via a serial interface with DOLBY digital processor and loads DRAS10 to program.

2. Calibrate the digital reader with a suitable test film (e. g. CAT 1011) under PC

control.

3. Set amplitude on oscilloscope to 1V/per unit and time base to 2 ms.

9-16

4. Shift holder of digital LED, signal B will change. The level of video signal (signal B) ranges between three and four Volts and has to show a straight top edge.

NOTE

Signal A represents the perforation holes.

??

If position of LED is inaccurate scalloping on the signal can be caused.

??

Do not move the digital LED holder to its end position.

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5. Adjust focus and picture width by turning focus adjusting ring .

6. Adjust azimuth with both adjusting screws

.

7. Adjust lateral position by turning adjusting screw at the p. c. board movement guide pins.

NOTE

??

Check and observe these adjustments (points 5 to 7) on PC and/or on video signal.

??

The digital error rate of the digital processor has to show a low value. The value depends on quality of film in use. In any case it must fall below 6.

NOTE

Because each film provides various values it is advantageous to use several test film loops and then average the results. This particularly concerns the lateral and vertical position, the track width and the azimuth.

Carry out these adjustments with projector running and with a test film loop. You should see the following values after your adjustments:

lateral position = ~ 0,5 vertical jitter = < 0,5 (is depending on film) track width = 100 azimuth = 0 corner found = ~ 94 focus = ~ 80 (is depending on film)

NOTE

??

The rectangle, symbol for data field, has to be centered with straight edges/lines.

??

Several older films with DOLBY digital sound tracks or films with splices cause the DA20 to show СFм (fault) although scanning of digital tracks works well. In such cases the DA20 is not defective, but there is an incompatibility between the new data format and the older control functions. Dolby assumes that only new film prints will be shown.

Service Chapter 9-17

9.4.1.3 Fine-Adjusting the Analog Sound Device

1. Thread a Buzz track film SMPTE-P35-BT. By running this center position of the LED is checked.

2. Shift mounting plate with p. c. board CAT 655 and adjust focus. On an oscilloscope 300 Hz and 1 kHz signals have become almost invisible.

NOTE

This check can also be done with the monitor loudspeaker in the amplifier rack. When doing this, the signals become almost inaudible.

Adjust focus (1st procedure)

Thread a sound focus film (9 kHz) or CAT 69T (1 kHz) and sharpen the signal (max. level) on oscilloscope by turning the focus adjusting ring.

Adjust focus (2nd procedure)

1. Thread CAT 69T pink noise film (observe direction of run).

2. Connect an analyser to the input board of the sound processor.

3. Set analyser on Сline inputм (Сleftм or Сrightм). Observe display and adjust focus for maximum (H.F.) values by turning the lens.

maximum H.F. minimum H.F.

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4. Compensate for slit losses by means of H.F. control on the input board of processor (e. g. CAT No. 510).

Service Chapter 9-19

Adjusting the azimuth

9.4.1.4 Check Cross Talk NOTE

This setting only changes if adjustments with buzz track film has not been optimized.

phase (azimuth) is not correct phase is correct

Adjust azimuth via XY mode on oscilloscope when turning adjusting screws.

With channel separation film CAT.97 running the center position of the DOLBY sensor is checked.

9.4.1.5 Final Check

1. Thread a Dolby CAT 251 test film (select format 10) and run an audio test.

2. Check focus and azimuth with CAT 69P test film and check level with CAT 69T

test film.

3. Lock mounting plate and azimuth adjustment.

Set amplitude to 0,5V/per unit and time base to 2 ms on oscilloscope. When the sine wave is visible on channel 1 it must not be visible on channel 2 and vice versa.

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9.4.2 Exchanging Reverse-Scan Sound Device Parts

9.4.2.1 Sound Optics

1. Remove guide roller.

guide roller azimuth adjusting screws sound optics sound optics tightening screw

2. Unplug connections.

3. Loosen azimuth adjusting screws.

4. Loosen sound optics adjusting screws.

5. Pull out p. c. board with mounting plate and optic.

6. Screw out the optic and screw in a new one.

7. Mount sound optics loosely.

8. Adjust sound optics, see chapter 9.4.1.

Service Chapter 9-21

9.4.2.2 Exchanging the p. c. Boards

1. Remove the four hexagonal socket screws (arrows) of each board to exchange them.

2. Adjust, see chapter 9.4.1, Adjusting the Sound Device.

9.4.2.3 Exchanging the LEDs Holder

1. To exchange LEDs holder you have to unsolder the three wires in the inside of the projector.

2. Remove holder by loosing the two fixing screws (arrows).

3. After mounting the new LED holder you have to adjust, see chapter

9.4.1, Adjusting the Sound Device.

9-22

FP 30 D

9.5 Intermittent Movement (Maltese Cross)

9.5.1 Disassembly of Intermittent Movement

1. Drain oil via hose (arrow).

1

2

runner strips aperture changer knurled screws of runner strips film pressure skate adjusting screw

3

2. Remove plastic nuts and remove shutter housing.

3. Tip skate away from film gate and

4

pull the skate upwards.

4. Remove the four knurled screws and take off runner strips.

5. Pull out aperture slide and remove driving pin out of slot of aperture

5

(with aperture changer).

6. Turn adjusting screw of intermittent sprocket anticlockwise about two turns.

Service Chapter 9-23

upper chain lower chain motor intermediate flange

7. Separate and remove both chains.

8. Disconnect motor from cable form.

9. Loosen motor with intermediate flange (three hexagonal socket screws) and remove motor.

10. Remove shutter by loosening and removing screw and clamp ring.

11. Remove the four fixing screws of film gate (operating side of projector) and remove film gate slowly with a simultaneous left turn of framing knob.

12. Loosen stop ring (arrow) of framing adjustment (when driven by a motor, loose the chain wheel) and pull out shaft about 50 mm out of projector.

13. Screw out the framing adjustment bushing as far as possible by turning to the left sleeve bearing of intermittent movement. Screw in a screw M 2,5 into bushing thread (see figure next page) and pull out the bushing completely.

14. By loosing the four tightening screws of intermittent movement (foreside of projector), simultaneously keep intermittent movement in projector. Remove intermittent movement.

9-24

FP 30 D

9.5.1.1 Disassembly and Assembly of Gear and Chain Wheel Unit

1. Remove chain wheel unit with spur wheel and shaft from intermittent movement and mount it into new movement as follows:

ATTENTION

Check if chain wheels and spur wheel are worn. In that case exchange the worn parts.

- Remove clamping screw of shutter flange and pull away flange from shaft. Remove locking rings of ball bearings at shutter flange with a special tool.

2. Mount chain wheel unit into the new intermittent movement in reverse order.

NOTE

The axial play of the shaft has to be slight.

Service Chapter 9-25

9.5.2 Assembly of Intermittent Movement

1. Put in intermittent movement without shutter. Screw in the four fixing screws but do not fasten them. Tighten these screws in a way that framing adjusting bush can easily move.

2. Put in framing adjusting bush without leaf spring through opening of projector housing about 30 mm into opening of intermittent movement.

3. Insert shutter and slightly tighten screws on clamping ring.

NOTE

The shutter must stand exactly vertically to the shutter opening of projector.

4. Then fasten the four fixing screws of intermittent movement. Pull out framing adjusting bush again and remove the screw M 2.5.

9.5.2.1 Inserting the Film Track

The adjustment screw and the locking screw of frontal film track bush are loosened.

1. Shove framing adjusting bush with leaf spring on tooth shaft end of film track with B side up to the rear film track bearing.

2. Lubricate the bush and the O ring with Esso oil.

3. Carefully push the framing adjusting bush placed on film track through opening of projector housing while simultaneously slightly turning the pully of intermittent movement. The gearing of the bush has to engage into the serrated shaft end of intermittent movement.

4. Loosely insert framing adjustment (black arrow) into intermittent movement.

5. Slightly press film track and turn framing knob (white arrow) clockwise until the film track is lying on projector housing.

6. Adjust film track (optical axis) with adjusting device and fasten film track.

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9.5.2.2 Adjusting the Intermittent Sprocket Shaft

1. Loosen intermittent sprocket fixing screw (white arrow).

2. Turn adjusting screw (black arrow) until you feel a resistance. Loosen the screw 1/8 turn.

9.5.2.3 Adjusting the Intermittent Sprocket

1. Turn clockwise framing knob about a є turn.

2. Insert a gauge 1 mm between sprocket and rear film track and push sprocket against gauge. Tighten intermittent sprocket fixing screw.

NOTE

The intermittent sprocket must have a little end play, because you can turn the framing knob alternately and easily. Check this by turning the framing knob.

9.5.2.4 Inserting the Chain Wheel Unit

1. Insert the chain wheel unit (arrow) from the operating side.

2. Adjust this unit in a way that there is still a perceptible play between gear in maltese cross and the gearing of shutter shaft.

3. Tighten the fixing screw which is between lens turret and film pressure skate on the front side of projector.

NOTE

If correctly adjusted, there is a total play of 3 to 4 mm measured on the outside diameter of the shutter.

Service Chapter 9-27

9.5.2.5 Tensioning the Chains

Replace both chains and close them with chain locks.

NOTE

The chains must not be too strong tensioned, but must also not flutter during movement.

Tension the chains as follows:

Upper chain

Loosen the feed sprocket (arrow) and shift it vertically until the chain is tensioned.

Lower chain

Loosen the three screws at bearing flange (arrow) of take-up friction. Turn flange in steps by 120° until the chain is tensioned. Tighten flange again.

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9.5.2.6 Inserting the Runner Strips and Film Pressure Skate

runner strips

1

film pressure skate knurled screw (one of four) clamping screw ball top threaded bolt

1. Insert runner strips in a way that they are lying vertically and adapted in film track, the ceramic

2

rollers are not touching them and the lower edges of the strips are

3

not lying on the teeth of sprocket.

2. Always start with tightening the lower knurled screw manually.

5

4

3. Put on film pressure skate.

4. To adjust the skate pressure place two short pieces of film into the film track.

5. Set scale of skate pressure in middle position.

6. Loosen clamping screw with two to three turns.

7. Adjust the ball top threaded bolt with a pin in such a way that the film pressure skate vertically has a slight play.

8. Tighten clamping screw slightly.

9.5.2.7 Assembly of Motor

1. Put couple on motor and fasten screws.

2. Put motor on flange of intermittent movement and center motor by turning itself. Slightly tighten screws on flange and simultaneously turn motor (there must be no noise and resistance).

3. Connect motor with plug.

Service Chapter 9-29

9.5.2.8 Rough Shutter Adjustment

2 of 3 fixing screws fixing ring screw of shutter shaft shutter

The fixing screws are lightly tightened.

1. Place a piece of film (approx. 1 m) into film track and around the intermittent sprocket (do not place on any other sprocket).

2. Horizontally tension the end of the film. With the other hand slowly turn motor clockwise until the film has advanced by two perforation holes (Ѕ frame). While holding the shutter shaft in this position turn shutter until the middle of the dark sector is in accordance with the middle of the film gate (optical axis).

3. Tighten the three screws and mark this adjustment. Draw a radial line across fixing ring up to shutter.

9.5.2.9 Fine Shutter Adjustment

1. Loosen hexagonal socket screw at shutter flange. Turn shaft clockwise shutter moves upwards. Turn shaft anticlockwise shutter moves lower.

If there are blurrings at the upper (right СEм) or the lower (left СEм) edge the shutter has to be adjust as follows:

9-30

2. Tighten the hexagonal socket screw.

3. If this does not correct the blurring, repeat rough adjustment.

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9.5.2.10 Filling in Oil

1. Remove hose from breather tube.

2. Remove plug from oil gauge.

3. Fill oil by means of funnel or squeeze container into the hose up to the level in the middle between the red and green oil level ring in the oil gauge glass.

4. Turn manually intermittent movement several times that air bubbles can escape. If necessary, replenish with oil.

5. Put plug on oil gauge.

6. Hang hose into clamp again.

9.5.3 Exchanging the Shaft Seal of a Maltese Cross Drive Tools you need:

fork wrench (36) box wrench (17) rubber mallet

Allen keys (4, 5)

hexagon-socket offset screw key (4)

pulling-off device

circlip pliers drift

Removing the motor with flange

1. First of all drain oil via hose:

Therefore remove cap on oil gauge glass and take hose out of clip. Let down the hose and drain oil in a receptacle.

2. Remove Motor by loosening the hexagon socket screw on motor shaft (Allen key 5) and the three hexagon socket screws on flange (hexagonsocket offset screw key 4).

Service Chapter 9-31

Removing the coupler

The following work can be done with mounted maltese cross drive in projector. But if you have some problems with handling you can remove the maltese cross drive by loosening the four hexagon socket screws on flange and the framing adjustment bushing (see chapter 9.5.1).

1. Loosen the coupler by using a wrench (36) and a box wrench (17) (see picture).

2. Remove the coupler by using a pullingoff device (see picture).

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Removing the cover

1. Remove the cover by loosening the four hexagon socket screws (Allen key 4).

shaft seal

2. Remove O-ring seal

Removing the shaft seal

O-ring seal shaft seal in cover

1. Remove circlips for shafts by using a circlip pliers.

circlips on shaft seal

Service Chapter 9-33

2. Remove shaft seal by opening with a drift (see picture).

30 mm

?

Mounting the new shaft seal

drift

25 mm

27.9 mm

?

1. Clean shaft seal seat with a soft cloth.

2. Lubricate the new shaft seal with oil, type EL 4854 (in service pack).

3. Put the shaft seal in cover opening (from outside) and press the seal with the aid of the drift into the hole until the stop (seat) is reached.

4. Centre the O-ring seal on the maltese cross flange and

very carefully

on it.

O-ring seal

put cover

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5. Lightly and evenly fasten the four hexagon socket screws so that you can move the cover.

6. Evenly fasten the screws until the stop is reached с the shaft cannot be turned с and then turn back є turn.

7. It is very important that the maltese cross shaft must be evenly moveable in any position. Therefore the following screw fastening is a by the touch work.

8. Simultaneously turn shaft and lightly hit with rubber mallet on the lateral cover housing to centre the O-ring seal.

9. If necessary loosen or fasten the corresponding hexagon socket screw.

10. If maltese cross shaft is turning evenly fasten the four hexagon socket screws.

11. Put coupler onto maltese cross shaft and fasten it.

11.

12. Put motor onto maltese cross drive and fasten it on flange.

13. Fasten hexagon socket screw on motor shaft again.

14. Fill in oil, type 3672. The oil level has to be between the red and green ring.

Service Chapter 9-35

9.6 Intermittent Sprocket

9.6.1 Exchanging the Intermittent Sprocket

runner strips film pressure skate (tilt) knurled screws fixing screw of sprocket adjusting screw hexagonal socket screws

(to tighten the bearing)

1. Remove skate : open it and push it out.

2. Remove the four knurled screws and remove the runner strips .

3. Remove fixing screw of sprocket.

4. Remove the four hexagonal socket screws of the front bearing bush.

5. Pull sprocket from shaft.

6. Clean and lubricate the shaft of sprocket with Esso universal oil and push on the new intermittent sprocket.

7. Screw on fixing screw (only the original one) , but do not tighten it.

8. Fasten the front bearing bush again.

ATTENTION

These four screws must be tighten slowly and evenly otherwise the bearing bush will be tilted and the sprocket shaft will be turned hardly.

9. Adjust intermittent sprocket with adjusting screw :

- Turn adjusting screw until you feel a light resistance.

- Loosen adjusting screw with 1/8 of a turn.

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FP 30 D

9.6.2 Exchanging the Intermittent Sprocket Shaft with Seal Ring

shutter housing with plastic nuts runner strips aperture changer knurled screws of runner strips film pressure skate adjusting screw hexagon socket screws

1. Disassemble film track:

- Remove plastic nuts and remove shutter housing.

- Tip skate away of film gate and pull the skate upwards.

- Remove the four knurled screws and take-off runner strips .

- Pull out aperture and remove driving pin out of slot of aperture (with aperture changer ).

- Turn anticlockwise adjusting screw of intermittent sprocket about two turns.

3. Remove intermittent sprocket:

- Remove fixing screw of intermittent sprocket.

- Remove the four hexagon socket screws of the front bearing bush.

4. Push out sprocket shaft through the rear bearing bush.

5. Remove seal ring out of bearing bush.

ATTENTION

Take care not to damage the bush during removal.

Service Chapter 9-37

6. Carefully press new oiled sealing ring with a suitable tool in the rear bearing bush.

7. Lubricate the new sprocket shaft with Esso universal oil and push it through the rear bearing bush.

8. Shove intermittent sprocket manually.

9. Tighten and adjust intermittent sprocket. See chapter 9.6.1, Exchange Intermittent Sprocket, point 7 to 9, regarding this.

9.7 Adjusting the Frequency Inverter

The frequency inverter (white arrow) is mounted in door of projector.

With the aid of a LCD keypad (adaptable, black arrow) you can set the operation parameters of the inverter.

The frequency inverter is factory-set in such a way that a suitable four-pole standard motor with a rated voltage of 230 V and 50 Hz can be operated without further settings.

During operation without keypad the operation state is displayed with two LEDs.

NOTE

For further information help yourself with the operating manual of frequency inverter.

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9.7.1 LCD Keypad

Function of keys

FP 30 D

The keypad is adapted on the inverter.

You can read the settings on display.

Key Function

increase display value

reduce display value

change between operating and code level

change between code and parameter level

inhibit controller

enable controller

fast increase display value (scroll up)

+

fast reduce display value (scroll down)

+

save changes of values

+

Service Chapter 9-39

Display

Display Description

OV IMAX PAR1 PAR2

SET

over-voltage set current limit exceeded parameter set 1 is active, PAR1 blinking: programing is possible parameter set 2 is active, PAR2 blinking: programing is possible set value selection via keyboard

7-Segment display

Display Description

OFF

Controller is inhibited because a LOW signal is applied to terminal 28.

STOP

AS_LC

STO

DC_b

LU

Controller is inhibited because Autostart-Lockout The parameter is saved. DC injection is braking active under-voltage

is pressed.

SET1 SET2

rEAd1 rEAd2 STOE

Parameter set 1 is overwritten by factory settings. Parameter set 2 is overwritten by factory settings. Parameter set 1 is overwritten by the data of the keypad. Parameter set 2 is overwritten by the data of the keypad. Parameter sets 1 and 2 are uploaded to keypad.

NOTE

For more information about display and fault indications, see operating manual for frequency inverter.

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9.7.2 Adjusting via Keypad NOTE

NOTE

Set value for parameter level PAR1 only.

??

Pressing after setting PAR1, PAR2 can be entered.

??

Set field frequency

What to do Display

Switch-on projector.

tip press press press + press (save)

FP 30 D

OFF C001

until

50 Hz

until

ST0

and then

PAR1

/

C011

PAR1

/

60 Hz

appears

blinks

appears

C011

Set V/f characteristics

What to do Display

C014

press press press + press (save)

Set V

min

until

0

PAR1

/

until 2 appears

ST0

and then

What to do Display

C016

press press press + press (save)

until

8.00

until

ST0

and then

/

25.00

Set JOG value 1

What to do Display

C037

press press press + press (save)

until

20

PAR1

/

48 Hz

until

ST0

und dann

appears

blinks

appears

PAR1

appears

blinks

C014

blinks

C016

appears

C037

Service Chapter 9-41

Set JOG value 2

What to do Display

C038

press press press + press (save)

until

30

/

until

ST0

Set JOG value 3

What to do Display

press press press + press (save)

until

40

/

until

ST0

appears

PAR1

blinks

50 Hz

appears

and then

C039

appears

PAR1

blinks

60 Hz

appears

and then

C038

C039

End of program

Press and then .

9.7.3 Code Table

Code Name Parameter Your settings

C011 Maximum

field frequency

C014 V/f charac-

teristics

C016 V C037 JOG value 1 0 to 480 Hz C038 JOG value 2 0 to 480 Hz

setting Factory setting depending on type 0 to 40%

min

30 to 480 Hz

-0- linear characterstics V ~ fd with Auto-Boost

-1- square characterstic V ~ f

-2- linear characterstic V ~ f U

boost

min

-3- square characterstic V ~ f V

boost

min

2

with Auto-Boost

d

2

with constant

d

2

with constant

d

50 Hz

2

25%

48Hz

50 Hz

9-42

C039 JOG value 3 0 to 480 Hz

60 Hz

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FP 30 D

9.8 Adjustments and Maintenance Work of Lens Turret and Aperture Changer

9.8.1 Retool and Grease Aperture Changer NOTE

Aperture Changers from 09. 99 on are mounted with plastic bushings in the brass tube. Do changers. The following description of retooling and greasing is only for aperture changers up to 09. 99 (without plastic bushings).

not grease

the brass tube or the steel rod of these new aperture

bar hold hut nut brass tube steel rod

2

3

9

1

4

10

7

8

5

6

screw hexagon nut threaded spindle linear drive and motor distance bolt 4 screws

Service Chapter 9-43

9.8.1.1 Change the Attachment of the Linear Drive (aperture changer up to 09.99 only)

To avoid a twisting of the linear drive you have to remove 2 of the 4 distance bolts and nuts. Proceed as follows:

?? ??

?? ?? ??

??

and tighten the 2 remaining distance bolts with the hex-socket set screws

Open the projector door. Remove the hexagon nut fixing the steel rod and the screw fixing the steel

plate spring. Pull out the steel rod . Loosen the linear drive: Remove the 4 screws . Remove the following 2 distance bolts :

Screw the delivered 2 hex-socket set screws with an Alan key (1.5) into the remaining distance bolts.

disc washer and 2 nuts on hex-socket set screw

linear drive

??

Put linear drive onto hex-socket set screws, fasten nut and fix with locknut.

no play!

The linear drive can be slightly move traversing - but there must not be a movement in axial direction.

??

Fasten steel plate spring with the screw .

9.8.1.2 Work the Steel Rod and the Brass Tube (aperture changer up to 09.99 only)

??

Smooth the steel rod with a very fine abrasive paper (400) and clean carefully afterwards.

??

Carefully clean brass tube .

??

Insert steel rod again and check the free movement. It must be turn readily and slightly push in and out. If the steel rod is not free moveable in brass tube you have to work the brass tube with a reamer ? 9,15. Afterwards you have to clean brass tube again.

??

If the steel rod is free moveable in brass tube you have to grease meticulously the steel rod with the delivered grease "Klёberplex BEM 34-132" or another heavy-duty grease, e. g. Molykote BR2plus.

??

Insert steel rod into brass tube and fasten it with hexagon socket screw.

9-44

??

If the threaded spindle is not running parallel then drive to position "CS" because the spindle has the closest distance to linear drive. Loosen the steel plate spring on the threaded spindle, correct the position and fasten nut again.

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FP 30 D

9.8.1.3 Grease Threaded Spindle (aperture changer up to 09.99 only)

Drive to the formats and simultaneously clean the spindle with a small brush. Do

??

this when the spindle is running to its full length, otherwise dirt can be pressed into the linear drive.

Grease the spindle during the aperture changer is running to the different

??

formats (Klёberplex BEM 34-132 or Molykote BR2plus).

9.8.1.4 Function Check (all aperture changers)

Visually inspect, whether the IR light barriers are contaminated with oil

??

(FP 30 D/ FP 38 D: chain sprays oil) or rubbed-off film parts. Check the functions of all positions and if necessary carry out an adjustment of

??

brightness values or exchange the aperture changer control board.

9.8.2 Adjusting Brightness LED Position Sensors

You can adjust the brightness LED position sensors of aperture changerҐs light barriers with an setting-PIC only, because in the installed micro controller is no EEPROM writing routine available. With this proceeding an unintentional writing of the EEPROM will be prevented.

Inserting the setting-PIC (software version 3.0 from 01/99 on), adjust the brightness LED position sensors as follows:

The adjustment of brightness LED position sensors will be carried out by the

??

software automatically, when the supply voltage (+24V to K1-5 and 0V to K1-4) is applied to p.c. board MSK-8103 for the first time. In doing so, the brightness LED position sensors of the analog voltage on the emitter of the photo transistor of the photo interrupters LS1, LS2 and LS3 are measured and stored in the EE-PROM. In future operation the measured analog values will always be standardized to the brightness value stored in the EEPROM.

ATTENTION

This adjustment of brightness values must only be done with the board removed from the projector and in an area with dim ambient light.

After a successful adjustment of brightness LED position sensors the green

??

D1

will be permanently illuminated.

In the case of a fault (U If the replacement of the photo interrupters is required during a repair, a new

??

adjustment of brightness values will have to be made, which

out with board removed from the projector.

<1.25 V) it will rapidly blink.

analog

Resetting values is initiated by

must be carried

connecting K1-1 (KEY1) and K1-2 (KEY2) with K1-4 (KEY-0V) or by pressing of the keys Key 1 and Key 2 during power up.

LED

Service Chapter 9-45

9.8.3 Mechanical Check of Lens Turret

9.8.3.1 Check Turret Rotation

1. Open projector on the backside and disconnect the 6pole motor plug (arrow).

2. Go in front of the projector and pull out the arresting magnet. Then evenly turn turret by hand.

The turret has to turn lightly and in one impetus and must not jam or turn hardly.

9.8.3.2 Check Arresting Magnet

1

3

The arresting magnet must dip to the same depth in all positions and must arrest surely.

arresting magnet

2

sensor board (light barrier)

without cover

positioning coding plate (1 of 3)

1. Manually turn turret to all positions and let magnet arrest at the left and the right side.

At each position, check how deep

2. the magnet arrests.

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9.8.3.3 Check Toothed Belt

NOTE

If a weld seam is defect, the belt has to be exchanged.

??

Exchange the toothed belt.

FP 30 D

1. Check belt tension (arrow) by pressing on it with your finger. The tension of the toothed belt has to be so strong that you can lightly press it a little bit.

2. One person should manually and slowly turn the turret during a second person is checking the belt over its whole length for a defect welding. If necessary use a lamp.

The new toothed belts are manufactured without weld seams.

??

If the turret jams or turns hardly or does the arresting magnet not arrest surely and dip to the same depth in all positions the turret has to be disassembled. Then you can check the rotor arresting bushings. If the bushings are damaged you can exchange them. If one of the bushings are damaged more than 1 to 2 mm in the depth you have to exchange the complete rotor (see chapter 9.8.6).

Service Chapter 9-47

9.8.4 Lens Turret / Aperture Changer Control Board

1,85 WS

1,66 NS

Cine

+

Status 0V/Return

Status 3

Status 2

Relay FEME 2xUM

BH GM

Motor aperture changer

Status 1

A1

A2

M

or

vio

sw sw

0V

U+

1

Filmtheater- un

d Studiotechnik

rs

gn

1

Status REV/Blink

-+

Drossel

-+

Blink

Status MASK

1,66 NS 1,85 WS

1

Motor turret

M

A1

Magnet turret

A2

Tp4

Tp3

Sensor turret MSK-81-04

1

Cine

GND

Tp2

Tp1

+24V

0V/GND

9-48

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FP 30 D

9.8.5 Adjusting the Lens Turret Positions

Check all turret positions with the measuring adapter.

??

If necessary measure the single values of each IR light barrier with a multimeter

??

and equalise them with the associated potentiometers.

9.8.5.1 Connection of a Measuring Adapter or/and a Multimeter

MSK8104

P7P8

P5

P6

TP3 TP4

TP2 TP1

Adapter MSK-81-05

+5V

TP3

TP4

TP2

TP1

0V

A r r a y

F l a t c a b l e t o board MSK8103

+

IC1

IC4

IC2

IC3

Bear.slit

Array

IC1/P5/TP1

2.001

IC4/P6/TP2

IC2/P7/TP3

IC3/P8/TP4

Coding

Coding control LEDs Monitoring IC3/P8/TP4

Monitoring IC2/P7/TP3 Bearing slit control LEDs

Monitoring IC4/P6/TP2 Monitoring IC1/P5/TP1

V=

Service Chapter 9-49

9.8.5.2 Checking and Adjusting the Sensor Board MSK 81-04 Sensor board

The following drawing shows the sensor board from the top view:

P8

P7

TP3

TP4

P6

IC1

P5

TP2 TP1

IC2

GND

IC3

IC4

Allocation: sensor с test point - potentiometer

The following table shows the allocation of the each IR sensor to the corresponding test point and adjusting potentiometer:

IR sensor Potentiometer Test point Function

IC1 P5 TP2 fine positioning, scanning the groove IC4 P6 TP1 fine positioning, scanning the groove IC2 P7 TP4 scanning the coding IC3 P8 TP3 scanning the coding

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FP 30 D

Adjusting the groove

Do the following adjustment as follows:

Manually turn lens turret to a position between two grooves. (Lift arresting pin

??

and turn manually).

The sensors must not мlookо into a groove с they must мlookо on the blank turret.

??

Check the two test points TP1 and TP2 with a voltmeter.

Both values have to be approx. 4.68 V to 4.73 V.

??

If necessary, adjust with the corresponding potentiometers (P6 and P5).

Observe, the potentiometers must not be adjusted to their stop (saturation), in this case a malfunction can be arisen.

The following drawing shows the best adjustment:

voltmeter value

4.7 V

potentiometer rotation

ATTENTION

After you have adjusted the potentiometers P5 and P6 to the correct position, you

must not turn

them for further adjustment!

??

Turn lens turret to its next groove position.

??

Now measure the volt values at test points TP 1 and TP2.

Ideally the values at both test points should be about 2.3 V (U

/ 2 = 2.3 V).

light

The values can vary between 1.4 V and 2.6 V, but they have to be as similar as possible.

??

You can reach this мsimilarо adjustment by moving manually the sensor board: Loosen the two screws and lightly move the board to match the values.

??

If you cannot match the values in this way, you have to remove the sensor board and file the fixing holes in form of long holes (approx. 1 mm):

Never turn the potentiometer!!

Service Chapter 9-51

Adjusting the coding

To adjust the coding turn lens turret to the NS position, because both sensors

??

reflect in this position. Measure with the voltmeter at test points TP3 and TP4.

??

Both values have to be between 4.5 V and 4.7 V.

If not, then adjust with the P7 and P8 potentiometers.

??

Then turn lens turret to WS position.

??

At TP 3 you have to measure a value less than 1 V - at TP4 approx. 4.6 V.

Then turn lens turret to CS position.

??

At TP3 you have to measure a value approx. 4.6 V - at TP4 less than 1 V.

The following drawing shows the sensor reflection (NS position: two sensors) at a certain turret position (NS, WS, CS):

NS coding

WS coding

CS coding

9-52

NOTE

D coding: => No coding plate and no groove will be detect.

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Kinoton FP 30 D User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual