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35mm UNITIZED PROJECTOR STRONG INTERNATIONAL a division of Ballantyne of Omaha, Inc. 4350 McKinley Street Omaha, Nebraska 68112 USA Tel 402/453-4444 • Fax 402/453-7238 www.strong-cinema.
SAVE THESE INSTRUCTIONS This equipment is intended FOR PROFESSIONAL USE ONLY Read and understand all instructions before using WARNING To avoid risk of fire, do not use nitrate or other flammable film. Use safety film only.
TABLE OF CONTENTS PREFACE FIGURE 1 FIGURE 2 INSTALLATION Unpacking Mounting Lamphouse Alignment Lamphouse Light Shield Picture Changeover Lens Turret Projection Lenses Flywheel Sound Reader Assembly Analog Digital START-UP PROCEDURES Initial Oiling Threading Initial Operation MAINTENANCE Lubrication Sprockets Pad Rollers Fastening Hardware Film Gate Film Trap Lens Turret Overall Appearance i 1 3 4 5 5 6 6 6 6 7 7 8 9 10 15 16 17 18 18 18 18 18 18 19 19
TABLE OF CONTENTS (continued) FIGURE 3 FIGURE 4 ADJUSTMENTS & REPLACEMENTS Intermittent Shoe Replacement Film Trap & Aperture Changer Pressure Strap Replacement Studio Guide Replacement Aperture Plate Adjustment Gear Compartment Cover Intermittent Movement Intermittent Sprocket Framing Light Pad Roller Assemblies Shutter Timing Shutter Replacement Film Gate Replacement Film Sprocket Replacement Sprocket Gear Replacement Automatic Lens Turret 20 21 PARTS LISTS 28 STRONG INTERNATIONAL a division of Balla
PREFACE THE SIMPLEX APOGEE PROJECTOR, combining rugged construction with ease of operation, provides theatre owners with a superior mechanism, engineered to the high standards set for all Strong International products. The following design features illustrate why the Simplex Apogee Projector is able to provide continuously excellent performance throughout its long operating life: UNIT DESIGN Unit method of design simplifies part replacement and maintenance. All units may be quickly removed and replaced.
MAIN FRAME The main frame casting forms a single unit that is noteworthy for its simplicity and strength. A single thread path serves all film-handling elements for both precise projection and sound reproduction. FILM SPROCKETS The upper feed and lower holdback sprockets, having twenty-four teeth each, reduce shaft speeds to prolong operating life, permit smoother wraparound, and lessen the danger of splice breakage. Exclusive use of VKF® sprockets insures minimum film wear.
FILM TRAP COOLING FANS SHUTTER ADJUSTING KNOB FOCUS KNOB PICTURE CHANGEOVER DEVICE TURRET “OPEN” LEVER CONTROL CABINET OIL FILL CUP DEADSTOP ADJUST DRIVE MOTOR FOCUS KNOB RESET LEVER, INDEX STOP PIN FIGURE 1 3
CHANGEOVER DEVICE FILM TENSION ADJUSTING KNOB GATE RELEASE PIN FRAMING LIGHT UPPER FEED SPROCKET APERTURE CUE SHUTTER GUARD RELEASE, APERTURE MOTOR COVER FRAMING HANDLE ANALOG SOUND READER TURRET RESET SWITCH DIGITAL SOUND READER INTERMITTENT SPROCKET HOLDBACK SPROCKET OIL SIGHT GLASS OIL DRAIN FIGURE 2 4 APERTURE LOGIC SENSING SWITCH
INSTALLATION EACH SIMPLEX APOGEE PROJECTOR is carefully inspected and film-tested before leaving the factory. Carefully inspect the unit on receipt for any shipping damage, and file any damage claims with the carrier immediately. It is the responsibility of the consignee, not Strong International or its dealers, to file such claims. THE FOLLOWING RECOMMENDATIONS should be studied carefully prior to installation.
LAMPHOUSE OPTICAL ALIGNMENT Carefully follow the lamphouse manufacturer’s instructions regarding correct optical alignment between the lamphouse and projector. The lamphouse is generally aligned to the projector aperture, but some consoles require positioning the projector to the optical center of the lamphouse. Never operate the lamphouse with the douser open unless the projector is running.
Lens Turret The MANUAL lens turret requires no electrical connections. Installer connections to the AUTOMATIC turret are made to the J4 terminals located on the printed circuit board on the control box door adjacent to the gear compartment cover on the side of the projector. The inputs (FEED, SPECIAL, FLAT, and SCOPE) are derived from an automation controller and/or other installer-supplied circuitry. NOTE: “SPECIAL” input applies only to a third lens in a three-lens turret.
SOUND READER ASSEMBLY ADJUSTMENTS to those components relevant to scanning the optical soundtrack are best performed by qualified personnel equipped with the necessary test equipment. Attempts to effect field repairs without use of the required test equipment are generally detrimental to sound quality. 1. 2. 3. An L.E.D. (Light Emitting Diode) is positioned directly behind the film plane to illuminate the soundtrack. The horizontal and vertical positioning is adjustable. The distance of the L.E.D.
The duty cycle (time ON) of the L.E.D. is the same as the projector motor and should parallel that of the xenon bulb; the lamphouse elapsed hour meter should indicate approximate L.E.D. hours. L.E.D. manufacturers have noted a 10-20% drop in light output after prolonged operation. If a sound signal loss cannot be corrected by fader gain, it may be necessary to replace the L.E.D. head. WIRING Install the LS-40 L.E.D. Power Supply to the projection console, pedestal, or to a rack adjacent to the soundhead.
Focus/Azimuth Clamping Screw Analog Signal Pickup Assembly L.E.D. Head Clamping Screw Azimuth Adjust Focus Adjust Horizontal Positioning Locknut Impedance Drum Loosen the focus/azimuth clamping screw and set the focus and azimuth by running the “pink noise” loop and adjusting the signal pickup assembly in the same manner as a conventional slit lens. Finalize the “A” chain installation by again checking the L.E.D. adjustment using Dolby Cat. No. 566 “illumination uniformity” test film.
To minimize microphonics, the L.E.D. must be very accurately aligned. • With the power amplifiers OFF, turn the processor and monitor gains FULL UP. Select a film format and the correct projector on the processor. Run the projector with no film. Fine-adjust the L.E.D. mount rotation to a point where the sound of the projector running is not heard through the sound system. The optimal adjustment will be found between two positions where the projector vibration can be heard quite clearly.
(Figure B is in optimal alignment) 12
2. Calibrate oscilloscope to processor: a) Thread a loop of Cat. No. 69P test film into projector and reader; start machine. b) Select Channel 2 for display. c) Adjust the horizontal position to line up the inside edge of the left “goal post” with the left edge of the graticule. d) Adjust the sweep vernier to line up the inside edge of the right “goal post” with the right edge of the graticule.
Digital Signal Pickup Assembly L.E.D.
START-UP PROCEDURES ALL SIMPLEX PROJECTORS are carefully “run-in” at the factory before shipping. No “run-in” period at the installation site is required. Some gear whine may be noticed initially, but should disappear after a few hours of operation. INITIAL OILING One quart of Simplex Projector Oil is included in the accessory kit supplied with new equipment. USE ONLY GENUINE SIMPLEX PROJECTOR OIL IN THE MECHANISM. Use of other lubricants may inhibit oil pump operation and damage moving parts.
THREADING Threading the projector correctly is one of the operator’s most important duties. Careful attention during this operation pays off in improved performances and long print life. Unlatch and open the turret. Rotate the framing handle (A) to position the intermittent sprocket (B) at the center of its adjustment range. Using the motor flywheel, turn the mechanism by hand to rotate the intermittent sprocket (B) to its “rest” position.
INITIAL OPERATION CLEAN ALL FILM-BEARING SURFACES BEFORE EACH THREADING OPERATION. Check all sprocket teeth for hooks or burrs; replace if required. Keep all pad rollers clean and operating freely. Make certain the turret is set to the correct lens and aperture for the desired screen format. FLAT format is generally used for initial setup of the projection system. The Film Trap Tension Knob is located at the top of the film trap, and is graduated from “minus” (-) to “plus” (+).
MAINTENANCE THE PROJECTOR MECHANISM should periodically undergo a careful and thorough inspection. A regular schedule of adjustments and replacement of wearing parts will insure long life, provide reliable performance, and minimize downtime. LUBRICATION Drain and discard the projector oil after six months of initial operation, and at least annually thereafter. Clean the oil pump intake filter and the oil reservoir. Replace with genuine Simplex Projector Oil (Part No.
MAINTENANCE (continued) LENS TURRET Periodically check the condition of the (2) O-ring drive tires on the auto turret drive wheel. Clean the surfaces of the O-rings and replace if worn or cracked. DO NOT LUBRICATE. Check the tension of the motor mount expansion spring and replace if stretched. The indexing plate of the lens turret rotates on (3) grooved ball bearings mounted to the turret ring casting. The uppermost bearing is retained by means of an eccentric bushing, allowing a degree of adjustment.
DOUSER LINKAGE ARM SHUTTER BLADE CHANGEOVER DOUSER HEAT SHIELD CHANGEOVER DOUSER PIVOT COVER, APERTURE MOTOR FILM TRAP FIGURE 3 20
UPPER FEED SPROCKET DRIVE GEAR OIL SLINGER UPPER FEED SPROCKET DRIVEN GEAR SHUTTER ADJUSTMENT KNOB INTERMITTENT MOVEMENT OIL TRAP MAIN OIL SUPPLY LINE VERTICAL SHAFT SHUTTER SHAFT SUPPORT SHUTTER SHAFT DRIVE GEAR INTERMITTENT MOVEMENT FLYWHEEL INTERMITTENT DRIVE GEAR FRAMING GEAR HOLDBACK SPROCKET DRIVE GEAR OIL PUMP HOLDBACK SPROCKET DRIVEN GEAR FIGURE 4 21
ADJUSTMENTS AND REPLACEMENTS REFER TO THIS SECTION in conjunction to performing the steps in the MAINTENANCE section. Conscientious maintenance and service of the Simplex Apogee Projector Mechanism will insure many years of excellent performance. ADJUSTMENTS are quickly accomplished, and replacements performed, as all units and components are readily removed. Adjustments and replacements described below may be performed by qualified projection booth personnel.
APERTURE PLATE ADJUSTMENT (continued) Horizontal travel of the aperture plate is also adjustable. The inboard stop is set by loosening the clamping screw (A) and rotating the slotted end of the slide shaft (B) to position the snap ring (C) at the desired stop point. Secure the clamping screw (A) after the adjustment is correct. The outboard stop is fixed by tightening or loosening stop screw (D) against the aperture slide bracket. Secure lock nut (E) after the outer stop adjustment is correct.
INTERMITTENT SPROCKET REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Remove the film gate runner. Dismount the film trap. Open the intermittent sprocket pad arm. Rotate the framing knob to its extreme clockwise position to expose the intermittent sprocket film stripper mounting screw. Remove the screw and stripper. Turn the projector mechanism by hand so that one of the collar index lines (A) aligns with the index mark on the outboard arm (B), and the sprocket mounting screw is exposed.
SHUTTER TIMING 1. 2. 3. 4. 5. 6. Place the shutter adjusting knob in its mid-position. To locate mid-position, rotate the knob to its stop, and reverse 1½ turns. Remove the shutter guard. Turn the projector mechanism by hand so that the index mark on the intermittent outboard bearing arm is centered between two of the collar index lines. Loosen the (2) socket head shutter hub clamping screws. With the screws loosened, the shutter blade should rotate freely on its shaft while the shaft remains stationary.
FILM SPROCKET REPLACEMENT 1. 2. 3. Open the pad roller arm. Remove the hex head sprocket fastening screw from the outboard end of the sprocket shaft and slide the sprocket from the shaft. Leave the spring washer and flat washer on the shaft. Slide the replacement sprocket onto the sprocket shaft, aligning the key in the sprocket with the keyway in the shaft. Secure with the sprocket fastening screw. FILM SPROCKET DRIVEN GEAR REPLACEMENT 1. 2. 3. 4. Remove the gear compartment cover (see previous).
AUTOMATIC LENS TURRET (continued) 6. 7. 8. 9. If a lens change fails to execute when cued, press the reset switch until the desired format is in place. Check the condition of the cuing material; foil tape may be worn, or bar code information may be obscured by scratches or dirt. Check for faulty cue detector or failed contact in automation controller. A malfunction in aperture/turret logic indicates a problem in the turret control board. Consult the factory.
PARTS LISTS Simplex Apogee Item 1 2 3 - Part No.
FILM GATE Assembly No. 52-00214 Item 1 2 3 4 5 6 7 8 9 10 11 Part No.
FILM TRAP Assembly No.
FILM TRAP & APERTURE CHANGER Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 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 - Part No.
FILM TRAP & APERTURE CHANGER, Parts List (continued) Item 41 42 43 44 45 46 47 48 49 50 51 52 53 54 Part No. 21-37008 52-00359 81-33017 82-20371 4060123 21-37055 41-98055 51-37009 4060250 81-37011 4030181 51-70037 4040620 82-20448 81-98121 81-37022 51-58007 52-00375 52-00452 31-98209 Description Dowel Pin, 1/2" x 1/8" Diameter (2 req’d.) Aperture Plate Drive Motor Assembly Gear Motor; 12 V.
TRAP BLOWER Assembly No. 52-00387 Item 1 2 3 4 Part No. 52-00338 52-00339 52-00343 4060250 Description Trap Heat Sink Heat Shield Air Channel Screw, 6-32 x 1/4" Pan Head (4 req’d.) Item 5 6 7 8 Part No. 52-00379 51-02002 51-02003 4081250 Description Plug, Air Channel Blower, 12 V.DC Blower Grille Screw, 8-32 x 1-1/4" Button Head, (8 req.d.
APOGEE LENS TURRET Assembly No.
APOGEE LENS TURRET Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Part No.
LENS TURRET, Parts List, continued Item 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 56 Part No. 4060250 52-00322 51-51011 21-58060 4370500 4372005 4378001 52-00277 52-00278 51-56002 4040372 4060370 51-04015 52-00275 4080250 52-00273 52-00274 51-98254 01704000 52-00397 51-58059 52-00346 51-37032 52-00282 4250755 21-70016 425050A Description Screw, 6-32 x 1/4" Pan Head Turret Latch Shoulder Screw (2 req’d.
Magnet OUTBOARD for SCOPE cue 37 Magnet INBOARD for FLAT cue 3i 3g 3h 3f 3d 3e 3b 3c 3a TURRET LENS PLATE Assembly No.
TURRET LENS PLATE ASSEMBLY Parts List Item 1 2 3 3a 3b 3c 3d 3e 3f 3g 3h 3i 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Part No.
Item 1 2 3 4 5 6 7 8 9 Part No. 52-00383 52-00386 41-98097 4061500 52-70077 61-98022 52-70080 52-70081 --- Description Box, Welded Assembly Transformer Standoff, 1/4" x 3/4" 6-32 Thrd. (4 req’d.) Screw, 6-32 x 1-1/2" Pan Head (4 req’d.) PC Board Assembly, “Power” Standoff (4 req’d.) Relay PC Board Assembly PC Board Assembly, “Control” Capacitor, 7.5 µf, 370 V.AC (with Motor) Item 10 11 12 13 14 15 16 17 18 Part No.
40 CONTROL CABINET, Wiring Diagram
TURRET CONTROL PRINTED CIRCUIT BOARD Wiring Diagram 41 REPLACEMENT CHIP (U1), Programmed 52-00391: Two-Lens 52-00392: Three-Lens
FRAMING SHAFT Assembly No. 52-00205 Item 1 2 3 4 5 6 7 8 9 10 11 Part No. 52-00207 51-04004 52-00206 51-28028 4507100 51-58036 52-00336 21-48024 4100500 51-48010 4101000 Description Framing Shaft Linear Bearing (2 req’d.) Framing Gear Framing Handle Flatwasher, 1/2" (2 req’d.
HORIZONTAL DRIVE SHAFT Assembly No. 52-00235 Item 1 2 3 4 5 6 6a 6b 6c * Part No. 52-00234 21-48027 51-27004 52-00166 51-04007 52-00335* 4080375 52-00233 51-36011 51-48007 Description Horizontal Drive Shaft Snap Ring, Truac 5100-50 (3 req’d.) Woodruff Key (P-1537) Main Drive Gear Ball Bearing (2 req’d.) Seal Plate Assembly Mounting Screw, 8-32 x 3/8" Pan Head Seal Plate Oil Seal O-Ring (2 req’d.
VERTICAL SHAFT Assembly No. 52-00253 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Part No. 52-00248 51-23018 52-00186 51-23009 52-00167 52-00249 51-04007 52-00250 52-00251 4507106 52-40181 408025D 51-58036 4080870 4060250 52-00384 Description Vertical Shaft Intermittent Movement Drive Gear (P-1418) Sprocket Shaft Drive Gear (2 req’d.) Shutter Shaft Drive Gear (G-1803) Vertical Shaft Main Driven Gear Bearing Block, Upper Ball Bearing (3 req’d.
DRIVE MOTOR Assembly No. 52-00204 Mounting Screws for Item 5 (1) 4250620 1/4-20 x 5/8" (upper) (2) 4250755 1/4-20 x 3/4" (lower) MOTOR HOOK-UP 115 Volt 230 Volt Fuse AC Input at 4 A. Item Part No. Description 1 51-33003 Motor, 115/230 V.AC, 50/60 Hz. 2 51-07011 Grommet, Shock Mount (8 req’d.) 3 51-16003 Coupler 4 52-00344 Inching Wheel 5 52-00203 Motor Bracket 6 4251500 Screw, 1/4-20 x 1-1/2" (4 req’d.) 7 4258001 Nut, 1/4-20 FlexLock (4 req’d.) 8 4257102 Flatwasher, 1/4" SAE (12 req’d.
G-4312 INTERMITTENT MOVEMENT Assembly No.
INTERMITTENT PAD ARM Assembly No. 52-00243 Item 1 2 3 4 5 6 7 8 9 10 11 Part No. 52-00236 31-37001 52-00237 21-37009 51-98099 4060253 52-00327 52-00019 4080120 52-00238 52-00280 Description Base, Upper Guide Spring Pin, 3/4" x .1875" Intermittent Pad Arm Spring Pin, 1-1/2" x .1875" Shaft, Eccentric (P-3135) Screw, 6-32 x 1/4" Intermittent Guide Roller Knob (P-3134) Set Screw, 8-32 x 1/8" Weighted Roller Shaft “B” Item 12 13 14 15 16 17 18 19 20 21 47 Part No.
UPPER/LOWER PAD ROLLER Assembly No. 52-00247 Item 1 2 3 4 5 6 7 8 9 10 11 12 Part No. 52-00244 52-00246 52-00245 51-98099 21-49004 52-00019 21-37009 4060253 4080120 51-58039 51-37028 4250750 Description Mounting Bracket Shaft, Pad Roller Arm Pad Roller Arm Shaft, Eccentric (P-3135), 2 req’d. Pad Roller (P-3085), 2 req’d. Knob (2 req’d.) Spring Pin, 1-1/4" x .1875" Screw, 6-32 x 1/4" Socket Head (2 req’d.) Set Screw, 8-32 x 1/8" (2 req’d.) Expansion Spring Spring Pin, 3/4" x .
OIL PUMP ASSEMBLY 49
OIL PUMP ASSEMBLY Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 * Part No. Description 51-23022* Oil Pump Driven Gear 52-00288 Pump Support Bracket 52-00001* Oil Pump Housing 51-39019* Oil Pump Gasket 51-98105* Oil Pump Drive Shaft 51-98016* Impellor Vane (2 req’d.) 51-58028* Compression Spring 4040751* Screw, 4-40 x 3/4" Socket Head 4040373* Screw, 4-40 x 3/8" Socket Head (3 req’d.) 52-20114* Pump Housing Cover 4110500 Screw, 10-32 x 1/2" Socket Head (2 req’d.
SHUTTER HOUSING Assembly No. 52-00365 Item 1 2 3 4 Shutter Cover 52-00374 Upper Mntg. Screw: 4080250 Lower Mntg. Screw: 4080375 51 Part No.
SHUTTER COMPENSATOR MECHANISM Assembly No.
SHUTTER COMPENSATOR ASSEMBLY Parts List P-1465 P-1466 P-1467 P-1470 P-1472 Compression Nut (51-35007) Compression Bushing (51-07005) Roll Pin, Framing Rod (52-20105) Spring Retaining Washer (51-70027) Bracket Casting, Shutter Adjusting Shaft (52-20038) P-1473 Pin, Shutter Adj.
G-9727 PICTURE CHANGEOVER DEVICE Assembly No. 52-60325 (110 V.AC) Assembly No. 52-60326 (220 V.
G-9727 PICTURE CHANGEOVER Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 -20 21 Part No.
APOGEE SOUND READER Assembly No. 52-00297 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part No. 52-00290 4100870 51-04006 52-00289 52-00276 4080502 52-00280 21-04003 52-20428 408025D 410050A 51-58047* 52-00295* 52-00294* 51-51013* Description Sound Reader Base, Machined Mounting Screw (to Main Frame), 10-32 x 7/8" Socket Head (3 req’d.
SOUND READER COMPONENTS Item 1 2 3 4 5 6 7 Part No. 5198413-1 5198413-2 5198413-3 5198413-4 5198413-5 5198413-6 5198413-7 Description Reader Plate Assembly Digital (Dolby®)Pick-Up Assembly Analog Pick-Up Assembly Outer L.E.D. Illuminator (Digital) Inner L.E.D. Illuminator (Analog) Standoff Block Stud Plate, Illuminators NOT SHOWN 4080502 410050A 51-35003 51-98415 57 Screw, 8-32 x 1/2" Socket Head Screw, 10-32 x 1/2" Flat Socket Head FlexLock Hexnut, 1/4-28 (P-1471) L.E.D.