Kinoton FP 75 E User manual

DIGITAL CINEMA
FILM TECHNOLOGY
STUDIO TECHNOLOGY
CUSTOMIZED SOLUTIONS
360° DISPLAY SYSTEMS
Operating Manual
FP 75 E Double-Format Cinema Projector



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, techni-
cal 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.

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
All rights reserved
© Copyright by KINOTON GmbH,
Industriestraße 20a
Germany - 8 21 10 Germering
Printed in Germany, Issue August 2012
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: 08/2012 
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 . . . . . . . . . . . . . . . . . . . . . 2
1.3 Special Hazard Points................................ 3
1.3.1 Electric Power Hazards.................................... 3
1.3.2 Warning Risk of Fire ...................................... 4
1.3.3 Lamphouse Hazards ...................................... 4
1.3.3.1 Broken Glass............................................ 4
1.3.3.2 Ultraviolet Radiation....................................... 4
1.3.3.3 High Voltage ............................................ 4
1.3.4 Mechanical Danger ....................................... 5
1.4 Preventing Projector Damage . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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 Water Flow Control ....................................... 8
1.6.5 Door Switches ........................................... 8


Issue: 08/2012

          
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 Additional Installation Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3.4 Installing and Connecting the Lamphouse Components . . . . . . . . . . 12
2.3.5 Projector Terminal Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3.6 Connecting the Water Cooling (option) . . . . . . . . . . . . . . . . . . . . . . . 14
2.3.7 Connecting the Non-Rewind System to the Projector . . . . . . . . . . . . 14
                      
3.1 Components Overview .............................. 16
3.1.1 Housing ............................................... 17
3.1.2 Projection Components................................... 17
3.2 Film Gate and Film Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2.1 Film Pressure Skate ..................................... 18
3.2.2 The Dowser............................................ 19
3.2.3 Single Aperture Plates.................................... 19
3.2.4 Lens Holder............................................ 20
3.2.4.1 Manual Focusing on the Lens Holder . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2.4.2 Electronically Controlled Lens Holder Focusing (option) . . . . . . . . . . 20
3.2.5 Opposed Rotating Double Shutter. . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2.6 Combined Intermittent Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.2.6.1 Framing ............................................... 22
3.2.7 Constant Speed Sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.2.8 Changing the Film Gate and Sprocket Parts (35 mm / 70 mm). . . . . 24

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Contents
Issue: 08/2012 
3.3 Sound Devices .................................... 25
3.3.1 Reverse-Scan Sound Device
(analog and optional DOLBY digital / upgradeable) . . . . . . . . . . . . . 25
3.3.1.1 Components ........................................... 25
3.3.1.2 Sound Tracks on the Films (35 mm) . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3.2 Magnetic Sound Device (70 mm lm) . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3.3 DTS/SDDS Reader ...................................... 26
3.4 Drive Components.................................. 27
3.4.1 Main Drive ............................................. 27
3.4.2 Intermittent Sprocket Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.4.3 Electronically Controlled Friction Drives . . . . . . . . . . . . . . . . . . . . . . 28
3.4.3.1 Friction Control ......................................... 28
3.4.3.2 Reel Shaft on Change Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.4.4 Shutter Drive ........................................... 29
3.5 Electronic Components.............................. 30
3.5.1 Components in the Projector Door . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.5.2 Components on the Basic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.5.3 Shutter Drive Frequency Inverter. . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.5.4 LED Board for Reverse-Scan Sound Device. . . . . . . . . . . . . . . . . . . 32
3.6 Automation Systems................................ 32
 
4.1 Main Switch....................................... 33
4.2 Operating Panel ................................... 33
4.3 Friction Control .................................... 34
4.4 Remote Control Panels (option) . . . . . . . . . . . . . . . . . . . . . . . 35
4.4.1 Projection Room Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.4.2 Auditorium Panel........................................36


Issue: 08/2012

                  
5.1 Switch on and Start Projector / Stop and Switch off Projector 37
5.2 Threading for Projection Operation . . . . . . . . . . . . . . . . . . . . . 38
5.3 Different Projection Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.3.1 General Keys...........................................40
5.3.2 Projection / Forward Running at 24 fps or 25 fps . . . . . . . . . . . . . . . 41
5.3.3 Reverse Running (option with reverse running unit) . . . . . . . . . . . . . 41
5.3.4 Projecting at VARIA Speed (option) . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.4 Change-Over Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.5 Changing the Film Format. . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.6 Troubleshooting.................................... 43
5.6.1 General Hints........................................... 43
5.6.2 Projector Troubleshooting Chart (Type 1 errors) . . . . . . . . . . . . . . . . 43
5.6.3 Projector Troubleshooting Chart (Type 2 errors) . . . . . . . . . . . . . . . . 43
5.6.4 Analog Sound .......................................... 45
5.6.5 Digital Sound........................................... 45
5.7 Error Indication with LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.7.1 Interface Board .........................................46
5.7.2 Intermittent Sprocket Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . 46
5.7.3 Main Board ............................................ 47


Contents
Issue: 08/2012 
                   
6.1 General Hints ..................................... 49
6.2 Cleaning ......................................... 49
6.3 Maintenance ...................................... 50
6.4 Repair ........................................... 51
6.4.1 Changing the Pilot Lamp.................................. 51
6.4.2 Changing a Constant Speed Sprocket . . . . . . . . . . . . . . . . . . . . . . . 52
6.4.3 Adjusting the Distance between Pad Shoe and Sprocket . . . . . . . . . 52
6.4.4 Adjusting the IR Reex Film Break Sensor . . . . . . . . . . . . . . . . . . . . 53
6.4.5 Adjusting the Film Pressure Skate. . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.4.5.1 Checking and Adjusting the Skate Lifting . . . . . . . . . . . . . . . . . . . . . 53
6.4.5.2 Checking and Adjusting the Film Pressure Skate Height . . . . . . . . . 54
6.4.5.3 Adjusting the Pressure of the Skate . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.4.6 Adjusting the Lens Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
                        
7.1 Film Gate Parts (35 mm / 70 mm) . . . . . . . . . . . . . . . . . . . . . . 57
7.2 Feed/Bottom Sprockets (35 mm / 70 mm) . . . . . . . . . . . . . . . 57
7.3 Guide Rollers and Pendulum Rollers (35 mm / 70 mm) . . . . . 57
7.4 Other Parts ....................................... 57
7.5 Film Spools ....................................... 60
7.6 Interchangeable Flanges with Shafts . . . . . . . . . . . . . . . . . . . 60


Issue: 08/2012

 
                  
8.1 Technical Data .................................... 61
8.1.1 Projector .............................................. 61
8.1.2 Reverse-Scan Sound Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8.1.3 Magnetic Sound Device Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8.2 Plans of Terminal Connections . . . . . . . . . . . . . . . . . . . . . . . . 63
8.2.1 Plan of X1 Main Terminal Connections . . . . . . . . . . . . . . . . . . . . . . . 63
8.2.2 Plan of X2 Terminal Strip for Projector Functions (optional). . . . . . . 64
8.2.3 Plan of X3 Terminal Strip for Auditorium Functions (option) . . . . . . . 65
8.2.4 BWR Control Panel on Terminal Strips X2 + X3 . . . . . . . . . . . . . . . . 65
8.2.5 35 mm Sound Output on 8-pole Terminal Strip . . . . . . . . . . . . . . . . 66
8.3 Block and Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
8.3.1 Block Diagram (Components Overview) . . . . . . . . . . . . . . . . . . . . . . 67
8.3.2 Main Board Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . 68
8.3.3 Lamphouse for 230 V Mains Connection. . . . . . . . . . . . . . . . . . . . . . 69
8.3.4 Lamphouse for 120 V Mains Connection. . . . . . . . . . . . . . . . . . . . . . 70


Safety Instructions
Issue: 08/2012 
 
 
 
»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: 08/2012

 
The projector is suitable to reproduce 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.
 
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 indicates a possibly dangerous situation. Disregarding this warning can
result in small personal injuries or damage to projector.


Safety Instructions
Issue: 08/2012 
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.
 
 

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 spill liquids of any kind on this projector. If any liquid is coming into the pro-
jector, switch off, disconnect from mains and call service.
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
lamphouse 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.


Issue: 08/2012

 

SDo not cover the projector or the lens with any material while the projector is in
operation.
SIn the event of re, use sand, , or ; never use
water on an electrical re.
SAlways have  on this projector performed by authorized service personnel.
S must be well ventilated or cooled in order to avoid build up of
heat.
 
 
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.
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.


Safety Instructions
Issue: 08/2012 
 

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.
 

UThe projector has been designed for use with a . Never use
another lamp than specied.
UIn order to ensure that the projector complies with electromagnetic capability (EMC)
and safety requirements, it should be always operated with all .
UDo not spill  of any kind on this projector. If any liquid is coming into the pro-
jector, switch off, disconnect from mains and call service.
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.


Issue: 08/2012

 

UAttempts to alter the  or to change other control
settings not specially discussed in this manual can lead to permanent damage to
the projection unit and cancellation of the warranty.
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: 08/2012 
 
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.
 
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: 08/2012

 
The ow control (arrow) monitors the continuous ow of the water cooling.
If this ow interrupts the lm break sequence will be triggered and the projector will be
stopped.
 
If the projector door or the shutter housing will be opened during projector is running the
shutter and the projector drive stop, the dowser closes and the xenon lamp gets off (if it
is not in continuous running mode).


Installation / Mounting
Issue: 08/2012 
 
 
»The projector is completely (with mounted lamphouse (up to 2000 W), without
lamphouse (2000 W - 7000 W) mounted on a pallet and secured with screws.
»With delivery to countries over-seas the projector secured on the pallet is packed in a
wooden crate.
»The accessories are packed into a box or into the wooden crate too.
»Weight (gross): about 425 kg (950 lbs)

If the projector is stored for a longer time:
»Only store in dry rooms.
»Choose a suitable protective cover or leave projector in the original cover.
X
Although most parts are delivered with a protective cover, you have to clean the
projector and its components before the rst start.
 
»Projector FP 75 E
- with opposed rotating double shutter
- with electronic friction drives for lm spools up to 2,000 m and
reel platters up to 600 m
- with roller set for using with a rewind system (option)
»Lamphouse
- up to 2000 W
- up to 7000 W
»Reverse-scan sound device
- only analog, not upgradeable to Dolby Digital
- optical stereo analog, upgradeable to Dolby Digital
- optical stereo analog and Dolby Digital (option)
»70 mm magnetic sound device (option)
»Lens holder
- electronic focusing control (option)
»Remote unit
- focusing control (option)
»Film gate cooling unit
»Water cooling system


Issue: 08/2012

»Automation system (option)
- DMP 1 Digital Matrix Programmer
- CCA3 Cue Code Automation
- SA2 Sequence Cinema Automation
- EMK 1 Electronic Automation System
»Pedestals
»Reader for DOLBY / DTS / SDDS (option)
• Projection room control panel (option)
• Auditorium control panel (option)
»Film cleaner (option)
»Operating manuals
 

UThe projector will be delivered completely wired and factory tested.
UOnly use suitable hoisting machines (crane, fork-lift).
UDo not use unit parts as climbing aid.
UThe electrical connections have to be in accordance with local regulations and be
installed professionally.
UAll installation should only be carried out by Kinoton service.
 
»The place on which the unit will be installed must be even, solid and clean.
»The gure on the next page shows the projector’s dimensions.
»Requirements of the projection room:
- humidity: 40 to 60 %
- temperature: 15 to 25° C
- maximum sea level: 2000 m