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Christie 35/70 Automated Film Projector

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2. Step Description Completed Item Verify that the projected picture does not have excessive jitter side weave or ghosting Table 7 13 Image Quality Checklist IMAGE QUALITY DIAGNOSTIC TABLE Poor Image Quality CONDITION 1 Frame line jumps in and out of picture area on the screen resulting in jitter one perf high This condition is the result of a missing pulldown index pulse or one that comes at the wrong time due to mis adjustment of the pulldown sensor Verify index pulse at U10 pin 11 of the 2293 card Connect oscilloscope to this point Move pulldown sprocket at least one quarter turn to produce one high going pulse If pulse is not present trace to the 2276 card and finally to the pulldown sensor to determine failure point Repair wiring fault or replace 2276 card or 2268 card as required If the pulse is present connect dual trace oscilloscope to TP13 of the 2293 card and pin 11 of U10 also on the 2293 card The signal at TP13 is the analog registration error signal the signal at U10 is the index signal Rotate the pulldown sprocket clockwise Note that the analog signal moves between 10 volts and 10 volts five times for every index pulse Rotate the pulldown sprocket clockwise until just before the index pulse goes positive 0 to 5 volt signal Verify that as the sprocket continues in a clockwise direction the index pulse is high at least from the time the analog voltage goes fro
3. m 18 LOWER LOOP GUIDES a XO ov 19 LOWER C V SPROCKET Ll 20 35mm OPTICAL HEAD 21 PRE AMPLIFIER LOWER PARTICLE TRANSFER ROLLERS 22 LOWER TACHO GENERATOR 23 LOWER TORQUE ARM ROLLER 24 LOWER REEL 25 LOWER FILM STRIPPER 26 UPPER C V SPROCKET wonoeungsptmro 10 Figure 4 2 Maintenance Locations on Projector Film Side 9 Check both upper and lower torque arm trip switches see Figure 4 1 Ensure that when the arm is relaxed to within one inch of its resting position the corresponding LED on the control panel goes on CHRISTIE IN C 35 70 Service PM M anual July 1997 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 Clean the DTS head or Magnetic head with a cotton swab dipped in isopropyl alcohol or using a soft brush 3 Open the back of the projector and vacuum the circuit boards 4 Generally clean all surfaces in the back of the projector Be careful to wipe
4. Refer to interconnect diagrams in Section 8 for proper cable connections CHRISTIE IN C 35 70 Service PM M anual July 1997 2 General Description Refer to Section 6 8 for correct voltage strapping of power supply transformers prior to connection CHRISTIE IN C 35 70 Service PM M anual July 1997 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 During normal operation all commands sent to the projector will be echoed back except when the projector is used in the SLAVE mode of operation Film and Shows The reeling system holds approximately 2000 of film The recommended type of film to use on the 35 70 projector is a polyester based film A film reel may contain from one to six different shows of varying length the projector assumes there is one show on a reel unless a greater value is programmed see Section 0 Each show is given a unique show number from one 1 to six 6 Show numbers can be designated with reflective tape Where possible low inertia reels with core sizes of 4 inches or greater are recommended to minimize the stress applied to the reeling syste
5. Unchanged Figure 2 3 SELECT FRAME RATES LED Display CHRISTIE INC 35 70 Service PM M anual July 1997 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 lt G gt lt 3 gt CODE G3 ACTION A Allows the douser to be automatically opened 3 seconds into the S film STATUS Unchanged G4 The LOAD REEL COUNTER Command DX This diagnostic command loads the time code value of the frame counter register into the reel counter register This command is used for motion programming and is not a part of normal operation ENTRY G 4 CoDE G4 ACTION Sets the reel counter equal to the frame counter 8 STATUS Unchanged G5 The SET PLATTER MODE Commands OP This operational command sets the projector to platter mode This command is recognized only in the NOT READY state ENTRY lt CMD G gt 5 CODE G5 ACTION Disables upper and lower torque arm operation Enter a NOT S READY command to reset projector to the default reel mode STATUS Unchanged CHRISTIE INC 35 70 Service PM M anual July 1997 3 Operating the Projector G6 The OUTPUT CUE TAPES Command DX This diagnostic command downloads the position of each BOF and EOF cue tape
6. Check for any loose connectors ARON Check douser limit bumpers for wear and replace if necessary Refer to the lamphouse manual for any other specific maintenance requirements CHRISTIE IN C 35 70 Service PM M anual July 1997 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 The projector houses most of the electronics as well as the position encoders power amplifiers and motors Functional Description of the Projector The overall block diagram of the projector is shown in Figure 5 1 Projector operation depends on five motor systems which deal with the shutter timing and film motion in both cine also called pulldown and slew also called high speed modes Shutter Control Circuit Constant Velocity Control Circuit Pulldown Motor Control Circuit Upper Torque Motor Control Circuit Lower Torque Motor Control Circuit The interrelationship and timing between these circuits is shown schematically in the film velocity diagram and the system timing diagram both in Section 8 15 Miscellaneous Diagrams The Shutter Control Circuit and
7. Sets maximum number of shows on the current reel of film 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 ENTRY CODE ACTION S STATUS LOCAL HE Take the projector out of interlock mode Unchanged HF The DISPLAY START Command DX This diagnostic command displays the GOTO frame that was programmed using the SET GOTO command see Section 0 ENTRY CODE ACTION S STATUS lt H gt lt F gt HF Displays the GOTO frame in the standard counter format of hh mm ss ff see Section 0 Unchanged CHRISTIE INC 35 70 Service PM M anual July 1997 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 This command is NOT part of normal projector operation The MEMORY INSPECT command can be used from the projector control console or from a serial communications service terminal However the input and command sequence differs somewhat F
8. 1K 22 oh S 2 01 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 If adjustment is required the 2 screws securing the pull down encoder to the framing ring can be loosened and the encoder moved up or down to achieve correct quadrature i 5 00V 2 amp 2 00V iPulldown Signal TP13 gt 90 degree Pulldown Sensor Figure 6 6 Phase Relationship of Pulldown Quadrature Signal CHRISTIE 35 70 Service PM M anual March 1997 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 V AC operation 1 Remove the jumper from terminals 1 amp 3 and 2 amp 4 on 1 and the jumper T1 terminals 2 amp 3 120 VAC Operation To configure the 35 70 projector for 120 V AC operation 1 Remove the jumper from terminals 2 amp 3 on T1 and jumper terminals 1 amp 3 and 2 amp 4 on TI CHRISTIE 35 70 Service PM M anual March 1997 6 Mechanical and Electronic Adjustments Pulldown Gain Adjustment This adjustment is factory set This setup procedure should be performed only i
9. Figure 5 8 Upper Reel Motor Control Circuit The reel motor control is accomplished by comparing the speed of a film driven Tacho roller with the voltage from the constant velocity tachometer using summing amplifier U25A In addition the upper torque arm position sensed by an optical pot feeds into the summing amplifier As the voltage becomes more negative more torque is applied in the take up direction The circuit is biased in such a manner that the input signal from the optical pot will be zero volts when the torque arm is at normal position independent of speed The output of U25A goes to an absolute value circuit formed by U25B and U26 where it is converted to a PWM signal by U40 U40 compares the analog voltage to the output of the sawtooth generator as is done by U42 for the shutter U25A also goes to a comparator U39 which determines the polarity of U25A and outputs a direction signal to the upper torque power amplifier The current limiting signal from the power amplifier turn on the photocoupler U41 which limits the voltage sent to the pulse width modulator U40 The Optical Sensor is also monitored by the CPU using comparator U34 Transistor Q9 turns off the drive to the reel motor in the Platter mode of operation The lower torque circuit is similar to the upper The major components of the lower reeling circuit are the lower reel motor and brake the tacho roller and the lower torque arm with its optical potentiometer The ma
10. ENTRY CODE ACTION S STATUS lt NOT RDY gt CB 1 Remove power from motor systems 2 Reinitialize software values and turns the AUTO DOUSER command off 3 Reset LED error indicators Set to B CHRISTIE INC 35 70 Service PM M anual July 1997 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 lt C gt lt D gt Cope CD INPUT 1 Show number Example CDI 2 Reel time for BOF EOF of selected show followed by lt ENTER gt Example 01 00 20 04 ACTION 1 Displays the entered BOF or EOF value on the LED display S 2 Stores the entered BOF or EOF value STATUS Unchanged Before beginning the manual logging process it is necessary to create a log sheet such as the one shown in Figure 2 2 Eu SHOW NAME START TIME STOP TIME 01 00 00 00 01 04 43 16 Cowboy 2 01 05 00 00 01 09 17 10 oroo S ewe T Nt Figure 2 2 Sample Log Sheet If a mistake is made the CLEAR key erases the last entry made When the BOF time is correctly displayed press ENTER Table 2 6 illustrates the sequ
11. 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 A two second timeout stops the pulldown motor if there is no film in the projector and illuminates LED 3 on the keypad A framing switch has been incorporated to aid the operator in proper framing The five positions of the framing switch allow the relationship between the encoder slot selected for registration and the indexing slot to be changed in increments of 1 film perforation for 70mm film For 35mm film the increments equal 1 5 of the 4 perforation film frame This avoids the need to relocate the film on the sprocket if the film is not framed CHRISTIE INC 35 70 Service PM M anual July 1997 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 D yaa Optical Sensor To CPU 2 4 Pa irie comp Tachometer O Z OZO ABS VAL AMP T U25A U25B U26 Current Limiting CV Tachometer U32 AMP SUMMING AMP p Direction
12. OP L This operational command causes the projection system to play the current show and then return to the head of the film When running the projector in a Master Slave configuration use the PLAY CURRENT SHOW CHRISTIE IN C 35 70 Service PM M anual July 1997 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 STATUS FOR Cl 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 Set to 1 while advancing with douser closed set to 3 while playing with douser open set to 0 when stopped at EOF marker set to 8 while moving to cue for next show set to A while parked at cue C2 The REVERSE Command OP L This operational command moves the film in a reverse direction to the start of the current show ENTRY CODE ACTIO NS STATUS REV C2 Reverse to head of current show Set to 8 while moving to cue for next show set to A while parked at cue CHRISTIE IN C 35 70 Service PM M anual July 1997 2 General Description C3 The OPEN DOUSER AND CINE Command OP This operational command opens the douser The film must be moving at cine spe
13. PERIODIC MAINTENANCE To properly maintain the CH RIS TIE 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 Tables 4 2 through 4 7 list the periodic procedures CH RIS TIE recommends that these tables be photocopied and used as preventive maintenance checklists and logs Do not use any film lubricants on the 35 70 projector Equipment Required for Preventive Maintenance Table 4 1 lists equipment that should be available in the projection booth It should be easy and convenient for the projectionist to perform any required maintenance If the proper tools are not at hand it is unlikely that the maintenance will be performed as directed Allen Keys Long handled ball end 0 050 5 16 Isopropyl alcohol for cleaning purposes Desoldering Tool Brush soft camel hair Nut Driver 3 16 Clean soft cloth Pin Extractor 0 063 MOLEX Compressed air can no more than 15 PSI Pin Extractor 0 093 MOLEX Cotton swabs Pliers Needle nosed Lens Cleaning Tissues or Wipes Pliers Snap ring 222 Loctite Ruler 6 Steel Silicone Grease Screwdrivers Assorted Flat Toothbrush ordina
14. 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 lt CMD G gt 6 CODE G6 ACTION 1 Outputs PROMPT followed by BOF for first show S 2 Outputs successive BOF and EOF positions each preceded by a PROMPT STATUS Unchanged lt PROMPT gt CR lt LF gt hh mm ss ff PROMPT BOF for Show 1 hh mm ss ff PROMPT EOF for Show 1 hh mm ss ff PROMPT BOF for Show 2 hh mm ss ff PROMPT EOF for Show 2 repeated for additional shows Table 2 8 OUTPUT CUE TAPES Data Format G7 The SHUTTER TEST Command DX This diagnostic command is used to test the speed of the shutter LED 0 on the control keypad is used as an indicator of this test s success or failure ENTRY lt CMD G gt lt 7 gt CODE G7 also HD from remote interface only ACTION LED 0 flashes and remains OFF if shutter speed is correct S LED 0 flashes and remains ON if shutter speed is incorrect STATUS Unchanged CHRISTIE INC 35 70 Service PM M anual July 1997 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 s ew mode at various speeds in the forward and reverse direction The projector must be powered up and in the READY state ENTRY CODE INPUT STEPS INPUT STATUS lt CMD G gt 8 G8 Enter a speed
15. disk with an offset hole is mounted on the torque arm shaft As the shaft rotates the disk blocks more or less of the light beam The disk is adjusted on the shaft so that the tension arm is at a center position causing the film to be under tension Both mechanical and electrical adjustments may be required The mechanical procedures apply to both upper and lower reels since they are identical in adjustment and operation The electrical adjustments are carried out using the Reverse Test Mode command for the projector CHRISTIE 35 70 Service PM M anual March 1997 6 Mechanical and Electronic Adjustments Test Point R149 R150 0 Volt Position m N an Test Point R 49 R150 ME 7 45 Volt Position 5 Volt Position PS Tension Adjust Rotate Disk to Set Range Sensor Lock set screw behind ccce Use Fine Adjust to Position Sensor with respect to Disk I Disk chector 1 EMITTER LED Locking Screws Adjust for 0 volts in center position Test Point R149 R150 Lo Test Point R149 R150 Westrex Tension Sensor Figure 6 2 Tension Sensor Adjustment for Reeling System Mechanical Adjustments Remove the back panel cover from the projector to access the tension sensor mechanism Apply power and keep the projector in NOT READY mode In the relaxed position the arm activates a limit switch
16. which will short the sensor output to the 15 volt supply This switch should activate when the arm is relaxed to within one inch of the rubber stop Remove the disk sensor cover Loosen the set screw holding the disk to its shaft Turn R2 to the maximum counter clockwise position then turn it back a quarter turn MO n B 2293 CPU Main Logic card and the test point for the lower torque arm is on the top of R149 Loosen the locking screws so that the sensor assembly can be moved with respect to the disk See Figure 6 2 Hold the torque arm in its mid travel position The test point for the upper torque arm is at the top of R150 on the a Rotate the upper optical disk so that the widest part of the disk is pointed upwards and secure the disk Note that the widest portion of the disk corresponds to one of the four tapped set screw holes in the disk b Rotate the lower optical disk so that the widest part of the disk is pointed downwards and secure the disk Move the sensor bracket until a reading of 0 volts is obtained and secure the bracket d Verify that the voltage at R149 and R150 varies by approximately 5V as the torque arm is moved to extremes Minor adjustments to R2 the sensor bracket and the sensor disk may be required to obtain the correct voltage fluctuations Do not allow the voltage fluctuation to exceed 8V as this may activate the torque arm limit circuit e Secure all set screws and install light cov
17. 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 These keys are used to enter values in base 16 notation sme Table 2 2 Keypad Functions for Entering Hex Values Keypad LED Indicators The LEDs associated with the keypad provide an indication of projector status Table 2 3 contains a list of the keypad LEDs and their indications Upon detection of a malfunction that causes NOT READY condition one of the 0 6 LEDs or the CLEAR LED will latch on indicating the cause of the fault These indicator LEDs can be reset once the NOT RDY gt button has been pressed and the cause of the malfunction has been corrected Frame Counter Display The frame counter is normally displayed here As explained in Section 0 this is a composite measure of elapsed time hours minutes seconds and frame count within a second expressed in the standard counter format AA mm ss ff Some of the 35 70 projector operating and diagnostic commands use positions on the frame counter LED display to display values or echo input for verification Refer to the individual command write ups in Section 0 for detailed explanations
18. Ok P Pulldown CNTR Drive CV Encoder 2275 PULLDWN3 em G CV Tach p P Main Electronics Card Pulldown Amplifier Card Figure 5 5 Slew Operation Pulldown Circuit CHRISTIE INC 35 70 Service PM M anual July 1997 5 Theory of Operation REGISTRATION MODE 0 deg sensor Pulldown 180 deg sensor Drive 2275 U1 Pulldown Sensor Main Electronics Card Pulldown Amplifier Card PULLDOWN MODE Pulldown Encoder Shutter Index Pulldown Drive 2275 Main Electronics Card Pulldown Amplifier Card Figure 5 6 Cine Operation Pulldown Circuit The operation of the pulldown circuit during cine motion is shown in Figure 5 6 During registration mode the Pulldown motor is used to maintain stationary registration by connecting the differential output of the zero and 180 degree sensors each partially blocked by the edge of a disk slot to the motor through amplifiers U21 and U1 Any motion of the disk edge across the face of the sensors creates a restoring signal to the motor During pulldown operation the CPU maintains direct control of the Pulldown motor PIA U10 provides an eight bit control signal to DAC U20 The analog control voltage is amplified by U55 U21 and Ul on the Pulldown Amplifier Card driving the Pulldown motor Figure 5 7 shows the timing relationships during the pulldown action Prior to time 0 on the diagram the film is in registration and is bei
19. Park on BOF mark STATUS Setto 8 while searching for next show set to A while parked at cue C9 The JAM Command DX This diagnostic command resets the frame counter for a show If a new frame counter was just loaded using the SET FRAME COUNTER command see Section 0 that value is loaded if no time has been set the frame counter setting defaults to one hour written as 01 00 00 00 The JAM command is useful if there is a requirement to inspect the new value immediately or to set MASTER and SLAVE start times to the same value CHRISTIE IN C 35 70 Service PM M anual July 1997 ENTRY CODE ACTION S STATUS 2 General Description lt CMD C gt 9 C9 Reset the frame counter Unchanged CA The READY Command OP This operational command initiates the READY sequence When the projector is in READY mode if the lt READY gt 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 STATUS lt READY gt CA 1 Apply power to motor systems 2 Check all limit switches 3 Check the CV Pulldown and Shutter motor systems 4 Set loop 5 Execute single frame advance and stop Set to 0 CB The NOT READY Command OP This operational command places the system in a NOT READY state When in this state the projector will not accept any commands that require film motion
20. S Wtooth Comp CPU Speed Speed Control Voltage Figure 5 2 Shutter Motor Control Shutter operation is diagrammed in Figure 5 2 above When the shutter is rotating at correct speed nominally 30 rps about 600 pulses per second are sent to the Shutter EPLD U29 by the 20 slot shutter encoder rotating on the same shaft as the shutter Since the shutter is locked to the line frequency this is either 10 times the 60 Hz rate or 12 times the 50 Hz rate Within the EPLD an edge detector produces a signal of four times this rate which is sent to the Tacho EPLD U33 The Tacho circuit produces output signal pulses that can be converted into a tachometer signal Integrating amplifier U31 produces this analog tachometer signal which is summed into amplifier U22 The speed control voltage into this amplifier is derived from the negative supply voltage The output of the summing amplifier U22 is sent to comparator U42 where the error signal is converted into a pulse width modulated PWM signal by comparing with a sawtooth input This output is sent through photocouplers to the PWM power amplifier the 2285 card which drives the shutter motor The current limiting signal from the Power Amplifier turns on the photocoupler U43 which limits the voltage sent to the pulse width modulator U42 While the circuitry described so far would result in an accurate rate of shutter rotation it is also desirable that the shutter rotation be held constant over the l
21. U36 The sawtooth is generated on capacitor C22 controlled by the charge and discharge rates of Q5 and Q6 The frequency is about 20 KHz Fault Indications Indications of operating faults are input to the main electronics card in connector J5 Upper and lower film buckle switches are monitored by the CPU and also combined in EPLD U29 to provide a ready signal to send to motor control cards This ensures the film comes to a smooth stop in the event of a problem eliminating film breakage and sprocket hole damage The Pulldown Sensor Circuit 2268 Signals from the zero degree sensor and the 180 degree sensor of the disk sensor card feed into a differential amplifier UL See the appropriate circuit diagram in Section 8 9 The output of U1 is Pin 1 at R6 The signal there is as shown in the second trace of Figure 5 7 As the slotted disk on the pulldown shaft turns the slots pass in front of the 180 degree sensor causing amplifier U1B to move positive Simultaneously another web passes in front of the zero degree sensor and causes UIA to go negative in turn causing U1B to go more positive The resulting pulses as the disk continues to turn are counted by the CPU Comparator U2 squares up the signal and sends it to the computer over parallel bus PIA2 PB4 When four positive and three negative transitions have been counted braking is applied to the pulldown motor As the amplifier comes down CHRISTIE INC 35 70 Service PM M anual July 199
22. a consistent jitter free picture while running cine forward Both a 90 degree and a zero degree signal are used to form a biphase signal that locks the pulldown sprocket to the constant drive sprocket during slew motion in either direction A fourth signal an index pulse is used by the CPU to keep the picture in frame The sensor card must be correctly positioned relative to the notched disk on the pulldown sprocket shaft See Figure 6 3 Pulldown Sensor Figure 6 3 Pulldown Sensor Position If the sensor card is adjusted improperly the pulldown gain can be too low Figure 6 4 a or too high Figure 6 4 b Either situation can cause excessive jitter The normal pulldown sensor signal is shown in Figure 6 4 c CHRISTIE 35 70 Service PM M anual March 1997 6 Mechanical and Electronic Adjustments 1 55 00 m 19 92 2 0087 mT Figure 6 4 a Pulldown Signal Gain Too Low i 55 00 19 9 2 0087 UM m dcs pura Inge albis wy Figure 6 4 b Pulldown Signal Gain Too High CHRISTIE 35 70 Service PM M anual March 1997 Pulldown Signal TP13 1 Pulldown Signal TP13 6 Mechanical and Electronic Adjustments 1 5 00v 19 9 2 000 E oU d Slight change in slope on eac i negative going transition 1 X dq AX ws Signal TP13 Figure 6 4 c Pulldown Signal Normal Gain The procedure for adjusting t
23. adjusted 2 Putthe film in motion and observe the film image Use as little pressure as possible while adjusting the cap screws to correct the image for jitter Excessive pressure on the film causes poor projector performance and increased film wear Film Edge Guide Adjustment 1 Load the film and adjust the focus Each edge guide has a socket cap screw with which the pressure on the film edge can be adjusted 2 Putthe film in motion and observe the film image Use as little pressure as possible while adjusting the set screws to adjust picture weave Too much pressure on the edge guides distorts the film path and causes uneven focus problems CHRISTIE 35 70 Service PM M anual March 1997 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 2 for part locations QNO Uv en pau des 10 11 12 13 14 15 Insure power is turned off to the projector Remove all 70mm reels and install 1 reel spacer on both the upper and lower reel shafts Remove the upper and lower C V sprocket pad sho
24. around bearings Do not let dust or debris get into the bearings 5 Lubricate the gate center pin with a small amount of silicone grease 6 Remove and clean the gate glass see Figure 4 2 with isopropyl alcohol and lens cleaning tissue 7 Ensure that the Delrin shoes on the movable gate have adequate spring tension adjust the tension if it is too weak 8 Check all mechanical connections screws etc and tighten as needed CHRISTIE IN C 35 70 Service PM M anual July 1997 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 m This check is accomplished by pushing the center of one xl le n Mace 2 side of the belt with moderate pressure and ensuring that the belt deflects approximately 4 6 mm 2 Service the air filter canister a Remove the wing nut on top of the air filter canister See Figure 4 3 It is not necessary to remove the hose clamp b Carefully lift off the top cover of the canister taking care not to kink the flexible hose Then slide the cylindrical shell of the canister up and set it aside c Unscrew the nut on top of the filter to free the filter from the threaded center post and slide the filter off d Ifreplacement is not necessary clean the element 1 Blow dry compressed air 30 PSI or less through the element from the
25. command set The following information is provided for each command e command name e command type operational OP or diagnostic DX e lock out condition for SLAVE projector commands L CHRISTIE IN C 35 70 Service PM M anual July 1997 2 General Description e brief description of the command e key sequence to trigger command e RS 232 code for command e data input description and format where applicable e resulting projector actions e 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 Thus OUTPUT STATUS is a command and status refers to the status value itself When a key entry or LED is described the key s identity is enclosed in brackets as STOP If more than one key must be hit keystrokes are separated by a comma C0 The STOP Command OP L This operational command causes the film to stop The douser automatically closes before the projector stops The douser cannot be opened if the film is at a stop ENTRY lt STOP gt CODE CO ACTIONS Ramp to a stop if film is in motion 2 Advance one frame when film is at stop 3 When operating in a MASTER SLAVE configuration a C4 CLOSE DOUSER gt command will be sent to the SLAVE prior to the CO STATUS Set to 0 C1 The FORWARD Command
26. diagram U1 is an 8192 byte RAM U4 U10 and U37 are PIAs used to communicate with the EPLDs and DACS and for sensing and controlling bilevel inputs and outputs U7 is the ACIA which communicates with the show controller or with the terminal for troubleshooting across the RS 232 interface U9 shifts the 0 to 5 volt output of the ACIA to 15 volts as required for an RS 232 interface U8 shifts incoming 12 volt levels to 0 5 volts for the ACIA The PTM divides the CPU clock to 153 6 KHz as required for the ACIA and scales other rates for motor drive circuits The ACIA communicates at 9600 baud CHRISTIE IN C 35 70 Service PM M anual July 1997 5 Theory of Operation Data Address Control Bus Parallel Communications Serial SA Parallel Communications Communications Figure 5 11 CPU Circuits Parallel Communications 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 After the RESET routines have been executed the processor executes the normal operating program This program monitors the PIAs and the ACIA and controls the PTM Based on the information received the processor sends the necessary control signals to the PIAs to operate the pulldown constant velocity and shutter motors A phase locked
27. functionality Fail safe hardware mechanisms back up the software for those critical functions that protect the film and provide safe operation At system start up initialization routines set up the hardware and software registers verify proper system operation and begin execution of the basic film motion interrupt routine background program which monitors the system fault status and the communication ports is also started The system is initially in a non operating state and must be placed into a ready condition by specific operator commands When the projector is in a ready state it can receive commands either to affect the movement and projection of film or to change the system state The system state is a combination of hardware and software values that are shared among various software subroutines and store information about previous operations for later use The selection of an alternate film speed is an example of a change to the system state The 35 70 software system can support extensive modifications to projector operation to enable improvements or implement diverse applications This flexibility does not compromise system performance Software modifications have the additional advantage of eliminating the need for system hardware modifications Figure 5 14 provides a high level flowchart of the system software Major system variables are listed in Appendix C the RAM Assignment Chart CHRISTIE INC 35 70 Service PM M anual July 199
28. if desired The new value must be a valid show number If PLAY CURRENT SHOW see Section 0 was the most recent play command the projector also cues to the next show The current show and next show values are displayed for one second before the numeric display reverts to the frame counter The new next show value must be entered while the show values are displayed ENTRY CODE ACTION S INPUT ACTION S STATUS CMD H 8 H8 1 Display current show in second from right position of numeric display 2 Display next show in rightmost position of numeric display Enter the number of the new next show using the numeric portion of the keypad The entered value may not exceed maximum shows see Section 0 1 Load the new next show value 2 If PLAY CURRENT SHOW is the most recent play command cue to the next show As indicated by necessary motion H9 The SET OPERATING FREQUENCY Command DX This diagnostic command selects the synchronization frequency or line frequency between 50 Hz and 60 Hz The default value is 60Hz operation The battery backup RAM on the CPU card will maintain the frequency setting so this command should only be used once 3 As shown in the two leftmost digits of the keypad LED display strip CHRISTIE INC 35 70 Service PM M anual July 1997 ENTRY CODE INPUT ACTION S STATUS 3 Operating the Projector CMD H 9 H9 Enter a 6 from the ke
29. 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 high pressure air hose is not recommended This activity drives the dust into the mechanisms where it can cause damage The preferred approach for dusting the projector is to wipe surfaces with a soft cloth or brush them with a camel hair brush Vacuuming is also acceptable If a part does not contain moving parts or dust trapping cavities remove it take it to a work area away from the projector and blow it clean with high pressure air If desired these parts can be cleaned on the machine with the soft cloth or camel hair brush Daily Preventive Maintenance Requirements Table 4 2 contains the daily preventive maintenance checklist log sheet 1 Remove all 4 particle transfer rollers from the projector and using a damp cloth or cloth with mild soap and water clean all debris from the rollers Insure that the rollers are completely dry before re installing 2 If necessary clean the projection lens using the lens cleaning kit 3 Using the soft cloth carefully wipe the guide rollers see Figure 4 2 4 Remove the gate see Figure 4 2 and clean the rails on both the movable and stationary gate portions thoroughly with a soft cloth and isopropyl alcohol If necessary use a wooden or plastic scraping tool to remove heavy build up Avoid scratching the guide rails with metal objects S
30. loop located on this card locks the internal signals to an external 50 or 60 Hz source The phase locked oscillator is U16 The PTM divides the oscillator output of 192 KHz to 60 Hz and provides a 5096 duty cycle to the comparator of the phase locked loop The PTM divider is under software control and can be adjusted to divide to 50 Hz operation U14 an EPLD is a DRM that uses the phase locked oscillator s output The 192 KHz signal input to the DRM can be multiplied by any value from 00 to 99 This function provides a precise set of frequencies that are stepped from one value to another to ramp motors up and down in speed with linear and consistent accelerations CHRISTIE 3 5 70 Service PM M anual July 1997 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 As noted above the motion of film in the projector is directly controlled in both cine and slew modes by speed control pulses commanded by the CPU and generated from the DRM These pulses control the shutter speed as shown in Figure 5 2 and the Constant Velocity Motor as shown in Figure 5 3 In each case signals are sent to U33 the Tacho circuit to genera
31. of the pulldown sprocket are not damaged and have less than 0 001 run out Realign or replace sprocket as necessary Table 7 14 Image Quality Diagnostic Table Continued 5 It is possible for one of the fuses associated with the Pulldown system to appear good but have too high a resistance to do a proper Pulldown Replace fuses 1 and 3 CHRISTIE INC 35 70 Service PM M anual July 1997 7 Troubleshooting Guide IMAGE QUALITY DIAGNOSTIC TABLE Poor Image Quality CONDITION 3 Projected picture has side weave in excess of 0 15 Verify the edge guides are adjusted properly and have the proper spring tension Adjust if necessary See Section 6 8 4 Poor Image Quality CONDITION 4 Projected picture exhibits ghosting Rotate shutter encoder assembly to eliminate ghosting This is a one time factory adjustment and should not be necessary unless parts associated with the shutter system have been replaced If the shutter ghosting adjustment must be made on a regular basis verify that all mechanical parts are properly tightened A loose coupling or set screw could allow the shutter blade to slip on its shaft and alter the shutter timing Ghosting can also be caused by a failure of the Pulldown system to pull down and register in the allowed time Check the Pulldown system fuses fuses 1 and 3 Verify that the 24 volt and 34 volt supplies are correct while the projector is moving forward in cine mode
32. of these instances CHRISTIE IN C 35 70 Service PM M anual July 1997 2 General Description KeypediED indication The CPU detected an error in the shutter speed C a The Lower Torque arm activated the limit switch 2 The Upper Torque arm activated the limit switch Lc was a pulldown malfunction 4 The Lower Buckle arm is out of position 5 The Upper Buckle arm is out of postion e The CPU detected a constant velocity fault There is EOF sensor tape in the gate o Keypad contol is enabled ee el NET function commands senec function commands function commands FOR Table 2 3 Keypad LED Indicators CHRISTIE IN C 35 70 Service PM M anual July 1997 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 System Status Searching for Cue Parked at Cue Point Stopped Moving Forward at Cine Speed Douser Open Not Ready Table 2 4 System Status Values Moving Forward at or approaching Cine Speed Douser Closed Thus a value of A2 indicates that the pro
33. problems if they occur The constant velocity drive sprocket pulldown and shutter motor systems are controlled by a microprocessor that normally phase locks all rates to the line frequency When the system powers up the processor determines whether the line is at 60 or 50 Hz and sets the proper multiplier to maintain the system clock at 192 KHz Crystal operation may be selected by a jumper plug on the Central Processing Unit Main Logic card CHRISTIE IN C 35 70 Service PM M anual July 1997 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 LEDs on the keys associated with projector commands toggle on to indicate projector action For example if the projector is stopped the light on the STOP key is on Westrex oe e e_ re e e Figure 2 1 Control Panel CHRISTIE IN C 35 70 Service PM M anual July 1997 2 General Description Keypad Input The control panel contains two keypad areas that can be used to communicate to the projector a
34. pulldown with the shutter and looks for the first frame of the show When the first frame is found the douser is enabled and the projector signals the show controller that play is beginning The douser open command may now be issued or if the AUTO DOUSER function is enabled the douser will open automatically 3 seconds into the film The douser closes automatically when it reaches the end of the current show If the next show has not already been identified to the projector the film decelerates to a stop in a smooth linear manner and waits for a command that sets the next show When the next show is identified the projector moves at two times the normal speed 120 fps cues to the CHRISTIE IN C 35 70 Service PM M anual July 1997 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 Monitoring Projector Performance Film advances through the projector in one of two ways In cine motion when a show is playing the projector jerks or pulls a film frame into position synchronized with the c
35. 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 lt CMD C gt 7 CODE C7 ACTION Outputs status over RS 232 interface 5 STATUS Unchanged An example of an output status return value is A2 where A Parked at Cue Point see Table 2 4 2 Show number 2 C8 The CUE Command OP L This operational command causes the projector to position the film at the start of the first show encountered when the projector moves in a forward direction The film advances in the slew mode If the CUE command is entered after the BOF marker in a show has been passed the projector will find the next show on the film this may not be the next show in a programmed sequence A CUE command must be issued prior to the first time a show is played after the system powers up thereafter the projector tracks the start point for every show on the film Do not enter a CUE command if the projector has already encountered the BOF marker of the last show on the film If a CUE command is entered at this point the projector will move forward until the film runs off the reel ENTRY lt CUE gt C8 ACTION Move forward in slew mode at 15 fps until BOF marker of the S next show is located 2 Update frame counter 3
36. that an external 12 or 15 VDC power supply be used to run the motor 2 Check EOF BOF sensor voltage and adjust if necessary See Section 6 2 3 Inspect CV buckle shoes for excessive wear Replace if necessary Yearly Preventive Maintenance Requirements Table 4 6 contains the annual preventive maintenance checklist log sheet Ensure that the coupling between the tacho roller and the tacho generator is secure and there is no slippage between the generator and the roller 2 Check all power supply voltages 5V 15V 34V and 24V 3 Ensure the reeling motor brakes are operating properly in the NOT READY mode and disengaging properly in the READY mode 4 Visually inspect the entire projection system for loose bolts or screws and damaged cables 5 Replace particle transfer rollers to maintain film cleaning effectiveness 6 Clean the back of the projector with the vacuum Preventive Maintenance Requirements for Lamphouse Table 4 7 contains the lamphouse preventive maintenance checklist log sheet The following steps should be performed with the lamp removed whenever the lamphouse bulb is replaced Always verify that the lamp is removed and power to the lamphouse is shut off Failure to do so can result in severe injury Clean lamphouse mirror with tissue paper or optical wipes Be very careful not to scratch the mirrored surface Clean the lamphouse assembly with the vacuum Check the lamp connectors for corrosion and security
37. the projector to high speed forward by pushing the button sequence CMD H 3 Step Description Completed Item Verify that the film accelerates to 120 frames per second in a smooth and linear motion Push the STOP button and after film motion stops push the REV button After film reaches 120 frames per second in the reverse direction push the STOP button Checklist Step Description Completed Item Verify that the film accelerates to 120 frames per second in the reverse direction in a smooth and linear motion Table 7 9 Slew Motion Checklist CHRISTIE INC 35 70 Service PM M anual July 1997 7 Troubleshooting Guide SLEW MOTION DIAGNOSTIC TABLE Film does not ramp smoothly to 120 frames per second CONDITION 1 Film ramps up smoothly to near maximum speed then becomes unstable Ren Verify that the 24VDC voltage at the positive end of C8 of the 2285 card is at the proper value If not repair 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 sw amens een 1 Verify that the Constant Velocity Tach voltage reaches the 2293 card If not repair wiring If condition remains replace the 2293 card Film does not ramp smoothly to 120 frames per second CONDITION 3 Film ramps up smoothly to near maximum speed but then upper or lower limit switch trips syste
38. time display to 1 00 00 00 if desired Enter the INTERLOCK press lt INTLK gt or enter lt HA gt command for the Slave projector Enter the SHOW CONTROL ENABLE lt G9 gt command for both projectors if not already enabled Operation of the projector is automatic 6 Enter a PLAY CURRENT SHOW H1 command from the Master projector or show controller to start The douser can be opened by entering an OPEN DOUSER AND CINE C3 command or automatically if the AUTO DOUSER G3 command has been entered When the EOF tape is detected on the Master both dousers automatically close and the film stops The Master projector then automatically cue s both projectors so that they are ready for the next show Repeat steps 1 to 7 to play the next show Master Motion Controller Operation If the projector is to be used in conjunction with a Master Motion Controller the following steps will need to be performed in addition to steps 1 to 7 in Section 3 3 1 Note that all commands starting with a K must be entered into the Master Motion Controller via the RS 232 communications port 1 2 Enter the CUE lt C8 gt or lt CUE gt command to cue the projector to the beginning of the show Enter the PARK ON CUE lt GD gt command to set the first frame of film in the gate Enter the JAM C9 command to reset the time display to 1 00 00 00 if desired Enter the INTERLOCK press lt INTLK gt or enter lt HA gt com
39. value of 10 on the keypad 2 Hit the ENTER key 3 Adjust R183 so that the upper torque arm sensor voltage as measured from the top of R150 is 0 volts 1 volt This adjusts upper torque arm position 4 Adjust R136 so that the upper torque arm sensor voltage as measured from the top of R149 is O volts 1 volt This adjusts lower torque arm position Repeat Steps 1 4 with speed value inputs of 20 30 40 and 50 5 Enter a speed value of 00 to stop the projector 6 Press the STOP key 7 Enter 00 to change the projector direction to forward 8 Press the STOP key Repeat the above Input sequence using R196 for the upper torque arm and R137 for the lower torque arm Enter the DISPLAY FRAME COUNTER G lt I gt command to return the display to normal Not applicable 1 Entering speed values greater than 50 can cause projector and film damage CHRISTIE INC 35 70 Service PM M anual July 1997 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 STATUS lt CMD G gt 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 Unchanged GA The OUTPUT L
40. 7 5 Theory of Operation Init Hardware Set Time Code Do Init ACIA Pulldn Init Motion Set to Not Ready Pulldown at Pulldown Do Cine Speed not at Pulldn Cine Speed No Frame Cntr Read Marks Frame Cntr Read Marks Status Safety Check Douser Change CV Speed Alarms Timers Keyboard Indicate Fault Set to C d Not Ready omman Execute Figure 5 14 System Software Architecture CHRISTIE INC 35 70 Service PM M anual July 1997 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 General Approach to Adjustments The adjustments and replacement procedures described in this section are ordinarily performed individually as the result of a repair or because a part has been accidentally disturbed The order and grouping of the adjustments in this section represents the typical approach to the projector and is related to the diagnostic approach embodied in the following chapter on troubleshooting The starting point is to ensure that the system will come into a READY s
41. 7 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 The Pulldown Power Amplifier Circuit 2275 The pulldown power amplifier circuit consists of a LM741 operational amplifier followed by an analog amplifier See the pulldown amplifier circuit diagram and component layout in Section 8 11 During final braking and registration the tach signal from the pulldown motor is summed with the pulldown signal to dampen oscillation The overall voltage gain of the power amplifier is slightly over 12 The two circuits are identical in operation differing primarily in their circuit board layout The Pulse Width Modulated Power Amplifier 2285 The 2285 power amplifier see Section 8 13 contains three LMD18200 integrated power switching amplifiers U5 U6 and U7 Their outputs are coupled to the motor through filters formed by L1 L6 and C12 C13 The filters contain the 20KHz switching frequencies to the board and also isolate U5 U7 Photocouplers U1 U4 isolate the power stages from the logic level circuits on the 2293 CPU Card U1 inputs the Pulse Width Modulated signal to U5 U7 while U2 inputs the direction signal U3 and U4 a
42. CHRISTIE INCORPORATED 35 70 Automated Electronic Film Projector Maintenance and Service Manual sia 550 E mden a s Ca dU 714 236 3610 Fax 714 229 3185 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 CH RISTIE 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 Cypress Ca 90630 Telephone 714 236 8610 FAX 714 229 3185 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 For operators and for general information see e Section 2 General Description Section 3 Operating the Projector Section 4 Periodic Maintenance e Section 8 Electronic Circuit Information For a more detailed understanding of the projection syst
43. EMORY INSPECT from a Service Terminal G1 The DISPLAY FRAME COUNTER Command DX This diagnostic command causes the current frame counter value to be displayed on the LED strip ENTRY CMD G lt I gt Gl ACTION Display the current frame counter value 5 STATUS Unchanged CHRISTIE INC 35 70 Service PM M anual July 1997 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 CODE INPUT ACTION 8 STATUS lt CMD G gt 2 G2 1 Select the frame rate e Enter a 2 from the keypad to select 24 frames per second e Enter a5 from the keypad to select 25 frames per second e Enter a3 from the keypad to select 30 frames per second e Enter a 4 from the keypad to select 48 frames per second e Enter a 6 from the keypad to select 60 frames per second 2 Select the number of film perfs e Enter a 5 from the keypad to select 5 perfs For models equipped with 8 perf capabilities enter an 8 from the keypad to select 8 perfs Reset frame rate and number of perfs 2 Display frame rate in the second and third last positions on the LED display as shown in Figure 2 3 3 Display number of perfs in the last position on the LED display as shown in Figure 2 3
44. O FRAME Command DX L This diagnostic command triggers the projector to move the film to the point in the show that was previously set with the SET GOTO command see Section 0 ENTRY CODE ACTION S STATUS lt CMD H gt 6 H6 1 Move forward or backward at 120 fps until the goto point specified with the SET GOTO command is reached 2 Update frame counter 3 Park Set to 8 while searching for goto point Set to 0 while stopped at goto point H7 The CUE NEXT Command OP L The CUE NEXT operational command differs from the CUE command see Section 0 in the way the projector finds the show that is to be cued CUE NEXT cues the projector in front of the next show in the pre programmed series of shows on the film The CUE command cues the projector to the next show located when moving the film in a forward direction CHRISTIE INC 35 70 Service PM M anual July 1997 ENTRY CODE ACTION S STATUS 3 Operating the Projector lt CMD H gt 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 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 The user may enter a new next show number
45. OG Command DX This diagnostic command is used to report the last five commands sent to the projector over the RS 232 communication port The status is output on the RS 232 port to the show controller or the service terminal These commands are recorded only when the projector is in READY mode The commands can be reported only when the projector is in the NOT READY mode ENTRY CODE ACTIO NS STATUS CMD G lt A gt GA The last five commands sent to the projector are output across the RS 232 communication port provided that the projector is in NOT READY The commands appear in the format mm ss ff cmd resp where mm SS lt gt lt gt minutes seconds frame count within the second command response To illustrate this format 03 57 14 H8 2 indicates that at 3 minutes 57 seconds the 14th frame the command H8 was received and the response 2 was made Unchanged CHRISTIE INC 35 70 Service PM M anual July 1997 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 CMD G lt B gt CopE GB ACTIO The current timecode is output across the RS 232 NS communication port in the counter format hh mmz ss ff see Section 0 STATUS Unch
46. OP STOP CO FORWA FORWARD RD C1 REVERS REVERSE E C2 OPEN DOUSER amp CINE CLOSE DOUSER amp SLEW SET SET LOOP LOOP C6 ov OUTPUT STATUS READY READY e READY DISPLAY REEL COUNTER NOT NOT READY RDY K m CD MANUAL SHOW CONTROLLER LOG SET REEL COUNTER AUTO CYCLE TEST CF samo _ m esos 07 SET FRAME COUNTER CHRISTIE IN C Service PM M anual July 1997 Appendix A RS 232 Command Protocol ne serwexrsuow m nr HC HC HE HF G0 G1 G2 G3 G4 G5 G6 G7 G8 G9 GA GB GC GD GE GF SET FREQUENCY HA INTERLOCK DISPLAY ERROR m ad READY NN NOT READY serwaxsmows f evor DISPLAY FRAME COUNTER ca SELECT FRAME RATES __ _ avropousee oa LOAD REEL COUNTER es armoo es ovreur cur tares summer Gs uevenseTESTMODE co _ SHOW CONTROL ENABLE formo cm mwecopemQUmY wes ENGAGESOUND SOFWARE VERSION CHRISTIE IN C Service PM M anual July 1997 Appendix A RS 232 Command Protocol CHRISTIE IN C Service PM M anual July 1997
47. OR AMPLIFIER PPER TORQUE MOTOR BRAKE AND PPER TORQUE MOTOR PPER TORQUE ARM AND OPTICAL MBLY PPER ARM LIMIT SWITCH PPER ARM TENSION SPRING PPER TACHO GENERATOR 285 SHUTTER MOTOR AMPLIFIER PPER BUCKLE LIMIT SWITCH 276 FRAMING SWITCH PPER C V PULLEY AND BELT 2293 MAIN CPU CARD 70mm DTS MAGNETIC HEAD MOUNTING ccc t2 c e AREA 31 2269 SHUTTER ENCODER SHUTTER MOTOR 2275 PULL DOWN AMPLIFIER CONSTANT VELOCITY C V MOTOR 2269 C V MOTOR ENCODER DOUSER INTERLOCK RELAY LOWER BUCKLE LIMIT SWITCH PULL DOWN MOTOR 2285 C V MOTOR AMPLIFIER LOWER C V PULLEY AND BELT DOUSER RELAY XLR AUDIO CONNECTOR 35mm DTS MOUNTING AREA 2273 BI PHASE INTERFACE CARD MAIN CONNECTOR PANEL LOWERTORQUE MOTOR LOWER TACHO GENERATOR LOWER TORQUE MOTOR BRAKE AND PULLEY 32 33 34 LOWER ARM LIMIT SWITCH 2285 LOWER TORQUE MOTOR AMPLIFIER LOWER TORQUE ARM AND OPTICAL ASSEMBLY 35 LOWER ARM TENSION SPRING Figure 4 1 Maintenance Locations on Projector Mechanical Side 4 Periodic Maintenance UPPER REEL UPPER TORQUE ARM ROLLER UPPER TACHO GENERATOR UPPER PARTICLE TRANSFER OLLERS ROLLER 70mm MAGNETIC HEAD FRAMING SWITCH UPPER BUCKLE PLATE S KON MOVABLE GATE 10 LENS MOUNT M C ewe d 11 WEAVE GUIDES J 4 j 12 GATE GLASS Se 13 GATE PIN iu 14 STATIONARY GATE aA N 1 15 PULL DOWN SPROCKET 3 16 2268 PULL DOWN SENSOR ue tU D __ _ 17 LOWER C V BUCKLE PLATE
48. Sound Heads The adjustments of sound heads is not covered as a part of this manual Refer to head manufacturer for alignment procedures CHRISTIE 35 70 Service PM M anual March 1997 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 However the procedures outlined in this section should identify the problem area Checklists and troubleshooting tables are provided for the following areas e Visual Checklist e Power On Checklist and Diagnostic Table e Ready Checklist and Diagnostic Table e Slew Motion Checklist and Diagnostic Table e Cine Motion Checklist and Diagnostic Table e Image Quality Checklist and Diagnostic Table Use of the Troubleshooting Tables This section presents a series of operational checklists and troubleshooting tables They have been created to be used as part of a deliberate organized approach to problem isolation This approach consists of starting with the projector turned off performing visual diagnostic checks threading the projector with film and performing operational checks A turn on and operating s
49. TIE INC 35 70 Service PM M anual July 1997 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 NOT RDY gt and 9 buttons should be on The shutter will not be rotating at this time Be sure film is properly mounted and threaded Enter the film rate at which the projector is to operate See Section 2 8 36 Press the READY key and observe the following sequence Refer to the operating commands outlined in Section 2 8 1 The projector performs a loop set and the Pulldown motor system is tested The LED on the SET LOOP gt key will go on Simultaneously the brake solenoids release and the torque arms move into position The constant velocity sprocket advances one frame and the CV motor system is tested The shutter comes up to speed and is tested The STOP and READY go on and the SET LOOP gt LED goes off Enter a CUE press lt CUE gt command The film moves forward in slew motion at 15 fps until the BOF tape is found AAR wD 7 Enter a SET CURRENT SHOW lt gt lt 5 gt command and indicate which show the projector is cued to The defau
50. Verify that the connections associated with the Pulldown motor are good Replace the 2275 card Check the brushes in the Pulldown motor Table 7 14 Image Quality Diagnostic Table Continued EN HEN EN NN E CHRISTIE INC 35 70 Service PM M anual July 1997 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 e Parts List e Circuit Diagram optional e Component Layout optional The following circuits are described in this section e 0207 Torque Arm Optical Pot Assembly e 0208 Optical Sensor Assembly e 0300 Sync Separator e 1008 Frame Counter Display e 1034 Power Supply Assembly e 2262 Bi Level Interface e 2267 Keypad e 2268 Pulldown Sensor e 2260 Shutter and CV Encoder e 2273 Pulse Drive Amplifier e 2275 Pulldown Amplifier e 2276 Framing Control e 2293 Central Processing Unit e 2285 PWM Amplifier e 5051 70mm BOF EOF Sensor e 5052 35mm BOF EOF Sensor In addition miscellaneous diagrams and parts lists that are not necessarily associated with a specific card are grouped at the end of this chapter e 35 70 System Interconnect Diagrams e Film Velocity Diagram e 35 70 Timing Diagram e Master Slave Interconnect Diagram CHRISTIE INC 35 70 Service PM M anual July 1997 Appendix A RS 232 Command Protocol 35 70 COMMAND SUMMARY ST
51. ain Logic card and displays it in the rightmost two digits of the corresponding numeric displays on the operator control consoles The projector must be in READY mode if the projector is in NOT READY mode this command will release the upper torque motor brake see Section 0 ENTRY CODE ACTION STATUS lt CMD H gt lt CMD C gt READY mode HC Displays pulldown gain Not applicable HC NOT RDY The BRAKE RELEASE Command DX This diagnostic command is used to release the upper torque motor brake to allow for easier film threading The projector must be in NOT READY mode or this command will display the pulldown gain see Section 0 ENTRY CODE ACTION S STATUS lt CMD H gt CMD C NOT READY mode HC Releases upper brake Not applicable HD The SET MAXIMUM NUMBER OF SHOWS Command OP This operational command enables the user to program into the projector the maximum number of shows on the current reel of film The command is used in conjunction with the commands AUTO LOG See Section 0 MANUAL LOG See Section 0 CYCLE TEST See Section 0 SET CURRENT SHOW See Section 0 and SET NEXT SHOW See Section 0 If this command is not used the default maximum number of shows is set to 1 CHRISTIE INC 35 70 Service PM M anual July 1997 ENTRY CODE INPUT ACTION S STATUS 3 Operating the Projector H D HD Number of shows on reel must be from 1 6
52. aintenance Checklist Log Sheet CHRIS TIE 35 70 Projector Semiannual Preventive Maintenance Log Sheet Year 19 Interval 1 Check brushes on servo motors and Pulldown motor Check BOF EOF sensor voltage Check CV Buckle shoes for wear Check brushes on servo motors and Pulldown motor Check BOF EOF sensor voltage Check CV Buckle shoes for wear Table 4 5 Semiannual Preventive Maintenance Checklist Log Sheet CHRISTIE IN C 35 70 Service PM M anual July 1997 4 Periodic Maintenance CHRIS TIE 35 70 Projector Annual Preventive Maintenance Log Sheet Year Action Required Date Performed Check coupling between tacho roller and tacho generator a vetito Goose bola NN Table 4 6 Annual Preventive Maintenance Checklist Log Sheet CHRISTIE 35 70 Projector Lamphouse Preventive Maintenance Log Sheet Perform Every Time Lamphouse Bulb is Replaced Lamphouse Hour Meter Reading Action Required Date Performed Clean lamphouse mirror Vacuum lamphouse assembly Check douser assembly Check cooling blowers Table 4 7 Lamphouse Preventive Maintenance Checklist Log Sheet CHRISTIE IN C 35 70 Service PM M anual July 1997 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
53. alog speed control voltage An offset derived from the plus voltage is also summed by U44 This speed control signal is compared to the CV tachometer signal by U23 and the absolute value of the error signal is derived by U23 in combination with U28 This unidirectional signal is converted to a PWM signal by comparator U12 and sent to the Constant Velocity PWM Amplifier 2285 Comparator U38 derives a direction signal which is also sent to the PWM Amplifier The current limiting signal from the power amplifier turns on the photocoupler U11 which limits the voltage sent to the pulse width modulator U12 In a manner similar to the case of the shutter motor control a signal representing the long term position error is also summed into U23 along with the speed control voltage and the tachometer signal This signal is derived from the CV encoder pulses and the DRM speed pulses using the SERVO9 EPLD U15 as an up down counter The eight bit output of this counter is converted into an analog voltage by DAC 052 and amplified by U18 before being summed into U23 To CHRISTIE INC 35 70 Service PM M anual July 1997 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 va
54. ame 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 seven segment 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 Framing Board 2276 The 2276 Framing Board see also Section 8 12 selects consecutive phototransistors on the pulldown encoder to allow convenient picture framing by the operator System Software This software theory of operation section offers a deeper appreciation of the basic structure and features of the software Some of the functions and features described here may not be pertinent to the current application of the electronic projector however future applications may make use of them A fuller understanding of the software requires familiarity with the 6809 assembly language code The software that governs the electronic projector system controls the various hardware elements to produce the desired film motion while handling system communication and fault detection The interweaving of event driven and real time interrupt routines with background routines for less time critical functions provides the speed required for projector operation along with the robustness of full command
55. and Electronic Adjustments for instructions on adjustment and component replacement VISUAL CHECKLIST At the film path side with film not mounted A Numbers in parentheses refer to details in Figure 4 2 Checklist Step Description Completed Item Check that the Upper and Lower Torque Arms 2 24 move freely and smoothly The click from the limit switch should be audible near the relaxed end of the arm motion Verify that all Guide Rollers rotate freely with a minimum of lateral play Note that the Torque Arm Rollers 2 24 rotate freely and have a wide range of lateral motion Verify Upper and Lower Loop Chutes are positioned correctly and are not loose A5 Verify Upper and Lower Feed Sprocket Shoes 6 17 move freely Buckle switch operation click should be heard close to the engaged position Verify Lower Constant Velocity Sprocket 19 moves freely without lateral play Verify that Upper and Lower Sprockets move in unison A3 Verify Upper Constant Velocity Sprocket 27 rotates properly and associated CV pad shoes have minimal end play Table 7 2 Visual Checklist Part A Projector Film Side CHRISTIE 35 70 Service PM M anual July 1997 7 Troubleshooting Guide VISUAL CHECKLIST At the projector head Numbers in parentheses refer to details in Figure 4 1 Verify that connectors to all boards are tight RR Gently verify Upper Torque Arm Sensor and Disk 4 are tight LERNEN Gently verify Lower To
56. anged GD The PARK ON Command OP This command is used to park the BOF sensor tape in the gate The use of this command is associated with operating the projector in the Master or Slave mode and can be issued after a CUE command See Section 2 8 9 has been issued By parking the BOF sensor tape in the gate proper frame synchronization between the Master and Slave projector is achieved ENTRY CMD G D CopE GD ACTIO Cues film forward and parks BOF sensor tape in gate NS STATUS Set to A while parked at CUE point GE The ENGAGE SOUND Command OP This command is used to engage the sound head lifter solenoid This command is mainly used when projectors are used in the Master Slave configuration ENTRY CMD G E Cope GE ACTIO Engages sound head lifter solenoid NS STATUS Unchanged CHRISTIE INC 35 70 Service PM M anual July 1997 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 lt CMD G gt lt F gt CODE GF ACTION Returns software version number S STATUS Unchanged CHRISTIE INC 35 70 Service PM M anual July 1997 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 p
57. at it is issued through the serial port via a show controller The format of the SHOW CONTROLLER LOG command from the show controller differs from keypad operation in that the CLEAR command is replaced with a hex 3A or the ASCII symbol 27 and the ENTER command is replaced with a hex 3B or the ASCII symbol Also leading zeroes may be omitted when data is entered from the show controller The entry from a show controller over the serial port for the example shown in Figure 2 2 and Table 2 6 would be CD11010000 1044316 1020000 1025000 1030000 1035000 CE The SET REEL COUNTER Command DX This diagnostic command allows the user to manually change the value of the reel counter ENTRY C E CODE INPUT Desired reel counter value in the counter format hh mmz ss ff see Section 0 ACTION Sets the reel counter to the new value S STATUS Unchanged CHRISTIE IN C 35 70 Service PM M anual July 1997 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 The number of cycled shows is equal to th
58. back on line at a time starting with the Lower Torque Follow with the Shutter the Upper Torque the Constant Velocity and finally the Pulldown replacing the required fuses as you progress After the Lower Torque system is on line the READY state must be achieved before the next four systems can become operational Verify that all buckle and limit switches are inactive or the projector will not go into READY state CHRISTIE INC 35 70 Service PM M anual July 1997 7 Troubleshooting Guide 1 SW 34 8A Pulldown Amp Fast Blow VDC 2 SW 24 8A C V Torque Fast Blow VDC 3 SW 24 8A Pulldown Amp Fast Blow VDC 424 VDC 4A C V Torque Fast Blow Shutter Table 7 1 35 70 Fuse Block Identification The corrective procedures in the checklist allow for recalibration of various electronic cards This should be necessary only in cases where cards have been replaced or unnecessary adjustments have previously been made All electrical adjustments are factory set additional adjustment should not be required especially on a projector that has been operating This troubleshooting procedure goes only to the card level Defective cards should be returned to CH RIS TIE for repair General Description of the Troubleshooting Approach Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 This step is described in Section 0 With power turned off and no film on the machine perform the General Visual Checklists designed to identify any o
59. clean side JA 0 2 necessary wash the element in warm 120 or FA M less water solution with household detergent ee Rinse thoroughly Examine pleated media carefully to determine that the media has not been damaged e Reassemble the filter canister in reverse order using a new filter 3 Remove all four cleaner brushes with snap ring pliers and clean the brushes with compressed air outside of the projection booth 4 Visually inspect the entire projection system for loose connections Figure 4 3 Air Filter Canisters Replace the element for ANY of the following reasons Pleated media is cut torn worn or uncleanable Metal end caps if so equipped are bent out of flat Perforated metal bent into pleated media Gasket is cut deformed or damaged in any manner CHRISTIE IN C 35 70 Service PM M anual July 1997 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 e When reinstalling old brushes for ANY motor ensure that the brushes are installed in their original location and in the same direction e installation of new pulldown motor brushes requires a burn in period of at least 24 hours The pulldown motor must be toggled between forward and reverse every hour to properly wear in the brushes and to prevent jitter It is recommended
60. cratches cause dirt to build up faster in the gate degrading picture quality 4 While the gate is out clean the trap see Figure 4 2 using the soft cloth Avoid areas near the BOF and EOF sensors As with the removable gate keep dust and debris from entering the clearance spaces Be certain that the guide rails are absolutely clean 5 The BOF and EOF sensors are optical devices Therefore they must be cared for just as the rest of the optics Due to their delicacy they must be cleaned gently with a soft camel hair brush Dust and vacuum the film side of the projector to remove any film debris Check the two buckle trips in the film path see Figure 4 2 for proper operation 8 Check the sprockets see Figure 4 2 or smooth movement Since the two constant velocity sprockets are driven together turn either one to check them both The pulldown sprocket see Figure 4 2 is directly driven and does not need to be checked SO CHRISTIE IN C 35 70 Service PM M anual July 1997 CHRISTIE IN C 35 70 Service PM M anual July 1997 ANAM A e Oooo ro c capa lt UR n n E 4 Periodic Maintenance PPER TOURQUE MOT
61. ctivate bilevel drivers Q2 and Q3 Q1 is used to activate photocouplers on the 2293 card that limit current by decreasing the input pulse width Q4 reduces and regulates the 24 volt supply to 5 volts as required by U1 U5 U6 and U7 This supply maintains isolation between signal and power level circuits Table 5 13 PWM Amplifier Bilevel Outputs The DC Power Supplies The projector power supply see Section 8 4 has regulated outputs The high power outputs 34 volts and 24 volts The voltages used by the pulldown motor are 24 volts and 34 volts these are switched by the READY relay which is part of the power supply The constant velocity shutter and torque motors use 24 volts This voltage is switched by another READY relay contact The regulated low power supplies 5 volts 15 volts and 15 volts for the CPU and other logic devices The Keypad 2267 The keypad consists of the keyboard card card 2267 See the keyboard component layout and circuit diagram in Section 8 8 The keyboard card is a 4 x 8 switch matrix The fifth column and the right hand four keys of the bottom row are not used The four rows of the matrix are scanned by strobes from multiplexer U46 on the CPU Main Logic card Each column is monitored for a switch closure by the PIA U37 on the CPU Main Logic card Latches U1 through U4 control the LED indicators on each key CHRISTIE INC 35 70 Service PM M anual July 1997 5 Theory of Operation The Fr
62. d the sprocket should resist motion in either direction Verify that the Pulldown also advances film one frame and locks Pulling the film loops or turning the pulldown sprocket by hand will verify the pulldown is locked 7 Verify that the shutter comes up to speed Table 7 7 READY Checklist CHRISTIE INC 35 70 Service P M M anual July 1997 7 Troubleshooting Guide READY DIAGNOSTIC TABLE KENNEN E 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 LED is on CONDITION 2 LED 5 is on 75 If LED 5 is illuminated close Upper Buckle plate press 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 Table 7 8 READY Diagnostic Table CHRISTIE INC 35 70 Service PM M anual July 1997 7 Troubleshooting Guide READY DIAGNOSTIC TABLE LED is on CONDITION 3 LED 1 is on If LED 1 is illuminated c
63. d verify quadrature If signals are not present or are not in quadrature determine wiring fault or defective encoder and repair or replace If shutter is not moving continue to step 4 4 Verify the reference frequency at TP33 of the 2293 card This square wave should have a frequency of 192 KHz If not determine wiring fault or defective 2293 card repair or replace 5 Disconnect J2 from the 2285 card and measure the resistance from J2 pin 4 to J2 pin 3 This should be the shutter motor armature and should measure about one ohm Reconnect J2 Determine wiring fault or defective motor repair or replace Table 7 8 READY Diagnostic Table Continued READY DIAGNOSTIC TABLE Shutter Failure 7 27 CONDITION 2 The Shutter movement is erratic a sound is heard that indicates the Shutter is hunting This may indicate worn brushes in the Shutter motor Replace brushes or motor nd Erratic Shutter movement may also be caused by an unstable 192 KHz m 3 1 2 reference from the 2293 card If required adjust R20 the phase locked loop circuit on the 2293 card Note that this adjustment will have no effect if running in crystal lock mode Table 7 8 READY Diagnostic Table Continued CHRISTIE INC 35 70 Service PM M anual July 1997 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 A Command
64. e this command instead of the FORWARD command to operate projectors configured for MASTER SLAVE operation ENTRY CODE ACTION S STATUS CMD H 1 HI Play current show 2 Stop at tail of show 3 Wait for SET NEXT SHOW command see Section 0 Set to 1 while moving to first frame Set to 3 while playing douser open Set to 0 when stopped at end of show H2 The SET GOTO Command DX This diagnostic command allows the user to enter a goto point for a subsequent GOTO action The goto point must be a frame counter value in the current show This command is used for motion programming and is not a normal part of system operations ENTRY CODE INPUT ACTION S STATUS CMD H 2 H2 1 Enter the desired goto point with the numeric portion of the keypad This is entered in the counter format A mm ss ff see Section 0 2 Hit the ENTER key Load the goto point value Unchanged CHRISTIE INC 35 70 Service PM M anual July 1997 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 ACTION S STATUS lt CMD H gt 3 H3 Move film forward at 120 fps Set to 8 H4 The SET FRAME COUNTER Command DX This diagnostic command allows the user
65. e value set with the SET MAXIMUM SHOWS command see Section 0 This sequence repeats until the projector is told to perform some other type of movement The test ends when a second CYCLE TEST command is entered The current cycle completes and the system returns to the start point of the first show A STOP command pauses the cycle a FORWARD or REVERSE command resumes operation ENTRY AUTO CODE CF ACTION l1 Play the show in cine mode 8 2 Cue to the next show in sequence 3 Park Repeats actions 1 3 until interrupted STATUS Setto A while parked at cue point set to 1 while moving to first frame set to 3 while playing set to 0 when stopped at end of show set to 8 while searching for BOF marker The above status sequence repeats until the cycle ends H0 The CUE ADVANCE Command OP L This operational command is identical to the CUE sequence described in Section 0 except that film advances in the cine mode ENTRY lt CMD H gt lt 0 gt CopE ACTION Move forward at 15 fps in cine mode until BOF marker is S located 2 Update frame counter 3 Park at BOF mark STATUS Set to 8 while searching for BOF marker set to A while parked at cue point CHRISTIE INC 35 70 Service PM M anual July 1997 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 Us
66. eceipt of the projector at the final destination unpack as follows 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 Remove any package accessories connectors cables power supply keypad etc Check all items against packing list Installation 1 Prepare the floor area required for projector installation The selected floor area should be of extremely solid construction to minimize transmission of floor vibration to projection equipment 2 When the projector is supplied without a lamphouse attach the projector with the four bolts supplied to the lamphouse base Refer to the lamphouse manual for physical mounting instructions for the lamphouse 3 Electrical connection for the 35 70 Projector consists of the following connections and cables e Power cable from power supply to projector head P N EC00215 39 e Communications cable from control keypad to projector head P N EC00215 41 e Power cables for blower motor and power supply P N EC00215 35 37 e Douserrelay connection via P15 e 5 232 communication connections via P18 and J25 e BI Phase input connections via P17 e BI Phase output connections via J13 e SYNC input via J11
67. ed for this command to take effect if the projector status is not equal to 1 the OPEN DOUSER command is ignored ENTRY lt CMD C gt lt 3 gt CODE ACTION Open the douser and put projector into cine mode 8 STATUS Set to 3 C4 The CLOSE DOUSER AND SLEW Command OP This operational command closes the douser The douser also closes automatically when the EOF marker is detected Since the douser is open only when the film is moving at cine speed a CLOSE DOUSER command has no effect unless the status value is 3 ENTRY lt CMD C gt lt 4 gt CopE C4 ACTION Close the douser and put the projector into slew mode S STATUS Set to 1 C5 The CLEAR CUES Command OP This operational command is used to erase all previously programmed BOF and EOF cue points ENTRY lt CMD C gt 5 CoDE C5 ACTION _ Erases pre programmed cue points for all shows 8 STATUS Unchanged C6 The AUTO LOG Command OP This operational command causes the projector to do a normal CUE and then high speed forward to the end of the reel logging EOF and BOF tapes as it moves The REEL TIMES are displayed logged and latched so that they may be recorded manually if desired If fewer than the maximum shows are to be programmed the STOP button terminates the command To perform auto logging the projector must be in the READY mode and the film must be loaded in the projector so that the BOF tape for Show 1 is above the gate or on the su
68. ee Section 0 normally shows the frame counter See Sections 0 and 0 for discussions of changing this display to and from the reel counter value An example of reel and frame positions is shown in Table 2 1 For simplification it is assumed that the BOF for Show 1 and the start of the reel are at the same position Using the figures from that example if the reel counter and frame counter were compared at the point that is 2 minutes 37 seconds and 15 frames into Show 2 their values would be Reel Counter 01 06 55 19 3 52 14 0 16 20 2 37 15 Frame Counter 01 02 37 15 Reel Contents Length Reel Counter Frame Counter Start End Start End Show 1 00 03 52 14 01 00 00 00 01 00 00 00 hh mm ss ff 01 03 52 14 01 03 52 14 Separation between shows 500 frames 01 03 52 14 01 03 52 14 from EOF 1 to BOF 2 00 00 16 20 01 04 09 04 01 04 09 04 Show 2 00 04 27 02 01 04 09 24 01 00 00 00 hh mm ss ff 01 08 36 26 01 04 27 02 Table 2 1 Reel Counter and Frame Counter Normal Operation When operating normally the projector is a completely automatic unit once loaded with film and initially framed it requires no operator The projector automatically sets the loop size reframes the film in the gate cues to at the head of the desired show and waits for a command that will cause the projector to play the show When that command is re ceived the projector accelerates the film to cine speed in a smooth linear manner synchronizes the
69. em see Section 5 Theory of Operation Section 8 Electronic Circuit Information Before performing adjustments and periodic maintenance during normal operation see e Section 6 Mechanical and Electronic Adjustments Section 7 Troubleshooting Guide Section 8 Electronic Circuit Information Additional reference information is contained in the appendices CHRISTIE INC 35 70 Service PM M anual March 1997 2 General Description GENERAL DESCRIPTION The 35 70 Automated Film Projector is a state of the art projector designed for the demanding requirements of high reality 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 Using advanced servomechanisms augmented by microprocessor control the projector handles film so precisely that print life is greatly extended Quality projected image full external control and the reliability to operate day after day month after month are the marks of the 35 70 projector The 35 70 Automated Film Projector can be used stand alone interlocked or used with a compatible show controller The operation of the show controller except as it interfaces directly with the 35 70 projection system is not covered in this manual The projector can operate at speeds of 24 25 30 48 or 60 frames per second and can be configured to use 35 m
70. ence of commands to program the shows from the Sample Log Sheet in Figure 2 2 C HA fl Snletttry is had Ipfe sS B7 RoMe Mtern When the displayed value is correct press ENTER July 1997 2 General Description Specify Show Cowboy 1 01135509 EOF time for Desert 01000000 BOF time for Cowboy Incorrect ENTER Accept displayed value CLEAR 01044316 EOF time for Cowboy 1 01 13 55 08 ae EOF time for esert ENTER Accept displayed value 15 ENTER Accept corrected value 6 01050000 BOF time for Cowboy 2 16 01140022 BOF time for Cactus lt ENTER gt Accept displayed value 17 ENTER Accept displayed value 8 01091710 EOF time for Cowboy 2 18 01163400 EOF time for Cactus 9 ENTER Accept displayed value 19 ENTER Accept displayed value 01092126 BOF time for Desert 20 CLEAR Signify end of film and exit ENTER Accept displayed value command sequence display shows current film position Table 2 6 Sample Command Sequence for Manual Logging The MANUAL LOG command can also be used to display and check the show lengths that have been entered Enter the C D command followed by a J to indicate Show 1 then press ENTER to step through the entire set of BOF and EOF reel times BOF and EOF values are not changed CD The SHOW CONTROLLER LOG Command DX The function of this diagnostic command is the same as the MANUAL LOG command except th
71. ent of the BOF tape can be calculated by multiplying the frame rate by 3 This will give the number of frame position before first frame of picture for the BOF tape CHRISTIE INC 35 70 Service PM M anual July 1997 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 7596 full For 35 millimeter film thread the film so that there are 20 frames plus 1 frame for every 50 feet of projector to screen distance of film between the aperture opening in the gate and the DTS sound head Setting the loop correctly is important in order to maintain proper sound to picture synchronization After the film has been threaded set upper and lower reel tension so the torque arms are approximately in their center positions Figure 3 1 EP 35 70 Projector Threading Diagrams 35mm Film Threading 70mm Film Threading 70mm Film Threading With DTS head With DTS Head With Magnetic Head CHRIS
72. enter 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 Monitor output voltage from the optical pot Verify range of 5 to 5 volts as arm is moved to its extremes zero volts should be near the center of travel Readjust if necessary Measure the output voltage from the lower tacho generator This should be approximately 3 0 volts with the projector running in REWIND Replace generator if necessary If the LED still remains lit the 2267 keypad or the 2293 CPU Main Logic card could be defective Repair or replace as necessary 4 LED is on CONDITION 4 LED 2is on If LED 2 is illuminated center the Upper 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 Monitor output voltage from the optical pot Verify range of 5 to 5 volts as arm is moved to its extremes zero volts should be near the center of travel Readjust if necessary 4 Measure the output voltage from the upper tacho generator This should be approximately 3 volts with the projector running in REWIND Replace generator if necessary 5 If the LED still remains lit the 2267 keypad or the 2293 CPU Main Logic card co
73. equence requires the technician to observe a sequence of projector operations continuing until an abnormal condition occurs For each observed abnormal condition an associated table isolates the particular failures or mis adjustments that can cause the condition Repair or adjustment is described to allow the technician to repeat the sequence progressing to the next abnormal condition This approach has the advantage of being effective in the case of multiple failures and of making the most basic corrections first in the sequence The tables have been arranged to be used as a checklist and data table While experienced technicians will often attempt to short cut the procedure or perform it by memory the most effective approach is to copy this section of the manual and use it as a checklist for troubleshooting and then retain it as part of the failure history of the projector at least until sufficient proper operation shows that the repair is truly verified These checklists should be performed as part of the technician s training on machines that are known to be operating correctly Familiarity with the visual conditions the amount of play in mechanical systems and the proper speed of operations is essential to the diagnostic process In a case where multiple failures are suspected remove the four fuses associated with the drive motor systems fuses 1 to 4 See Table 7 1 for fuse block identification Start through the checklist and bring one system
74. er CHRISTIE 35 70 Service PM M anual March 1997 9 10 6 Mechanical and Electronic Adjustments f Issue a REVERSE TEST MODE lt G gt lt 8 gt 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 Reattach the spring to the torque arm Replace the back panel of the projector Electrical Adjustments The initial settings of pots R136 R137 R183 and R196 on the 2293 CPU card are set for 11 turns clockwise after adjusting the pots completely counter clockwise 2 3 COND t 10 11 With the projector powered up and in READY enter the REVERSE TEST MODE lt G gt lt 8 gt command Enter a speed value of 10 on the keypad Adjust R183 so that the upper torque arm sensor voltage as measured from the top of R150 is 0 volts 1 volt This adjusts upper torque arm position Adjust R136 so that the upper torque arm sensor voltage as measured from the top of R149 is 0 volts 1 volt This adjusts lower torque arm position Repeat steps 3 5 with speed values of 20 30 40 50 60 70 and 80 Enter a speed value of 00 to stop the projector Press the STOP button Enter 00 to change the projector direc
75. es Loosen both the upper and lower C V sprocket film stripper posts Remove the upper and lower C V sprocket knobs and sprockets Install a C V shaft spacer 35mm C V sprocket and 35mm C V sprocket knob on both the upper and lower C V sprocket shafts Insure that the allen set screws used to hold the sprockets and knobs are tightened against the flats on the shafts Install the 35mm C V sprocket pad shoes on the upper and lower C V sprockets Insure that the gap between the Delron pad and the sprocket is approximately equal to the thickness of two pieces of film Rotate the upper and lower film stripper posts so that the stripping bar is pointed towards the sprocket and the post is not touching the sprocket teeth Secure the post Remove the movable gate using the two thumb screws Disconnect the EOF BOF sensor cable and remove the fixed gate Install the 35mm fixed gate threading the EOF BOF sensor cable above the pull down sprocket Reconnect the cable and insure that the cable is not coming in contact with the sprocket Install the movable 35mm gate Remove the 70mm steel upper buckle plate and install the 35mm buckle plate Secure the plate such that it does not interfere with the opening and closing of the gate Minor adjustments may need to be made to the gate assembly to minimize film pinching Refer to Section 6 8 To convert the projector from 35mm to 70mm follow the above steps removing all spacers and using 70mm parts
76. f 1 is known to be out of adjustment 1 After powering up the projector and putting it into READY mode enter the PULLDOWN GAIN DISPLAY lt H gt lt C gt command and note the gain value indicated by the two rightmost digits 2 Runthe projector in CINE FORWARD mode and adjust VR1 until the gain value is equal to the value noted in step 1 Note that this adjustment does not have to be precise in order for the projector to operate correctly 3 Enter the DISPLAY FRAME COUNTER lt G gt lt 1 gt command to return the display to normal Film Gate Adjustments Pulldown Sprocket In Out Adjustment The adjustment of the pulldown sprocket has been preset during manufacturing Slip the sprocket onto the shaft until it seats onto the Pulldown Encoder disc The outer edge of the sprocket will be adjusted to within 0 003 inches 0 01 mm from the outer edge of the rail on the fixed film gate Movable Gate Stop Adjustment The gate stop can be moved in or out by first back threading the 4 20 socket cap screw then adjusting the stop limit set screws for the desired gap Verify that when the adjustment is complete the film is not being pinched in the gate and the 14 20 screw is tight Movable Gate Spring Tension Adjustment This adjustment must be made while the projector is running 1 Load the film and adjust the focus Each gate shoe has two 2 4 40 socket cap screws with which the pressure on the film through the aperture can be
77. he base side CHRISTIE 35 70 Service PM M anual March 1997 i eS 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 TP7 TP5 VR6 VR7 6 144MHz TP4 Figure 6 1 BOF and EOF Adjustments Connect an oscilloscope or voltmeter to test point TP7 using TP4 as a ground reference See Figure 6 1 If using an oscilloscope set it for 1 millisecond per division horizontally and 1 0 volts per division vertically Set the trigger to automatic If using a voltmeter set the scale to 20 Volts To adjust the BOF sensor voltage adjust VR7 for a level of 2 0 Volts Move the test probe to TP5 To adjust the EOF sensor voltage adjust VR6 for a level of 2 0 Volts The trip point for the sensors is at 5 Volts When the sensors see the reflection from the tape the voltage is near 15 Volts depending on the tape reflectivity Reeling System Adjustment The torque arm position is monitored by an optical potentiometer consisting of an infrared LED and a phototransistor A
78. he pulldown is given below Film must be mounted for this adjustment 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 Apply power to the lamphouse strike the lamp and power the projector Enter a READY command hit the READY key Slightly loosen the two screws securing the pulldown sensor card Enter a FORWARD command the FOR key and monitor the waveform on the scope If the waveform is as shown in Figure 6 4 a or 6 4 b move the sensor card until the waveform more closely matches the one shown in Figure 6 4 c For this adjustment the sensor card should be moved in a horizontal direction only When the waveform is correct monitor the picture for jitter You may have to fine tune the adjustment to minimize the jitter The resultant scope waveform may not conform exactly to the waveform shown in Figure 6 4 c Tighten the two screws securing the sensor card CHRISTIE 35 70 Service PM M anual March 1997 6 Mechanical and Electronic Adjustments
79. illimeter or 70 millimeter film The projector is a single unit that attaches to a lamphouse for its support The projector s power supply and keypad are located outside the projector head in separate enclosures External connections are provided for BI PHASE RS 232 SYNC and external douser interfaces Built into the 35 70 projector is the capability to accommodate 35millimeter DTS 70 millimeter DTS and 70 millimeter Magnetic sound head equipment The projector can operate at 50 Hz or 60 Hz line frequency and can be configured for 120 or 240 volt operation The projector can also operate in precise synchronization with other film equipment via 10 pulse per frame bi phase or NTSC PAL or SECAM video equipment Through the use of the interlock provision on the 35 70 projector two projectors can run in a Master Slave configuration with or without shutter phasing to accommodate the showing of 3 D films CHRISTIE IN C 35 70 Service PM M anual July 1997 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 IN C 35 70 Service PM M anual July 1997 2 General Description The lamphouse is not part of the projector system CHRISTIE IN C 35 70 Service PM M anual July 1997 2 General Description Unpacking Upon r
80. ing Circuit BOF EOF Sensor Supply Reel Circuit CN Control Circuit Shutter Control Circuit Pulldown Control Circuit Takeup Reel Circuit 5051 Power Supply Upper amp Lower Buckle Swt E Thanrv nf Oneratinn Supply Torque Motor Supply Brake Supply Supply PWM Reel Te Amplifier 2 7 Optical Sensor Tach a Qv C Roll WA Supply 2285 C W E Torque Arm F4 Limit Switch Constant Velocity BkPhase EE Amplifier Amplifier c 2273 2285 Shutter Motor Shutter m Shutter Encoder DTS PWM Shutter Head Amplifier P E ji j Douser Douser o 2285 Interlock Relay r PD Tach Pulldown Amplifier 2275 EE uy Framing gt gt Sprocket Switch 2276 4 Takeup Torque Motor Supply Takeup Brake Takeup PWM Reel Amplifier P RS Optical Sensor 2285 i ias Tach a lt 2 Takeup Rater i Torque Arm Limit Switch Figure 5 1 35 70 Electronic Projector Block Diagram 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 The pulldown motor is slaved to the constant velocity motor so film moves through the film gate smoothly During slew operation the douser blocks the illumination of the film In interlock operatio
81. jector and control panel is not damaged and is properly inserted Frame counter does not function CKENNNMNMNMAN Verify 5 volt supply at pin 14 of U9 of the 1008 card in the control head If not correct determine fault and correct Verify that the ribbon cable is not damaged and is properly inserted between the 2267 and the 1008 cards If not properly insert or replace cable If failure remains replace the 1008 card Table 7 6 Power On Diagnostic Table CHRISTIE INC 35 70 Service PM M anual July 1997 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 Step Description Completed Item Visually verify that LED 4 Lower Buckle LED 5 Upper Buckle LED 1 Lower Arm Limit LED 2 Upper Arm Limit are off Push the lt READY gt button and verify that the READY LED illuminates and the READY relay activates Visually verify that the Upper and Lower Torque Arms move to centered position and that the reel brakes are released Verify that system is stable reels do not oscillate Visually verify that the projector performs a loop set The loop set should be accomplished in about one to two seconds and the upper buckle switch should not trip EE 5 Verify that the Constant Velocity sprocket advances film one frame and locks When locke
82. jector is parked at the cue point for Show 2 The system status is output over the RS 232 interface in response to an OUTPUT STATUS command see Section 0 Normally the show controller receives the system status When the system is operating in DEBUG mode the system status is displayed on the service terminal The 35 70 Command Set Projector commands are encoded in a hexadecimal character format They are sent to the projector by the show controller by a service terminal or from the keypad Some common commands have been assigned to specific keys on the command area of the keypad When operating the 35 70 projector in a MASTER SLAVE configuration the serial communications port on the SLAVE projector connected to the MASTER will lock out certain commands from the MASTER projector When in the SLAVE mode the SLAVE projector will not echo any commands or provide prompts In order to accomplish full duplex communications for a MASTER SLAVE configuration to a show controller the show controller will require two separate serial ports There are two types of command operational and diagnostic Operational codes are those commands used by the show controller or an operator during normal projector use Diagnostic commands are used for debugging or service adjustment for setup and for other special operations Some diagnostic commands may be used to enable features not currently implemented on the 35 70 Projector Appendix A summarizes the entire system
83. jor electronic components are the PWM Amplifier and the Reel Control circuitry on the Main Electronics Board See Figure 5 9 CHRISTIE IN C 35 70 Service PM M anual July 1997 5 Theory of Operation U34 Optical Sensor To CPU MM M COMP Tachometer ABS VAL AMP U54A Us4B U24 CV Tachometer U32 AMP SUMMING AMP U17 Direction 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 U17 determines the polarity and outputs a direction signal to the lower torque power amplifier The current limiting signal from the power amplifier turns on the photocoupler U45 which limits the voltage sent to the pulse width modulator U53 The Optical Sensor is monitored using comparator U34 Transistor Q10 disables the PWM output in the Platter mode of operation The Sync Separator Card 0300 The Sync Separator card see Section 8 2 is used to extract vertical sync timing information from a composite NTSC PAL or SECAM video input signal This card is also used to select the type of reference signal being supplied to the projector The jumper settings on the board control 50 60Hz line frequency external 60Hz vertical video synchronization and internal synchronization See Table 5 10 When operating the 35 70 projector in the Master Slave mode it is important the both projecto
84. lldown system Verify that the 34 volt supply does reach the 2275 card Verify that the input to the 2275 card at R102 or at TP12 on the 2293 goes positive for the first 2 seconds and then goes negative as film moves up If the voltage is not correct replace the 2293 card If the voltage is correct replace the 2275 card Loop set does not function Pulldown System CONDITION 4 The Pulldown sprocket turns with enough force or speed to trip the buckle switch or damage film nem Loop set does not function Pulldown System CONDITION 5 The Pulldown sprocket starts a Loop Set operation but stops part way Loop Set will continue or complete if film loop is restarted with assist by hand swe This indicates worn brushes in Pulldown motor Replace brushes or motor Table 7 8 READY Diagnostic Table Continued CHRISTIE INC 35 70 Service PM M anual July 1997 7 Troubleshooting Guide READY DIAGNOSTIC TABLE 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 Ren 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 The Constant Velocity sprocket will not advance film o
85. losed portion of the shutter Each advance of the film is called a pulldown In slew motion when advancing or rewinding to a new cue position the film moves smoothly and the douser prevents image projection Picture quality is maintained by several automatic systems which function without operator assistance Proper framing of the film in the gate is monitored during every pulldown If an out of frame condition is detected the projector determines the number of perforations in error and corrects the error during the next pulldown by pulling either more or less film as appropriate The pulldown is automatically synchronized with the shutter as the running frame rate is reached This automatic process maintains a ghost free picture The shutter action is adjusted during the manufacturing process shutter adjustments are not normally required Another automatic system maintains a jitter free picture by positioning the film in the gate in a manner that corrects for temperature changes film type gate pressure and other conditions that would otherwise require operator adjustments The projector has been designed with built in safety features to protect the film in case of malfunction One such feature is the douser interlock relay a solid state relay that allows the douser to open only if the film is moving forward This prevents the possibility of film burns due to an electronic malfunction In addition latching LED indicators help in troubleshoot
86. lt show number is 1 The projector is now ready for the first show If the film length BOF EOF markers or shows have been changed new show times must be entered into the projector First clear all stored time codes with the CLEAR CUES command see Section 2 8 6 Then enter new cue points by the AUTO LOG see Section 2 8 7 MANUAL LOG see Section 2 8 13 or SHOW CONTROLLER LOG see Section 2 8 14 commands or in DEFAULT LOG mode Section 2 3 1 Operation of the projector is automatic 1 Enter a FORWARD command press lt FOR gt to start 2 The douser can be opened by a show controller command by entering an OPEN DOUSER AND CINE C3 command or automatically if the AUTO DOUSER G3 command has been entered 3 When the EOF tape is detected the douser automatically closes and the film stops The projector then automatically cue s the film so that it is ready for the next show The projector will not pick up commands from the show controller until after a SHOW CONTROL ENABLE G9 command is entered CHRISTIE INC 35 70 Service PM M anual July 1997 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 2 Enter the PARK ON CUE lt GD gt command for both Master and Slave projectors Enter the JAM lt C9 gt command for both projectors to reset the
87. m Shows may be played in any order The projector keeps track of the number of the show that is currently being played called current show and the number of the show that is to be played next called next show The projector has sensors that detect the reflective tape used to indicate the show number beginning of film BOF and end of film EOF markers To reduce the possibility of mis reading film cues film should be spliced with either clear splice tape or an ultrasonic film splicer When splicing film on 35 70 projectors running in the Master Slave mode insure that the film length on both projectors remain the same to maintain film sync Programming Beginning and End of Shows The BOF and EOF marks can be programmed by the 35 70 Projector in several ways e DEFAULT Mode The projector programs itself as shows are played in the course of operation After all shows have been shown once the projector logs all BOF and EOF cues e MEMORY Mode The optional battery backup on the CPU card enables the projector to remember all cue points from the last programming mode even if the projector has been turned off in the meantime e AUTO LOG Mode This mode of operation enables the projector to automatically log the positions of all the cues See Section 0 e MANUAL LOG Mode This mode of operation allows the operator to manually enter all cue points into the projector s memory See Section 0 e SHOW CONTROLLER Mode This mode of operati
88. m 5 volts to 5 volts This is required so that the CPU can determine if the projector is in frame otherwise it will do 4 perf and then 6 perf pulldowns trying to bring the picture in frame If necessary recalibrate the pulldown sensor assembly the 2268 card See Section 6 5 3 This condition can also occur due to worn brushes on the pulldown motor Replace brushes or motor assembly as required Table 7 14 Image Quality Diagnostic Table CHRISTIE INC 35 70 Service P M M anual July 1997 7 Troubleshooting Guide IMAGE QUALITY DIAGNOSTIC TABLE Poor Image Quality 2 CONDITION 2 Projected picture has vertical jitter in excess of 0 15 Sm Dame 2 Verify there is proper spring tension on the movable portion of the gate Adjust if necessary See Section 6 8 Verify that both the fixed and movable sections of gate area are free of emulsion buildup Clean if necessary Verify proper right left adjustment of pulldown sensor by following procedure in calibration section Adjust if necessary See Section 6 5 4 It is possible for a Pulldown amplifier to have defective output transistors and function in all modes except Pulldown Replace 2275 card Verify the edge guides are adjusted properly and do not interfere with the film path Adjust if necessary See Section 6 8 4 7 Verify the Pulldown sprocket is properly aligned to the gate Realign if necessary See Section 6 8 1 Verify that the inner and outer race
89. m to NOT READY 1 Verify that 24VDC voltage to the associated 2285 card is at the proper value If not repair 2 If condition remains replace the 2285 card associated with the defective system Table 7 10 Slew Motion Diagnostic Table CHRISTIE INC 35 70 Service PM M anual July 1997 7 Troubleshooting Guide SLEW MOTION DIAGNOSTIC TABLE Film does not ramp smoothly to 120 frames per second CONDITION 4 Film ramps up to maximum speed but motion is not smooth GEMMAM 8 This may indicate worn brushes in the Constant Velocity Tach Replace brushes or motor tach assembly 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 Tighten as required Verify the spring tension of the Upper and Lower Torque Arm assemblies are equal and at their proper value An imbalance puts excessive load on the Constant Velocity system Readjust if necessary See Section 6 3 Film does not ramp smoothly to 120 frames per second CONDITION 5 Film ramps up to maximum speed then ramps down to a stop with the 6 LED illuminated Rem _ 1 Verify all power supply voltages to CV 2285 card Repair connections or power supply as necessary 2 Determine problem to be either defective 2285 amplifier card or defective 2293 CPU Main Logic card Repair or replace Film does
90. mand Enter the SHOW CONTROL ENABLE G9 command if not already enabled Operation of the projector is automatic 5 6 7 Enter a JAM lt 9 gt command into the Master Motion Controller to reset the timecode to 1 00 00 00 Entering a PLAY CURRENT SHOW K1 into the Master Motion Controller will start the show Sending a OPEN DOUSER C3 command to the projector will project the picture or it will occur automatically if the AUTO DOUSER G3 command has been entered CHRISTIE INC 35 70 Service PM M anual July 1997 3 Operating the Projector 8 Atthe end of the show a CLOSE DOUSER C4 command must be sent to the projector to close the douser and a STOP K0 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 HE command and rewound to the start of the show by entering a CUE NEXT H7 command into the projector 10 Repeat steps 2 to 9 to play the next show Power Down Sequence To turn off power to the projector enter the following command key sequence lt G gt lt 9 gt Re activate the projector keypad STOP Stop the projector if it is in motion NOT RDY Remove power from projector motors Power to the projector lamphouse and show controller may then be removed in any order CHRISTIE INC 35 70 Service PM M anual July 1997 4 Periodic Maintenance
91. n the CPU signal that controls the Constant Velocity motor is replaced by an external interlock signal This interlock signal when supplied from a Master projector is derived from the pulses coming back from the C V motor of the Master projector The remainder of the operation remains the same Additional functions such as beginning of show and end of show sensing and control of various projector elements are also provided by the CPU CHRISTIE INC 35 70 Service PM M anual July 1997 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 The shutter encoder provides 20 pulses per revolution of the shutter and two index mark indications per revolution corresponding to the two shutter apertures The encoder pulses are used to control the speed of the shutter the index pulses control frame pulldown in cine mode and are used a reference when shutter phasing is enabled The electronic control portion consists of the Shutter PWM Amplifier 2285 and the shutter control circuitry on the 2293 Main Electronics Board U33 Derived Tachometer Voltage U22 Current Limiting Shutter LX PWM Signal Amp 2285 S Amp
92. ne frame and lock CONDITION 2 The constant velocity sprocket turns with enough force or speed to trip the buckle switch or damage film swe Ren The Constant Velocity sprocket will not advance film one frame and lock CONDITION 3 The constant velocity sprocket does not advance film and can be turned by hand at least in one direction 758 If it resists in one direction but not the other replace the 2285 card otherwise continue to Step 2 While in the READY mode verify that there is a 34 volt supply voltage at the positive end of C8 on the 2285 card If not check the fuse fuse 2 wiring ready relay and power supply associated with the Constant Velocity system Repair if problem is found Table 7 8 READY Diagnostic Table Continued CHRISTIE INC 35 70 Service PM M anual July 1997 7 Troubleshooting Guide READY DIAGNOSTIC TABLE 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 em This indicates worn brushes in the Constant Velocity motor Replace brushes or motor The Pulldown System has performed a proper Loop Set but failed to advance film and lock Since a Loop Set was performed in Section 3 of this table those checks need not be repeated CONDITION 1 P
93. ng illuminated by the shutter At time 0 a shutter index pulse signals the CPU to initiate a pulldown The CPU opens the TACH AND ANALOG switch U27 and closes the PULL switch U47 A signal is sent through the PIA and DAC to command the pulldown motor to full speed The CPU monitors the signal from the pulldown disk sensor which has been squared up by comparator U2 on the sensor board When the fourth slot on the five slots per frame sensor is in the sensor area which is to say the seventh edge has passed the sensor the CPU initiates a positive voltage to the motor to achieve the desired braking As the motor comes to a stop the shutter tachometer signal is summed into U1 on the pulldown amplifier board by closing the TACH analog switch portion of U27 This provides damping The circuit is placed into registration mode and the trailing edge of the fifth slot is used to resume registration for the next frame of the film An automatic circuit detects any incorrect registration such as might be caused by a change in motor characteristics If registration is not correct the correction voltage used on the next pulldown is changed to ensure correct registration CHRISTIE 3 5 70 Service PM M anual July 1997 j35 00v 420 0V Figure 5 7 Pulldown Circuit Timing for 60FPS 5 Theory of Operation Pulldown Tachometer 5 00 v Pulldown Signal TP13 5 00 v 90 degree Pulldown Sensor 5 00 v Pulldown Motor Voltage 20 00 v
94. not ramp to 120 frames per second in the reverse direction in a smooth and linear motion sep agnosie _ Repeat the steps described in A 1 through A 4 of this table using the REV button to initiate film motion Table 7 10 Slew Motion Diagnostic Table Continued CHRISTIE INC 35 70 Service PM M anual July 1997 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 FOR button After film speed stabilizes enter the lt C gt lt 3 gt command to cause the douser to open Step Description Completed Verify that the film accelerates to the pre programmed film rate in a smooth and linear motion and performs pulldowns without losing either the upper or lower loop of film above and below the film gate 2 Verify that the douser opens when commanded and closes as the EOF tape is detected 3 Verify that the projector responds properly to the BOF and EOF tapes as they pass though the sensors Table 7 11 Cine Motion Checklist CHRISTIE 35 70 Service PM M anual July 1997 7 Troubleshooting Guide CINE MOTION DIAGNOSTIC TABLE Loop is lost as projector does Pulldowns 1 Verify proper adjustment of 1 on the 2293 card Adjust if necessary See Sec
95. 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 Readjust if necessary Monitor supply voltage at the plus side of the 2285 card as the READY button is pushed This signal will remain for at least one second even if the READY condition does not hold If voltage is not found determine failure point faulty fuse relay power supply or wiring Repair or replace Measure motor resistance to determine if the associated wiring or the motor is open The resistance of the motor pins 3 and 4 should be about 10 ohms Table 7 8 READY Diagnostic Table Continued CHRISTIE INC 35 70 Service P M M anual July 1997 7 Troubleshooting Guide READY DIAGNOSTIC TABLE Failure of Upper or Lower Torque System CONDITION 2 The system is not stable reel and torque arm oscillate HEMNMNMNMAERNH 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 Verify that the mechanical adjustments to the Torque Arm assembly are correct The spring tension adjustment should be checked and corrected if necessary See Section 6 3 3 Oscillation could indicate worn brushes in
96. on allows the projector to accept cue points from a show controller through its serial communications port Procedures for programming the projector using these modes are described in detail in the command descriptions in Section 0 CHRISTIE IN C 35 70 Service PM M anual July 1997 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 Both counters are expressed as a composite measure of time and frame position in the form hh mm ss ff where hh hours 0 99 mm minutes 0 59 ss seconds 0 59 ff frame count within the second called frame number 0 29 The frame counter begins counting at the beginning of each show and measures 30 frames for each second By convention each show s starting time is set to one hour and zero frames This is displayed as 01 00 00 00 The reel counter begins counting at the beginning of the reel It also measures 30 frames for each second and is initially set to 01 00 00 00 However unlike the frame counter the reel counter is not reinitialized at the start of a new show The value of the reel counter is the cumulative or elapsed time and frame from the start of the reel The frame counter display on the control panel s
97. ong term operation of the system This requires that any rotational lag or lead that develops due to mechanical or circuit perturbations be zeroed out To accomplish this a positional correction has been incorporated The pulses from the Shutter encoder are compared with the control rate by means of an up down counter in the shutter EPLD U29 Each pulse from the control rate input causes the counter to count up each pulse from the encoder causes the counter to count down The eight bit output of this counter is sent to a DAC U30 where an analog voltage proportional to the number of pulses by which the shutter lags or leads the reference is generated This voltage is amplified by U22 and applied to the summing amplifier U22 along with the control and velocity inputs Having both the long term and short term rotational rates of the shutter precisely controlled allows the pulldown operation to be controlled by the shutter index pulse Without this control long term effects would eventually cause the pulldown to over run the film loops and stop operation of the projector As a further refinement in support of telecine applications a circuit has been incorporated which ensures the shutter is synchronized to the vertical blanking time of a video frame EPLD U19 detects the relative occurrence of the shutter edge and the 60 Hz reference crossover and adds or subtracts pulses from the 24 KHz reference to the Shutter EPLD to ensure synchronization This also ensu
98. pen connectors loose film guides failed bearings broken belts etc See Tables 7 2 7 3 and 7 4 Correct any deficiencies found in the visual check This step is described in Section 0 Load film on the machine Apply power and check the Power On Checklist Table 7 5 to verify the machine is ready to be commanded into the READY condition Correct any deficiencies pointed to on the Power On Checklist Diagnostic Table Table 7 6 This step is described in Section 0 Command the system into a READY condition and perform the Ready Checklist Table 7 7 If the READY condition is not achieved refer to the Ready Checklist Diagnostic Table Table 7 8 and take corrective action This step is described in Section 0 Perform the Slew Motion Checklist Table 7 9 Correct deficiencies pointed to by the Slew Motion Checklist Diagnostic Table Table 7 10 This step is described in Section 0 Perform the Cine Motion Checklist Table 7 11 Correct deficiencies pointed to by the Cine Motion Checklist Diagnostic Table Table 7 12 This step is described in Section 0 Perform the Image Quality Checklist Table 7 13 Correct deficiencies pointed to by the Image Quality Checklist Diagnostic Table Table 7 14 CHRISTIE INC 35 70 Service P M M anual July 1997 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
99. pply reel Then follow the command sequence described BOF and EOF tapes must be affixed to the film for all shows that are to be programmed CHRISTIE IN C 35 70 Service PM M anual July 1997 2 General Description ENTRY lt CMD C gt 6 CODE C6 ACTION Projector logs all BOF and EOF sensor tapes on the reel 5 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 Load the film on the reel so that the BOF tape for Show 1 Chapter 3 is above the gate or on the supply reel READY READY Puts projector into Section 0 READY mode dns SET MAX SHOWS 5 lt H gt lt D gt Sets number of shows oo Section 0 5 to 5 SET NEXT SHOW 1 H 8 Sets Show 1 as next Section 0 lt 1 gt show SET CURRENT SHOW 1 lt H gt lt 5 gt Sets current show to 1 Section 0 I CUE CUE Projector cues on BOF Section 0 of Show 1 Dur AUTO LOG C 6 Projector logs all BOF and EOF tapes on the Section 0 reel SET NEXT SHOW H 8 Sets Show 2 as next Section 0 lt 2 gt show CUE CUE Projector cues on BOF Section 0 of Show 2 rad Table 2 5 Command Sequence for Auto Logging CHRISTIE IN C 35 70 Service PM M anual July 1997 2 General Description C7 The OUTPUT STATUS Command DX This diagnostic command
100. res exact frame per frame blanking correspondence for multiple projector applications CHRISTIE 3 5 70 Service PM M anual July 1997 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 ABS VAL AMP U23 U23 U28 Current Limiting VE PWM Signal Direction 2285 Sawtooth COMP DRM Speed SERVO9 U38 DRM Speed Direction Speed Control Voltage Direction Figure 5 3 Constant Velocity Motor Control Constant Velocity operation is diagrammed in Figure 5 3 A signal with frequency proportional to the desired film rates is generated by the Digital Rate Multiplier EPLD U14 and associated Programmable Timer Modules The rates generated for various film speeds in pulses per second are given below in Table 5 4 Frames Pulses per per Second Second 24 FPS 240 PPS 30 FPS 300 PPS 48 FPS 480 PPS 60 FPS 600 PPS 120 FPS 1200 PPS Table 5 4 Constant Velocity Rates for Film Speeds A direction signal is also supplied by the CPU These signals are processed by the Tacho EPLD U33 whose output is integrated by U44 into an an
101. riation exists crystal oscillator control may be selected by a jumper on the 2293 board Pulldown Control Circuit The primary mechanical elements of the pulldown circuit are the pulldown motor the pulldown disk sensor the tachometer and the pulldown sprocket all located on the pulldown assembly The major electronic assemblies are the Pulldown Amplifier 2275 and the associated pulldown circuitry on the 2293 Main Electronics Board The action of the pulldown circuit is different in slew and in cine mode During slew operation the pulldown motor must be locked to the constant velocity motor so film moves smoothly through the film gate Figure 5 5 shows the pulldown circuit configured for slew operation To lock the speed of the pulldown motor to the constant velocity motor the two tachometer signals are fed into U21 as a differential amplifier The bi directional error output is amplified by U21 and sent to the Pulldown Amplifier Board 2275 On the amplifier board the signal is amplified by U1 and sent to the motor drive circuitry To further ensure full synchronization between the two motors the respective encoder signals are sent to EPLD U19 operating as an up down counter The eight bit output of this counter is sent to the DAC U20 amplified by U55 and summed with the pulldown tachometer to provide precise positional control between the two motors Pulldown Tach U1 U20 PD Disk Sensor Yp pw
102. rojector 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 e BOF indicator e EOF indicator e SHOW NUMBER indicator optional Thus if three shows are used nine tape strips would be installed The BOF sensor is located next to the inboard away from the user film perforations while the EOF sensor is next to the outboard toward the user film perforations Tape should be placed on the emulsion side of the film as it might not be read through the film if it is positioned on the base side When a start command is given the film accelerates to cine speed before it encounters the BOF marker The film decelerates to a stop after the projector detects the EOF marker The projector determines the show number by measuring the length of reflective tape placed on the inboard side directly opposite the EOF tape with the BOF sensor The show number tape is measured in units of frame lengths For example show number two must have a tape length of two frames The EOF tape opposite the show number tape must extend beyond both ends of the show number tape If the projector is to automatically open the douser by use of the AUTO DOUSER command See Section 2 8 37 the BOF marker on the film must be positioned so that it is 3 seconds before the first frame of picture The placem
103. rom the projector control console the sequence is All alphabetic characters terminal hexadecimal digits entered into the service terminal must be upper case ENTRY CODE INPUT ACTION S INPUT ACTION S INPUT STATUS lt G gt 0 GO Enter the four digit hexadecimal address that is to be updated Press the lt FOR gt key to increment the address press the REV key to decrement the address Example Entry 32AB FOR 32AC FOR 32AD REV 32AC Displays the two digit hexadecimal data stored at the specified address in the two rightmost digits of the LED display Enter the new two digit hex value for the chosen address Updates the address contents To exit the MEMORY INSPECT command 1 Press STOP to exit 2 Enter the GI command to return to the frame counter display Unchanged The sequence of commands and inputs from a service terminal is shown in Table 2 7 CHRISTIE INC 35 70 Service PM M anual July 1997 3 Operating the Projector input Rem G9 Must be entered from console Activates the serial RS 232 communications port see Section 0 followed by desired Data stored at the chosen address is hexadecimal memory location use shown to the right of that address on upper case for alpha characters the terminal s display yy New value for memory location two Value at selected address is updated hex digits Table 2 7 M
104. rque Sensor and Disk 34 are tight Po Verify that the four belts are undamaged and properly tensioned Le B5 Verify Upper and Lower Brakes 2 31 are engaged and that there is no play between brake and shaft B6 Verify that all cooling hoses are in place Ld Table 7 3 Visual Checklist Part B Head and Reeling Cabinet VISUAL CHECKLIST Step Description Completed EEOE IO CI o Verify Interlock Relay is tight in its socket REI Table 7 4 Visual Checklist Part C Power Supply Area CHRISTIE INC 35 70 Service PM M anual July 1997 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 Step Description Completed Visually verify that the LED on the lt NOT RDY gt button on the control panel comes on Visually verify that the Frame Counter reads one hour 01 00 00 00 Table 7 5 Power On Checklist POWER ON DIAGNOSTIC TABLE maene 1 Verify 5 volt supply is correct at J1 of the 2267 card in the control panel head If not determine fault and repair 2 Verify that the ribbon cable to the 2267 card is not damaged and is properly inserted If not properly insert or replace cable 3 Verify that the 25 conductor cable between the pro
105. rs are receiving their sync from the same source Signal Type JP1 JP2 JP1 2293 Video Sync amp 2 External 2 amp 3 2 amp 3 1 amp 2 50 60Hz Line N A N A 1 amp 2 Crystal4 N A N A 2 amp 3 Table 5 10 Sync Separator Card Jumper Settings 4 This setting is not recommended for use with Master Slave projector configurations CHRISTIE INC 35 70 Service PM M anual July 1997 5 Theory of Operation The CPU Main Logic Card 2293 The CPU Main Logic card card 2293 contains e the 6809 microprocessor CPU e parallel interface adapters PIAs the control read only memory ROM that contains the program e the RS 232 asynchronous communication interface adapter chip for serial communication e the programmable timer module PTM chip that generates the clock rates for the ACIA and motor circuits e the scratch pad random access memory RAM e the digital to analog converters DACs that allow the CPU to generate motor drive voltages e Erasable Programmable Logic Devices EPLDs that contain complementary metallic oxide semiconductor CMOS logic elements such as gates and flip flops e Control Circuitry much of which is described in Section 5 1 The CPU Section The CPU section of card 2293 illustrated in Section 8 7 uses a 6809 processor with a built in crystal oscillator The CPU section is shown in the diagram of Figure 5 11 The computer program resides in a single 27128 EPROM designated U2 in the circuit
106. ry Screwdrivers Assorted Phillips Explosion Vest for lamp replacement Side Cutters Full face Safety Mask for lamp replacement Soldering Iron 40W Gloves for handling lamphouse bulb Wire Strippers Crimpers Digital Multimeter Wrench Adjustable Oscilloscope Dual trace Analog 20mhz Wrench 1 4 Open end Vacuum Cleaner with Hose and Nozzle Table 4 1 Commonly Used Maintenance Tools CHRISTIE IN C 35 70 Service PM M anual July 1997 4 Periodic Maintenance CHRISTIE 35 70 Projector Daily Preventive Maintenance Log Sheet Week Beginning Tue Thu Action Required 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 2 Daily Preventive Maintenance Checklist Log Sheet CHRIS TIE 35 70 Projector Weekly Preventive Maintenance Log Sheet LT T ODOREM NNNM emps weese LLL Gewwwsamrapwar Wemeenepn 7 LL CO BO Check gate shoe spring tension Check all mechanical connections Table 4 3 Weekly Preventive Maintenance Checklist Log Sheet CHRISTIE INC 35 70 Service PM Manual J uly 1 997 4 Periodic Maintenance CHRIS TIE 35 70 Projector Monthly Preventive Maintenance Log Sheet Year 19 Action Required Date Performe Check belt tension Check all electrical connections Table 4 4 Monthly Preventive M
107. tate and that the shutter and optical system are performing satisfactorily Next the constant velocity system and the film handling loops and gate are set up and the film is correctly threaded on the machine With the film handling in place the reeling system is set up allowing the film to be transported in slew modes Finally the pulldown system is set up to allow cine motion and the projection of the image In many cases the adjustment sequence must be repeated to obtain optimum performance Coarse adjustments are first made to get the system operating then finer adjustments are made often by observing the projected image CHRISTIE 35 70 Service PM M anual March 1997 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 The sensors are located just above the pulldown sprocket in the gate area Tape should be placed on the emulsion side of the film CHRISTIE 35 70 Service PM M anual March 1997 6 Mechanical and Electronic Adjustments Tape may not be seen through the film if it is placed on t
108. te a speed control voltage and to an up down counter to provide precise positional control Pulldown in cine mode is synchronized by the shutter index pulses and in slew mode the pulldown motor follows the Constant Velocity Motor The torque arms operate the reel motors with the help of the CV Tach To operate in interlock mode the signals generated by the CPU to the constant velocity circuit are replaced by pulses sent from an external biphase source which is referenced to the line frequency or some other reference source which is common to all the machines being controlled Interlock operation is selected by giving the CPU the appropriate command Interlock signals are input at connector J11 on the Main Electronics Card EOF and BOF Detection The beginning of show BOF and end of show EOF signals are input into the main electronic card on connector J6 The circuitry is shown in the diagram of Figure 5 12 See also Section 8 14 The EOF tape is detected by comparator U35A The output of U35A goes high while the tape is being detected it is input to the CPU through a PIA The BOF tape is processed in a similar manner by U35B When a projector is operated in the Slave mode the detection of EOF signals is disabled 5 U35A G U35B 0 as AMP AMP EOF BOF Figure 5 12 EOF and BOF Detection Circuits PWM Sawtooth Ramp The sawtooth ramp used to generate the PWM signals for motor controllers is generated by two sections of U34 and two of
109. the Constant Velocity Control Circuit are directly controlled in both cine and slew motion modes The desired film speed is normally 30 frames per second in cine and 120 frames per second in slew mode The shutter rotation speed is normally 30 rotations per second The microprocessor CPU generates signals which are used to precisely control these two motor speeds which are locked to the line frequency using a phase locked loop The shutter has two openings so the film frames are illuminated 60 times per second In cine operation the pulldown motor must move the film in such a way that a frame is stationary in the film gate during two illuminations and then must move a new frame of film into the gate during the closed portion of the second shutter cycle The shutter provides an index signal to the pulldown circuit which indicates the precise moment of shutter closure and initiates the pulldown action The next frame is pulled into place and held in registration by monitoring an edge indication from the slots on the pulldown disk encoder CHRISTIE IN C 35 70 Service PM M anual July 1997 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 Keypad Show Display 2267 1008 Controller Interface Main Electronics Board 2263 Fault Detecting Warn
110. the Torque motor or tacho generator assembly Replace brushes or motor tach assembly Loop set does not function Pulldown System CONDITION 1 Film is moved from the upper loop to the lower loop but does not move back up oe KHENMNMNMKAENM E Check the 8 amp fuse fuse 3 associated with the 24 volt supply of the pulldown system replace if defective Verify that the signal from the 2293 card at TP12 on the 2293 card first goes positive as film moves down to the lower loop and then goes negative If not correct replace the 2293 card if voltage is correct replace the 2275 card Table 7 8 READY Diagnostic Table Continued CHRISTIE INC 35 70 Service PM M anual July 1997 7 Troubleshooting Guide READY DIAGNOSTIC TABLE 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 sw 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 Loop set does not function Pulldown System CONDITION 3 Film does not move until after 2 seconds and then only moves from the lower loop to the upper loop Ae MEM EN Check the 8 amp fuse fuse 1 associated with the 34 volt supply of the Pu
111. tion 6 7 2 It is possible for a Pulldown amplifier to have defective output transistors and function in all modes except Pulldown Replace 2275 Douser does not function Douser has been found to be mechanically free and relays are secure in their sockets Verify that the douser relay does function Determine bad solenoid or wiring fault and repair or replace If relay does not function determine if fault is the driver on the 2285 shutter card the solid state douser interlock relay the relay itself the control signal from the 2293 card or a wiring fault Replace or repair Projector does not respond to the EOF or BOF Damme Verify adjustment procedures for EOF and BOF sensors have been properly executed Adjust if necessary See Section 6 2 2 If adjustment procedure is not successful determine the fault to be associated with the EOF BOF sensors or the circuits on the 2293 card Replace as required Table 7 12 Cine Motion Diagnostic Table CHRISTIE INC 35 70 Service PM M anual July 1997 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 FOR button and after film speed stabilizes enter the lt C gt lt 3 gt command to cause the douser to open
112. tion to forward Press the STOP button Repeat steps 3 to 8 using R196 for the upper torque arm and R137 for the lower torque arm Enter the DISPLAY FRAME COUNTER lt G gt lt 1 gt command to return the display to normal Shutter Timing Adjustment 2269 Encoder The shutter encoder outputs an index pulse each time the shutter blade completely blocks the light from the lamphouse The index pulse must be adjusted so that the film stops before the shutter opens The projector must be running for this adjustment Do not touch belts or other moving parts in the projector while making this adjustment 1 Open the back cover and locate the shutter encoder at the back of the shutter motor 2 Loosen the Phillips head screws holding the encoder mounting bracket to the back of the shutter motor 3 Entera FORWARD command the FOR key 4 Open the douser 5 Rotate the encoder by hand until the picture is ghost free 6 Tighten the Phillips head screws This completes the shutter adjustment CHRISTIE 35 70 Service PM M anual March 1997 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
113. to load a new value into the frame counter The command should only be used if there is a problem with the current value ENTRY CODE INPUT ACTION S STATUS CMD H 4 H4 Enter the new value for the frame counter in the counter format hh mm ss ff see Section 0 2 Press ENTER Set the frame counter Unchanged H5 The SET CURRENT SHOW Command OP This operational command causes a display of the current show and the next show in the two rightmost digits of the numeric display respectively The user may enter a new current show number if desired The new value must be a valid show number The current show and next show values are displayed for one second before the numeric display reverts to the frame counter The new current show value must be entered while the show values are displayed CHRISTIE INC 35 70 Service PM M anual July 1997 ENTRY CODE ACTION S INPUT ACTION S STATUS 3 Operating the Projector CMD H 5 H5 1 Display current show in second from right position of numeric display 2 Display next show in rightmost position of numeric display 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 Load the new current show value Unchanged H6 The GOT
114. uld be defective Repair or replace as necessary Table 7 8 READY Diagnostic Table Continued CHRISTIE INC 35 70 Service PM M anual July 1997 7 Troubleshooting Guide READY DIAGNOSTIC TABLE READY relay does not activate or READY LED does not go on 58 If 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 Verify that all cables going to the lower torque 2285 amplifier card and READY relay are not damaged and are correctly plugged in Verify that the time delay relay contacts on K2 in the power supply are closing approximately 3 seconds after power up If not re adjust or replace relay Verify that the collector of Q3 on the 2293 CPU Main Logic card goes low when READY is commanded If the signal is present replace the lower torque 2285 card or READY relay If the signal is not present the problem could be with either the 2293 CPU Main Logic card or the 2267 keypad card Repair or replace as necessary Table 7 8 READY Diagnostic Table Continued CHRISTIE INC 35 70 Service PM M anual July 1997 7 Troubleshooting Guide READY DIAGNOSTIC TABLE Failure of Upper or Lower Torque System CONDITION 1 Upper or lower torque arm does not center Verify that the brake associated with the defective system comes off while in READY The reel should move freely if the brake is
115. ulldown sprocket offers no resistance to movement by hand mem oBawone If problem still exists replace 2293 card Ld The Pulldown System has performed a proper Loop Set but failed to advance film and lock CONDITION 2 Pulldown sprocket is not stable oscillation produces audible sound This is caused by a fault in tach circuit 73 1 The fault could be associated with the tach circuit on the 2293 card Replace 2293 card 2 The brushes associated with the tach on the Pulldown motor assembly could be worn Replace brushes or motor assembly Table 7 8 READY Diagnostic Table Continued CHRISTIE INC 35 70 Service PM M anual July 1997 7 Troubleshooting Guide READY DIAGNOSTIC TABLE 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 _ 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 2 Verify supply voltage of 24 volts at plus side of C8 of the 2285 card If not determine fault and repair Verify quadrature of the shutter encoder s phase A and phase B outputs a If shutter is moving connect dual trace oscilloscope to pins 23 and 24 of U29 on the 2293 card an
116. ypad to select 60 Hz operation 2 Enter a 5 from the keypad to select 50 Hz operation The synchronization frequency is reset accordingly Unchanged HA The INTERLOCK Command OP This command puts the projector into interlock mode Interlock mode allows the projector to be interlocked via BI PHASE to an external motion source or MASTER projector Commanding the projector into INTERLOCK mode before a READY causes the projectors shutter to lock into a position 180 degrees out of phase This mode is useful for applications that require shutter phasing for 3 D films To prevent film damage enter this command only when the external motion source is idle ENTRY CODE ACTION S STATUS lt INTERLOCK gt HA The projector is set to interlock mode Unchanged HB The DISPLAY ERROR Command DX This diagnostic command triggers a Cause of Fault message over the RS 232 interface The message displays on a workstation that is connected to the RS 232 ENTRY CODE ACTION S STATUS lt CMD H gt lt B gt HB Send error message coded in ASCII over RS 232 Unchanged CHRISTIE INC 35 70 Service PM M anual July 1997 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 M

Christie 35/70 Automated Film Projector

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