Kinoton FP 25 D User manual

DIGITAL CINEMA
FILM TECHNOLOGY
STUDIO TECHNOLOGY
CUSTOMIZED SOLUTIONS
360° DISPLAY SYSTEMS
Operating Manual
FP 50 D Projector

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
Dear customer,
this operating manual will help you get acquainted with the projector and to make use of
its possible applications in accordance with the requirements.
This operating manual includes important hints for a safe, proper, correct and economic
operation.
It will also help you to avoid danger, to reduce failures and to increase life and reliability
of the projector.
This operating manual includes useful hints for proprietor and personnel obligations.
It does not substitute, but supports, a thorough training period.
We conrm that the information given in this manual is true and correct to the best of our
knowledge and belief. However, notwithstanding all best care and attention, technical
inaccuracies and typographical errors cannot be fully excluded.
As far as we did not assure explicitly and written form any special characteristics and
suitability of a product for a certain intended purpose, the statement in this manual are
generally without obligation.
All descriptions, illustrations and technical data comply with the technical status of the
product at the date of printing of this manual. Any modications are subject to change
without prior notice due to ongoing further development.



All rights reserved
© Copyright by KINOTON GmbH,
Industriestraße 20a
Germany - 8 21 10 Germering
Printed in Germany, Issue April 2011
This operating manual – even in extracts – may only be reprinted or otherwise copied
with special, written permission from KINOTON GmbH.
Editor responsible for the contents: KINOTON GmbH
Editing and layout: Carmen Auer - KINOTON GmbH



Issue: 04/2011 
Contents
Contents
 
1.1 Safety Notes ....................................... 1
1.1.1 General Hints............................................ 1
1.1.2 Dangers when Working with the Projector. . . . . . . . . . . . . . . . . . . . . . 1
1.1.3 Intended Purpose ........................................ 2
1.1.4 Guarantee and Liability .................................... 2
1.2 Explanations of Symbols and Notes . . . . . . . . . . . . . . . . . . . . . 3
1.3 Special Hazard Points................................ 4
1.3.1 Electric Power Hazards.................................... 4
1.3.2 Lamphouse Hazards ...................................... 5
1.3.2.1 Broken Glass............................................ 5
1.3.2.2 UV Radiation ............................................ 5
1.3.2.3 High Voltage ............................................ 5
1.3.3 Mechanical Danger ....................................... 5
1.4 Preventing Projector Damage . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5 Service ........................................... 6
1.6 Protective Devices................................... 7
1.6.1 Main Switch............................................. 7
1.6.2 IR Reex Film Break Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.6.3 Film Stripper ............................................ 7
1.6.4 Lamphouse Door Switch ................................... 8
1.6.5 Lamphouse Airow Switch.................................. 8
          
2.1 Transportation...................................... 9
2.2 Delivery or Equipment Variations . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Installation........................................ 10
2.3.1 Place of Installation, Place of Operation . . . . . . . . . . . . . . . . . . . . . . 10
2.3.2 Important Hints for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3.3 Installation Hints ........................................ 12


Issue: 04/2011

2.4 Mounting ......................................... 12
2.4.1 Filling with Oil........................................... 12
2.4.2 Installing and Connecting the Lamphouse Components . . . . . . . . . . 13
2.4.3 Connecting the Water Cooling (option) . . . . . . . . . . . . . . . . . . . . . . . 14
2.5 Connecting the Projector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.6 Connecting the Non-Rewind System to the Projector . . . . . . . 14
                      
3.1 Components Overview .............................. 15
3.1.1 Projection Drive.........................................15
3.1.2 Console ............................................... 15
3.1.3 Xenon Unit............................................. 15
3.1.4 FP 50 D Variations....................................... 16
3.1.5 Projector Head.......................................... 18
3.2 Film Gate and Film Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2.1 Film Pressure Skate ..................................... 19
3.2.2 The Dowser............................................ 20
3.2.3 Single Aperture Plates (only with manual lens turret or lens holder). 21
3.2.4 Aperture Changer (option, only with electronic lens turret) . . . . . . . . 21
3.2.4.1 Drive and Control........................................ 22
3.2.4.2 Format Change with Three Lenses . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.2.4.3 Format Change with Two Lenses Turret . . . . . . . . . . . . . . . . . . . . . . 22
3.2.4.4 Changing the Format Combination . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2.5 Lens Holder............................................ 23
3.2.6 Lens Turret (option)...................................... 24
3.2.6.1 Manual Lens Change..................................... 24
3.2.6.2 Electronically Controlled Lens Change (option). . . . . . . . . . . . . . . . . 25
3.2.7 Focusing .............................................. 26
3.2.7.1 Manual Focusing with Lens Turret / Lens Holder . . . . . . . . . . . . . . . 26
3.2.7.2 Electronic Focusing with Lens Turret (option) . . . . . . . . . . . . . . . . . . 26
3.2.7.3 Electronically Controlled Lens Holder Focusing (option) . . . . . . . . . . 26
3.2.8 Rotating Shutter......................................... 27
3.2.9 Intermittent Sprocket ..................................... 28
3.2.10 Framing ............................................... 28
3.2.11 Constant Speed Sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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Contents
Issue: 04/2011 
3.3 Reverse-Scan Sound Device . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3.1 Analog Reverse-Scan Sound Device (non-upgradeable) . . . . . . . . . 30
3.3.2 Reverse-Scan Sound Device Analog and optional DOLBY Digital
(upgradeable) .......................................... 31
3.3.2.1 Components ........................................... 31
3.3.3 Sound Tracks on the Films . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4 SDDS Reader / DTS Reader (option) . . . . . . . . . . . . . . . . . . . 32
3.5 Film Cleaner (option)................................ 32
3.6 Film Transport Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.6.1 Friction Shafts with Film Spools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.6.2 Guide Roller Set for Operation
with a Platter System (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.6.3 Friction Shafts and Guide Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.7 Drive Components in the Projector Head . . . . . . . . . . . . . . . . 35
3.7.1 Main Drive ............................................. 36
3.7.2 Intermittent Movement
(also called a Maltese Cross or a Geneva Movement) . . . . . . . . . . . 36
3.8 Electronic Components.............................. 37
3.8.1 Automation Systems ..................................... 38
3.8.2 Rectiers .............................................. 39
3.8.3 Xenon Sensor (option).................................... 39
3.9 Lamphouse Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.9.1 Xenon Unit............................................. 41
3.9.2 Xenon Bulb ............................................ 41
3.9.3 Mirror.................................................42
 
4.1 Projector Console .................................. 43
4.1.1 Main Switch............................................ 43
4.1.2 Projector Operating Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.1.3 Auditorium Remote Operating Panel (option) . . . . . . . . . . . . . . . . . . 44


Issue: 04/2011

4.2 Projector Lamphouse ............................... 45
4.2.1 Ammeter .............................................. 45
4.2.2 Operating Hour Counter ..................................45
4.2.3 Fuse.................................................. 45
4.2.4 Main Switch............................................ 45
4.2.5 Ignition Button .......................................... 46
4.3 Rectier.......................................... 46
                  
5.1 Switching On and Starting the Projector . . . . . . . . . . . . . . . . . 47
5.2 Stopping and Switching Off Projector . . . . . . . . . . . . . . . . . . . 47
5.3 Threading for Projection Operation . . . . . . . . . . . . . . . . . . . . 48
5.3.1 General Threading....................................... 48
5.3.2 Threading from a Non-Rewind / Platter System . . . . . . . . . . . . . . . . 49
5.4 Troubleshooting.................................... 50
5.4.1 General Hints........................................... 50
5.4.2 Projector Troubleshooting Chart (Type 1 errors) . . . . . . . . . . . . . . . . 50
5.4.3 Projector Troubleshooting Chart (Type 2 errors) . . . . . . . . . . . . . . . . 50
5.4.4 Analog Sound .......................................... 52
5.4.5 Digital Sound........................................... 52
5.4.6 Lamphouse Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 53
                   
6.1 General Hints ..................................... 55
6.2 Cleaning ......................................... 55
6.3 Maintenance ...................................... 57
6.3.1 Drain and Rell Oil (Kinoton type 3672 oil):. . . . . . . . . . . . . . . . . . . . 58
6.3.2 Changing the Intermittent Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.4 Repair and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.4.1 Changing the Pilot Lamp..................................58
6.4.2 Adjusting the Film Pressure Skate. . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.4.3 Adjusting the Height of the Film Pressure Skate . . . . . . . . . . . . . . . . 60
6.4.4 Changing the 35 mm Film Runner Strips . . . . . . . . . . . . . . . . . . . . . 61

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Contents
Issue: 04/2011 
6.4.5 Adjusting the Lens Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.4.6 Changing a Constant Speed Sprocket / Pad Shoe . . . . . . . . . . . . . . 62
6.4.7 Adjusting the Tension of the Pad Shoe Spring . . . . . . . . . . . . . . . . . 63
6.4.8 Adjusting the Distance between Pad Shoe and Sprocket . . . . . . . . . 63
6.4.9 Adjusting the IR Reex Film Break Sensor . . . . . . . . . . . . . . . . . . . . 63
6.4.10 Tension the Chains ...................................... 64
6.4.11 Adjusting the Mechanical Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.4.12 Changing and Lubricating the Felt Disk of the Mechanical Friction. . 66
6.4.13 Adjusting the Tension of the Friction Toothed Belt . . . . . . . . . . . . . . 66
6.4.14 Changing the Xenon Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.4.15 Adjusting the Illumination of Screen . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.4.16 Adjusting the Intensity of Currents. . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.4.17 Checking the Light Arc Stabilizing Magnet . . . . . . . . . . . . . . . . . . . . 71
6.4.18 Changing the Reector ................................... 72
6.4.19 Changing the Heat Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
                        
7.1 Film Gate Parts.................................... 77
7.2 Feed/Bottom Sprocket Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7.3 Guide Roller Parts.................................. 77
7.4 Other Parts ....................................... 77
7.5 Parts for Drive and Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.6 Film Spools ....................................... 78
7.7 Friction Shafts and Interchangeable Flanges with Shafts . . . . 78
7.8 Electronic and Control Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.9 35 mm Apertures for Aperture Changer . . . . . . . . . . . . . . . . . 83
7.10 Single Apertures ................................... 83
7.11 Adapter Rings for 35 mm Lenses . . . . . . . . . . . . . . . . . . . . . . 84
7.12 Xenon Bulbs and Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . 84


Issue: 04/2011

 
                  
8.1 Technical Data .................................... 85
8.1.1 Projector .............................................. 85
8.1.2 Reverse-Scan Sound Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
8.2 Plans of Terminal Connections . . . . . . . . . . . . . . . . . . . . . . . . 87
8.2.1 Relay Control Board 8134-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
8.2.2 Basic Unit Overview...................................... 88
8.2.3 Main Terminal Strip (optional with terminal 25 - 50) . . . . . . . . . . . . . 89
8.2.4 Terminal Strip with CCA3, DMP1 or SA2 . . . . . . . . . . . . . . . . . . . . . 90
8.3 Circuit Diagrams ................................... 91
8.3.1 230 V / 400 V 3-ph Mains Connection. . . . . . . . . . . . . . . . . . . . . . . . 91
8.3.2 208 V - 240 V Mains 3-ph Connection (USA) . . . . . . . . . . . . . . . . . . 92
8.3.3 208 V - 240 V Mains 3-ph Connection (Japan) . . . . . . . . . . . . . . . . . 93
8.3.4 Lamphouse ............................................ 94


Safety Instructions
Issue: 04/2011 
 
 
 
»Read this operating manual before operating the projector.
»This operating manual is to be kept with the projector at all times.
»For safe and trouble free operation of the projector a good working knowledge of
basic safety regulations and the projector’s correct use is required.
»This operating manual contains the most important instructions for running the projec-
tor safely.
»This operating manual must be read and understood by all persons working with the
projector, with particular emphasis on all aspects regarding safety.
»In addition, all valid regulations and measures concerning accident prevention must
be observed.
»The owner is responsible to assure that all persons who work with and / or operate
the projector are familiar with safe operating practices and accident prevention tech-
niques and have a complete working knowledge of the projector and all additional
machines and components of the system.
»Those persons who work with the projector are responsible:
- to observe safe operating practices and accident prevention techniques
- to have read and fully understand the safety chapter and the warnings within this
operating manual.
»The place on which the projector will be installed must be even, solid and clean.
»Installation and basic adjustment must always be carried out by trained service
personnel.
 
Projectors are constructed according to the latest engineering and state-of-the art safety
standards. The projector is only to be used for its intended purpose and is only used
when functioning absolutely perfectly.
Serious danger may result from improper use of the projector, causing injury to the user
or a third person, or damage may be done to the projector or other items in the vicinity.
Faults that could adversely affect safety must be rectied immediately.
The projector must not be used until any faults are rectied.


Issue: 04/2011

 
The projector is suitable to reproduce 35 mm lm images and sound.
Any other or further use is not classied as an “intended purpose”. KINOTON cannot be
held liable for any damage resulting from different or extended operation.
As part of the “intended purpose” these tasks must be performed:
»Observing all instructions and warnings contained in this manual
»Inspecting the equipment for damage and correct function
»Implementation of maintenance and repair work.
 
By reference KINOTON’s “General Terms of Business” apply. They are available to the
customer on conclusion of sale at the latest.
Guarantee and liability claims for damage to persons and property are invalid if due to
one of the following causes:
»Improper use of the projector
»Improper assembly, commissioning, operating and maintenance of the projector
»Operation the projector with defective and / or non-functioning safety and protection
devices
»Activating the lamphouse via the rectier and not via the projector
»Disregarding of the instructions in the manual concerning transportation, storage,
assembly, commissioning, operation and maintenance
»Modication of the projector without written authorisation from the manufacturer
»Connecting to power other than as specied
»Failure to monitor and/or replace parts subject to wear and tear
»Improper repairs
»Emergencies due to inuence from outside bodies or force majeure.


Safety Instructions
Issue: 04/2011 
 
Throughout this manual you will nd the following symbols:

This symbol indicates an imminent threat of danger to life and personal health.
Disregarding this warning can result in serious personal injuries or highly dangerous
injuries.

This symbol warns from UV radiation and that eye and skin protection during installation
and servicing must be put on.

This symbol indicates a possibly dangerous situation. Disregarding this warning can
result in small personal injuries or damage to projector.
X
This symbol indicates where notes, user tips and useful information can be found.
They serve to help use the projector to its fullest.
Always wear  when changing the xenon lamp.
Always wear  when changing the xenon lamp.
Always wear  when changing the xenon lamp..


Issue: 04/2011

 
 

SThe access to power supply must always be kept closed. Only authorized service
personnel may access this area.
SInstallation according to the local electrical code and regulations an work on the
electrical supply conductors or circuits must only be done by qualied technical
personnel.
SThis projector should be operated from an AC power source. Ensure that the mains
voltage and capacity matches the projector electrical ratings. Do not defeat the pur-
pose of the grounding.
SDo not allow anything to rest on the power cable and do not locate the projector
where persons will walk on the cable.
SDo not operate the projector with a damaged cable or if the projector has been
dropped or damaged - until it has been checked for operation by a qualied service
technician.
SPosition the cable so that it will not be tripped over, pulled, or contact hot surfaces.
SIf an extension cable is necessary, a cable with a current rating at least equal to that
of the projector should be used to avoid overheating of the cable.
SDo not use an accessory attachment which is not recommended by the manufac-
turer.
SThe rectier must be exclusively enabled from projector only.
SThe 4060 DC ignition unit is directly supplied via the rectier. Therefore the lamp
can be ignited by switching on the rectier itself. Igniting the lamp by switching on
the rectier at open lamphouse can cause serious injuries and damages to the lam-
phouse and projector.
SThe safety devices in the lamphouse (door switches and air ow switch) must not be
deactivated. Safe service work on open lamphouse is possible with functional safety
devices only, because rectier and mains power will be switched off.


Safety Instructions
Issue: 04/2011 
 
 
In cold condition the xenon lamp has an inner pressure of about 8 to 10 bar (145 psi)
and in hot condition of about 30 bar (435 psi). When a xenon lamp bursts, broken glass
can cause suffer injury to face, eyes and arteries. Therefore it is absolutely necessary to
wear protection with open lamphouse.

SNever bypass a door switch.
SOnly work on open lamphouse and with xenon bulb with face protection (shield),
neck protection and safety gloves which reach to the elbow.
If the xenon lamp explodes you can suffer injury to face, eyes and arteries.
SDispose of the xenon bulb: Before removing xenon lamp put protective cover
around it, pack xenon bulb in original package and give it back to your supplier.
SOnly insert the new xenon bulb in protective cover. Remove cover after mounting
the xenon bulb.
 

SOperate projector with a closed lamphouse only.
SUse UV radiation eye and skin protection during adjustment of the lamp and conver-
gence.
SIf you do some adjustments with an open lamphouse (look through visual hole), you
have to use visual protection which blocks the ultraviolet radiation.

 

Ignite xenon lamp in closed lamphouse only.
 

SDo not work around the machine with long loose hair, or loose clothing such as
scarves or ties, they may get trapped in the drive mechanism and pull you in.
SOnly open shutter housing when projector is standing still with power disconnected.
If the projector is running with covers open be careful and do not touch the rotating
shutter or other moving parts. Serious cuts can result.
SDo not put your ngers between the lm track and lm pressure skate or between
sprockets and pad shoes.


Issue: 04/2011

 

UAlways switch off main switch, before  the projector housing. To keep the
cabinet looking brand-new, periodically clean it with a soft cloth. Stubborn stains
may be removed with a cloth lightly dampened with mild detergent solution. Never
use strong solvents, such as thinner or benzine or abrasive cleaners, since these
will damage the cabinet surface.
UTo ensure the highest optical performance and resolution, the projector lenses are
specially treated with an anti-reective coating. Therefore, avoid touching the coated
lens surface.
To remove dust on the lens, use a soft dry cloth (Cleaning set from Kinoton).
Do not use a damp cloth, detergent solutions or thinner.
 

UDo not attempt to  this projector yourself. Refer all projector servicing to a
qualied Kinoton service center.
UWhen replacement parts are required, be sure the service technician has used
 or authorized replacement parts which have the
same characteristics as the original parts. Unauthorized substitutions may result in
degraded performance and reliability, re, electric shock or others hazards.
Unauthorized substitutions may void warranty.
UUpon completion of any service or repairs to this projector, ask the service techni-
cian to  to determine that the projector is in proper operation
condition.
UXenon compact arc lamps are under high pressure. The lamp must be handled with
great care. They may explode if dropped or mishandled. Whenever the protective
cover is removed from the lamp, authorized protective clothing must be worn.

Copyright of this manual remains in possession of KINOTON.
This manual is intended for the user and its staff only.
It contains regulations and operating notes that must not be copied, reproduced or
otherwise transmitted, in whole or in part.
Infringement of copyright laws may lead to prosecution. Due to ongoing development,
design details, features and specications are subject to change without notice.


Safety Instructions
Issue: 04/2011 
 
All existing safety devices must be checked regularly
 
In case of an emergency, you can switch off the projector using the main switch (under
the projector door). Push the switch to position “0”. The red lamp in the switch turns off.
 
The lm break sensor (arrow) switches off the projector when no lm is passing the sen-
sor (e. g. at a lm break). In this case the projector will be stopped.
X
If your projector is equipped with an automation system the lm break sensor can
trigger a run of events.
 
The lm stripper (arrow) prevents lm from winding around the sprocket after a lm
break or loss of a tape xing has happened.
Film strippers are attached to all sprockets.


Issue: 04/2011

 
On both sides door switches (arrows) are mounted in the lamphouse frame. The xenon
lamp only ignites when both lamphouse side doors are closed.

Never activate the lamphouse via the rectier.
 
As soon as the projector is switched on, the radial blower starts the operation. It is rea-
sonable to cool the xenon bulb directly.
If the air ow is interrupted, the xenon lamp will be switched off by the airow switch (ar-
row).
If the projector and the xenon lamp are switched off, the blower should run after about
ten minutes.


Issue: 10/2010 
 
 

»Projector is mounted (without lamp house and lm reel) on a pallet and xed with
screws.
»With delivery to countries over-sea the projector on pallet is packed in a wooden
crate.
»The accessories are packed into a box or into the wooden crate too.
»Weight (gross): about 400 kg (640 lbs)

If projector is stored for a longer time:
»Only store in dry rooms.
»Choose a suitable protective coating or leave projector in the original coating.
X
Although most parts are delivered with a protective cover, you have to clean the
projector and its components before the rst start.
 

»Friction drives (option)
- take-up friction with extension arm and motor
- take-off friction with extension arm
»Roller set for using with a rewind system (option)
»Xenon unit in lamphouse
- up to 2000 W
- up to 7000 W
»Reverse-scan sound device
- optical stereo, non-upgradeable
- optical stereo, upgradeable to Dolby Digital (option)
- optical stereo and Dolby Digital (option)
»Remote unit
- focusing control (option)
»Lens holder
- electronic focusing control (option)
Transport / Installation


Issue: 10/2010

»Lens turret
- 2 lenses and manual lens change
- 2 lenses and automatic lens and aperture change
- electronic focusing control (option)
- 3 lenses and manual lens change
- 3 lenses automatic lens and aperture change
- electronic focusing control (option)
»Automation system (option)
- DMP 1 Digital Matrix Programmer
- CCA 3 Cue Code Automation
- SA 2 Sequence Cinema Automation
- EMK 1 Electronic Automation System
»Film gate cooling unit (option)
»Water cooling system (from 4000 W lamp capacity on)
»Reader for DOLBY / DTS / SDDS (option)
»Rectier
- Standard rectier
- 65 to 85 A
- 75 to 95 A
- 100 to 140 A
- Kinoton rectier
- KEX 110 (up to 110 A)
- KEX 170 (up to 170 A)
»Film cleaner (option)
»Operating manuals
 

UThe projector will be delivered completely wired and factory tested.
UAll installation has to be carried out by experts.
UOnly use suitable hoisting machines (crane, fork-lift).
UDo not use unit parts as climbing aid.
UElectrical connections have to be in accordance with local regulations and be
installed professionally.
 
»The place on which unit will be installed must be even, solid and clean.
»The projector’s dimensions is showed on the next page.
»Requirements of the projection room:
- humidity: 40 to 60 %
- temperature: 15 to 25° C
- max. sea level: 2000 m