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CHRISTIE INCORPORATED 35/70 Automated Electronic Film Projector Maintenance and Service Manual CHRISTIE INC. 10550 Camden Dr.
The information in this document is subject to change without notice and does not represent a commitment on the part of CHRISTIE. CHRISTIE does not assume responsibility for errors that may appear in this document. CHRISTIE or its subsidiaries, designated representatives, and any other vendor of the 35/70 Automated Film Projector are not responsible in any way for any liabilities or loss resulting from the use or misuse of this document. This manual prepared by: CHRISTIE INCORPORATED 10550 Camden Dr.
1. Introduction INTRODUCTION Contents of the Manual This manual contains operation, maintenance, and service information for the 35/70 Automated Film Projector. The material covered includes: • • • • • • general description operating the projector theory of operation electronic adjustments periodic maintenance troubleshooting guide. Who Should Use the Manual? This manual provides levels of detail that are suitable for various purposes.
2. General Description GENERAL DESCRIPTION The 35/70 Automated Film Projector is a state-of-the-art projector designed for the demanding requirements of highreality motion picture projection. Full microprocessor control results in a system that combines excellent image stability with high-speed motion, both forward and reverse, and complete external RS-232 computer control.
2. General Description Installation and Unpacking This section provides unpacking information, installation data, and external connection data for the 35/70 Projector. For physical and electrical installation of the lamphouse, refer to the lamphouse manual. CHRISTIE INC.
2. General Description The lamphouse is not part of the projector system. CHRISTIE INC.
2. General Description Unpacking Upon receipt of the projector at the final destination, unpack as follows: 1. Examine shipping crate or carton for visible shipping damage prior to removing the projector. Note any damage. 2. Carefully remove the shipping crate or carton from the unit. 3. Inspect the projector for shipping damage. Notify the carrier if such damage exists. 4. Remove rear panels of cabinet, and remove all packing material and restraints.
2. General Description Refer to Section 6.8 for correct voltage strapping of power supply transformers prior to connection. CHRISTIE INC.
2. General Description Control Ports The projector has two serial control ports. In normal operation, they carry commands from a show controller or master projector. For debugging purposes, the ports can be connected to a service terminal. Commands can also be input from the projector control panel. The serial communications protocol is set to 9600 baud; No Parity; 8 Data Bits, and 1 Stop Bit (9600/N/8/1).
2. General Description Film Position Two counters are stored in the projector memory space to track the position of the film. These are referred to as the reel counter and the film counter. The reel counter tracks timing for an entire reel of film, whereas the frame counter tracks the timing within an individual show.
2. General Description desired show, and waits for the command that will start play. This motion may be either forward or reverse depending on the position of the next show relative to the current show. Certain commands input from the keypad or the remote interface (the show controller or a service terminal) suspend normal operation and allow the user to examine system state or modify constants for troubleshooting. In this mode, all film motion and other projector functions may be controlled manually.
2. General Description The Control Panel The operation of the projector can be monitored by viewing the information displayed on the keypad with its associated LED display strip as shown in Figure 2.1. The keypad LED display strip normally indicates the frame counter for the current show. However, this display strip may also display other command-specific information, as explained in the descriptions of the individual commands in Section 0.
2. General Description Keypad Input The control panel contains two keypad areas that can be used to communicate to the projector: a 4X4 numeric keypad area on the left, which contains numeric and some function keys, and a 3X3 command keypad area in the center, which contains keys that execute the most commonly used functions. The numeric area can also be used for some commands. In addition, hexadecimal representations above 9 (A - F) can be entered from the numeric keypad area, as shown in Table 2.2.
2. General Description Keypad LED 0 1 2 3 4 5 6 7 8 9 CLEAR AUTO G H C FOR STOP REV INTERLOCK LOCAL SET LOOP READY CUE NOT RDY Indication The CPU detected an error in the shutter speed. The Lower Torque arm activated the limit switch. The Upper Torque arm activated the limit switch. The CPU detected that there is no film in the gate or there was a pulldown malfunction. The Lower Buckle arm is out of position. The Upper Buckle arm is out of position. The CPU detected a constant velocity fault.
2. General Description System Status The system status identifies the show being played and the current action of the projector. This value is displayed in the rightmost two positions of the frame counter LED. The current show is the rightmost character of the two-character value, and the status is the leftmost character. The status identifies the type of operation the projector is executing. Valid status values and their meanings are shown in Table 2.4.
2. General Description • • • • • brief description of the command key sequence to trigger command RS-232 code for command data input description and format, where applicable resulting projector actions • status changes as a result of the command. When a projector command is referenced, it is written in bold, upper-case typeface. When a value that is stored in a memory register and tracked by the projector is referenced, it is written in lower case and underlined.
2. General Description command (See Section 2.8.18). Using the FORWARD command will cause the projectors to loose sync with each other. ENTRY: CODE: ACTION S: C1 1. Accelerate to cine speed. 2.Enable douser at or about first frame, so that the OPEN DOUSER command will be accepted. If the AUTO DOUSER command has been entered the douser will automatically open after 3 seconds. 3. Play current show. 4. Stop at EOF marker. 5. Rewind to head of show.
2. General Description C3: The OPEN DOUSER AND CINE Command [OP] This operational command opens the douser. The film must be moving at cine speed for this command to take effect; if the projector status is not equal to 1, the OPEN DOUSER command is ignored. ENTRY: CODE: , <3> C3 ACTION S: Open the douser and put projector into cine mode. STATUS: Set to 3. C4: The CLOSE DOUSER AND SLEW Command [OP] This operational command closes the douser.
2. General Description ENTRY: CODE: , <6> C6 ACTION S: Projector logs all BOF and EOF sensor tapes on the reel. STATUS: Unchanged. Table 2.5 illustrates the sequence of commands necessary for auto-logging. In this example, the number of shows is equal to five, and the first show to be shown after all cues have been logged is Show #2. Command Input Result (Load the film on the reel so that the BOF tape for Show #1 is above the gate or on the supply reel.
2. General Description C7: The OUTPUT STATUS Command [DX] This diagnostic command requests an output of the current status. The rightmost character of the two-character display contains the number of the current show; the leftmost character contains the status. The status is output on the RS-232 port to the show controller or the service terminal. ENTRY: CODE: , <7> C7 ACTION S: Outputs status over RS-232 interface. STATUS: Unchanged.
2. General Description ENTRY: CODE: , <9> C9 ACTION S: Reset the frame counter. STATUS: Unchanged. CA: The READY Command [OP] This operational command initiates the READY sequence. When the projector is in READY mode, if the key is pressed again, the LED display strip displays the reel counter. To return the show counter to the display, enter a G1 (DISPLAY COUNTER) command. ENTRY: CODE: ACTION S: CA 1. Apply power to motor systems. 2. Check all limit switches. 3.
2. General Description CD: The MANUAL LOG Command [OP] This operational command enables manual entry of reel time values for shows marked with BOF tape at the head of each show. The command sequence is repeated for each show on the film. All reel times must be entered in the standard format, where the hours value defaults to 01. These values represent points on the film, rather than elapsed times. ENTRY: , CODE: CD INPUT: 1. Show number. Example: CD1 2.
2.
3: Operating the Projector CF: The CYCLE TEST Command [DX] This diagnostic command initiates a CYCLE test for the projection system. When in the CYCLE mode, the projector plays all programmed shows on the current reel of film in cine mode, then reverses to the beginning of Show #1 and repeats the sequence. If the AUTO DOUSER command (See Section 2.8.37) has been entered prior to the CYCLE TEST command, then the projector will automatically open the douser for each showing.
3: Operating the Projector H1: The PLAY CURRENT SHOW Command [OP,L] This operational command causes the system to play the current show. The command should be issued from a cue point. Use this command instead of the FORWARD command to operate projectors configured for MASTER/SLAVE operation. ENTRY: CODE: ACTION S: , <1> H1 1. Play current show. 2. Stop at tail of show. 3. Wait for SET NEXT SHOW command (see Section 0). STATUS: Set to 1 while moving to first frame.
3: Operating the Projector H3: The FAST FORWARD Command [DX,L] This diagnostic command moves the film in a forward direction at a rate of 120 fps. The douser is closed. This command must be followed by a STOP command, or the film will run off the reel. ENTRY: CODE: , <3> H3 ACTION S: Move film forward at 120 fps. STATUS: Set to 8. H4: The SET FRAME COUNTER Command [DX] This diagnostic command allows the user to load a new value into the frame counter.
3: Operating the Projector ENTRY: CODE: ACTION S: , <5> H5 1. Display current show in second-from-right position of numeric display. 2. Display next show in rightmost position of numeric display. INPUT: Enter the number of the new current show, using the numeric portion of the keypad. The number entered cannot exceed the maximum shows, which is 3 by default but may be set as high as 6 with the SET MAXIMUM NUMBER OF SHOWS command (see Section 0). ACTION S: Load the new current show value.
3: Operating the Projector ENTRY: CODE: ACTION S: , <7> H7 1. Move forward or backward at 120 fps until the BOF marker for the next show is located. 2. Update frame counter. 3. Park at BOF mark. STATUS: Set to 8 while searching for BOF marker of next show. Set to A while parked at cue point. H8: The SET NEXT SHOW Command [OP] This operational command causes a display of the current show and the next show, respectively, in the two rightmost digits of the numeric display.
3: Operating the Projector ENTRY: , <9> CODE: H9 INPUT: 1. Enter a 6 from the keypad to select 60-Hz operation. 2. Enter a 5 from the keypad to select 50-Hz operation. ACTION S: The synchronization frequency is reset accordingly. STATUS: Unchanged. HA: The INTERLOCK Command [OP] This command puts the projector into interlock mode. Interlock mode allows the projector to be interlocked via BIPHASE to an external motion source or MASTER projector.
3: Operating the Projector HC (READY): The PULLDOWN GAIN DISPLAY Command [DX] This diagnostic command is used for calibration and setup. When the projector is in READY mode and has been given the command to cue cine forward, this command checks the gain value for VR1 on the CPU/Main Logic card and displays it in the rightmost two digits of the corresponding numeric displays on the operator control consoles.
3: Operating the Projector ENTRY: , CODE: HD INPUT: Number of shows on reel (must be from 1 – 6). ACTION S: Sets maximum number of shows on the current reel of film. STATUS: Unchanged. HE: The LOCAL MODE Command [DX] This diagnostic command takes the projector out of interlock mode. Interlock mode allows the projector to be interlocked, via BI-Phase, to an external motion source or MASTER projector. To prevent film damage, enter this command only when the external motion source is idle.
3: Operating the Projector G0: The MEMORY INSPECT Command [DX] Altering the projector memory contents may damage the film and/or the projector! To protect against such damage, allow only qualified service personnel to use this command. This powerful diagnostic command is used to view and update data in the memory of the projector CPU.
3: Operating the Projector Input Comment Result Must be entered from console. Activates the serial RS-232 communications port (see Section 0). “M” followed by desired hexadecimal memory location (use upper case for alpha characters). Data stored at the chosen address is shown to the right of that address on the terminal’s display. yy New value for memory location (two hex digits). Value at selected address is updated. ↑ Up-arrow cursor. Increment memory location. ↓ Down-arrow cursor.
3: Operating the Projector G2: The SELECT FRAME RATES Commands [DX] This diagnostic command allows entry of the selected frame rate and the number of perfs per frame. Default values are 30 fps and 5 perforations unless specified otherwise. When using 35mm film select 5 perforations. ENTRY: , <2> CODE: G2 INPUT: 1.
3: Operating the Projector G3: The AUTO DOUSER Command [OP] This operational command enables the projector to automatically open the douser 3 seconds into the film after the projector has been commanded to run FORWARD. This function is reset when the projector goes into a NOT READY condition. ENTRY: CODE: , <3> G3 ACTION S: Allows the douser to be automatically opened 3 seconds into the film. STATUS: Unchanged.
3: Operating the Projector G6: The OUTPUT CUE TAPES Command [DX] This diagnostic command downloads the position of each BOF and EOF cue tape, as it has been loaded into the projector, to the show controller. The output data is in the format shown in Table 2.8. ENTRY: CODE: ACTION S: , <6> G6 1. Outputs PROMPT followed by BOF for first show. 2. Outputs successive BOF and EOF positions, each preceded by a PROMPT. STATUS: Unchanged.
3: Operating the Projector G8: The REVERSE TEST MODE Command [DX,L] This diagnostic command is used to adjust the position of the torque arms and run the projector in slew mode at various speeds in the forward and reverse direction. The projector must be powered up and in the READY state. ENTRY: , <8> CODE: G8 INPUT: 1. Enter a speed value of 10 on the keypad. 2. Hit the key. 3.
3: Operating the Projector G9: The SHOW CONTROL ENABLE Command [OP] This operational command toggles projector control between the right half of the control keypad and the RS232 communication port. ENTRY: CODE: ACTION S: , <9> G9 1. If the 9 LED is on, RS232 communication port control is disabled and keypad control is enabled. 2. If the 9 LED is off, keypad control is disabled and RS232 communication port control is enabled. STATUS: Unchanged.
3: Operating the Projector GB: The TIMECODE INQUIRY Command [DX] This diagnostic command is used to report the current timecode stored in the projector’s internal buffer. The status is output on the RS-232 port to the show controller or the service terminal. ENTRY: CODE: ACTIO NS: STATUS : , GB The current timecode is output across the RS-232 communication port in the counter format hh:mm:ss:ff (see Section 0). Unchanged.
3: Operating the Projector GF: The SOFTWARE VERSION Command [DX] This diagnostic command triggers the output of an ASCII string containing the software version number. ENTRY: CODE: , GF ACTION S: Returns software version number. STATUS: Unchanged. CHRISTIE INC.
3: Operating the Projector OPERATING THE PROJECTOR Although film projection using the show controller requires no operator intervention, certain procedures must be followed to prepare the film and projector for playing shows. This section describes the setup and operating procedures. Marking Shows on the Film Reflective tape must be installed for each show on the film reel. Up to three pieces of tape per show are required: • • • BOF indicator EOF indicator SHOW NUMBER indicator (optional).
3: Operating the Projector Threading Film Consult the threading diagram in Figure 3.1, and thread the film as shown. The film must be threaded so that the emulsion side is toward the lamp. It is important that the right amount of film is in the gate area so that the projector can effect a proper loop set. For 70 millimeter film thread the film so that, when the top loop is pulled into the bottom, the total bottom loop guide is 75% full.
3: Operating the Projector Operating Instructions Do not strike the lamp unless the projector is OFF or in the NOT READY state. Failure to comply with this procedure could result in damage to the projector or film. Normal Operation Apply power by positioning the PROJECTOR ON/OFF switch on the power supply switch panel to ON. The frame counter display should read 01:00:00:00 (one hour). The LED’s on the , and <9> buttons should be on. The shutter will not be rotating at this time.
3: Operating the Projector Master/Slave Operation If the projector is to be used in a Master/Slave configuration, the following steps will need to be performed, in addition to steps 1 to 7 in Section 3.3.1. 1. Enter the PARK ON CUE () command for both Master and Slave projectors. 2. Enter the JAM () command for both projectors to reset the time display to 1:00:00:00 if desired. 3. Enter the INTERLOCK (press or enter ) command for the Slave projector. 4.
3: Operating the Projector 8. At the end of the show a CLOSE DOUSER () command must be sent to the projector to close the douser and a STOP () command must be sent to the Master Motion Controller to stop the projector. 9. From this point the projector must be taken out of interlock, with the LOCAL MODE () command, and rewound to the start of the show by entering a CUE NEXT () command into the projector. 10. Repeat steps 2 to 9 to play the next show.
4: Periodic Maintenance PERIODIC MAINTENANCE To properly maintain the CHRISTIE 35/70 Automatic Electronic Projector and avoid damage to the film, a certain amount of routine preventive maintenance is required. Proper maintenance aids in preventing untimely system breakdowns. This section describes the appropriate maintenance procedures. Maintenance procedures are performed at daily, weekly, monthly, six-month (semiannual), or yearly (annual) intervals, as well as when the lamphouse bulb is replaced.
4: Periodic Maintenance CHRISTIE 35/70 Projector Daily Preventive Maintenance Log Sheet Week Beginning: ______/______/______ Action Required Mon Tue Wed Thu Fri Sat Sun Clean Particle Transfer Rollers Clean lens Clean rollers Clean gate Clean gate trap, guide rails Clean sensors General dusting Check buckle trips Check Sprockets Check torque arms Check picture quality Table 4.
4: Periodic Maintenance CHRISTIE 35/70 Projector Monthly Preventive Maintenance Log Sheet Month: ______________________ Action Required Year: 19 ________ Date Performed Check belt tension Clean air filter Check all electrical connections Table 4.
4: Periodic Maintenance CHRISTIE 35/70 Projector Annual Preventive Maintenance Log Sheet Year: _____________ Action Required Date Performed Check coupling between tacho roller and tacho generator Check power supply voltages Check reeling motor brakes Visual inspection (loose bolts, screws, damaged cables, etc.) Replace Particle Transfer Rollers Clean back of projector with vacuum Table 4.
4: Periodic Maintenance Projector Dusting Guidelines The most important part of the maintenance program is cleaning. Dust on surfaces that the film touches can scratch the film and render it useless for future exhibition. Dust does not remain in one place, but migrates to all parts of the projector, causing film damage and possible bearing failure. Blowing dust off projector parts and surfaces with a highpressure air hose is not recommended.
4: Periodic Maintenance 1. UPPER TOURQUE MOTOR AMPLIFIER 2. UPPER TORQUE MOTOR BRAKE AND PULLEY 3. UPPER TORQUE MOTOR 4. UPPER TORQUE ARM AND OPTICAL ASSEMBLY 5. UPPER ARM LIMIT SWITCH 6. UPPER ARM TENSION SPRING 7. UPPER TACHO GENERATOR 8. 2285 SHUTTER MOTOR AMPLIFIER 9. UPPER BUCKLE LIMIT SWITCH 10. 2276 FRAMING SWITCH 11. UPPER C.V. PULLEY AND BELT 12. 2293 MAIN CPU CARD 13. 70mm DTS/MAGNETIC HEAD MOUNTING AREA 14. 2269 SHUTTER ENCODER 15. SHUTTER MOTOR 16. 2275 PULL-DOWN AMPLIFIER 17.
4: Periodic Maintenance 1. UPPER REEL 2. UPPER TORQUE ARM ROLLER 3. UPPER TACHO GENERATOR 4. UPPER PARTICLE TRANSFER ROLLERS 5. ROLLER 6. 70mm MAGNETIC HEAD 7. FRAMING SWITCH 8. UPPER BUCKLE PLATE 9. MOVABLE GATE 10. LENS MOUNT 11. WEAVE GUIDES 12. GATE GLASS 13. GATE PIN 14. STATIONARY GATE 15. PULL-DOWN SPROCKET 16. 2268 PULL-DOWN SENSOR 17. LOWER C.V. BUCKLE PLATE 18. LOWER LOOP GUIDES 19. LOWER C.V. SPROCKET 20. 35mm OPTICAL HEAD 21. PRE-AMPLIFIER LOWER PARTICLE TRANSFER ROLLERS 22.
4: Periodic Maintenance 10. Check picture quality to ensure that ghosting, jitter, and weave are within acceptable limits. Refer to the troubleshooting guide (Chapter 7) if adjustments are necessary. Weekly Preventive Maintenance Requirements Table 4.3 contains the weekly preventive maintenance checklist/log sheet. 1. Using the ordinary toothbrush, brush off the teeth on all the sprockets. The sprockets are as shown in Figure 4.2. 2.
4: Periodic Maintenance Monthly Preventive Maintenance Requirements Table 4.4 contains the monthly preventive maintenance checklist/log sheet. 1. Check the belt tension on all four belts (see Figure 4.1). This check is accomplished by pushing the center of one side of the belt with moderate pressure and ensuring that the belt deflects approximately ¼" (6 mm). 2. Service the air filter canister: a. Remove the wing nut on top of the air filter canister. (See Figure 4.3.
4: Periodic Maintenance Semiannual Preventive Maintenance Requirements Table 4.5 contains the semiannual preventive maintenance checklist/log sheet. 1. Check the brushes on all five servo motors. 2. 3. • When reinstalling old brushes for ANY motor, ensure that the brushes are installed in their original location and in the same direction. • The installation of new pulldown motor brushes requires a burn-in period of at least 24 hours.
5: Theory of Operation THEORY OF OPERATION This section describes the theory of operation for the 35/70 projector. The description introduces a general view at an overall block diagram level, and then details the function of each block in subsequent paragraphs. Circuit diagrams and component layouts for each card are found in Section 8 of this manual. The projector is self-contained except for the power supply and control console.
5: Theory of Operation Figure 5.1: 35/70 Electronic Projector Block Diagram The incremental motion of the film in the gate is taken up by the film loops maintained for this purpose. The upper and lower torque motors are controlled by the position of the respective torque arms, and operate to maintain the torque arms stationary, independently of the amount of film on the supply and take-up reels. During slew operation the speed and direction of the constant velocity motor is controlled by the CPU.
5: Theory of Operation Actual operation of the control loops is somewhat more complex than the introductory description above, and will be discussed in detail in subsequent paragraphs. Shutter Control Circuit The primary mechanical elements of the shutter control circuit are the shutter, the shutter encoder, and the shutter motor, located on the shutter assembly.
5: Theory of Operation Constant Velocity Motor Control As seen in Figure 5.1, the main mechanical elements of the Constant Velocity Motor circuit are the Motor, encoder, tachometer and constant velocity drive sprocket contained on the constant velocity drive assembly. The electronic portion of the control circuit is the Constant Velocity PWM amplifier 2285 and the CV control circuit on the 2293 Main Electronics Board.
5: Theory of Operation ensure that the counter does not overflow and cause a sudden transient to the motor during rollover, pending overflow is detected and the CPU reduces motor speed so overflow does not occur. Locking the Constant Velocity motor to the line frequency has advantages where line frequency variations are minor. Where excessive variation exists, crystal oscillator control may be selected by a jumper on the 2293 board.
5: Theory of Operation REGISTRATION MODE E T U2 13 0 deg sensor Lead Network 180 deg sensor D-AMP ANALOG Pulldown Drive 2275 VF TACH U1 Open Main Electronics Card Pulldown Sensor M Pulldown Amplifier Card PULLDOWN MODE Pulldown Encoder E Shutter Index T TACH PIA U1 U20 Pulldown Drive 2275 U55 PULL DAC 37 U10 AMP 12 VF U21 Main Electronics Card M D-AMP Pulldown Amplifier Card Figure 5.
5: Theory of Operation 1 Pulldown Tachometer (5.00 v) 2 Pulldown Signal (TP13) (5.00 v) 3 90-degree Pulldown Sensor (5.00 v) 4 Pulldown Motor Voltage (20.00 v) Figure 5.7: Pulldown Circuit Timing for 60FPS The pulldown circuit also performs the Automatic Loopset function. Under CPU control, the pulldown sprocket is turned slowly until the film speed drops below a set value. The CPU rewinds four and one-half frames and stops in registration.
5: Theory of Operation The Reeling System Circuitry The major components of the upper reeling circuit are the upper reel motor and brake, the tacho-roller, and the upper torque arm with its optical potentiometer. The major electronic components are the Supply PWM Amplifier (2285) and the Supply Reel Control circuitry on the Main Electronics Board. (See Figure 5.8.
5: Theory of Operation 10 U34 Optical Sensor To CPU COMP E Tachometer U54A T ABS VAL AMP U54B/U24 Current Limiting 36 U32 U53 23 CV Tachometer 24 AMP Film PWM Signal 2285 M Sawtooth SUMMING AMP COMP U17 Direction 25 COMP Figure 5.9: Lower Reel Motor Control Circuit The lower reel motor controls summing amplifier U54A. The absolute-value circuit is formed by U54B and U24; the PWM conversion is done by U53.
5: Theory of Operation The CPU/Main Logic Card (2293) The CPU/Main Logic card (card 2293) contains: • • • • • • • • • the 6809 microprocessor (CPU) parallel interface adapters (PIAs) the control read-only memory (ROM) that contains the program the RS-232 asynchronous communication interface adapter (ACIA) chip for serial communication the programmable timer module (PTM) chip that generates the clock rates for the ACIA and motor circuits the scratch pad random access memory (RAM) the digital-to-analog con
5: Theory of Operation Data, Address, Control Bus 6809 CPU Serial Communications 27128 EPROM Battery Backup RAM PTM PIA Parallel Communications ACIA PIA Parallel Communications PIA Parallel Communications Figure 5.11: CPU Circuits The CPU section operation is typical of any microcomputer: 1. The restart logic applies a RESET command to the processor when power is applied. 2. The processor then begins to execute the program stored at the RESET address, which is located in the EPROM. 3.
5: Theory of Operation Interlock Operation The 35/70 Projector has the capability to be directly controlled by an external input in a manner quite different from the normal Show Controller interface. This feature, called interlock, is normally used when the 35/70 projector is operated in a Master/Slave configuration or is being driven by an external bi-phase source.
5: Theory of Operation toward zero volts for the fifth time, the pulldown motor has nearly slowed to a stop. At this point both optical pickups are partially on, and registration begins. The sensor circuit also has a 90-degree sensor and an index sensor. Their outputs are squared by U2 and sent to the Main Logic/CPU card, along with the zero-degree and 180-degree outputs.
5: Theory of Operation The Frame Counter Display (1008) The digits for the frame counter display are sent by means of a four-bit binary coded decimal (BCD) code and eight strobes, one for each digit. The strobe lines drive non-inverting buffers U9 and U10. U1 through U8 are "smart" sevensegment displays with internal latches and seven-segment decoders. When strobed, the BCD data on pins 3, 2, 13, and 12 are latched, decoded, and displayed. Refer to the frame counter diagram in Section 8.3.
5: Theory of Operation START INTRPT Init Hardware Set Time Code Init ACIA Yes Init Motion Set to Not Ready Pulldown not at Cine Speed CONTRL Yes Do Pulldn? Yes Shutter? Do Pulldn? No No No Frame Cntr Read Marks Yes RS-232 Char? Pulldown at Cine Speed CV Int Fwd? No RT1 No Yes Warning? Frame Cntr Read Marks Yes CV Int Rev? No No Status Safety Check Douser RT1 Yes Keybd Char? 60 Hz Int? No Yes Change CV Speed No Yes Alarms Timers Keyboard Warning? No Indicate Fault Set to Not R
6: Mechanical and Electronic Adjustments MECHANICAL AND ELECTRONIC ADJUSTMENTS This section describes the overall mechanical configuration of the projector and details adjustments that may be required as the result of repair or parts replacement. All necessary mechanical and electronic adjustments are made before the projector is shipped from the factory. Figures 4.1 and 4.2 illustrate the features of the film path side and the mechanical side, respectively, of the 35/70 Projector.
6: Mechanical and Electronic Adjustments BOF and EOF Adjustments The BOF and EOF sensors are VR7 and VR6, respectively, on the CPU/Main Logic card circuit diagram in Section 8.7. These sensors operate by detecting either the amount of light reflected from the film (non-active) or a piece of FORMLINE silver tape attached to the film (active). The tape should be 3/8 inch wide; it should be placed near the sprocket holes on the inboard side for the BOF sensor and on the outboard side for the EOF sensor.
6: Mechanical and Electronic Adjustments Tape may not be seen through the film if it is placed on the base side.
6: Mechanical and Electronic Adjustments Film must be mounted on the projector to make adjustments to the BOF and EOF sensors. The film should be positioned in the projector so that the reflective tape is not in the area of the gate. The sensor adjustment is made based on the reflectivity of the film, rather than the reflectivity of the tape. TP5 VR6 VR7 TP7 BOF/EOF J6 EOF EOF BOF VR6 VR7 560K TP5 5.
6: Mechanical and Electronic Adjustments Test Point R149, R150 0 Volt Position Test Point R149, R150 +5 Volt Position Test Point R149, R150 -5 Volt Position Tension Adjust Limit Switch Rotate Disk to Set Range Sensor Use Fine Adjust to Position Sensor with respect to Disk. Lock set screw behind Disk. Cllector EMITTER -LED Mexico Locking Screws +LED Adjust for 0 volts in center position R1 R2 68 1K +5V 1 3 5 8 Sensor Test Point R149, R150 GND R2 13 +15V CONTRACT NO.
6: Mechanical and Electronic Adjustments f. 8. Issue a REVERSE TEST MODE (,<8>) command to set upper and lower Torque arm pots (See Section 0). Use a spring scale to pull the torque arm to the center position. The scale should read 32 ounces for 70-mm film. Disconnect the spring from the torque arm. Use the tension adjustment screw to achieve the correct reading. Do not allow the limit switch to be activated while making this adjustment. 9. Reattach the spring to the torque arm. 10.
6: Mechanical and Electronic Adjustments Pulldown Sensor Adjustment The pulldown sensor provides position information to the CPU/Main Logic card. The sensor card has four infrared LED’s and photo-transistor detectors. An encoder disk is mounted on the pulldown motor shaft next to the sprocket. Zero- and 180-degree signals are used to continuously adjust the drive to the pulldown motor to maintain a consistent jitter-free picture while running cine forward.
6: Mechanical and Electronic Adjustments Pulldown Signal (TP13) Figure 6.4-a: Pulldown Signal Gain Too Low Pulldown Signal (TP13) Figure 6.
6: Mechanical and Electronic Adjustments Slight change in slope on each negative-going transition Pulldown Signal (TP13) Figure 6.4-c: Pulldown Signal Normal Gain The procedure for adjusting the pulldown is given below. Film must be mounted for this adjustment. 1. Connect an oscilloscope to test point TP13 on the CPU/Main Logic card, card 2293. (See Figure 6.5.) Set the vertical deflection to 5.0 volts per division, and the horizontal to 2 milliseconds per division. 2.
6: Mechanical and Electronic Adjustments Figure 6.5: Pulldown Sensor Test Point After completing the above adjustment, check the 90-degree output by connecting the second channel of the scope to pin 3 of U19. The phase relation should be about 90 degrees, as shown in Figure 6.6. The quadrature relationship is required when the projector executes high-speed slew motion operations.
6: Mechanical and Electronic Adjustments Line Voltage Selection To locate jumpers and terminals, refer to the 35/70 Power Supply component layout in Section 8.4. 240-VAC Operation To configure the 35/70 projector for 240-VAC operation: 1. Remove the jumper from terminals 1&3 and 2&4 on T1 and the jumper T1 terminals 2&3. 120-VAC Operation To configure the 35/70 projector for 120-VAC operation: 1. Remove the jumper from terminals 2&3 on T1 and jumper terminals 1&3 and 2&4 on T1.
6: Mechanical and Electronic Adjustments Pulldown Gain Adjustment This adjustment is factory-set. This setup procedure should be performed only if VR1 is known to be out of adjustment. 1. 2. 3. After powering up the projector and putting it into READY mode, enter the PULLDOWN GAIN DISPLAY (,) command and note the gain value indicated by the two rightmost digits. Run the projector in CINE FORWARD mode and adjust VR1 until the gain value is equal to the value noted in step (1).
6: Mechanical and Electronic Adjustments Focus Blower The focus blower control valve controls the amount of air flow onto the film. This valve is adjusted so that the film frame in the aperture opening remains stable, thus reducing the effect of film breathing. Film Format Conversion The 35/70 projector is capable of being converted from a 35mm projector to a 70mm projector in a matter of 15 minutes. The conversion process for converting from 70mm to 35mm is as follows. (Refer to Figure 4.
7: Troubleshooting Guide TROUBLESHOOTING GUIDE Only technicians who are familiar with the detailed circuit descriptions in Section 5 and the adjustment procedures in Section 6 should attempt to troubleshoot or repair a problem. This section provides information for diagnosing and troubleshooting operational problems with the 35/70 projector. The projector consists of hundreds of components. It is impossible to foresee all problems that might occur.
7: Troubleshooting Guide Fu se Voltage Amp s Controls Type 1 SW -34 VDC 8A Pulldown Amp Fast Blow 2 SW +24 VDC 8A C.V., Torque Fast Blow 3 SW +24 VDC 8A Pulldown Amp Fast Blow 4 +24 VDC 4A C.V., Torque, Fast Blow Shutter 5 110 VAC 5A Main Fast Blow Table 7.1: 35/70 Fuse Block Identification The corrective procedures in the checklist allow for recalibration of various electronic cards.
7: Troubleshooting Guide Visual Checklist Perform the following steps. In each case, corrective action is self-evident, so a diagnostic table is not included. Refer to Chapter 6, Mechanical and Electronic Adjustments, for instructions on adjustment and component replacement. VISUAL CHECKLIST A Checklist Item At the film path side, with film not mounted (Numbers in parentheses refer to details in Figure 4.2.
7: Troubleshooting Guide VISUAL CHECKLIST B Checklist Item At the projector head (Numbers in parentheses refer to details in Figure 4.1) Step Description B1 Verify that connectors to all boards are tight. B2 Gently verify Upper Torque Arm Sensor and Disk (4) are tight. B3 Gently verify Lower Torque Sensor and Disk (34) are tight. B4 Verify that the four belts are undamaged and properly tensioned.
7: Troubleshooting Guide Power-On Checklist and Diagnostic Table Thread the projector with film that has the proper BOF and EOF markers installed. Perform the checklist in Table 7.5. Refer to the accompanying diagnostic table, Table 7.6, for corrective action. POWER-ON CHECKLIST Turn projector power on Checklist Item Step Description 1 Visually verify that the LED on the button on the control panel comes on. 2 Visually verify that the Frame Counter reads one hour (01:00:00:00).
7: Troubleshooting Guide Ready Checklist and Diagnostic Table Perform the checklist in Table 7.7. Refer to the diagnostic table, Table 7.8, for corrective action. READY CHECKLIST Turn projector power on Checklist Item Step Description 1 Visually verify that LED #4 (Lower Buckle), LED #5 (Upper Buckle), LED #1 (Lower Arm Limit), LED #2 (Upper Arm Limit) are off. 2 Push the button and verify that the READY LED illuminates and the READY relay activates.
7: Troubleshooting Guide READY DIAGNOSTIC TABLE 1-1 Step LED is on – CONDITION 1: LED #4 is on. Diagnostic 1 If LED #4 is illuminated, close the Lower Buckle arm, press the NOT RDY button, and ensure that the LED goes out. If the LED remains lit, proceed to Step 2. 2 Check the buckle switch and associated wiring. If the LED still remains lit, proceed to Step 3. 3 The 2267 keypad or the 2293 CPU/Main Logic card could be defective. Repair or replace as necessary.
7: Troubleshooting Guide READY DIAGNOSTIC TABLE 1-3 Step LED is on – CONDITION 3: LED #1 is on. Diagnostic 1 If LED #1 is illuminated, center the Lower Torque Arm, press the NOT RDY button, and ensure that the LED goes out. If the LED remains lit, proceed to Step 2. 2 Check the limit switch and associated wiring. If the LED is still lit, proceed to Step 3. 3 Monitor output voltage from the optical pot.
7: Troubleshooting Guide READY DIAGNOSTIC TABLE 1.5 Step READY relay does not activate or READY LED does not go on. Diagnostic 1 If the READY relay does not pull in, check to see if there is +24VDC present at J3-3 on the lower torque 2285 amplifier. If not correct, determine the fault and correct. 2 Verify that all cables going to the lower torque 2285 amplifier card and READY relay are not damaged and are correctly plugged in.
7: Troubleshooting Guide READY DIAGNOSTIC TABLE 3-1 Step 1 2 Failure of Upper or Lower Torque System – CONDITION 1: Upper or lower torque arm does not center. Diagnostic Verify that the brake associated with the defective system comes off while in READY. The reel should move freely if the brake is off. Monitor output voltage from the optical pot at the 2293 CPU/Main Logic card. Verify range of approximately +5 to -5 volts as arm is moved to its extremes; zero volts should be near the center of travel.
7: Troubleshooting Guide READY DIAGNOSTIC TABLE 3-2 Step Failure of Upper or Lower Torque System – CONDITION 2: The system is not stable; reel and torque arm oscillate. Diagnostic 1 Verify that the locking nut that holds the reel to the shaft is tight. Also check for a loose belt or loose set screws that hold pulleys to their shaft. Any mechanical play between the Torque motor and the reel will result in oscillations. Tighten as required.
7: Troubleshooting Guide READY DIAGNOSTIC TABLE 4-2 Loop set does not function, Pulldown System – CONDITION 2: Film is moved from the upper loop to the lower loop and then back to the upper loop but does not stop. Step Diagnostic Result Verify that the index and the 90-degree signal from the Pulldown Sensor do pass though the 2276 card and reach U10 pin 11 and U19 pin 3 on the 2293 card. Isolate problem to the sensor, the 2276 card, or the wiring. If not any of these, replace the 2293 card.
7: Troubleshooting Guide READY DIAGNOSTIC TABLE 5-1 The Constant Velocity sprocket will not advance film one frame and lock – CONDITION 1: The constant velocity sprocket advances film forward, but does not stop after one frame. Step Diagnostic Result This condition is caused by a failure of the Pulldown system. The Constant Velocity system will continue to move film forward until the CPU receives the zero-degree and index signals from the Pulldown Sensor. Repair as indicated.
7: Troubleshooting Guide READY DIAGNOSTIC TABLE 5-4 The Constant Velocity sprocket will not advance film one frame and lock – CONDITION 4: The constant velocity motor starts to move film, but stops part way. Motion continues or completes if CV sprocket is restarted with assist by hand. Step Diagnostic Result This indicates worn brushes in the Constant Velocity motor. Replace brushes or motor. 6-1 The Pulldown System has performed a proper Loop Set, but failed to advance film and lock.
7: Troubleshooting Guide READY DIAGNOSTIC TABLE 7-1 Step Shutter Failure – CONDITION 1: Shutter is at speed when phase A and phase B are measured to be 600 Hz at U29 pins 23 and 24 of the 2293 card. The shutter index pulse at U37 pin 18 of the 2293 card should measure 60 Hz. (Note: speed referenced to 60FPS operation.) If this is not the case: Diagnostic 1 Verify that the low voltage power supply, +5 volt, is present at the regulator Q4 of the 2285 card. If not, determine fault and repair.
7: Troubleshooting Guide Slew Motion Checklist and Diagnostic Table Perform the checklist in Table 7.9. Refer to the diagnostic table in Table 7.10 for corrective action. SLEW MOTION CHECKLIST A Checklist Item Command the projector to high speed forward by pushing the button sequence , <3>. Step Description Completed Verify that the film accelerates to 120 frames per second in a smooth and linear motion.
7: Troubleshooting Guide SLEW MOTION DIAGNOSTIC TABLE A-1 Step Film does not ramp smoothly to 120 frames per second – CONDITION 1: Film ramps up smoothly to near maximum speed, then becomes unstable. Diagnostic Result Verify that the +24VDC voltage at the positive end of C8 of the 2285 card is at the proper value. If not, repair. A-2 Step Film does not ramp smoothly to 120 frames per second – CONDITION 2: Film ramps up smoothly to maximum speed but upper loop is lost while going forward.
7: Troubleshooting Guide SLEW MOTION DIAGNOSTIC TABLE A-4 Step Film does not ramp smoothly to 120 frames per second – CONDITION 4: Film ramps up to maximum speed, but motion is not smooth. Diagnostic 1 This may indicate worn brushes in the Constant Velocity Tach. Replace brushes or motor/tach assembly. 2 If condition continues, check for a loose belt or loose set screws that hold pulleys to their shaft. Any mechanical play between the CV motor and the sprockets will result in irregular motion.
7: Troubleshooting Guide Cine Motion Checklist and Diagnostic Table This procedure requires the film to be CUED at the beginning of a show. Perform the checklist in Table 7.11. Refer to the diagnostic table, Table 7.12, for corrective action. CINE MOTION CHECKLIST Push the button. After film speed stabilizes, enter the ,<3> command to cause the douser to open.
7: Troubleshooting Guide CINE MOTION DIAGNOSTIC TABLE 1 Loop is lost as projector does Pulldowns. Step Diagnostic 1 Verify proper adjustment of VR1 on the 2293 card. Adjust if necessary. (See Section 6.7.) 2 It is possible for a Pulldown amplifier to have defective output transistors and function in all modes except Pulldown. Replace 2275 card. 2 Step Douser does not function. Diagnostic 1 Douser has been found to be mechanically free, and relays are secure in their sockets.
7: Troubleshooting Guide Image Quality Checklist and Diagnostic Table This procedure requires the lamp house to be on with suitable lens and screen setup. Perform the checklist in Table 7.13. Refer to the associated diagnostic table, Table 7.14, for corrective action. IMAGE QUALITY CHECKLIST Push the button and after film speed stabilizes enter the ,<3> command to cause the douser to open.
7: Troubleshooting Guide IMAGE QUALITY DIAGNOSTIC TABLE 2 Step Poor Image Quality – CONDITION 2: Projected picture has vertical jitter in excess of 0.15%. Diagnostic 1 Verify that both the fixed and movable sections of gate area are free of emulsion buildup. Clean if necessary. 2 Verify there is proper spring tension on the movable portion of the gate. Adjust if necessary. (See Section 6.8) 3 Verify proper right/left adjustment of pulldown sensor by following procedure in calibration section.
7: Troubleshooting Guide IMAGE QUALITY DIAGNOSTIC TABLE 3 Poor Image Quality – CONDITION 3: Projected picture has side weave in excess of 0.15%. Step Diagnostic Result Verify the edge guides are adjusted properly and have the proper spring tension. Adjust if necessary. (See Section 6.8.4.) 4 Poor Image Quality – CONDITION 4: Projected picture exhibits ghosting. Step Diagnostic 1 Rotate shutter encoder assembly to eliminate ghosting.
7: Troubleshooting Guide ELECTRONIC CIRCUIT INFORMATION This section contains current data for the electronic circuits used in the 35/70 Automated Film Projector. For each circuit, the following information is included: • Parts List • Circuit Diagram (optional) • Component Layout (optional).
Appendix A: RS-232 Command Protocol 35/70 COMMAND SUMMARY ENTRY STOP COMMAND STOP C0 FORWA RD C1 FORWARD REVERS E REVERSE C2 C3 OPEN DOUSER & CINE C4 CLOSE DOUSER & SLEW C5 CLEAR CUES SET LOOP SET LOOP C6 C7 CUE OUTPUT STATUS CUE C8 C9 READY CA READY CA NOT RDY JAM READY (NOT READY) DISPLAY REEL COUNTER (READY) NOT READY CB CC Not used CD MANUAL/SHOW CONTROLLER LOG CE SET REEL COUNTER AUTO CYCLE TEST CF H0 CUE/ADVANCE H1 PLAY CURRENT SHOW H2 SET GOTO H3 FAST FORWARD H4 SE
Appendix A: RS-232 Command Protocol H5 SET CURRENT SHOW H6 GOTO FRAME H7 CUE NEXT H8 SET NEXT SHOW H9 SET FREQUENCY HA INTERLOCK HB DISPLAY ERROR HC PULLDOWN GAIN DISPLAY (READY) HC BRAKE RELEASE (NOT READY) HD SET MAX SHOWS HE LOCAL MODE HF DISPLAY START G0 MEMORY INSPECT G1 DISPLAY FRAME COUNTER G2 SELECT FRAME RATES G3 AUTO DOUSER G4 LOAD REEL COUNTER G5 PLATTER MODE G6 OUTPUT CUE TAPES G7 SHUTTER TEST G8 REVERSE TEST MODE G9 SHOW CONTROL ENABLE GA OUTPUT LOG
Appendix A: RS-232 Command Protocol CHRISTIE INC.