Sony FLEXICART BFC-1 User manual

MULTI CASSETTE SYSTEM
FLEXICART
FLEXIBLE CART MACHINE CONSOLE
BFC-1
FLEXIBLE CART MACHINE BIN UNIT
BKFC-8D
BKFC-10B
BKFC-10S
BKFC-21DV
FLEXICART VTR MOUNT KIT
BKFC-52
BKFC-53
BKFC-54
FLEXICART SERIAL INTERFACE BOARD
BKFC-100
FLEXICART DV HAND KIT
BKFC-210
INSTALLATION MANUAL
2nd Edition (Revised 1)
Serial No. 10412 and Higher (BFC-1 for USA/Canada)
Serial No. 20522 and Higher (BFC-1 for Europe)

!WARNING
This manual is intended for qualified service personnel only.
To reduce the risk of electric shock, fire or injury, do not perform any servicing other than that
contained in the operating instructions unless you are qualified to do so. Refer all servicing to
qualified service personnel.
!WARNUNG
Die Anleitung ist nur für qualifiziertes Fachpersonal bestimmt.
Alle Wartungsarbeiten dürfen nur von qualifiziertem Fachpersonal ausgeführt werden. Um die
Gefahr eines elektrischen Schlages, Feuergefahr und Verletzungen zu vermeiden, sind bei
Wartungsarbeiten strikt die Angaben in der Anleitung zu befolgen.Andere als die angegeben
Wartungsarbeiten dürfen nur von Personen ausgeführt werden, die eine spezielle Befähigung
dazu besitzen.
!AVERTISSEMENT
Ce manual est destiné uniquement aux personnes compétentes en charge de l’entretien. Afin
de réduire les risques de décharge électrique, d’incendie ou de blessure n’effectuer que les
réparations indiquées dans le mode d’emploi à moins d’être qualifié pour en effectuer d’autres.
Pour toute réparation faire appel à une personne compétente uniquement.
BFC-1 (UC) Serial No. 10412 and Higher
BFC-1 (EK) Serial No. 20522 and Higher
BKFC-8D Serial No. 10531 and Higher
BKFC-10B Serial No. 14601 and Higher
BKFC-10S Serial No. 10156 and Higher
BKFC-21DV Serial No. 10001 and Higher
BKFC-52 Serial No. —
BKFC-53 Serial No. —
BKFC-54 Serial No. 10001 and Higher
BKFC-100 Serial No. —
BKFC-200 Serial No. 10001 and Higher
BKFC-210 Serial No. 10001 and Higher

1
BFC-1
1. OUTLINE
1-1. OUTLINE......................................................................1-1
2. PACKING
2-1. BFC-1.............................................................................2-1
2-2. BIN UNIT.....................................................................2-2
2-3. RACK MOUNT KIT...................................................2-3
2-4. BKFC-100
(Optional: for RS-422A serial interface) .......................2-4
2-5. BKFC-210 (Hand conversion kit for DVCAM)............2-4
3. INSTALLATION CONDITIONS
3-1. EXTERNAL DIMENSION AND MASS ..................3-1
3-1-1. External Dimension ................................................3-1
3-1-2. Mass........................................................................3-2
3-2. INSTALLATION CONDITION...................................3-2
3-2-1. Operating Condition ...............................................3-2
3-2-2. Notes on Installing Place........................................3-2
3-2-3. Door Dimension and Ceiling Height......................3-3
3-2-4. Maintenance Space.................................................3-4
3-3. POWER SUPPLY.........................................................3-5
3-3-1. AC Power Supply...................................................3-5
3-3-2. Power Cord.............................................................3-5
3-4. TRANSPORTATION.....................................................3-5
3-4-1. Move with Caster of Console.................................3-5
3-4-2. Move with Fork Lift ...............................................3-5
4. INSTALLATION AND
ASSEMBLING PROCEDURE
4-1. PRECAUTION..............................................................4-1
4-2. PREPARATION.............................................................4-1
4-2-1. Combination to Install Equipments........................4-1
4-2-2. Fixture.....................................................................4-1
4-2-3. Front Door Removal...............................................4-2
4-3. INSTALLATION FLOWCHART.................................4-3
4-4. CONSOLE FIXING......................................................4-4
4-5. VOLTAGE SELECTOR CHECK................................4-5
4-6. CIRCUIT BREAKER CHECK ...................................4-5
4-7. SWITCH ON CPU-107 BOARD SETTING..............4-6
4-8. SWITCH ON IF-373 BOARD SETTING..................4-8
4-9. SHIPPING PLATE REMOVAL ..................................4-9
4-10. VTR/BIN UNIT INSTALLATION
(FOR D-2 VTRs) .........................................................4-10
4-10-1. Select BIN Unit and Rack Mount Kit....................4-10
4-10-2. Installing the Rack Mount Kit and VTR ...............4-11
4-10-3. Installing the Bin Unit...........................................4-21
4-11. VTR/BIN UNIT INSTALLATION (FOR BETACAM,
HDCAM, MPEG IMX and S-VHS VTRs)....................4-24
4-11-1. Select BIN Unit and Rack Mount Kit....................4-24
4-11-2. Installing the Rack Mount Kit and VTR ...............4-25
4-11-3. Installing the Bin Unit...........................................4-36
4-12. VTR/BIN UNIT INSTALLATION
(FOR DVCAM)............................................................4-39
4-12-1. Installing the Rack Mount Kit and VTR ...............4-39
4-12-2. Installing the Bin Unit...........................................4-49
4-12-3. Remodeling the Hand Assembly
(for DVCAM)........................................................4-52
4-12-4. Moving of Cassette Sensor Board.........................4-58
4-13. CABLE CONNECTION/DISPOSITION.....................4-60
4-13-1. Control Digital System..........................................4-60
4-13-2. Video/REF (Digital System)..................................4-62
4-13-3. Audio/Time Code (Digital System).......................4-64
4-13-4. Control Analog System .........................................4-66
4-13-5. Video/REF (Analog System).................................4-68
4-13-6. Audio/Time Code (Analog System)......................4-70
4-13-7. Cable Disposition ..................................................4-72
4-14. CASSETTE LOADING AND REMOVAL................4-72
5. OPERATION CHECK.............................................5-1
6. INPUT/OUTPUT INTERFACE
6-1. MATCHING CONNECTORS
AND CABLES..............................................................6-1
6-2. SIGNAL INPUTS AND OUTPUTS..........................6-2
TABLE OF CONTENTS

1-1
BFC-1
1-1. OUTLINE
The Flexicart *1) is an automatic cassette changer system that features several VTRs and cassette shelves called "bin units". Using the
Flexicart, efficient recording or program transmission is possible.
The Flexicart console (BFC-1) is 600 mm wide to accommodate VTRs and bin units. You can select from several VTR formats (D-2,
Betacam SP *2), S-VHS or DVCAM).
The VCC *3) interface (RS-232C/422A) allows you to control the Flexicart from an external controller such as a personal computer. You
can also control the Flexicart via its parallel I/O interface.
Optional application software packages for IBM PC/AT *4) compatible personal computers are available from Sony.
The Flexicart is highly flexible cart machine that is well-suited to today's broadcast business.
Besides this installation manual, there are following manuals for the Flexicart. Refer to them, as necessary.
.Operation manual of the Flexicart (supplied with the BFC-1)
Introduces the Flexicart and, explains how to operate and the message informations output to its display panel.
.Maintenance manual of the Flexicart (supplied with the BFC-1)
Explains how to maintain the Flexicart.
.User's Guides supplied with the BZC-100/BZC-200 series flexible cart machine software.
Explain how to install and start-up the software to control the Fleicart from an IBM PC/AT compatible personal computer. Refer to the
on-line manuals of the software for an explanation of the routine operations.
.Flexicart VCC Interface Specifications (Optional)
Explains the protocol for controlling the Flexicart via the VCC interface.
*1) Flexicart is a trademark of Sony Corporation.
*2) Betacam SP is a registered trademark of Sony Corporation.
*3) VCC stands for Versatile Cart Controller.
*4) IBM PC/AT is a registered trademark of International Business Machines Corporation.
SECTION 1
OUTLINE

2-1
BFC-1
2-1. BFC-1
Note: The blank panel (1U) is provided against the space
between BIN unit and VTR or VTR and VTR. In the
case of the blank panel shortage even the five acces-
sories, please contact to sony's service organization.
(Sony Part No.: 3-179-787-00)
BFC-1
BFC-1
BELT RETAINER
SUPPLIED
ACCESSORY
Note : After unpacking, remove four
belt retainers which hold supplied
accessory from the console.
If the belt retainers are left
to install, VTRs cannot be mounted
in the cart machine. Supplied Accessories:
Extension Board EX-362
Operation Manual
Installation Manual
Maintenance Manual
Number Sheet
Nylon Rivet
AC Power Cord
Plug Holder
Blank Panel (1U)
B 5x10 (Screw)
B 5x10
x1
x1
x1
x1
x28
x32
x1
x1
x5
x10
SECTION 2
PACKING

2-2 BFC-1
2-2. BIN UNIT
.BKFC-8D (for D2)
.BKFC-10B (for BETACAM, HDCAM, MPEG IMX)
.BKFC-10S (for S-VHS)
.BKFC-21DV (for DVCAM)
Supplied Accessories:
1Guide Pin x2
2BIN Shutter Plate x1
3Screw (+B 5x10) x4
4Screw (+PWH 3x6) x2
FRONT
RONT
FRONT
FRONT
1
2
3
4
BKFC-8D/10B/10S
*BKFC-21DV has
some differences in package

2-3
BFC-1
2-3. RACK MOUNT KIT
.BKFC-52 ( for DVR-10/20 series, DVR-18/28 series)
: Prepare BKFC-52 having a product code ending with
-1 or higher when installing the DVR-18/28 series
VTRs.
Supplied Accessories:
Rack Mount (R2) Assy x1
Rack Mount (L2) Assy x1
Guide Plate (R) x1
Guide Plate (L) x1
Plate Nut F x4
VTR Shutter Plate x1
Guide Pin x2
Screw (+PWH 3x6) x2
Screw (+B 5x10) x4
Screw (+B 4x6) x4
Screw (+B 4x8) x16
Washer ( 4) x4
.BKFC-53 ( for BETACAM, HDCAM, MPEG IMX and S-VHS)
: Prepare BKFC-53 having a product code ending with
-1 or higher when installing the BETACAM UVW
series VTRs.
Prepare BKFC-53 having a product code ending with
-2 or higher when installing the Digital BETACAM
VTRs, BETACAM SX VTRs, HDCAM VTRs.
Prepare BKFC-53 having a product code ending with
-3 or higher when installing the MPEG IMX VTRs.
Supplied Accessories:
Rack Mount (R1) Assy x1
Rack Mount (L1) Assy x1
Guide Plate (R) x1
Guide Plate (L) x1
Plate Nut F x4
VTR Shutter Plate x1
Guide Pin x2
Screw (+PWH 3x6) x2
Screw (+B 5x10) x4
Screw (+B 4x8) x8
Screw (+B 4x12) x4

2-4 BFC-1
.BKFC-54 ( for DVCAM)
: Prepare BKFC-54 having a product code ending with
-1 or higher when installing the DSR-1600/1800 se-
ries VTRs.
Supplied Accessories:
Rack Mount (R1) Assy x1
Rack Mount (L1) Assy x1
Guide Plate (R) x1
Guide Plate (L) x1
Plate Nut F x4
VTR Shutter Plate x1
Guide Pin x2
Screw (+PWH 3x6) x2
Screw (+B 5x10) x4
Screw (+B 4x8) x8
Screw (+B 4x12) x4
Contents:
1Finger (DV) 1 pc
2Push rod (DV) 1 pc
3Shutter (DV) 2 pcs
4BCR retainer 1 pc
Shaft cap 2 pcs
Screw PWH 3x6 3 pcs
2-4. BKFC-100 (Optional: for RS-422A serial interface)
2-5. BKFC-210 (Hand conversion kit for DVCAM)
BKFC-100
3
*2pcs
1
2
4

3-1
BFC-1
3-1. EXTERNAL DIMENSION AND MASS
Machines having serial numbers 10169 (for UC) /20091 (for EK) and former have some parts
whose shapes and dimensions differ.
3-1-1. External Dimension
(1090)(600)
80 1980
527.2 497.4
R535
509.2
for fixed overhead support (
(
2-M12
940
350 480 490 600
1035
1090
150
55
for fixed base installation (
(
4- 16 hole
Unit : mm
SECTION 3
INSTALLATION CONDITIONS

3-2 BFC-1
3-1-2. Mass
BFC-1 Console 250 kg
BIN unitBKFC-8D 4.5 kg
BKFC-10B 4.2 kg
BKFC-10S 4.2 kg
BKFC-21DV 2.6 kg
Rack mount kit
BKFC-52 8.5 kg
BKFC-53 6.0 kg
BKFC-54 6.4 kg
Example
Following equipments are installed to the BFC-1.
.BKFC-8D x5
.BKFC-52 x2
.DVR-28 x2
Total mass is about 410 kg.
Design and specifications are subject to change without notice.
3-2. INSTALLATION CONDITION
3-2-1. Operating Condition
Operating temperature +5˚C to +35˚C
Storage temperature _40˚C to +60˚C
Humidity 25% to 80%
3-2-2. Notes on Installing Place
Install the console on a flat and firm place.
Do not install the unit in the following locations:
.Places at the exhaust of air conditioner
.Places exposed directly to sun light or powerful light
.Dusty places
.Places subjected to vibration
.Places exposed to strong electric or magnetic fields
.Places where produces the static noise

3-3
BFC-1
3-2-3. Door Dimension and Ceiling Height
.Door Dimension
The minimum door dimensions should be 2000 mm in height,
and 700 mm in width.
If eye bolts are installed on the top panel, the minimum door
height should be 2050 mm.
.Ceiling Height
Sufficient dimension to fix with eye bolts should be maintained.
more than 700mm
more than 2000mm

3-4 BFC-1
3-2-4. Maintenance Space
To facilitate the maintenance, secure a sufficient space when
pulling out the VTR from the console during work.
.When the VTR is installed based on a front drawer system:
Front side : Approx. 1.0 m
Rear side : Approx. 0.5 m
.When the VTR is installed based on a rear drawer system:
Front side : Approx. 1.0 m
Rear side : Approx. 1.5 m
[Reference]
Determine whether to use the front or rear drawer system in con-
sideration of the maintenance of head cleaning after the flexible
cart operation is initiated. For more details of the installation, re-
fer to Section 4.
EYE BOLT (50)
(1500)
Rear side (1000) Front side
Rear drawer system Front drawer system
Unit : mm

3-5
BFC-1
3-3. POWER SUPPLY
3-3-1. AC Power Supply
Power Supply Voltage: 120/220/230/240 V
Power Supply Frequency: 50/60 Hz
Consumption electric power: 600 VA (without VTR)
3-3-2. Power Cord
Approx. 2.4 m in lengh
For USA/Canada
For Europe
3-4. TRANSPORTATION
The Cart Machine can be lifted and moved with a fork lift in the
packing cases, or unpacked. Once unpacked, the console can be
movable around on the casters which are fitted to the base, if the
floor is suficiently even.
3-4-1. Move with Caster of Console
Tighten shipping plates and shipping screws to fix the elevator.
(See section 4-9 "SHIPPING PLATE REMOVAL".) Turn the
floor levelers not to touch them to the floor.
3-4-2. Move with Fork Lift
Tighten shipping plates and shipping screws to fix the elevator.
Set the console on the vehicle, using a lifting fork at the specified
position which is not to touch the casters and floor levelers.
Move BFC-1 carefully not to fall.
Note: Eye bolts are for fixing the cart machine.
Do not lift the cart machine with eye bolts.
4.75
21
17
1.5
11 12.5
LIVE
NEUTRAL
GND
13
12.7
11.9
6.3
Unit : mm
23.5
74.5
26.519.5
14
SAFETY EARTH
NEUTRAL
LIVE
LIVE (BROWN)
NEUTRAL
(BLUE)
SAFETY EARTH
(GREEN/YELLOW)

4-1
BFC-1
4-1. PRECAUTION
At least two or more persons are required for the cart machine in-
stallation to be safe.
4-2. PREPARATION
4-2-1. Combination to Install Equipments
Table. 4-2-1 shows combination list to install equipments.
Confirm that required equipments are prepared before installa-
tion.
4-2-2. Fixture
Fixtures to install the cart machine are introduced below.
.Wrench (to opposite side: 30 mm)
It is used when adjustment of caster on the console and floor
leveler.
.Hexagonal Wrench (to opposite side: 3 mm)
It is used when front door removal.
.Screw Driver (No. 2: for M3 through M5)
It is used when install the rack mount and the BIN unit.
Short screw driver is efficient because maintenance space is
limited.
.Adjustment Stick
It is used when rotary switch on the following board of BIN unit
is set.
SE-198 board: for BETACAM, HDCAM, MPEG IMX and
S-VHS
SE-200 board: for D2
SE-481 board: for DVCAM
.Flat-blade screwdriver
Tightening the guide pins.
.Tweezers (for BKFC-210)
To hook the tension spring to the hand block.
* 2
* 3
* 1
* 1:
* 2:
Table 4-2-1.
VTR Rack Mount Kit BIN Unit Hand KIt
Prepare BKFC-53 having a product code ending with -1
or higher when installing the BETACAM UVW series VTRs.
Prepare BKFC-53 having a product code ending with -2
or higher when installing the Digital BETACAM DVW series
VTRs, BETACAM SX VTRs and HDCAM VTRs.
Prepare BKFC-53 having a product code ending with -3
or higher when installing the MPEG IMX VTRs.
Prepare BKFC-52 having a product code ending with -1
or higher when installing the DVR-18/28 series VTRs.
Prepare BKFC-54 having a product code ending with -1
or higher when installing the DSR-1600/1800 series VTRs.
.
.
.
BETACAM
HDCAM
MPEG IMX
D-2
S-VHS
BKFC-53
BKFC-52
BKFC-53
BKFC-54
BKFC-10B
BKFC-8D
DVCAM BKFC-21DV
—
—
BKFC-210
* 3:
—
SECTION 4
INSTALLATION AND ASSEMBLING PROCEDURE

4-2 BFC-1
4-2-3. Front Door Removal
It is recommended to remove the front door before installation
not to damage it.
.Open the front door
1. Rotate the screw counterclockwise (in the direction of the ar-
row 1) with hexagonal wrench (to opposite side: 3 mm) and
either slide the lock cover.
2. Raise the lock plate with finger.
3. Hold the door lock window, and pull the front door in the di-
rection of the arrow 2to open the door.
.Remove the front door
1. Pull out the door hinge at the top-right of the front door.
2. Remove the door while supporting it.
LOCK
COVER
SCREW
LOCK
PLATE
1
DOOR LOCK
WINDOW
2
DOOR
HINGE
FRONT DOOR

4-3
BFC-1
4-3. INSTALLATION FLOWCHART
The installation procedure is shown in the following flowchart.
See each section about the detail.
START
4-1. PRECAUTION
4-2. PREPARATION
4-4. CONSOLE FIXING
4-5. VOLTAGE SELECTOR CHECK
4-6. CIRCUIT BRAKER CHECK
4-7. SWITCH ON CPU-107 BOARD SETTING
4-8. SWITCH ON IF-373 BOARD SETTING
4-9. SHIPPING PLATE REMOVAL
4-10. VTR/BIN UNIT
INSTALLATION
4-13. CABLE CONNECTION
4-14. CASSETTE LOADING AND REMOVAL
END
4-11. VTR/BIN UNIT
INSTALLATION 4-12. VTR/BIN UNIT INSTALLATION, etc
BETACAM, S-VHS DVCAM
D-2

4-4 BFC-1
4-4. CONSOLE FIXING
After installation, it is recommended to fix the console to prevent
danger such as fall.
1. Cart machine console fixing
Install the console on a flat and firm place, lower the floor
leveler of the console until they contact the floor.
Turn the floor levelers half another after they touch the floor
to fix the console.
(to opposite side of wrench: 30 mm)
2. Fixing from the ceiling
Two eye bolt holes are at the top plate. Mount eye bolts at
the holes to fix the console and ceiling, pole or wall with
chain or rope.
(screw diameter of eye bolt: M12)
Note: Be sure to don't put up by the eye bolt.
FLOOR LEVELER
EYE BOLTS
Tigten the eye bolts with bar.