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Telex 2200 Service Manual

1. Figure 19 Stop Fast Forward 2270 Model D FAST REWIND 2270 MODELS Power is supplied to all the projector circuits by operating the Main Power Switch S14 to ON With the Rewind Button depressed the Master Con trol Lever in the Fast Mode and the Main Power Switch ON switches S2B S2C and S2D and 14 are closed The movable contacts C are connected to the normally open N O con tacts on switches 53 55 and 86 Switch S9 may be in the Hi or Lo position Switch S2FJ is connected to terminal 6 and S2GH is connected to terminal 8 Relay K3 is operated closing its normally open contacts Switch S2A is open The LIVE side of the line is connected to the black wire of the start winding and the yellow wire of the run winding of the Main Drive Motor The NEUTRAL side of the line is connected to the white wire of the start winding and the brown wire of the run winding of this motor Thus the phase relationship is estab lished between the two windings which causes the metor to run in reverse Relay K1 is operated because one side of its winding terminal 9 is connected to the line NEUTRAL through switches S3 and S4 and the other side of its winding terminal 11 is connected to the line LIVE through switch 56 Relay contacts K3 and switches S2C and S14 The normally closed contacts F1A open open breaking the exciter lamp circuit along with open
2. FRAME GROUND Ta amo wS sa 046678 AMI BEHEART veez Figure 17 Fast Forward Initially On cr DIS TO SIAF 370 vae INITIALLY ka I iwas o ovde An INSTA LOAD XL 2200 SERIES This interlock system is activated and held by Relay K2 and Interlock Solenoid 502 When the projector is initially turned on in the Fast Forward mode Relay K2 does not operate because capacitor C18 acts as a momentary short across it while it is charging After 3 to 5 seconds C18 is charged and K2 operates to connect the LIVE side of the line to Interlock Solenoid 502 and Interlock Indicator Lamp L3 These operate because their other side is connected to the line NEUTRAL through the N O contacts of Switch S3 and Switch 4 Interlock Solenoid SO2 operates the mechanism which locks the Master Control Lever in the Fast Mode position during Fast Forward operation Interlock Indicator Lamp L3 lights to show that the mechanism is in the Fast Mode function a g KER rn r I 3 R 20v RUS A Ja ma j c 305 70 339 AF 370 vac FRAME GROUND TAM Jey SEE 646678 AMP SCHEMATIC em C138 wa FR star CHARGED 36 tee mer Da 6 8K N Figure 18 C 18 Charged When the projector is turned off
3. Service rewind No Rewind clutch clutch to elim Ipulley turns inate binding freely Check entire film path for binding rollers etc 6 1 INSTA LOAD XL 2200 SERIES Auto Loop Restorer Cycles Continuously Film sprocket holes are in good condition Yes Use film with I sprocket holes intact Adjust claw arm pin protrusion Claw arm pin protrusion is between 035 and 040 Pressure shoe is seated pro perly in aper ture plate Adjust pressure shoe Adjust lenshold er stop pin Lensholder stop pin is 135 to 141 from ap erture plate Yes Raised lip on reset gear ec centric is in good condition Replace reset gear examine latch tab on re set arm Take up tension 3 lis between 4 and 6 ounces Yes Adjust take up tension Check entire film path for damaged or binding parts Auto Loop Restorer Recycles Continuously In Fast Forward Reset arm Adjust reset eccentric seat arm eccentric ed properly in master control lever cradle Replace reset Raised lip on re gear set gear eccen tric is in good condition Not worn If the gear eccentric is worn carefully examine the latch tab on the Loop Resetting Arm for rough edges or burrs 6 2 INSTA LOAD XL 2200 SERIES Auto Loop Restorer Doesn t Cycle
4. DISTANCE A DISTANCE B DISTANCE B VIEWED FROM BEHIND Figure 3 27 SIDE CLEARANCE 1 Thread an old film in the projector do not use a 2 Rotate the Inching Knob clockwise until the Claw good film for this adjustment and adjust the Arm Pins are in the Aperture Plate Slot at the Framing Knob to eliminate any frame lines at the bottom of their travel Insert the Stroke Setting top or bottom of the projected image with the pro Gauge ST 5880 into the Aperture Plate Film jector running in FORWARD If excessive noise Channel Close the Film Gate Make sure the results when the Framing Knob is moved stop Pressure Shoe seats properly Push the Gauge the projector and check the location of the Claw down until it hits the Claw Arm Pins 3 15 INSTA LOAD XL 2200 SERIES Rotate the Inching Knob clockwise through enough cycles of the Claw Arm to draw the Target in the Gauge into the Aperture Be careful not to allow the Claw Arm to move up at any time when the Pins are engaged in the sprocket holes The Pins must pull the Gauge down smoothly for the meas urement to be valid After the Gauge Target has been moved into the Aperture continue turning the Inching Knob clock wise so the Claw Arm Pins withdraw at the bottom of the stroke and raise to the top of the stroke STOP turning the Inching Knob when the Pins re enter the sprocket holes BEFORE they start moving down The Shutter Blade will be even wit
5. C 5 lt KHz FILTER AMPLIFIER ADJUSTMENT 1 Connect a jumper wire between Test Point 15 and Test Point 19 on the 5K Hz Filter Board 2 Perform the Buzz Track Adjustment and the Sound Optic Focusing Adjustment per the procedures for those adjustments 3 Remove the jumper connected in Step 1 above 4 Thread a continuous loop of 400 Hz Signal Level Test Film SMPTE P16 SL in the projector 5 Connect an Oscilloscope and or an AC VTVM between pin 1 of Z1 Test Point 6 and ground Test Point 9 on the main amplifier board 6 Run the projector in Forward and adjust the Reserve Gain Potentiometer VR 1 on the main amplifier board for a reading of 3 0 volts RMS 8 5 volts P P 5 2 TO VOLUME CONTROL FROM PREAMPLIFIER GROUND Odbm JACK 775V RMS 23v P P ACROSS 600 ohms J1 20 11 y M 27V oc Odbm CIRCUIT 13 Figure 5 4 0 dbm CIRCUIT BOARD Plug an 8 ohm 25 watt dummy load into the ext speaker jack JS 1 and connect the Oscilloscope VTVM combination across this load Set the Tone Control to its mid position and adjust the Volume Control for a reading of 11 volts RMS 31 volts P P Remove the 400 Hz loop from the projector and run the projector in Forward without film in it DO NOT MOVE THE TONE OR VOLUME CONTROL The VTVM reading should be 11 volts RMS or less 31 volts P P This repre sents a Signal to Noise Ratio of 40db Thread a continuous loop of 5K Hz Test Fi
6. Rewind Sluggish or Fails Rewind brake cable is adjust ed properly Adjust cable make sure rewind solenoid operates properly Check interlock solenoid circuit and solenoid repair as nec essary Interlock sole noid operates properly Clean and lube rollers and shafts Reinstall with pro per end play Film path rollers No turn freely no binding Replace supply reel arm belt supply reel arm belt is in good condition Not slipping Yes Motor belt ten No Adjust motor belt sion is correct 0 Itension replace no slipping belt if necessary Yes Adjust fast for No Fast forward ward drive belt drive tension is correct Yes Reel arm pulleys No a binding Clean or replace reel arm pulleys Clean reel arm pulley bearings Yes Replace feed No Roll pin is intact sprocket clutch Tin feed sprocket drive gear clutch drive gear Yes Rewind clutch is supplying posi tive drive Check actuator cap clutch spring and arbor repair or replace as neces Recheck entire system check for binding or slipping of trans port or drive mechanisms Omit this step if the projector has no fast forward function This step applies to Simplified Control models only 6 5 Fast Forward Sluggish or Fails Check fast for ward solenoid circuit and sol enoid repair INSTA LOAD X
7. TOP CLAW ARM PIN ENTERS TOO LOW POSITION OF TOP CLAW ARM PIN AT REENTRY INTO SPROCKET HOLE OF GAUGE STROKE TOO SHORT PROJECTED IMAGE 3 14 TURN CLOCKWISE TO LENGHTEN STROKE POSITION OF PIVOT Figure 3 25 CLAW PULL DOWN STROKE ADJUSTMENTS INSTA LOAD XL 2200 SERIES 9 If the stroke was adjusted repeat Steps 3 through 8 When performing Step 6 it is quite probable that the bottom step of the projected Target no longer rests on the reference line ADJUST THE ELEVATION to line up the bottom step of the projected Target with the reference line and then proceed with Steps 7 and 8 It may be nec essary to repeat this sequence of steps several times until correct stroke and side clearance are obtained 10 A final dynamic check for proper Side Clearance is made during the Framing Adjustment which follows Claw Arm Adjustments Model 2280 Side Clearance Pull down Stroke CAUTION When working on Model 2280 Project x ors NEVER LOOK AT THE LAMP Figure 3 26 CLAW ARM ADJUSTMENTS It is advisable to wear dark or tinted glasses preferably safety glasses when working on these projectors Arm Pins in the sprocket holes of the film When Framing is correct the Top Claw Arm Pin should be the same distance from the inside edge of the sprocket hole at the top of its stroke as it is from the outside edge of the sprocket hole at the bottom of its stroke Figure 3 27 Loosen Screw 14 and adjust the
8. e Tighten the W point screw and recheck the re quiremements of step d above If tightening the W point screw results in failure to meet these requirements repeat steps c and d until tighten ing of the W point screw no longer causes failure f Tighten the W point serew and the inner oval point screw to 140 inch ounces of torque Replace the outer oval point screw to 140 inch founces of torque If a torque wrench is not available tighten the screws until the allen wrench shaft starts to twist N LENSHOLDER STOP PIN THEORY The Lensholder Stop Pin limits the distance that the bottom of the pressure shoe moves away from the Aperture Plate when the Loop Restorer resets the lower loop This should be checked and reset if necessary each time preventive maintenance or overhaul is performed on the projector LENSHOLDER STOP PIN GAGE Lay the Protrusion Gage G10 38000 on a flat surface with the protrusion measuring steps facing up With a set of calipers or a depth gage measure from both steps to the flat surface Select the step which measures 138 003 for the lensholder stop pin adjustment If neither step measures 138 003 build up the back side of the gage with tape until the correct thickness is obtained 2 16 SHUTTER CAM POSITION WHEN ADJUSTING CLAW ARM PIN PROTRUSION FRONT VIEW OVAL POINT INNER Either step may ba used may be used 10 38000 Protrusion Gage on fl
9. slots 2230 T V Projector Drive Motor Plate Modification Holes A 7 16 end mill B with end mill 2230 T V Projector Lampholder Modification to hold Opal Glass aa 3 holes a le S 8 gt ell a a 128 This assembly in A hole only Other two holes delete item 3 Install Opal glass coated side to lamp 1 38473 PTX Washer 2 41086 P8 Spacer 3 AV16 41 8 Retainer 4 1 8 x 1 4 Pop Rivet 1 12 NSTA LOAD XL 2200 SERIES Low VoLTAGE REMOTE TIMP RH Mt PIM SOCKET ORN _ aw or REMOTE EDGE AOCAL O CONNECTOR DIODES IN2069 RELAYS PEB RI0 E2 W2 V700 SWITCH 43178 P4 ag su PPRESSORS 44007 P2 1 13 INSTA LOAD XL 2200 SERIES J1 20 TO VOLUME CONTROL FROM PREAMPLIFIER GROUND Odbm JACK 775V RMS 2 3v P P ACROSS 600 ohms gt 27 v oc 43176 P2 Triad T32X 42267 P1 45147 P6 415B P472K C 402 18 0 3 406 392 3 406 822 3 406 103 3 406 333 3 406 154 3 40761 P12 42727 P1 AV16 12 11 43618 G2 39472 P1 43485 P1 200 4 116 4R 4H INSTA LOAD XL 2200 SERIES 0 dbm List of Materials Jack Transformer Capacitor 10 mfd 25 volt Capacitor 40015 mfd 100 volt Capacitor 0047 mfd 12 volt Resistor 18 ohm 1 2 watt Resistor 3 9K 1 4 watt Resistor 8 2K 1 4 watt Resistor 10K 1 4 watt Resistor 33K
10. 20 SERVICE MANUAL INSTALOAD XL 2200 SERIES SERVICE INSTRUCTIONS CUSTOMER SERVICE 30e 12 6 07 TELEX TELEX COMMUNICATIONS INC 9600 Aldrich Ave So Minneapolis MN 55420 U S A VOLUME 2200A Litho in U S A November 1984 For SECTION 1 SECTION If SECTION JI SECTION TV SECTION V SECTICN VI Cyanetovsk System S INSTA LOAD XL 2200 SERIES GENERAL INFORMATION PREVENTIVE MAINTENANCE DISASSEMBLY and REASSEMBLY ADJUSTMENTS ELECTRICAL SYSTEM ELECTRICAL CIRCUIT ADJUSTMENT TROUBLE SHOCTING H m Buttetin 9 520 INSTA LOAD XL 2200 SERIES SECTION I GENERAL INFORMATION PRINCIPLES OF OPERATION All Telex Insta Load XL projectors may be divided into eight basic functions The Main Drive System The Feed and Rewind System The Gate and Lens Mount The Auto Loop Restorer Som THE MAIN DRIVE SYSTEM All functions are driven from a single drive shaft 34 which is turned by a reversible motor through a drive belt Figure 1 Two worm gears 20 amp 32 drive gears pinned to the shaft drive the Take Up Clutch gear and the Feed Sprocket Clutch gear The Shutter 25 and the Safety Shutter 24 in models which have the still feature are mounted on this same drive shaft Reverse operation of the projector is accomplished by changing the direction of rota tion of the drive shaft by reversing the drive motor See Power Supply and Motor Drive Circuits
11. LIVE AC power is removed from the Main Drive Motor M1 Relays K1 K2 and K3 and Fast Forward Solenoid S03 Relays K1 and K3 and Fast Forward Solenoid S03 release Relay K2 remains operated for 3 to 5 seconds while C18 discharges through it The contacts of K2 continue to apply LIVE AC power to the Interlock Solenoid S02 and now also to the Rewind Solenoid S01 through the N C con tacts of Relay K1 and the N O contacts of Switch 5 The Interlock S lenoid SO 2 remains operated for 3 to 5 seconds preventing the Master Control Lever 4 4 from being raised before the film comes to a complete stop The Rewind Solenoid S01 operates to lock the Rewind Clutch in direct drive braking the front reel and stopping fast film movement through the pro jector After 3 to 5 seconds Capacitor C18 discharges sufficiently so Relay K 2 releases and removes power from this entire circuit causing the Rewind Solenoid SO1 and the Interlock Solenoid S02 to release thus restoring the circuit to its rest condition INSTA LOAD XL 2200 SERIES zov evs sey or ay onus m awar 370 var p Au 277 szja FRAME GROUND TEMP ay see 646678 AMP SCHEMATIC AND INTERLOCK REAR SPOLE BRAKE 18 no cis DISCHARGING ae evoe ner
12. sary Supply or take up reel bent Replace bent reel Claw protrusion stroke or side clearance out of adjustment Aperture plate or pressure shoe dirty Adjust protrusion stroke and side clearance Clean aperture plate and pres sure shoe with isopropyl alco hol or chlorothene 1 1 1 6 9 INSTA LOAD XL 2200 SERIES TROUBLE CAUSE i Picture jumps possible loss of loop Continued j Picture motion side to side Pressure shoe not aligned properly Claw arm damaged Film edge guide spring weak or assembled improperly REMEDY Align pressure shoe Replace claw arm Replace spring or assemble properly k Picture goes in and out of focus at random m Picture streams vertically Sound System Troubles a Exciter lamp blows or has short life Exciter lamp doesn t light Speaker hiss increases with volume control c Exciter lamp doesn t light No speaker hiss Bad film Pressure shoe damaged or out of adjustment Check projector with known good film Replace or adjust pressure shoe Pressure shoe not aligned Claw arm protrusion too short Film edge guide spring not assembled properly Defective lamp 3 Z3 or R38 Defective lamp Q3 23 or R38 Exciter lamp socket defective or open leads to the lamp socket Switch S2A defective or Relay K1 defective Model 2270 Switch S2A defective or Sw
13. 1 4 watt Resistor 150K 1 4 watt Potentiometer 100K Transistor 2N2923 Circuit Board Cable Butt Connector 0 dbm Label Standoff Nut 4 40 Serew 4 40 X 1 4 115 1416 INSTA LOAD XL 2200 SERIES TI Tovams i DIRECT DRIVE FRAME GROUND SE INTERLOLK FRANT SPIMDLE k r PROJECTOR SCHEMATIC DIAGRAM MODEL 2210 WITH SYNCHRONOUS MOTOR NSTA LOAD XL 2200 SERIES temme ster GAN WHT 84 ri FRAME GROUND PROJECTOR SCHEMATIC DIAGRAM MODEL 22 O Pin SKET 1 17 1 18 INSTA LOAD XL 2200 SERIES GRN 50 7 REVERSE PROTECT 4 PROJECTOR SCHEMATIC DIAGRAM MODEL 2230N REF FIGURE EA H J K M U V We K Y 2 INSTA LOAD XL 2200 SERIES SECTION II PREVENTIVE MAINTENANCE TITLE CLEANING and LUBRICATION SPRING LINK ADJUSTMENT COUNTER ADJUSTMENT LOOP SETTING CABLE REQUIREMENT amp ADJUSTMENT LOOP SETTING GEAR AND ARBOR INSTALLATION RERL ARM PULLEY SERVICING SOUND DRUM AREA SERVICING FILM DAMPENER ARM ADJUSTMENT FRONT PRESSURE ROLLER ADJUSTMENT CAM LUBRICATION PAD SERVICING INTERNAL MECHANISM SERVICING MOTOR PULLEY SERVICING SAFETY SHUTTER SHUTTER AND CAM OPERATION amp ADJUSTMENT SIDE CLEARANCE CLAW PIN REQUIREMENT amp
14. 6 Stop the projector i 7 Plug an 8 ohm 25 watt dummy load into the speaker jack JS1 8 Set the volume control to its extreme Left pos ition and the Tone Control to its extreme Right position 9 Disconnect the Oscilloscope and or VTVM FA from pin 1 of Z1 and connect them across the 8 ohm resistor 10 Run the projector in Forward and gradually move the Volume Control to the Right increasing volume until the signal on the oscilloscope just starts to show clipping of the peaks Figure 5 2 CIRCUIT BOARD TEST POINTS 11 The voltage across the 8 ohm resistor should be 14 volts RMS minimum 39 5 volts P P 25db 13 The reading on the Oscilloscope and or VTVM should be 14 volts RMS i 5 12 Remove the 400 Hz loop from the projector 15 aby Yas mamii yoe R P and run the projector in Forward without film in it DO NOT MOVE THE TONE OR VOLUME CONTROL This is equivalent to a signal to noise ratio of 40db INSTA LOAD XL 2200 SERIES 8 2K Figure 5 3 BOdbm ADJUSTMENT 1 Adjust VR 1 on the main amplifier board per procedure 2 With the 400 Hz Signal Level Test Film SMPTE P16 SL Singer P N 45191 G7 running in Forward through the projector plug a 600 ohm 1 Watt re sistor into the 0 dbm jack J 7 and connect an AC VTVM across the resistor Adjust VR 6 on the 0dbm Circuit Board for Odbm reading on the AC VTVM 775 volt
15. Drive belt off pulley pulley setscrews loose pinion defective Loop setting pinion turns when project or runs flywheel drive mechanism not operating Replace defec tive gear Pivot binding spring washer missing under idler arm Kick spring for ces resetting gear into idler gear when loop setting roller is raised Gears are in good condition Loop setting arm No bottom arm spring intact Pivot moves idler gear into resetting gear when loop setting Yes Kick spring bro ken or missing Yes Yes Replace spring P N 44843 P1 roller is raised SEMICONDUCTOR TESTING 1 Transistors An effective but simple transistor test for leakage amplification and short circuit conditions may be performed using any standard 20 000 ohm volt multimeter Connect the transistor under test in the circuit shown observing polarity 1KQ Use the X100 scale for regular small signal devices and X10 scale for power types All readings are referred to the X1 scale With the base switch open the reading should be above 200 ohms A lower reading indicates exces sive leakage or a shorted transistor With the base switch closed the reading should be less than 500 ohms A higher reading indicates low gain and a very high reading indicates an open transistor Polarity is shown for NPN transistors using a Simpson 260 270 Multimeter with the
16. IC1 conditions the fully on allowing the boost capacitor C18 to series regulating circuit to turn Transistor Q7 charge 4 11 INSTA LOAD XL 2200 SERIES MARC 300 POWER SUPPLY 15 VOLTS c STRIKING STRIKE CIRCUIT CAPACITOR CHARGES CAPAC cw ror O The high output from pin 14 of IC1 turns transistor capacitor C8 to the 375 volt breakdown voltage Q2 fully on so the high voltage winding F D of of the spark gap auxiliary transformer T1 can charge the strike MARC 300 POWER SUPPLY ornikina ISPARKI cmevit SAP Boost CAPACITOR sp When the spark gap arcs C8 discharges through the applies a 15 000 volt pulse onithe anode of the primary winding of pulse Transformer T2 which Gemini 300 Lamp 4 12 INSTA LOAD XL 2200 SERIES MARC 300 POWER SUPPLY L 7 5 VOLTS BOOST OAPAOITOR OG BOOST STRIKING AADI Rih CIRCUIT CAPACITOR DISCHARGES The Arc Lamp ignites and the boost Capacitor C18 discharges through it to sustain conduction long MARC 300 POWER SUPPL enough for the series regulated circuit to take over Nero ai LAMP STRIKING CIRCUIT CURRENT REGULATED BOOST CAPAOITOR oF A voltage appears across Resistor R22 which causes a high to appear at pins 5 and 8 of IC1 The high output from pin 2 of IC1 conditions the series regulating circuit to drop th
17. d Film spills at supply reel Reverse operation e Clicking noise film picking f Damaged film at take up g Film spills in FORWARD at supply reel h Loose film on reel after rewind i Picture jumps possible loss of loop Solenoid 501 defective Rewind clutch actuator cap not engaging clutch spring properly Feed sprocket clutch not driving Teeth of feed or take up sprocket damaged or out of alignment Claw arm teeth worn damaged or missing Pressure shoe not seated properly Claw arm out of adjustment Film take up tension too high Bottom idler roller pressure too high or too low Take up sprocket defective Rewind clutch driving REMEDY Replace claw arm Clean the film Clean with Isopropyl Alcohol or Chlorothene 1 1 1 Clean and lubricate film path rollers Clean or replace reel arm pulley and bearing Adjust end play by reducing number of washers 35473 P48 Replace feed sprocket Replace Solenoid SO1 Check cap spring engagement Replace actuator cap or spring as necessary Check feed sprocket clutch spring and arbor Replace as necessary Replace feed or take up sprocket Replace claw arm Adjust pressure shoe Adjust stroke and or protrusion Adjust take up tension Adjust pressure roller eccentric Replace take up sprocket Clean and adjust rewind clutch Check rewind clutch for pro per end play Replace actuator cap spring or arbor as neces
18. Assembly 26 along k the main shaft toward the rear of the projector as far as it will go 9 Pull the Inching Knob 9 off the front of the main shaft and push the main shaft toward the rear of the projector as far as it will go 4 10 Tuck a cleaning cloth under the main shaft bear ings Remove C Ring 29 located between the Shutter and Cam Assembly 26 and the Front Bearing 28 11 Remove C Ring 16 12 Drive Pin 21 completely out of Gear 20 13 Remove the cam Lubricating Pad 14 Put the Inching Knob 9 back on the front of the 5 main shaft and pull the main shaft toward the front of the projector removing the Pulley 13 and other parts in order until the Shutter and Cam Assembly 26 can be removed N Reassembly of Main Shaft 1 Assemble the parts to the main shaft in reverse hs order from which they were removed 3 10 Apply a thin coat of DC 44 grease 39479 P9 to the outside circumference of main shaft Bearings 15 and 28 Install C Rings 16 and 29 with Waldes retain ing ring applicator CR 0310 Align the Set Screws 31 in Collar 30 with their corresponding recesses in the main shaft and start tightening them Be sure the points of the screws seat properly in the recesses Otherwise the main shaft will be burred and will not be position ed properly in the projector It is best to tighten each one a little bit at a time and alternately with the other one until they cannot b
19. FEED AND REWIND SYSTEM The feed and rewind system consists of three clutches the Feed Sprocket Clutch 37 the Rewind Clutch 27 and the Fast Forward Clutch 32 on models having that feature Figure 2 The Feed Sprocket Clutch is driven by the front worm gear on the main drive shaft Figure 1 It in turn drives the Fast Forward and Rewind Clutches The drive it supplies is direct in all forward modes and in Rewind and clutched in Reverse The Rewind Clutch slips freely in all forward modes but is locked in direct drive in Reverse and Rewind by the Rewind Solenoid It therefore provides no drive to the supply reel in forward modes but always supplies direct drive to the supply reel through the reel arm belt in Reverse and Rewind The Fast Forward Clutch slips freely in every mode but Fast Forward In the Fast Forward mode it is locked into direct drive by the Fast Forward Solenoid and drives the take up reel through the Fast Forward Drive Belt and the Take up Reel Arm Belt The Sound Drum and Optic The Take Up System The Flywheel Drive System The Electrical System Om IG thorough understanding of each function and its relationship with the other functions will be a great assistance in servicing these projectors Figure 2 INSTA LOAD XL 2200 SERIES FORWARD Figure 3 The tail of the Clutch Spring 6 is permanently trapped in a notch N in the Clutch Gear 14 The coil of the spring
20. Models 2270 and 2280 speaker Replace defective component Defective C23 C24 C9 Replace defective component TROUBLE Miscellaneous Troubles a Motor runs drive shaft does not rotate b Failure to start on low power c Loss of power and or speed d Failure to set upper loop e Master control lever binds when moving from LOAD to PROJECT f Projection lens binds g Projection lens loose INSTA LOAD XL 2200 SERIES REMEDY Motor belt tension low belt slips Main shaft pulley loose Belt and pulleys dirty Motor pulley pin broken Kick spring on main drive motor hub not functioning properly Adjust belt tension Tighten setscrews Clean with isopropyl alcohol or chlorothene 1 1 1 Replace pulley or pin 39092 P1 Check as follows 1 Hold pulley without binding motor shaft Wind spring to fully tight position by rotating fan 2 Re lease fan Spring must throw fan 180 If less than 180 clean and lubricate replace spring if necessary Extremely low line voltage Low drive belt tension Loop set cables loose or off pulley Defective loop setting gear or drum in front sprocket assy Defective loop setting gear or drum in front sprocket assy Lensholder stop pin not set correctly Front sprocket clutch spring assembled improperly Lens locking screw binding on lens housing Rack and pinion damaged Pinion retainer worn or damaged
21. P16 SL Signal Level Test Film Optical 400 Hz 12 Pi5 PP SMPTE Jiffy Test Film Available in 100 Roll from Test Film Dept Society of Motion Picture amp Television Engineers 862 Scarsdale Avenue Scarsdale NY 10583 Also available through above source CLAW ARM PROTRUSION GAUGE STROKE SETTING GAUGE SHUTTLE CAM ADJUSTING TOOL ROLL PIN INSERTING AND EXTRACTING TOOL REPLACEMENT PIN FILM TENSION GAUGE WALDES TRU ARC NO 52 APPLICATOR WALDES TRU ARC NO 54 APPLICATOR WALDES TRU ARC NO CR 31 APPLICATOR SOUND DRUM LOCATING PLUG INSTA LOAD XL 2200 SERIES DRIVE UNIT ASSEMBLY TV TRIM MOTOR SHAFT 5 16 AFTER LOCATING 06 HOLE pe 7 CLEARANCE GROOVE 8 TO PERMIT ACCESS 1 2 TO COLLAR SCREWS Wey 067 Hole L in shaft 1 4 W 1 8 D 9 32 DIA LD 1312 TYPICAL ASSEMBLY 18 MOTOR 40459 G3 VIEW OF DRIVE SHAFT END PART No DESCRIPTION PART No DESCRIPTION 1 39099 COLLAR 10 GROUND STRAP 2 38206 3 BEARING 11 35473 46X WASHER 3 40465 G2 PULLEY ASSEMBLY 12 39081 SPACER Rubber 4 39098 P1 SPRING 13 30473 P73H WASHER 5 42872 G1 HUB ASSEMBLY 14 32090 P48 SPACER 6 192 4 8 PIN 15 265 5 GROMMET 7 39128 P1 FAN 16 47239 G1 MOTOR PLATE 8 257 2 RETAINER Modified 17 116 10R 8H SCREW Mounting 9 203 8 NUT Stop 18 40459 G3 MOTOR ASSEMBLY 40460 P2 MOTOR 44360 P1 TERMINAL Not Shown 44505 P9 HOUSING Not Shown INSTA LOAD XL 2200 SERIES Top edge of new holes must not extend original
22. ams et i I REITER LAMP i 4 9 INSTA LOAD XL 2200 SERIES THE MAIN AMPLIFIER The Main Amplifier consists of Preamplifier Z1A and Z1B Tone Control VR 2 Volume Control VR 3 Mixer Amplifier Z4D and Driver and Power Amplifier Z2 Q1 and Q2 The variations of light intensity produced by the exciter lamp shining through the sound track on the film are picked up by a photo sensitive diode PD 1 and converted to elec trical variations These electrical variations are fed into the Preamplifier Z1A and Z1B where they are amplified and fed to the Tone Volume Control VR 2 and VR 3 From there they pass into the Mixer Amplifier Z4D and then into the Driver and Power Amplifier 22 Q1 and Q2 The Power Amplifier then drives the Speakers LS1 and LS2 mounted in the pro jector A standard 4 audio jack JS1 is provided for connecting an external speaker The external speaker plug opens the normally closed contacts of this jack and removes the internal speakers from the circuit THE MICROPHONE PREAMPLIFIER With the Microphone plugged into the Mic Jack JM 1 and the Microphone Level Control VR4 adjusted to the desired level the signals intro duced by the microphone are amplified by the Pre amplifier Z4A and Z4B and fed from the Level Control VR4 to the Mixer Amplifier Z4C From there they are fed to the Drive and Power Ampli fier 22 Q1 and Q2 and then to the Speakers
23. defective Switch S7 defective Model 2270 Switch 82 defective Relay K3 defective Models 2270 and 2280 c Projector operates but projec tion lamp does not illuminate when the FORWARD button is pressed d Low light level on screen during projection e Film burns in still mode f Projector does not operate when REVERSE button is depressed g Fast mode interlock light does not come on with Master Control Lever in LOAD FAST and FOR WARD or REVERSE button pressed Projection lamp defective Transformer Tl defective Switch 82 defective Switch S9 defective Switch S7 defective Models 2270 and 2280 Lamphouse cover not in place properly Model 2280 Switch S8 defective Model 2280 Safety shutter not lifting Safety shutter sticking Safety shutter defective Safety shutter sticking on bumper pad Safety shutter return spring unhooked or missing Safety shutter defective Switch 82 defective terminals H 8 or J 6 Interlock lamp L3 defective Capacitor C18 shorted Relay K2 defective Diode D3 open Resistor R27 open Replace Blower Motor Replace Blower Motor Relay K7 on 2270 and K6 on 2280 Replace Switch 82 Replace Switch S7 Model 2270 Replace Switch 82 Replace Relay K3 Replace lamp Replace transformer Replace Switch 82 Replace Switch 9 Replace Switch S7 Assemble lamphouse cover to projector properly Replace Switch 88 Redampen with DC200 39479 P13 Visual
24. drum holds the film firmly against the sound drum and a damp ening roller behind the sound drum maintains a constant film speed over the sound drum for maximum fidelity of sound reproduction The movement of film over the sound drum causes the sound drum to rotate A balanced flywheel mounted on the end of the sound drum shaft main tains a constant rotational speed of the sound drum which also insures maximum fidelity of sound reproduction TAKE UP SYSTEM Film is drawn through the sound drum portion of the projector by the take up sprocket then passed ovey the reel tension arm pulley and is gathered on the take up reel Figure12 The take up sprocket turns at a constant rate of speed since it is attached to the shaft of the take up gear which is driven by the rear worm gear on the main drive shaft Film is thus fed to the take up reel at a constant rate of speed However the take up reel must be able to turn at variable speed since the diameter of its take up surface varies continuously as film is gathered on it The drive mechanism which drives the take up reel with the reel arm belt is therefore continuously clutched and self adjusting to compensate for the increased diameter and weight of the take up reel Take Up Clutch Figure 12 INSTA LOAD XL 2200 SERIES Ex The clutching action is provided by the interaction of the take up clutch arm and pulley 9 the take up clutch liner 16 and the take up
25. gt 4 TOP STEP MOVES DOWN TO REFERENCE LINE FOR CORRECT STROKE 5 GAUGE TOUCHES PIN Figure 3 30 CLAW PULL DOWN STROKE 10 Adjust stroke by placing the Shuttle Cam Adjust ing Tool ST 5884 on the Claw Arm Pivot 18 Figure 3 26 loosening Screws 14 and 19 and rotating the Pivot 18 and the Bushing 8 the same amount in the same direction simul taneously Turn counterclockwise as viewed from the front of the projector to shorten the stroke and clockwise to lengthen the stroke Figure 3 31 Note Theoretically turning the Pivot 18 and the Bushing 8 equally will change Pull Down Stroke but not Side Clearance How ever Side Clearance should be checked REQUIREMENT The Top Claw Arm Pin should be the same distance from the inside edge of the Gauge sprocket hole at the top of its stroke as it is from the outside edge of the Gauge sprocket hole at the bottom of its stroke Figure 3 27 INSTA LOAD XL 2200 SERIES Loosen Screw 14 and adjust the Bushing PIVOT 18 MUST ALWAYS BE BETWEEN 8 Figure 3 26 so these two distances 6 and 9 O CLOCK AS VIEWED FROM THE are equal FRONT OF THE PROJECTOR IF NOT the cam follower on the Claw Arm may be WHEN ADJUSTMENTS ARE COMPLETE severely worn requiring replacement of THE ECCENTRIC PIN IN THE FRONT the Claw Arm IMAGE MOVES DOWN WHEN GAUGE IS MOVED UP prs Jue gt INITIAL REFERENCE LINE CORRECT STROKE ie am Noe TOP CL
26. ohmmeter voltage selector switch set on positive DC PNP transistors may be checked by reversing the VOM polarity Observe opposite polarity of terminal voltage when using Weston or Triplett instruments 2 Diodes Front to back resistance ratio will indicate silicon and germanium diode defects Using the RX100 multimeter scale a diode should measure a very low resistance with one lead test probe polarity and very high resistance with leads reversed 3 Zener Diodes Depending on voltage rating Zener diodes will exhibit lower reverse resistance than regular diodes but a marked front to back ratio should be evident 63 INSTA LOAD XL 2200 SERIES Take up Sluggish Erratic or Fails Clean take up reel arm pulley shaft and bear ing Adjust lift off Check and adjust take up tension 4 to 6 ounces Take up functions No Replace clutch liner gear clean clutch arm pulley shaft and bearing Projector Exhibits WOW In Sound 6 4 Film dampener arm drops in 3 to 5 seconds Reform spring of Front sound drum front pressure pressure roller roller tension is 3 to 5 Adjust eccentric Rear sprocket pressure rollers are adjusted Remove sound drum Clean sound drum shaft and oilite bearing Check for binding rollers etc Add or remove DC 200 dampen ing fluid from dampener arm Adjust take up tension INSTA LOAD XL 2200 SERIES
27. oil 39479 P8 and assemble as shown The loop setting gear should turn smoothly in both directions Move the master control lever up and down several times after assembling each part If binding occurs the last part assembled is probably the cause Continue assembling the sprocket and film stripper and check for smooth operation of the Master Control Lever F REEL ARM PULLEY SERVICING OILITE bearings in the Reel Arms require clean 4 ne pommel ing and lubricating each time preventive main hu tenance or overhaul is performed Remove and discard the reel belts INSTA LOAD XL 2200 SERIFS Mark one of the flat sides of the reel arm lock with a felt marker and mark the face of the pulley to correspond with this mark so proper orienta tion of the roll pin hole can be maintained during reassembly Use the roll pin inserting and extracting tool T 38000 N to remove and insert the roll pin shown being inserted The roll pin may be removed by using a pin punch Support the spindle on a block of wood when knock ing out the pin Clean the oilite bearing with a cotton swab saturated with Teresso Instrument Oil 39479 P8 DO NOT USE SOLVENTS ON OILITE BEARINGS Clean the pulley and shaft with crocus cloth DO NOT USE SANDPAPER OR EMERY PAPER If the shaft is scored the pulley assembly must be replaced 2 8 INSTA LOAD XL 2200 SERIES Insert the new spring bel
28. start winding and the brown wire of the run winding of the Main Drive Motor The NEUTRAL side of the line is connected to the white wire of the start winding and the yellow wire of the run winding of this motor Thus the phase relationship is estab lished between the windings which causes the motor to run in forward Relay K1 is operated because one side of its winding terminal 9 is connected to the line NEUTRAL through switches 53 and S4 and the other side of its winding terminal 11 is connected to the line LIVE through switch S6 Relay contacts K3 and switches S2C and S514 The normally closed contacts K1A open breaking the exciter lamp circuit to mute the sound in the fast mode Contact K1B connecta the line or matna NEUTRAL to the Fast Forward Sol noid SO3X terminal 5 The solenoid operates be cause its other end terminal 6 is connected to line LIVE through switch S2GH Relay K3 and switches S2C and 14 With the Fast Forward solenoid operated the Fast Forward Clutch is locked into direct drive to transport film rapidly through the projector in the forward direction When film is transported rapidly IN PATH through the projector it must not be possible to raise the Master Control Lever to the Project Mode and close the mechanism tightly on the film or else the film would be damaged A Fast mode interlock system is used to prevent this from happening
29. thin coat of dampening fluid on the post on which the arm mounts and reassemble the arm and spring to the projector Add more dampening fluid if the arm drops in less than 3 to 5 seconds Remove fluid if the arm drops too slowly 2 10 Reassemble the Sound Drum and Flywheel With the Master Control Lever in the PROJECT pos ition raise the film dampener arm Rehind the sound drum to its uppermost position When released it should take 3 to 5 seconds to drop to its rest position INSTA LOAD XL 2200 SERIES G2 FRONT PRESSURE ROLLER ADJUSTMENTS Connect the take up tension gage T 38000 S to the sound drum front pressure roller with small loop of film as shown When the gage measures 3 to 5 ounces the roller should just start to move away from the sound drum Form Front Pressure Roller Spring along its entire length to increase or decrease pressure DO NOT BEND THIS SPRING FORM IT The front pressure roller must be square and parallel with the sound drum Make sure pressure roller rivets or pressure roller spring rivets are not loose Tighten by squeezing with vise grips ROLLER SQUARE amp PARALLEL Twist the pressure roller spring if necessary to obtain parallelism Recheck pressure roller lift off tension H CAM LUBRICATING PAD SERVICING The Cam Lubricating Pad must be changed each time preventive maintenance or overhaul is per formed on a projector WITH DRUM GP INST
30. through the wind switches 5 5 and 5 3 ing of K3 to terminal 7 of 52 sf BOY eM dtg cou i KT m cottars Er rs Ti Aik 52 rga war Gard P23 er 4 i fr st L ais ro sane ES 370 var wee E 4 a Am a u 4 par fen m7 sem aly FRAME GROUND f RIS me 32 aon ay etz c seo L K wa ys 1 sj Rip 5 a 7 wis He HOV N a Figure 15 Forward Project INSTA LOAD XL 2200 SERIES Switches S2D and S7 are closed applying either 22 or 24 volts AC from the Hi Lo Lamp Switch 59 to the Blower Motor Relay K7 and Projection Lamp Li The Relay operates since the other side of its coil is connected directly to the NEUTRAL side of the primary of the Transformer T1 The Projection Lamp lights having its circuit completed through the C and NC contacts of switch 83 and the blower Motor operates with LIVE power connected to one side of it through the closed contacts of Relay K7 and NEUTRAL power connected to its other side through the C and N C contacts of Switch 53 NOTE The Projection Lamp and Blower Motor oper ate only when the Master Control Lever is in the PROJECT position Switches S83 and 57 move to their N O contacts when the Master Control Lever is in the LOAD position removing pow
31. up clutch pulley with the take up clutch liner It is accomplished by adjusting the bottom two nuts on the threaded rod so the pulley exerts just the right amount of pressure on the liner Too little pressure will result in erratic take up and too much pressure may break the take up gear Mount an empty 400 foot reel on the take up arm move the master control lever to PROJECT and run the projector in FORWARD Turn both bottom nuts up until the 400 foot reel just stops turning Make sure the flat plate always remains firmly trapped between these two nuts Mark one face of the bottom nut for reference and turn the bottom nut down three turns Turn the top nut down until it snugs tightly against the flat plate This establishes correct lift off U FAST FORWARD DRIVE REQUIREMENT Place an empty 400 foot reel on the take up arm Connect the Take up Film Tension Gage T 38000 S to this reel about 3 out from the center by means of a paper clip or other wire suitable for this purpose Run projector in FAST FORWARD mode The gage should read 13 to 18 ounces INSTA LOAD XL 2200 SERIES FAST FORWARD DRIVE BELT ADJUSTMENT Loosen the screw holding the Adjusting Plate and move the plate either up to decrease torque or down to increase torque Tighten the screw Note If this fails to change the torque make sure the FAST FORWARD Solenoid is causing the FAST FORWARD clutch to engage Asa last resort it is permi
32. very careful that the Cam Follower on the Claw Arm contacts the radial surface of the Cam 12 13 14 Note Be very careful not to damage the Claw Arm pins Perform all Claw Arm adjustments Pin protru sion Side clearance Pull down stroke and Fram ing Align the main shaft Pulley 13 with the motor pulley for proper drive belt tracking Lubricate the Drive Gears 20 and 32 witha thin coat of DC 44 grease 39479 P9 Lubricate the Safety Shutter 24 with DC 200 Dampening Fluid 39479 P13 Lubricate the Pinion 22 with a light coat of DC 44 39479 P9 FRONT VIEW OVAL POINT 1 171 A6 3 OVAL POINT 3 171 A6 3 W POINT 2 43496 P001 TORQUE ALL SCREWS 140 In Oz SHUTTER CAM POSITION WHEN ADJUSTING CLAW ARM PIN PROTRUSION Figure 3 20 REMOVAL AND REASSEMBLY OF CLAW ARM P Removal of Claw Arm Note Extreme care should be exercised during this procedure to insure that the pins on the Claw Arm are not allowed to hit the aperture plate or any other part of the projector causing damage to them Unhook the top of the Claw Arm Spring 15 from the Framing Arm 20 and make sure all tension is off the Claw Arm 13 before proceeding with these instructions Remove the oval point Jam Screw 3 in the Shut ter and Shaft Alignment insert on Figure 3 20 and loosen the remaining two Setscrews 1 and 2 in the insert and move the Shutter and Cam Assembly back on the main shaf
33. 0 SERIES PHOTO DIODE INSULATING RETAINER p TUBING SOUND DRUM SUPPORT CABLE CUT AWAY VIEW CABLE TIE 5 Figure 3 33 REPLACING PHOTO DIODE CHIP IN SOUND DRUM SUPPORT Mix 100 parts of Hysol R9 2039 Resin to 11 parts of Hysol H2 3404 Hardener by weight Dip a toothpick or paperclip in the cement mixture and apply cement to the slot contacting the front edge of the Photo Diode so the cement will run under the Diode DO NOT allow the cement to get on the top surface of the Diode Allow the cement to dry thoroughly overnight before proceeding Slide the insulating tubing on the leads of the Photo Diode and make sure that the third piece of tubing is on the shield of the Cable 4 Solder the Black lead of the Photo Diode to the Shield of the Cable and the Red lead to the Center Conductor Slide the tubing over the solder connections It may be helpful to cut the Cable Tie 5 so the Cable can be lifted out of the slot for soldering Dress the wires into the slot and replace the Cable Tie if cut Measure the resistance between the Shield of the Cable and the Sound Drum Support with an Ohm meter The resistance must be 5 Megohms MIN IMUM T Sound Drum Adjustments 1 Loosen the Sound Optic Setscrew and remove the Sound Optic Cartridge This Cartridge may be very difficult to remove due to the wedging action of the nylon plug used to lock it in place Rotating it back and forth while push
34. 02 4 6 When the projector is initially turned on in the Rewind mode Relay K2 does not operate because capacitor C18 acts as a momentary short across it while it is charging After 3 to 5 seconds C18 is charged and K2 operates to connect the LIVE side of the line to Interlock Solenoid SO2 and Inter lock Indicator Lamp L3 These operate because their other side is connected to the line NEUTRAL through the N O contacts of Switch S3 and Switch 84 INSTA LOAD XL 2200 SERIES En T Zov RMS Jc Ki de rs ET mik 52 aa Fand te x NS on p23 4 com c 7 f 3 q E ais wawar Ho g 370 var der Ki ii n2 az z FRAME GROUND Te me ae wa 096678 AMP SCHEMATIC 2 1 vea 32 2 DIRECT Deve en caa lt Liu CHARGED de a pa ne bo ve DN T hs Figure 21 Rewind 2270 C 18 Charged Interlock Solenoid 502 performs two distinct functions in Rewind First it operates the mechan ism which locks the Master Control Lever in the Fast Mode position Second it causes the Feed Sprocket Clutch to go into direct drive so it will not slip when driving the Rewind Clutch in Rewind See REWIND under FEED AND REWIND SYSTEM Interlock Indicator Lamp L3 lights to show that the mechanism is in a Fast Mode function When the projector is t
35. 1 51 and LS2 Since the Microphone signal is fed through Mixer Amplifier Z4C at the same time that the Main Amplifier signal is fed through Mixer Amplifier Z4D it is possible to talk over the sound on the film with the microphone It is also possible to use the projector as a P A amplifier by using just the microphone feature with no film running in the projector THE MUTING CIRCUIT The purpose of the Muting Circuit is to open the eireuit between the Main Amplifier output and the speakers each time a button on the Main Control Switch is depressed thereby eliminating switch clicks or popping in the speakers caused by transients produced from opening and closing switch contacts Half Wave Rectifier D2 and Filter Capacitor C40 produce the positive voltage required to operate Transistors Q4 Q5 and Q6 A small portion of this positive voltage is impressed on the base of Q5 through Resistors R62 R63 and R65 forward biasing the transistor and allowing it to conduct In turn Q5 forward biases Q6 and it conducts through Relay K4 The Relay operates and its contacts close completing the speaker 4 10 circuit Transistor Q4 is cut off at this time by the ground connected to ite base through the switches 511 and S2E When any button is depressed on the Main Control 4 Switch 82 contact S2E opens as the button starts down and closes when the button reaches the bottom of its travel This lift
36. 14V DC 5 6 DC Q3 R 38 gt T1 L2 gt Exciter Lamp 27v DC Figure 5 7 DC Power Supply Fxciter Lamp voltage on all 2200 Series Projectors should be approximately 5 6 volts DC WITH THE Lamp removed from the circuit the open circuit EXCITER LAMP IN THE CIRCUIT With the Exciter voltage is 18 volts DC INSTA LOAD XL 2200 SERIES SECTION VI TROUBLE SHOOTING TROUBLESHOOTING AID CHARTS The Troubleshooting Aid Charts are included as a logical approach to a troubleshooting procedure They are by no means the final word on how troubles should be traced but they are designed to eliminate as much duplica tion of effort as possible Simply follow the direction of the arrow describing the condition existing during any given test If following arrows results in a closed loop then a trouble most likely exists in that area and further testing in that area is recommended Loses Upper Loop Use film having good sprocket holes No Sprocket holes Jinfilmare good Claw Arm pin protrusion is between 035 Adjust pin protrusion Pressure shoe seated proper ly in aperture plate Adjust pressure shoe Adjust take up tension Replace spring and or arbor Front sprocket clutch spring and arbor are O K Yes Supply reel arm pulley turns freely Clean supply reel arm bear ings replace pulley No
37. 21 loosening Screws 14 and 19 and rotating the Pivot 18 and Bushing 8 the same amount in the same direction simultaneous ly Turn counterclockwise as viewed from the front of the projector to shorten the stroke and clockwise to lengthen the stroke Figure 3 25 Note Theoretically turning the Pivot 18 and the Bushing 8 equally will change Pull Down Stroke but not Side Clearance How ever Side Clearance should be checked REQUIREMENT The Top Claw Arm Pin should be the same distance from the inside edge of the Gauge IMAGE MOVES DOWN sprocket hole at the top of its stroke as it is from the outside edge of the gauge sprock et hole at the bottom of its stroke Figure 3 22 Loosen Screw 14 and adjust the Bushing 8 Figure 3 21 so these two distances are equal WHEN ADJUSTMENTS ARE COMPLETE THE ECCENTRIC PIN IN THE FRONT PIVOT 18 MUST ALWAYS BE BETWEEN 6 AND 9 O CLOCK AS VIEWED FROM THE FRONT OF THE PROJECTOR IF NOT the cam follower on the Claw Arm may be severely worn requiring replacement of the Claw Arm SPROCKET WHEN GAUGE IS MOVED UP HOLE CLAW ARM PIVOT F 0015 TOP CLAW ARM PIN ECCENTRIC REFERENCE LINE CORRECT STROKE ra REFERENCE LINE STROKE TOO LONG REFERENCE LINE lo CORRECT ENTRY OF TOP CLAW ARM PIN TOP CLAW ARM PIN ENTERS TOO HIGH PIN STARTING POSITION NS TURN COUNTER CLOCKWISE TO SHORTEN STROKE KS
38. 4 TAKE UP SPROCKET LOADING 3 7 INSTA LOAD XL 2200 SERIES J Spring Loading Tip 1 An easy way to load the Spring is to use the projector drive motor running in REVERSE 2 Assemble the spring to the projector as describ ed above 3 While holding both the Spring 9 and the Sprocket 10 push the REVERSE button and allow the turning of the shaft to wind the Spring 4 When the Spring is small enough it can be pushed into the Sprocket The same method may be used to load the Spring after the Stop 7 has been in stalled Figure 3 15 WINDING TAKE UP SPROCKET SPRING Spring 44843 P001 Figure 3 16 AUTOMATIC LOOP RESET REMOVAL AND REASSEMBLY K Removal of Automatic Loop Reset Assembly 1 Remove the venturi plate 1 4 Slide the Arm Complete 4 out of its mounting hole in the main casting 2 Remove the sound drum Flywheel 2 5 Loosen the Set Screws 5 remove Belt loop setter 6 the 3 With a long flat blade screwdriver reach in behind the Pulley 7 and slide the Pinion 8 out of the bearing of the blower venturi plate and remove the E Ring 3 Pivot 9 6 Remove the E Ring 10 the Gear 11 and the Kick Spring 12 INSTA LOAD XL 2200 SERIES L Reassembly of Automatic Loop Reset Assembly Ref Figure 3 16 Clean the Oilite Bearing in the Pivot 9 with a cotton swab moistened with Teresso Instrument Oil 39479 P8 Assemble the Kick Spring 12 immediately next to
39. 6 Clear General Electric Co Schenectady New York 3 oz 39490 P1 Glyptal No 7526 Blue General Electric Co Schenectady New York 3 oz LP A 963 B Cement W J Ruscoe Co Akron Ohio LP Hysol R9 2039 Resin Hysol Corp Olean New York LP Hysol H2 3404 Hardener Hysol Corp Olean New York LUBRICANTS 39479 P4 FS 1290 Flourosilicone Grease Dow Corning Corp Midland Michigan 1 2 oz 39479 P5 DC 200 Silicone Fluid 200 000 Centistroke Viscosity Dow Corning Corp Midland Michigan 1 2 oz 39479 P13 DC 200 Silicone Fluid 200 Centistroke Visosity Dow Corning Corp Midland Michigan 1 2 oz 39479 P7 009 Lubricant Keystone Carbon Co St Mary s Pa 1 2 oz 39479 P8 Instrument Oil N 75 2 oz 39479 P9 DC 44 Silicone Grease Light Consistency Dow Corning Corp Midland Michigan 2 oz 39479 P14 G E Versilube G 322L Za 39479 P15 Vischem 352 Ultra Chem Inc Wilmington Del 2 oz MISCELLANEOUS 39490 P4 Clyptal Thinner 1511M 8 oz LP 8101 S Silicone Compount General Cement Rockford IL LP Chlorothene Dow Chemical Co Midland Michigan 1 1 1 LP Methyl Alcohol TEST FILMS TV16AS 16mm Television Test Film Alignment amp Resolution 40 Loop 40478 P3 45191 G7 sole D TOOLS G10 38000 ST 5880 ST 5884 T 38000 N T 38000 N1 T 38000 5 T 38000 U T 38000 V T 38000 X T 38001 G 1 10 P16 SF A 7000 Hz Film PH 22 42 7 12 P16 B T Buzz Track Film PH22 57 12 16 RT 16mm Registration Test Film 12
40. A LOAD XL 2200 SERIES Loogen the two lube pad spring retaining screws and replace pad New Pads are supplied with the correct amount of lubricant already on them 16 drops of Teresso Instrument Oil 39479 P8 J INTERNAL MECHANISM SERVICING The internal mechanism must be thoroughly cleaned and relubricated Clean Worm Gears with a clean dry cloth or a clean dry toothbrush DO NOT USE SOLVENTS Relubricate by brushing DC44 Grease 39479P9 into the teeth K MOTOR PULLEY SERVICING If the motor pulley wobbles on the shaft replace the nylon pulley bearing Carefully tap out the 1 16 roll pin which secures the fan hub to the motor shaft INSTA LOAD XL 2200 SERIES Slide the fan hub motor pulley and bearing from the motor shaft carefully noting the positioning of the fiber washer and nylon bearing Wash all parts in alcohol or chlorothene 1 1 1 Lubricate the inside and outside of the nylon bearing with FS 1290 grease 39479P4 Lubricate the fan hub kick spring by applying Vischem 352 grease 39479P15 between the spring and the fan hub When reassembling make sure that the pin on the motor pulley and the pin on the fan hub do not trap one of the tails of the spring between them There should always be spring action between these two pins otherwise damage may result to the projector L SAFETY SHUTTER THEORY The safety shutter is operated by a Viscous Fluid which sets up a drag between
41. ADJUSTMENT PRESSURE SIOE AUTOMATIC LOOP RESET SERVICING DRIVE BELT REWIND BRAKE TAKE UP ADJUSTMENT LIFT OFF FAST FORWARD BUZZ amp SOUND OPTIC FOCUSING SOUND OPTIC FOCUSING ADJUST MENT BUZZ ADJUSTMENT FINAL PERFORMANCE TEST PREVENTIVE MAINTENANCE LUBRICATION CHART OVERHAUL MAINTENANCE LUBRICATION CHART OPERATION CHECK INSTA LOAD XL 2200 SERIES SECTION H PREVENTIVE MAINTENANCE To insure proper operation of Telex Model 2200 Projectors preventive maintenance should be performed every 500 hours or once a year whichever occurs first The Projector should be thoroughly cleaned and then checked for proper operation before any parts replacement or adjustments are attempted 10 11 12 13 14 15 16 17 18 19 Reel Spindle Lock Lever Take up Sprocket Lamphouse Cover Framing Knob Feed Sprocket Reel Arm Lock Manual Advance Knob Elevation Knob Auto Loop Restorer Hi Lo Lamp Switch Speaker Jack Film Control Buttons Film Pressure Shoe Volume Tone Control Main Power Switch 2270 amp 2280 Microphone Jack 2270 amp 2280 Microphone Control 2270 amp 2280 Master Control Lever Film Counter START WITH A CLEAN BENCH FINISH WITH A CLEAN BENCH Left over parts Check your reassembly 2 1 INSTA LOAD XL 2200 SERIES Cleaning Suggestions Claw Arm Remove all lint and dirt All dust and grime should be removed te from external surfaces of covers main casting
42. AW ARM PIN RE FERENCES ENTERS TOO HIGH o REFERENCE LINE TOP CLAW ARM PIN ENTERS TOO LOW SPROCKET HOLE CLAW ARM PIVOT TOP CLAW SEM FIN ECCENTRIC PIN CORRECT ENTRY OF TOP CLAW ARM PIN STARTING POSITION N TURN COUNTER CLOCKWISE TO SHORTEN STROKE Q TURN CLOCKWISE TO LENGHTEN STROKE STROKE TOO LONG POSITION OF TOP CLAW STROKE TOO SHORT ARM PIN AT REENTRY INTO SPROCKET HOLE PROJECTED IMAGE OF GAUGE POSITION OF PIVOT Figure 3 31 CLAW PULL DOWN STROKE ADJUSTMENTS 11 Ifthe stroke was adjusted repeat Steps 2 through projected Target with the reference line and 10 When performing Step 8 it is quite probable then proceed with Steps 9 and 10 It may be that the bottom step of the projected Target no necessary to repeat this sequence of steps sev longer rests on the reference line ADJUST THE eral times until correct stroke and side clear ELEVATION to line up the bottom step of the ance are obtained 3 17 INSTA LOAD XL 2200 SERIES R Framing Adjustment After the Claw Arm Adjustments have been checked and or made the Framing Limit Plate can be adjusted Figure 3 32 Thread film in the Projector and run it in FOR WARD Adjust the Framing Knob to eliminate any frame lines at the top or bottom of the pro jected image Loosen two Screws 41 and slide the Framing Limit Plate 40 so the top of the Framing Arm 43 is centered in the notch of the Framing Limit Plate 40 T
43. Arm Adjustment Model 2280 FRAMING ADJUSTMENT REPLACING PHOTO DIODE CHIP IN SOUND DRUM SOUND DRUM ADJUSTMENTS FEED SPROCKET CLUTCH FAST FORWARD and REWIND CLUTCHES SWITCH ADJUST MENTS FILM COUNTER INSTA LOAD XL 2200 SERIES SECTION III SERVICE PROCEDURES A GENERAL This section provides repair reassembly adjustments and preventive maintenance instructions B TOOLS AND EQUIPMENT Servicing Telex INSTA LOAD 2200 SERIES Projectors will be facilitated by tools and equipment described in this section Some tools are standard tools Special tools have been assigned tool numbers and are available from Telex Communications Inc 1 Special Tools Special tools required in the repair of the projector are listed below For a description of these tools refer to the applicable illustration FRONT VIEW ST 5884 Claw Arm Adjusting Tool Pg 3 ii G10 38000 Claw Arm Protrusion Gage Pg 3 iii T 38000 N Rollpin Insert and Extracting Tool Pg 3 iii T 38000 S Take up Film Tension Gage Pg 3 iii ST 5880 Stroke Setting Gage Pg 3 iii REAR VIEW T 38001 G Sound Drum Locating Plug Pg 3 iv S 305 Be re Gage Used to adjust claw arm side clearance and I i T 43411 G1A Solenoid Holding Clamp pull down stroke Pg 3 iv 88 327 Solenoid Stroke Gage CLAW ARM ADJUSTING TOOL Pg 3 iv No ST 5884 T 43680 G1G Sound Optics Adjusting Tool Pg 3 iv 2 Commercial Tools The commercial tools used in th
44. Bushing 8 Figure 3 26 so these two distances are equal Remove the film from the projector after proper Framing and Side Clear ance are established Note These two adjustments are interdependent and must be adjusted at the same time If either one is adjusted the other must be checked and adjusted as necessary until requirements for both can be met A good starting position for the Pivot 18 Fig ure 3 26 places its eccentric pin at about 7 o clock when viewed from the front of the pro wee APERTURE jector See Figure 3 25 The notch in Bushing 8 should be slightly below the notch in Pivot 18 so an imaginary line drawn across the top of the Bushing notch aligns with the bottom of the Pivot notch Before attempting any adjustments manually MAIN CASTING gt DISTANCE A rotate the Inching Knob to make sure the Claw Arm pins do not strike the sides of the Aperture bis AT Top IQ Plate Claw Slot At the top of the Claw Arm OF STROKE APERTURE PLATE Stroke the Top Claw Arm Pin will be nearer CLAW SLOT the inside edge of the Aperture Plate Slot Fig ure 3 27 At the bottom of its travel this Pin TOP CLAW will be nearer the outside edge of the Aperture PIN AT BOTTOM O Plate Slot Loosen Screw 14 and adjust Bush OF Steger ing 8 Figure 3 26 so these two distances are I equal Removing the Lamphouse Cover and viewing the Pins from behind the Aperture Plate aids in this adjustment REQUIREMENT
45. Check line voltage consult with power company Adjust drive belt tension Reassemble tighten and adjust Replace defective part s Replace defective part s Adjust lensholder stop pin Reassemble properly Reassemble screw properly Replace defective part s Replace defective part s 6 11 INSTA LOAD XL 2200 SERIES 6 12 CIRCUIT BOARD TEST POINTS
46. Continuity indicates correct protrusion between 035 and 040 No continuity indicates protrusion is less than 035 and should be adjusted Figure B 035 0 89MM 040 102MM NOTE The protrusion on NEW projectors is get at 040 to 045 to allow for run in This measurement is acceptable for NEW projectors However when re placing the claw arm adjust to the 035 to 040 re quirement EARLY CURRENT EARLY CURRENT REFERENCE TOP PIN AT NO GO TOP PIN AT GO 0 040 GAGE STEP 0 035 GAGE STEP INSTA LOAD XL 2200 SERIES CLAW PIN PROTRUSION ADJUSTMENT a To adjust loosen the W point screw and remove the outer oval point screw b Position the gage with the bottom step aligned with the top pin of the Claw Claw must be positioned as in step d above Grasp the Shutter and loosen the inner oval point screw c Move the shutter on the Main Drive Shaft while observing the meter or tester When continuity is established allow the shutter to move back to the point of just breaking continuity and tighten the inner oval point screw on the flat of the shaft Rocking the shutter slightly while tightening this screw will insure proper alignment on the flat of the shaft d Push the gage down as in step g above and check for continuity If no continuity exists repeat this entire process until no continuity exists on the lower step of the gage but continuity does exist on the upper step
47. D REASSEMBLY PROCEDURES Where disassembly and reassembly seems straightfor ward and self explanatory no procedures are given in this service manual However where certain steps may not be obvious or where a definite order of steps should be followed we would like to pass on a few tips or tricks we ve learned to make your job a little easier and cut repair time Disassembly of the projector and subassemblies thereof should only be performed to the extent necessary to accomplish repair Note Internal electrical connections may be LIVE when covers are removed USE CAUTION Always clean parts thoroughly before any lubrication or reassembly is attempted See cleaning suggestions under Preventive Maintenance Section II A Removal of Lensholder 1 Remove the Film Stripper 8 the C Ring 11 and the Front Sprocket 10 Figure 3 1 2 Loosen Screw 53 enough to allow the Lobster Claw 62 to slip off the Guide Arm Roller 47 A Move the Master Control Lever to the LOAD posi tion and remove Screw 44 This Screw is access ible from the back of the projector below the front Worm Gear and to the right of the motor start capacitor Slide the Lensholder 43 off its mounting rod taking care not to lose the Spring 45 and the Guide Arm Roller 47 Reassembly of Lensholder to Projector Raise the Master Control Lever to the PROJECT pos ition and make sure the Lensholder Link is str ight and resting on t
48. EARANCE Ta pr EEE Figure 3 23 CLAW PULL DOWN STROKE SET UP Pull up on the Gauge The projected Target will move down The upper Target step must touch the reference line drawn in Step 6 for correct stroke Figure 3 24 2 Remove the Motor Drive Belt or disconnect the 3 PULL Motor wires so the Main Drive Shaft will not turn GAUGE UP during the next adjustments Be careful not to dis connect the Blower wires As an alternative the STILL button may be de pressed on models having that feature 3 Rotate the Inching Knob clockwise until the Claw Arm Pins are in the Aperture Plate Slot at the bottom of their travel Insert the Stroke Setting Gauge ST 5880 into the Aperture Plate Film Channel Close the Film Gate Make sure the Pressure Shoe seats properly Push the Gauge down until it hits the Claw Arm Pins 4 Rotate the Inching Knob clockwise through enough cycles of the Claw Arm to draw the target in the Gauge into the Aperture Be careful not to allow the Claw Arm to move up at any time when the Pins are engaged in the sprocket holes The Pins must pull the Gauge down smoothly for the meas urement to be valid lt gt 0015 DU 4 TOP STEP MOVES DOWN TO REFERENCE LINE FOR CORRECT STROKE 5 GAUGE TOUCHES PIN Figure 3 24 CLAW PULL DOWN STROKE 3 13 INSTA LOAD XL 2200 SERIES 8 Adjust stroke by placing the Shuttle Cam Adjust ing Tool ST 5884 on the Claw Arm Pivot 18 Figure 3
49. ERSE button Check that sprockets and supply reel operate in the fast reverse mode On fast forward models interlock light will light 11 Press STOP button Projector should stop On Fast Forward models the interlock light should remain on for three to five seconds 12 Thread an old film into the projector and move the Master Control Lever to the PROJECT position 13 Check for proper threading by manually rotating the manual advance knob and checking the film movement through the projector 14 Press the FORWARD button and observe that film moves smoothly through the projector and is gathered on the take up reel Set volume and tone controls for comfortable listening 15 Check for proper film handling in the film gate by observing smooth quiet operation in this area 16 Check picture for focus double image or ghosting 17 Adjust framing knob maximum clockwise and then maximum counterclockwise Observe that the frame line moves an equal distance into the top and bottom of the projected image Check for picture jump side shake or weave and mechanical noise at both extremities of framing 18 Readjust framing knob to eliminate frame line from projected image 19 Press REVERSE button and observe that the film moves smoothly and quietly through the projector and is gathered on the supply reel Note At this point the balance of the old film may be run through the projector and rewound or rewound immediately at the operato
50. L 2200 SERIES Fast forward solenoid oper ates properly as necessary reel arm belt Wipe clean and adjust fast for ward drive belt Replace belt if Replace take up Yes Clean and lube rollers and shafts Reinstall with pro per end play Film path rol lers turn freely Yes Take up reel arm belt is in good condition no slipping Yes No Adjust motor belt __ tension replace belt if necessary Ye Fast forward drive tension is correct Check actuator cap clutch spring and arbor Replace or repair as necessary Clean and lub ricate clutch pulley No Reel arm pulleys _No Clean or replace turn freely no reel arm pulleys binding Clean reel arm pulley bearings Yes Fast forward clutch is sup plying positive drive Yes No Adjust lift off Try turning nuts down only 2 1 2 turns instead of 3 Take up clutch lift off is adjust ed properly Yes Take up clutch pulley is clean and turns freely Yes Recheck entire system check for binding or slipping of trans port or drive mechanisms INSTA LOAD XL 2200 SERIES CAUSE REMEDY Control System Troubles a Blower Motor does not operate in any mode b Projector does not operate when FORWARD button is depressed Blower Motor defective Blower Motor Relay defective Models 2270 and 2280 Switch S2
51. Move the Master Control Lever down and open the lensmount just enough to insert the gate Then raise the control lever just enough to hold the gage snugly in place NOTE Do not insert the gage and then close the lensmount The lensmount may pop open and not hold the gage properly c Connect the screw on the Prot rusion Gage to one side of the continuity meter Connect the other side of the continuity meter to the chassis of the pro jector connecting point must be free from paint dirt or grease d Rotate the Inching Knob clockwise and observe the Claw Arm Stop rotating the Inching Knob when the Claw Arm Pins enter the slot in the Aperture Plate and start down The edge of the Shutter blade will be just below the Aperture e Push the Claw Arm toward the Aperture Plate and gently push the Gage down until the bottom of the gage touches the top pin of the Claw Arm The ohm meter or continuity tester will show continuity f Release the Claw Arm and reference the position of the red and yellow reference tapes to a point on the projector Slide Gage down 1 2 width 1 4 width with new style gage of either tape The Bottom step of the gage shauld be opposite the top pin of the Claw Arm Figure A 9 If the meter or tester shows continuity protrusion is more than 040 and should be adjusted If no continuity is shown gently push gage down one width of tape The top step of the gage should be opposite the top pin of the Claw Arm
52. N POINT DIAGRAM INSTA LOAD XL 2200 SERIES Z OPERATION CHECK It is recommended an old film be used for the initial part of this check This will prevent damage to a valuable test film in case the projector is mal functioning to the extent that it damages film An SMPTE jiffy test film Mo P16 PP should be used for the latter portion of this check 1 Connect power cord to AC receptacle supplying correct line voltage and frequency Swing reel arms up until they lock 2 Set Master Control Lever to PROJECT position 3 Press FORWARD button Check that sprockets and reels turn properly that screen is illuminated evenly and blower is operating Listen for unusual noises 4 Press Still button if projector has this feature Illumination should decrease and motion of sprockets and reel pulleys should stop Screen may be partially or totally dark If so rotate manual advance knob slightly to move shutter blade away from aperture 5 Press REVERSE button Check that sprockets and reels turn properly 6 Press STOP button Projector should stop 7 Move Master Control Lever to LOAD FAST MODE 8 Press FAST FORWARD button on projectors with this option Check that sprockets and take up reel operate and the fast mode interlock light comes on after a slight delay 9 Press STOP button Projector should stop and fast mode interlock light on FAST FORWARD models should remain on for three to five seconds 10 Press REV
53. RT NUMBER 39338 41004 38298 39321 38998 42423 43042 42717 43457 41338 43965P1 45144P1 44549P1 41098P1 38994P1 44508P1 44360P1 44360P2 WIRE SIZE 16 22 AWG 16 22 AWG 14 22 AWG 20 24 AWG 18 22 AWG 20 22 AWG 14 18 AWG 18 22 AWG 18 24 AWG 18 20 AWG 14 18 AWG 20 26 AWG 20 22 AWG 18 22 AWG 16 20 AWG 24 30 AWG 18 24 AWG 18 24 AWG INSTA LOAD XL 2200 SERIES INSULATION 140 max 140 max 1050 115 048 071 90 132 075 max 120 170 060 100 100 max 080 120 105 145 035 080 060 100 060 100 090 230 060 120 060 120 TAB STRIPPING SIZE SCREW 155 215 48 155 215 6 125 185 1 8 1 4 250 125 185 210 240 250 195 225 250 125 155 1156 219 103 220 280 125 285 155 185 100 155 185 110 125 185 187 100 125 125 155 125 155 ILLUSTRATION Di PART NUMBER 41438 43225 41440 43497 WIRE SIZE 14 18 AWG 20 22 AWG 14 18 AWG 16 22 AWG 18 22 INSULATION 100 130 080 100 100 130 136 max INSTA LOAD XL 2200 SERIES TAB STRIPPING SIZE 140 170 125 185 140 170 3 or 7 32 4 Screw 250 280 6 Screw ILLUSTRATION ay D 1 9 INSTA LOAD XL C MATERIALS 2200 SERIES ADHESIVES 39490 P2 Glyptal No 127
54. Tool ST 5884 Upper Left c Stroke Gage ST 5880 second from left d 050 Allen wrench e 1 16 Allen wrench f 1 4 3 16 open end wrench g Continuity Tester MI SIDE CLEARANCE ADJUSTMENT Before attampting any adjustments manually rotate the inching knob to make sure the Claw Arm Pins do not strike the sides of the Aperture Plate Claw Slot At the bottom of its travel this Pin will be nearer to the outside edge of the Aperture Plate Slot To observe this condition watch the back of the aperture plate as the Claw Arm is cycled slowly through its stroke by turning the main shaft APERTURE PLATE FILM EDGE GUIDE 082 f AG DRILL WITH FRAME CONTROL AT MIO POSITION UPPER CLAW PIN SHOWN AT START A END OF STROKE To adjust loosen the setscrew in the Claw Arm with the 050 Allen wrench and m ve the oilite bushing so the two distances are equal INSTA LOAD XL 2200 SERIES M 2 CLAW PIN PROTRUSION REQUIREMENT Pin protrusion is the distance which the Claw Pins extend through the aperture plate and is one of the most critical adjustments on all Singer 16mm Projectors If protrusion is not correct the operation of the machine may be erratic even though all other adjustments are correct The end of the Claw Pin must extend 035 to 040 beyond the film rail of the aperture plate CLAW PIN PROTRUSION MEASUREMENT a Raise the Master Control Lever to PROJECT position b
55. Washers 31 36 38 and 39 12 Be careful not to allow the Fast Forward Drive Belt to touch the Fast Forward Clutch Shaft and pick up lubricant on its driving surface D Reassembly of Front Clutches to Projector 1 Clean the front sprocket clutch Main Casting Oilite Bearing with a cotton swab moistened with Teresso Instrument Oil 39479 P8 2 Lubricate the gear teeth of the Front Sprocket Clutch and the Rewind and Fast Forward Clutches with a light coat of DC 44 grease 39479 P9 3 Lubricate the rewind and fast forward clutch Shafts with a thin film of Extreme Pressure Lube 3 39479 P16 and assemble Washers 31 and 36 4 Assemble Washers 38 and 39 to the shaft of the Front Sprocket Clutch 37 and start the shaft into the Main Casting Bearing cn Inspect the needle bearings in the pulleys of the Rewind and Fast Forward Clutches to make sure all are in place and none are missing 6 Engage the gear teeth of the Rewind and Fast Forward Clutches with the gear teeth of the clutched gear on the Front Sprocket Clutch and align the Rewind and Fast Forward Clutches with their shafts 7 Push all three clutches toward the main casting simultaneously until the Rewind and Fast Forward Clutches have started onto their shafts 8 Continue pushing the clutches toward the main casting until the fast forward Drive Belt can be seated on the Fast Forward Clutch Pulley Seat the belt and push the three clutches all t
56. aker terminals and set the meter range switch to read 50 volts full scale minimum e Run the projector Forward and adjust the Volume Control for comfortable listening level Adjust the voltmeter range scale for a reading between 1 2 scale and full scale 900 Hz BUZZ TRACK SOUND FOCUSING FILM SK or TK Ha EMULSION OUT 7K CYCLE FILM INSIDE OUTSIDE LOOP 2 21 INSTA LOAD XL 2200 SERIES Requirement Meter readings from both sections of the loop must be within 3 db of each other If the meter used does not have db scales set the Volume Control so one section of the loop produces one of the Set Value voltage readings shown in the Chart and check that the other section of the loop meets the Allowable Deviation Requirements If this requirement cannot be met proceed to Step f Otherwise disconnect the meter and proceed with the Buzz adjustment Loop Section I Loop Section II Set Value Allowable Deviation Maximum Reading Minimum Reading 2775 VAC 1 10 VAC 54 VAC 2 450 VAC 3 45 VAC 1 73 VAC 7 750 VAC 10 95 VAC 5 40 VAC Loosen the Sound Optics Setscrew and remove the Sound Optics It may be difficult to remove due to the wedging action of the nylon plug used to lock it in place Rotating it back and forth while pushing up on it will aid in its removal DO NOT pry up on the bottom of the cartridge as this may damage the bottom lens Inspect bottom element for damage Turn the set
57. and the correct number of Washers 12 to allow for 003 to 007 end play of the sprocket 10 when the Grip Ring 11 is in stalled Figure 3 12 Install Inside Washer 8 and Spring 9 The Spring 9 should be installed so turning the Sprocket 10 clockwise will tighten the Spring 5 Install Outside Washer 8 after lubricating the sur face of the Spring 9 with Terreso Instrument Oil 39479 P8 Figure 3 13 REMOVAL AND REASSEMBLY OF TAKE UP GEAR Wind the Sprocket 10 clockwise until the Spring 9 is fully wound Then allow the Sprocket to unwind one full turn Use the pin in the Sprocket as your point of reference Note the position of the slot in the end of the shaft with relation to the pin in the Sprocket This determines which way the Stop 7 will be installed to stop the sprocket rotation as soon as possible during its next rotation Release the sprocket and allow the spring to unwind completely Install the Stop 7 in the position determined in Step 7 above but allow the end of the Stop 7 to be lifted up enough to allow the Sprocket Pin to ro tate under it when the Spring 9 is wound Wind the Sprocket 10 until the Spring 9 is completely wound and then allow the Sprocket to unwind just enough that the Sprocket Pin passes under the Stop 7 once Push the Stop down all the way and allow the Sprocket to unwind until the Pin comes to rest against the Stop Figure 3 1
58. arm belt should Ee en Ke bind in the counterclockwise direction but move freely in the clockwise direction MANUALLY If the above requirements are not met make sure the brake cable is on the pulleys If so adjust the brake cable by loosening the clamp screw on the solenoid paddle and lengthen or shorten the cable as required S TAKE UP ADJUSTMENT Take up tension is adjusted with the nut directly under the bias spring Place an empty 400 foot reel on the take up arm Thread the projector Film may be pulled from the front reel directly to the rear sprocket bypassing the normal film path if desired INSTA LOAD XL 2200 SERIES Insert the film tension gage T 38000 5 as illus trated with the idler directly above the last roller of the film path Hold the gage at about a 30 angle operate the projector in FORWARD PROJECT The gage should read 4 to 6 ounces with 25 to 40 feet of film on the take up reel Favor the low side of this requirement with the blue or green clutch liner Adjust the take up tension adjusting nut up to increase tension and down to decrease it If difficulty is experienced meeting the take up adjustment requirement perform the lift off adjustment and try the take up adjustment again If the take up requirement is met it is not necessary to do the lift off adjustment T LIFT OFF THEORY AND ADJUSTMENT The lift off adjustment establishes the proper point of contact of the take
59. at surface with maaa uring tepe facing up Apply tape to back of gage to achieve 130 003 Flat Surface INSTA LOAD XL 2200 SERIES LENSHOLDER STOP PIN ADJUSTMENT Move the Master Control Lever to LOAD and remove the lensholder cover Rotate the inching knob until the Claw Arm pins have been completely retracted from the Aperture Plate Insert the Protrusion Gage in the Aperture Plate with the measuring steps facing the lensholder stop pin and the 138 003 step directly in line with the pin Move the master control lever to PROJECT Loosen the Stop Pin Setscrew and adjust the Pin until it just touches the 138 003 step Tighten the screw 0 PRESSURE SHOE REQUIREMENT Move the Master Control Lever to LOAD AND assemble the Lensholder Cover with the Pressure Shoe TOP VIEW 006 C 13 mm 010 36mm Place an Index Card below the Pressure Shoe and sight down the edge of the Pressure Shoe as the Master Control Lever is moved toward PROJECT The Pressure Shoe should enter the aperture plate channel without striking either side The outside edge clearance should be 005 to 010 PRESSURE SHOE ADJUSTMENT Adjust by loosening the two socket head screws which hold the C carrier to the lensholder and moving the carrier to obtain the 005 to 010 dimension Loosen the screws just enough to permit carrier movement with considerable resistance The carrier should not be too loo
60. aw Arm 13 into the projector be both can be met tween the Framing Arm 20 and the Shutter and Cam Assembly good starting position for the Pivot 18 Fig ure 3 21 places its eccentric pin at about 7 4 Lubricate both sides of Washer 17 with FS 1290 o clock when viewed from the front of the pro lubricant 39479 P4 jector See Figure 3 25 The notch in Bushing 8 should be slightly below the notch in Pivot 5 Assemble Pivot 18 Washer 17 Claw Arm 18 so an imaginary line drawn across the top 13 Bushing 8 Washers 11 and 10 and of the Bushing notch aligns with the bottom of Nuts 9 the Pivot notch 6 Tighten Nuts 9 for 001 end play and coat Nuts N with Blue Glyptal 39490 P1 The outside Nut is a jam nut to prevent the inside nut from turn ing off the Pivot shaft 7 Rotate the Pivot 18 so the Eccentric Pin is be tween 6 and 7 o clock when viewed from the front of the projector Tighten the Pivot Setscrew 19 8 Rotate the Bushing 8 so its circumference lines up with the circumference of the Pivot 18 and the groove in its side is slightly below the groove in the side of the Pivot 18 Tighten the Claw Arm Setscrew 14 9 Gently push the Shutter and Cam Assembly for ward while pushing down on the Claw Arm 13 making sure the cam follower on the Claw Arm slides under the Cam Tighten the Setscrew 1 in the Shutter and Shaft Alignment insert of Figure 3 21 CLAW ARM ADJUSTMENTS Figure 3 20 on the
61. base of the projector Remove the Pin 16 Arbor 15 and Gear 17 Remove the C Ring 20 Screws 25 and 26 and the reel arm Belt Guide 24 Remove the three Screws 4 which hold the Solenoid Package in place and lay the Solenoid Package 3 to one side out of the way Be careful not to allow the Rewind and Fast For ward Clutch Actuator Caps 6 and 7 to drop off their shafts until you have noted which one goes where THEY ARE DIFFERENT Remove the Front Reel Arm Belt Move the Master Control Lever to the PROJECT position Remove E Rings 28 and 33 and start sliding the Rewind Clutch 27 and the Fast Forward Clutch 32 off their shafts While sliding the Rewind and Fast Forward Clutches off their shafts push in on the shaft of the Front Sprocket Clutch 37 The Washers 21 may lodge in the C Ring slot of the shaft making it difficult to push the shaft out of the bearing Move the Washers 21 around while pushing in on the shaft until the shaft pushes in easily While pushing in on the shaft of the Front Sprocket Clutch and pulling out on the Rewind and Fast Forward Clutches a point will be reached where the Fast Forward Drive Belt will prevent further movement of these clutches Reach in and push the drive belt over the flange of the Fast Forward Clutch Pulley and draw the Rewind and Fast Forward Clutches and the Front Sprocket Clutch out of the projector 11 11 Be careful not to lose
62. ch is locked into direct drive as described above Now the Fast Forward solenoid and the Interlock solenoid operate to lock the Fast Forward clutch 32 into positive drive and freeze the grt closing mechanism respectively Film is thus troos ported rapidly forward either In Path or Reel to Reel REWIND Figure 3 When the projector is operated in the Rewind mode the interlock solenoid operates and pushes the Guide Pin 2 in Since the Spring 1 is threaded through the Guide Pin 2 and into the Gear Pin 11 both the spring and the gear are also pushed in The gear pin strikes the side of the Roll Pin R in the Clutch Gear 14 and locks the clutched gear and the clutch gear together to provide direct drive in the rewind mode The interlock solenoid also pushes an interlock pin through the main casting into the film gate closing mechanism to prevent the gate from being closed on the film when film is being rewound rapidly In Path Figure 4 INSTA LOAD XL 2200 SERIES GATE AND LENS MOUNT The film is held securely in place against the aperture plate by the film pressure shoe Figure 5 It is fed into this channel from the feed sprocket which is just above the lens mount When the Master Control Lever is moved from LOAD to PROJECT the loop setting cables turn the front sprocket approximately 3 4 turn counterclock wise to establish the upper loop The pins on the claw arm enter the spro
63. cket holes from behind the aperture plate and pull the film down through the channel one frame at a time Figure 6 When the framing adjustment is properly made each picture frame will line up exactly in front of the hole in the aperture plate through which the projection lamp shines The light shines through the film and the image is projected onto a screen and focused by means of the projection lens The film is moved through the film gate at the rate of 24 frames second by moving the claw arm into the sprocket holes then down then out of the sprocket holes and then up to start the cycle over again During the actual movement of the film through the gate area by the claw arm light is prevented from being projected onto the screen by one of the shutter blades which moves between the projection lamp and the film As soon as the claw arm has moved the film into position in front of the hole in the aperture plate the shutter blade moves out of the way to allow light to pass through the film and project an image on the screen This momentary interruption of light by the shutter blade while the film is moving prevents what would appear to be streaming of the picture However the light interruption is so rapid that only a small amount of flicker is discernible by the human eye The claw arm and shutter are synchronized by a cam which is part of the shutter assembly and turns at the same rate of speed as the main shaft Figur
64. clutch gear 17 Figure 13 The liner fits snugly inside the gear and the pulley fits inside the liner The clutch is adjusted so the top part of the pulley contacts the liner when the projector is run in the forward mode The gear is driven by the worm gear on the main shaft and rotates continu ously while the machine is running The liner rotates along with the gear and turns the pulley The pulley drives the reel arm pulley by means of the reel arm belt The surface of the clutch pulley is polished and can slip on the liner when necessary to provide the clutching action The system is designed so the take up reel is capable of taking the film faster than the film is fed to it by the take up sprocket so film will not be spilled when the clutch is working properly Since the take up reel tries to take up film faster than the film is being fed to it the mechanism which drives it must provide a sufficient amount of drive while at the same time be able to slip to prevent film from being pulled through the take up sprocket The fact that the take up elutch pulley can slip inside the take up clutch liner allows for this to happen The mechanism is self adjusting during the entire take up cycle because of the way the take up reel arm is attached to the take up clutch arm The shaft of the take up reel arm passes through a hole in the take up clutch arm A roll pin is inserted in a hole in the reel arm shaft and pushes d
65. d with Isopropyl Alcohol Chlor othene 1 1 1 or equivalent Be sure to clean the claw thoroughly Remove all accumulated dirt from the claw pins INSTA LOAD XL 2200SERIES The idlers at the take up sprocket are secured with grip rings The idler must turn freely with approx imately 0 002 to 0 005 0 05 to 0 13mm end play Assemble grip rings with the sharp edge away from Khe part being held in place so the ring will grip the GRIP RING ASSEMBLY shaft better B SPRING LINK ADJUSTMENT With the Master Control Lever in the PROJECT posi tion loosen the brass pivot screw and adjust the pivot Counterclockwise until the lower idler roller touches the take up sprocket enough to cause the gap in the spring link to close 0 003 to 0 005 0 08 to 0 13mm c COUNTER ADJUSTMENT After mounting the counter Fast Forward Models be sure the idler arm swings open freely when moving the control lever to the LOAD position If the arm is slug gish reposition the counter until the arm swings freely Tighten the screws and check for free arm movement INSTA LOAD XL 2200 SERIES D LOOP SETTING CABLE REQUIREMENT Hang a claw arm 38041 G1 on the cable as shown The top edge of the claw arm should be parallel with the bottom edge of the Master Control Lever E LOOP SETTING CABLE ADJUSTMENT Position the cable drum with the gear section located between 6 and 9 o clock Align the rig
66. e 6 AUTOMATIC LOOP RESET THEORY The automatic loop reset is driven by a neoprene drive belt from the flywheel drive shaft Figure 7 INSTA LOAD XL The small pinion gear and idler gear run continuously while the projector is operating The large loop resetting gear turns only when the lower loop is being reset IDLE POSITION KICK SPRING ON CORNER OF O HUB WILL TURN ALM IDLER TIGHT FILM LOOP WILL LIFT LEVER FROM GEAR LATCH Figure 9 When the lower film loop is lost the loop reset arm is pulled up lifting the gear latch tab away from the raised lip on the eccentric stud The kick spring forces the loop reset gear to turn slightly counterclockwise to the flat of the D shaped shaft This rotation forces the ramp down allowing the idler gear to engage the loop reset gear and start it turning The eccentric stud forces the loop reset arm down and up to reset the lower film loop At the end of the cycle the ramp forces the idler gear away from the loop reset gear and the raised lip on the eccentric stud latches against the gear latch tab on the loop reset arm 14 2200 SERIES In the idle position the ramp on the back edge of the loop resetting gear holds the Idler Gear away from the Resetting Gear The loop resetting gear is prevented from turning by the engagement of the gear latch tab on the loop resetting arm with the raised lip on the eccentric stud of the loop resettin
67. e diameter of Pin 2 with Teresso Instrument Oil 39479 P8 and insert the pin in the hole in the end of the shaft of Gear 14 Figure 3 35 Insert the Spring 1 through the hole in the end of Pin 2 and then into the hole in the end of Pin 11 Push the Spring 1 onto the Roll Pin protruding from the Gear and Hub Assembly 3 On Fast Forward models be gure the cross pin in Pin 11 is pointing toward the shaft of Gear 14 EC Figure 3 36 FEED SPROCKET CLUTCH ADJUSTMENT V Fast Forward and Rewind Clutches 1 2 5 Fast Forward Pulley is Smaller Figure 3 37 REWIND and FAST FORWARD CLUTCH REASSEMBLY Lubricate the outside diameter of the shaft of the 4 Pulley Assembly 8 and assemble the Gear 7 and the Drum 6 to the shaft as shown Figure 3 37 Seat the notches of the Drum 6 over the raised lugs inside the Cup Gear 7 5 Assemble the Arbor 4 on the shaft of the Pulley 8 and tighten the Setscrew 5 in the notch in the end of the shaft allowing for end play of 005 to 010 Apply three or four small drops of Teresso Instru ment Oil 39479 P8 on the Arbor 4 and push the Spring 1 over the Arbor until it is seated on the Drum 6 with its tail trapped in the slot in the Drum Assemble Screw 2 and Washer 3 to the Drum 6 trapping the tail of the Spring 1 permanently in the slot of the Drum 6 Assemble the Clutch to the projector see Reas s
68. e repair of the projector are listed in the table below These tools are available from Telex Communications Inc EDUC ATION YSTEMS NO DESCRIPTION USE 55 307 Waldes Retaining Ring Applicator M C 012 To install retaining rings T 38000 U Waldes Tru Arc No 1520 Applicator To remove and install small retaining rings T 38000 V Waldes Tru Arc No 1540 Applicator To remove and install large retaining rings T 38000 W Claw Cam Wrench Pair Claw arm eccentric pivot nuts T 38000 X Waldes Tru Arc No CR 0310 To remove and install C rings 3 H INSTA LOAD XL 2200 SERIES Used to set claw pin protrusion electrically CLAW ARM PROTRUSION GAGE No G10 38000 DETAIL 0 540 0 300 50005 T0008 he 0 005 Se ee 0 055 0 005 5029 REPLACEMENT PINAT 38000 NI MAT L 5 32 DRILLROD BREAK ALL EDGES 0 005 3 8 R x 0 040 DEEP SET SCREW NO ITIA6 3L SARGENT NO 1818 A PLASTIC CEMENT IN PLACE ROLLPIN INSERT AND EXTRACTING TOOL No T 38000 N h5 p n 252 3 p n 38228 Used to measure forward take up tension belt tension and fast forward take up tension The scale reading is twice the actual film tension TAKE UP FILM TENSION GAGE No T 38000 S 0015 3 0001 This gage is a piece of stainless steel with perfora tions simulating double perforated 16mm motion pic ture film This gage is used to adjust the stroke of the projector The pro
69. e tightened further The main shaft should visibly move forward during the tightening process Manually pushing the main shaft forward while starting to tighten these screws will help insure they are seated properly Tighten Set Screws 19 in Collar 18 observing the proper alignment and seating of the Set Screw points as noted in Step 4 The main shaft will not move forward when these screws are tightened Use a new Roll Pin 21 P N 191 N6 9 when re assembling Gear 20 to the main shaft Position the Pinion 22 146 to 156 diameter of a 5 32 drill bit from the Drive Gear 20 and tighten Screw 23 on the flat of the main shaft 8 10 00 44 Grease U aypa U Fs 1290 INSTA LOAD XL 2200 SERIES Install a new Cam Lubricating Pad P N 39002 G3 Rotate the Main Shaft 34 until the flat on the shaft just behind the Front Bearing 28 is at about 2 o clock See Shutter and Shaft Alignment insert on Figure 3 19 Rotate the Shutter and Cam Assembly 26 until the Setserew 1 in insert lines up with the flat on the Shaft 34 Gently push the Shutter and Cam Assembly forward while pushing down on the Claw Arm until the cam fol lower on the Claw Arm slips under the the Cam Tighten the Setscrew 1 in insert on the flat of the Shaft 34 Make sure the Claw Arm is not hit ting the Aperture Plate Note Be very careful not to damage the Claw Arm pins Hook the Claw Arm Spring on the Framing Arm being
70. e voltage on the base of Q7 so it will regulate current in the series regula ted circuit to 7 7 amps as preset by resistor R7 The low output from pin 14 of IC1 turns transistor Q2 off and disables the strike circuit A reduction in lamp current reduces the voltage across R22 reducing the high applied to pin 5 of IC1 The output high from pin 2 of IC1 is reduced conditioning the series regulating circuit to allow Q7 to conduct more to compensate for the reduction in lamp current The converse is true if lamp current increases 4 13 INSTA LOAD KL 2200 SERIES SECTION V ELECTRONIC CIRCUIT ADJUSTMENTS Driver amp Tone amp Power 27V Volume Amplifier B Control 1 5V RMB Figure 5 1 16mm AUDIO AMPLIFIER BLOCK DIAGRAM A ADJUSTMENT OF VR 1 Before attempting to adjust VR 1 perform the Buzz track adjustment and the Sound Optic Focusing ad justment 1 Thread a continuous loop of 400 Hz Signal Level Test Film SMPTE P16 SL in projector 2 Connect an Oscilloscope and or an AC VTVM between pin 1 of Z1 Test Point 6 and ground Test Point 9 E Jr 3 Run the projector in Forward and observe the w 2 i signal on the oscilloscope Ee EN R24 5 DY REV 2 s4 4 The Signal should be an undistorted sine wave 452 TOPSGREEN 46617P2 REV N og GI 2A with an amplitude of 1 5 volts RMS 44 volts P P se 4 D is S 5 Adjust VR 1 to obtain the above reading
71. embly of Front Clutches to Projector 3 21 INSTA LOAD XL 2200 SERIES W Switch Adjustments 1 Switches S 3 5 5 S 6 and S 7 should be adjusted to actuate in the LOAD position and re lax in the PROJECT position Figure 3 38 2 Switch S 4 should be adjusted to relax in the LOAD and PROJECT positions and actuate be tween these two positions Figure 3 38 OPERATING LOGIC SWITCH CLUSTER X Film Counter 1 Lubricate the interfaces of the Idler Gear Assembly Shaft 8 and the Bearing 10 with Teresso Instrument Oil 39479 P8 Figure 3 39 2 When the Gear 6 is rotated the entire gear train and counter must operate freely and smoothly 3 22 Switch Figure 3 39 FILM COUNTER Stacked PARA A INSTA LOAD XL 2200 SERIES SECTION IV ELECTRICAL SYSTEM TITLE FORWARD PROJECT REVERSE PROJECT FAST FORWARD FAST REWIND AUDIO AMPLITIER MARC 300 POWER SUPPLY PAGE INSTA LOAD XL 2200 SERIES SECTION IV ELECTRICAL SYSTEM Swinger GH of S2 feeds the LIVE side of the line from terminal 7 to S2B which is also closed to The electrical system in the 2200 series projectors connect the LIVE power to the brown wire of the is divided into two sections Main Drive Motor run winding 1 Motor Drive and Mode Logic Circuits f S2 al ly LIVE power to 2 Audio Amplifier and miscellaneous circuits Contacts GB of 52 also supply por terminal 6 of the Fast Forward Sole
72. er from the Lamp and Blower Motor Relay circuits Switch S2A closes only when the Forward button on the Main Control Switch is depressed It com pletes the exciter lamp circuit through the nor mally closed contacts of Relay K1 allowing the exciter lamp to light and produce sound from the film 20 EMS REM 315 10 334AF 370 VAG Kor i nm fro FRAME GROUND z mp ae s r 046678 AMP SCHEMETIC wz Figure 16 Reverse Project B REVERSE PROJECT 2270 MODELS With the Reverse button depressed the Main Con trol Lever in the Project mode and the Main Power Switch ON switches S2B S2C S2D and S14 are closed The movable contacts are connected to the normally closed contaets on switches 53 and 55 and Relay K 1 Relay K 3 is operated closing its normally open contacts Switch 5 6 is open Switch 8 9 may be in the Hi or Lo position Switch S2FJ is connected to terminal 6 and S2GH is connected to terminal 8 4 2 The LIVE side of the line is connected to the black wire of the start winding and the yellow wire of the run winding of the Main Drive Motor The NEUTRAL side of the line is connected to the white wire of the start winding and the brown wire of the run winding of this motor Thus the phase relationship is estab lished be
73. esso Instrument Oil Figure 3 10 CLEAN and SERVICE CLUTCH ARM 3 5 INSTA LOAD XL 2200 SERIES F Take Up Clutch Reassembiy i Reassemble the take up clutch and assemble it to the projector 2 Press a new roll pin in place making sure that it extends far enough to contact the roll pin on the take up arm Figure 3 11 INSTALL ROLL PIN Figure 3 12 REMOVAL AND REASSEMBLY OF TAKE UP SPROCKET G Removal of Take Up Sprocket and Gear 1 Remove the Take Up Clutch 5 Remove the Spacer 5 Outside Washer 8 Spring 9 and Inside Washer 8 The two washers 8 are 2 Remove the Grip Ring 6 and manually rotate the usually removed easily with a magnet take up Sprocket 10 clockwise slightly to move the sprocket Pin away from the stop 7 Figure 3 12 6 mes Grip Ring 11 Washer 12 and Sprocket 10 3 Grasp the Stop 7 with a pair of pliers and pull it straight out 7 Slide the Take Up Gear out of the mnin casting bearing Figure 3 13 4 Slowly release your grip on the Sprocket 10 and allow the Spring 9 to unwind 3 6 H Reassembly of Take Up Gear and Sprocket 1 10 INSTA LOAD XL 2200 SERIES Clean the main casting Oilite Bearing with a cotton swab moistened with Teresso Instrument Oil 39479 P8 Lubricate the teeth of the Take Up Gear with a light coat of DC 44 grease and push the shaft of the gear through the main casting Oilite Bearing Assemble the sprocket 10
74. ete Any good household de tergent should be sufficient Projection lens Remove lens Re 8 move dust from front and rear ex posed lens surfaces by hrushing gently with a soft brush Then wipe lens gently with a clean lens tissue slightly moistened with lens cleaner if necessary CAUTION Never pour lens cleaner or other solvents on the lens elements DO NOT use silicone impregnated lens tissue Projection Lamp and Exciter Lamp 10 Remove dust by brushing gently with a soft brush Then wipe gently with a clean lens tissue slightly moistened with lens cleaner if necessary 1 Aperture Plate and Film Pressure Shoe Open the film channel by moving the Master Control Lever to PROJECT Turn the lens forward Insert the Aperture Brush Cat 3694 into the top of the channel and move it vigor ously up and down Use care to keep the shaft of the brush away from the pressure shoe or the film track If necessary necessary dampen the brush with solvent to loosen and remove any hardened substance 12 14 from pins on Claw Arm with a soft bristled brush Examine pins for looseness or grooves cut in them by film Solvents may be used for this cleaning Film Rollers lor proper cleaning Rotlers should be removed and wiped thoroughly with clean dry rag Re move stubborn dirt from plastic Rollers with detergent and warm water Dry thoroughly Shaft holes may be cleaned with cotton swabs or a pipe cleaner moiste
75. flat of the main drive shaft See Step 9 under Reassembly of Main Shaft Before attempting any adjustments manuall AE gt y ie Claw Arm 13 is not hitting the rotate the inching knob to make sure the Claw Arm pins do not strike the sides of the Aperture 5 Plate Claw Slot At the top of the Claw Arm 10 Hook the top of the Claw Arm Spring 15 on the Stroke the Top Claw pi Pin will be nearer Framing Arm 20 being very careful that the cam follower on the Claw Arm contacts the radial surface of the Cam Note Be very careful not to damage the Claw Arm pins the inside edge of the Aperture Plate Slot Fig ure 3 22 At the bottom of its travel this Pin will be nearer the outside edge of the Aperture Plate Slot Loosen Screw 14 and adjust Bush ing 8 Figure 3 21 so these two distances are equal Removing the Lamphouse Cover and viewing the Pins from behind the Aperture Plate aids in this adjustment INSTA LOAD XL 2200 SERIES 1 Thread an old film in the projector do not use a 5 good film for this adjustment and adjust the Framing Knob to eliminate any frame lines at the top or bottom of the projected image with the pro jector running in FORWARD If excessive noise results when the Framing Knob is moved stop the projector and check the location of the Claw Arm Pins in the sprocket holes of the film When Framing is correct the Top Claw Arm Pin should be the same distance from the inside edge of the sp
76. g gear The loop resetting gear is held under tension by the kick spring which is cocked against the upper corner of the D shaped mounting hub of the loop setting gear SPRING WILL KICK GEAR D HUB WHEN LEVER IS IDLE POSITION DRIVE HELD OUT BY GEAR RAMP FILM PULL LOSS OF LOOP LIFTS GEAR LATCH TAB AWAY FROM ECCENTRIC DRIVE Figure 10 INSTA LOAD XL 2200 SERIES SOUND DRUM AND OPTIC After leaving the gate and lens mount area the film passes over the sound drum It is here that the sound information recorded on the sound track portion of the film is detected Sound information is recorded on the film by caus ing an audio signal to vary the intensity of a beam of light which is focused on the sound track portion of the film The varying intensity of the light exposes the film in varying degrees corresponding to the frequency and amplitude of the audio signal itself To replay the audio track a beam of light from an exciter lamp is passed through this exposed part of the film and onto a light sensitive device which transforms it into electrical energy Figure 11 The electrical energy will then vary at the same rate and with the same amplitude as the exposed Figure 11 portions on the film sound track These electrical variations are fed into the audio amplifier where they are amplfied and eventually drive the speakers to reproduce the original sound A pressure roller in front of the sound
77. g the trans ister to conduct less and maintain a constant current at its emitter When the input DC voltage drops due to a drop in line voltage the voltage at the emitter of Q3 tries to drop With the base still held at a constant voltage by the regulator chip Z3 this attempted drop in voltage at the emitter causes greater forward bias the transistor conducts more and the output at its emitter remains the same Resistor R38 is in a series with the exciter lamp L2 to reduce the 18 volt regulated supply to approximately 5 6 volts for the exciter lamp When the exciter lamp is removed from the circuit the voltage measured be tween P1 8 and P1 9 will be 18 volts This is an open circuit voltage since no circuit is flowing in the circuit with the exciter lamp removed INSTA LOAD XL 2200 SERIES MARC 300 POWER SUPPLY STRIKING CIRCUIT ANITIAL CONDITION BOOST CAPACITOR CB FE MARC 300 POWER SUPPLY The key to operation of the regulated Mark 300 Arc the Power Pack is initially turned on there is no Lamp Power Supply is the voltage developed across voltage across R22 and a low appears on pins 5 Resistor R22 when Arc Lamp current flows When and 8 of IC1 MARC 300 POWER SUPPLY fice HE Dot ahem SERIES REGULATING CIRCUIT T 15 VOLTS Oo R CURRENT ADJUST STRIKING BOOST CiRCUIT CAPACITOR CHARGES einen oe CITOR f The low output from pin 2 of
78. gear friction forces the drive tire away from the Flywheel preventing the mechanism from driv ing it However in the reverse modes the gear friction forces the drive tire onto the flywheel causing it to rotate B SPECIFICATIONS Figure 15 Height 14 5 36 83cm Depth 17 75 45 08cm Width 11 625 29 530m Weight Simplified Control Models Approximately 36 Ibs 16 20kg Fast Forward Models Approximately 38 Ibs 17 10kg International Models Approximately 40 Ibs 18 20kg Base to Optical Centerline 8 20 32cm Film Speed 24 frames per second Auto Loop Reset Automatically maintains image to sound synchronization when film has damaged perforations Exciter Lamp ANSI Code BSW P N 38386 P2 amp Projection Lamp ANSI Code ELC P N 42782 P2 24 volt 250 watt ARC Medes VEGG P N ULBE VPT Cesme aes Lamp Position Lamp Life Hi Approx 50 hours Lo Approx 150 hours Amplifier 25 watt RMS continuous power per ANSI Standard PH 7 2 Speakers Twin 3 x 5 7 69cm x 12 82cm Oval case mounted External Speaker Standard 1 4 6 35mm jack Use 8 ohm speaker for optimum performance Internal speakers are bypassed when using an external speaker Microphone Standard 1 4 6 35mm jack 400 ohm impedance Power Requirement Standard Model 120V 60 Hz 4 amp International Models 100V 50 60 Hz 4 amp 120V 50 60 Hz 4 amp 220V 50 60 Hz 2 amp 240V 50 60 Hz 2 amp 1 7 TERMINALS PA
79. h the bottom edge of the Aperture Note If you go too far go back to Step 2 and repeat Modify a discarded 42994 G1 Safety Shutter as shown in Figure 3 28 A similar heat filter may be used CUT AND BEND p HEAT FILTER Figure 3 28 MODIFIED SAFETY SHUTTER 42994 G1 6 Hang this Heat Filter on the front of the Arc Lamp Mounting Bracket so it is between the Lamp and the Aperture Make sure there is enough clearance so the Douser does not hit the Filter when the Douser is raised Operate the LAMP switch to ON Leave the main pushbutton switch on STOP It is suggest ed that the Lamp be left ON during the remain ing tests If the Lamp is turned OFF it must be allowed to cool before it will strike again Manually raise the Douser and project an image at least 8 wide a wide angle lens will help achieve this width at a shorter projection dis tance raise the elevation approximately 1 this will get you set up in case stroke is in need of adjustment and draw a reference line the full width of the Target on the bottom step Figure 3 29 3 16 PROJECTED IMAGE ee ae DRAW REFERENCE LINE 1 SHUTTER JUST BELOW APERTURE CLEARANCE PIN ENTERS STOP UNDER PIN Figure 3 29 CLAW PULL DOWN STROKE SET UP 9 Pull up on the Gauge The projected Target will move down The upper Target step must touch the reference line drawn in Step 8 for correct stroke Figure 3 30 3 PULL GAUGE UP
80. he way to the main casting 9 Use the correct number of Washers 30 and 35 to obtain an end play of 001 to 005 on clutches 27 and 32 when Washers 29 and 34 and E Rings 28 and 33 are assembled 10 Assemble the correct number of Washers 21 to obtain an end play of 001 to 005 on clutch 37 when C Ring 20 is assembled Apply a light coat of DC 44 grease 39479 P9 to gear 17 and assemble the gear to the shaft of the Front Sprocket Clutch 37 12 Assemble Arbor 15 to the shaft and pin it in place with Pin 16 INSTA LOAD XL 2200 SERIES Figure 3 2 REMOVAL AND REASSEMBLY OF FRONT CLUTCHES 13 Apply a light film of Teresso Instrument Oil 16 Apply a thin film of Extreme Pressure Lube 3 39479 P8 to the surface of Arbor 15 and 39479 P16 to the tail of the clutch Springs in assemble the Clutch Spring 14 on the Arbor the Rewind and Fast Forward Clutches Make sure the tails of the Spring turn away from the raised sector of Gear 17 The Master Control Lever should move up and down easily 17 Assemble the rewind and fast forward clutch x Hii Actuator Caps 6 and 7 such that the ramps with no binding after the Spring 14 is installed on the Caps engage the tails on the clutch Springs to make the springs wrap tighter 14 Assemble the Front Sprocket 10 using the k correct number of Washer 13 to obtain an end around er arbors when the Actuator Caps play of 003
81. ht edge of the bottom tooth with the back edge of the bearing slot Hold the drum in position with a rubber band as illustrated pull the inside cable Short end tight wrap it counterclockwise twice around the post on the Master Control Lever and secure it under the front screw and washer Thread the outside cable Long end as illustrated Wrap it clockwise twice around the post on the Master Control Lever and secure it under the rear screw and washer CABLE THREADING Hang a claw arm 38041 G1 on the cable as shown and adjust the cable tension until the top edge of the claw arm is parallel with the bottom edge of the Master Control Lever Tighten the screws holding both ends of the cable to the Master Control Lever to 5 5 to 6 5 inch pounds of torque and recheck the position of the claw arm Remove the rubber band from the cable drum and operate the Master Control Lever between the LOAD and PROJECT positions several times In the LOAD position the left edge of the bottom tooth of the cable drum gear should align with the front edge of the bearing slot In the PROJECT position the right edge of the bottom tooth should align with the back edge of the bearing slot If not readjust the cables 2 6 INSTA LOAD XL 2200 SERIES LOOP SETTING GEAR AND ARBOR INSTALLATION Lubricate the loop setting gear with a film of DC 44 grease 39470 P9 Lubricate the clutch spring arbor with a drop of Teresso Instrument
82. ighten the two Screws 41 Run the projector in FORWARD and adjust the Framing Knob maximum in both directions A frame line should move into the projected picture an equal amount on both top and bottom Readjust the Framing Limit Plate 40 until this require ment is met Note If the projector becomes noisy when the Framing Knob is rotated maximum in either direction the Side Clearance is not correct and must be adjusted See Claw Arm Adjustments Figure 3 32 FRAMING ADJUSTMENT Replacing Photo Diode Chip in Sound Drum L Mark the body of the Sound Drum Support at the outer end of the Photo Diode this establishes proper orientation for installation of a new Diode Remove the Retainer 1 and the Photo Diode 2 out of the slot Clip the leads and discard the Diode Figure 3 33 Remove the Insulating Tubing 3 and unsolder the remaining portion of the Diode leads Clean the residual epoxy cement from the Photo Diode Slot Position a new Photo Diode into the slot with the shiny black surface up red wire and the end aligned with the mark made in Step 1 Assemble the Retainer 1 to hold the Photo Diode in place orienting the Retainer as shown in Figure 3 33 Make sure the Photo Diode is perfectly flat in the slot The end of the Photo Dicde should be 293 about 9 32 from the end of the Sound Drum Support THE PHOTO DIODE IS VERY FRAGILE BE VERY CAREFUL NOT TO BREAK IT INSTA LOAD XL 220
83. ing up on it will aid in its removal DO NOT pry up on the bottom of the Cartridge as this will damage the bottom lens Inspect the bottom lens element for damage Insert the Sound Drum Locating Plug T 38001 G in place of the Sound Optic Cartridge Push the Plug down until the small pin in its end is just above the Photo Diode in the Sound Drum Support the pin should not touch the Diode Loosen the Sound Drum Support Retaining Screw and rotate the Support until the Photo Diode notch of the Support is centered on the pin in the end of the locating Plug The sound drum support Set screw is accessible through a small hole in the bottom of the projector base Use a long bladed 1 16 Allen Wrench 3 19 U 1 2 INSTA LOAD XL 2200 SERIES Insert the Sound Drum in the Sound Drum Support and push this entire assembly toward the main casting until the back edge of the Sound Drum just touches the Pin on the Locating Plug Figure 3 34 Be sure to maintain the centering accomplished in Step 3 while making this adjustment Note Be sure the Sound Drum is butted against the end of the Sound Drum Support during this adjustment Having the Flywheel attach ed during this adjustment will help in hold ing these parts together in proper orien tation Feed Sprocket Clutch Lubricate the Spring 6 with 009 Lubricant 39479 P7 Figure 3 35 Assemble the Lubricating Pad 7 and the Clutch Spring 6 making sure the tai
84. itch S9 defective Model 2280 Fuses F1 and F2 blown Defective Di T1 C23 d Exciter lamp O K No sound from film Speaker hiss in creases with volume control e Exciter lamp O K No sound from film Speaker hiss but volume control has no affect on hiss f Exciter lamp O K No sound hum or hiss Defective Photo diode PD1 Z1 C1 C5 broken or shorted wire from sound drum defective P1 15 or 16 Defective Z1 C10 P1 15 or 16 Z4 Models 2270 and 2280 Defective Fuse F3 Switch S2A Models 2210 2220 and 2220L Speaker jack JS1 C34 Q1 Q2 Z2 Bad connection to speaker In addition for models 2270 and 2280 Defective S2E K4 S11 D2 Q4 Q5 Q6 Align pressure shoe Adjust protrusion Reassemble properly Replace lamp first then try each component Replace lamp first then try each component Replace lamp socket after checking for open leads to the socket Replace defective component Replace defective component Check for defective component then replace fuses Check for open or shorted wire from sound drum then check each component and plug P1 Check P1 contacts replace de fective component Check for bad fuse and bad con nections then replace defective component Replace defective component g Exciter lamp O K Distorted sound h Excessive hum with sound 6 10 Defective Z1 Z2 Q1 Q2 C24 C1 C5 C10 C13 C34 Z4
85. jector functions as an optical comparator when this tool is used STROKE SETTING GAGE No ST 5880 S iii INSTA LOAD XL Section III 2200 SERIES Service Procedures u 0 000 0 6245 0005 BRASS ROD 1 875 LONG 1 8 Used to locate the lateral and rotational position of the sound drum SOUND DRUM LOCATING PLUG 133 327 No T 38001 G S Used to set solenoid stroke i 3 8 SOLENOID STROKE GAGE No 85 327 7 32 MATERIAL 025 PHOS BRONZE OR SPE BR C3 T D RETAINER FEELER GAGE No SS 305 Used to set Sound Optics SOUND OPTICS ADJUSTING TOOL No T 43680 G1 G C MATERIALS Materials required are listed in the following table The stock numbers of materials available from Telex Communications are Used to hold solenoid while setting stroke given If there is no number the product will not be supplied by Telex Communications Only those test films showing our stock SOLENOID HOLDING CLAMP numbers can be procured others must be ordered by PH number No T 43411 G1 A from SMPTE 3 iv Section III INSTA LOAD XL Service Procedures 2200 SERIES LUBRICANTS AND CEMENTS STOCK PACKAGE DESCRIPTION 39479P5 DC 200 Silicone Fluid 200 000 centistroke viscosity Dow Corning Corp Midland Mich 39479P13 D200 Silicone Damping Fluid 200 centistroke viscosity Dow Corning Corp Midland Mich 39479P7 1 2 oz 009 L
86. l of the Spring 6 is trapped in the Notch N of Gear 14 Assemble Pin 11 to the Gear and Hub Assembly 3 and assemble the remaining parts on the shaft of Gear 14 in the order shown Adjust the Nut 8 to obtain 002 to 010 end play on the Gear and Hub Assembly 3 Assemble the clutch to the projector see Reas sembly of Front Clutches to Projector STEPS 6 THROUGH 10 PERTAIN TO FAST FORWARD PROJECTORS ONLY PROCEED TO STEP 11 IF YOUR PROJECTOR IS NOT A FAST FORWARD MODEL 3 20 BACK EDGE OF SOUND DRUM JUST TOUCHES PIN ON 10 SOUND DRUM LOCATING PLUG T 38001 G GAUGE S UND DRUM SOUND DRUM SUPPORT Figure 3 34 SOUND DRUM ALIGN MENT Assemble Stop 9 and Nut 15 and tighten the Nut 15 just enough to hold the Stop in place Depress Pin A and turn Clutch Gear B clock wise until Pin A touches Pin C HOLD GEAR B DO NOT ALLOW IT TO SPRING BACK Figure 3 36 Position the Stop D so that the corner or edge is just over the small cross pin of Pin A as shown Hold Nut F to prevent it from turning and tighten Nut E being careful not to allow Stop D to turn during this tightening process Recheck the end play of the Gear and Hub Assem bly B for 002 to 010 Repeat Steps 6 through 9 until the Stop D is positioned properly and the end play is correct MAIN CASTING r hot ie 11 12 13 INSTA LOAD XL 2200 SERIES Lubricate the outsid
87. ley 13 so the Pulley will rotate freely on the Main Shaft Figure 3 19 T Loosen both Set Screws 19 in the Collar 18 so the Collar will rotate freely on the Main Shaft 34 Loosen Set Screw 23 in the pinion 22 so the Pinion will rotate freely on the main shaft Figure 3 17 KICK SPRING ORIENTATION Figure 3 18 LOOP RESET ARM ECCENTRIC ORIENTATION Remove the oval point Jam Screw 27 and loosen the remaining two Set Screws in the Shutter and Cam Assembly 26 so the Cam Assembly will rotate freely on the Main Shaft Loosen both Set Screws 31 in the Collar 30 so the Collar will rotate freely on the Main Shaft Loosen Set Screw 25 in the Safety Shutter 24 so the collar of the Safety Shutter rotates freely on the Main Shaft Unhook the Link 2 from the Safety Shutter and allow the Spring 1 to pull the Link against the Pin on the Bracket Assembly 3 Disregard for projectors having no Safety Shutter 3 9 INSTA LOAD XL 2200 SERIES NOTE Items 9 amp 10 reversed on all projectors except 2120L amp 2151 FRONT VIEW OVAL POINT 1 FLAT ON 171 A6 3 MAIN SHAFT g SN OVAL POINT 3 AN 171 A6 3 yr Yr POINT 2 P00 CAM FLAT 43400 POD1 PULL DOWN TORQUE ALL SCREWS 140 In Oz SHUTTER CAM POSITION WHEN ADJUSTING CLAW ARM PIN PROTRUSION SHUTTER amp SHAFT ALIGNMENT Figure 3 19 REMOVAL AND REASSEMBLY OF MAIN SHAFT 8 Slide the Shutter and Cam
88. lm SMPTE P16 SFB in the projector and run it in Forward Adjust the 5K Hz Null Potentiometer VR 5 on the 5K Hz Filter Board for a minimum reading on the VTVM or Oscilloscope This reading should be 348 volts RMS or less 984 P P This represents a 30db rejection of the 5K Hz signal from the audio output INSTA LOAD XL 2200 SERIES 27V 31 20 From Pre Amplifier J20 2 9 Ground J2u 1 1 20 To Volume pg Control Figure 5 5 2220L 5K Hz Driver Training Filter Circuit 12 Connect the Oscilloscope and or VTVM across the 5K Hz Jack JS 1B and terminate the jack with a 1000 ohm 1 watt resistor 13 Adjust the 5K Hz Output Level Potentiometer VR 4 on the 5K Hz Filter Board for 505 volt RMS 1 43 volts P P If 505 volt cannot be obtained by adjusting VR 4 leave it at maxi mum and adjust VR 1 on the main amplifier board for 550 volt RMS 1 55 volts P P at JS 1B 14 Remove the 1000 ohm resistor from the 5K Hz Jack JS 1B 15 Adjust VR 4 on the 5K Hz Filter Board to reduce the 5K Hz output at JS 1B to 180 volt This is a requirement for all driver trainer projectors Failure to meet this require ment indicates a problem in the 5K Hz circuit Figure 5 6 2220L 5K Hz Driver Training Filter Board 16 Readjust VR 4 on the 5K Hz Filter Board for 505 volt at the 5K Hz Jack JS 1B with the 1000 ohm 1 watt resistor terminating the jack 27V DC
89. ly align the safety shutter midway between the shutter and cam assembly Safety shutter spring and link must clear the shutter cam by 1 8 Replace safety shutter Replace bumper pad Reassemble or replace spring Replace safety shutter Replace Switch 82 Replace Lamp L3 Replace Capacitor C18 Replace Relay K2 Replace Diode D3 Replace Resistor R27 6 7 TROUBLE h Fast mode interlock light does not remain on for five seconds after STOP button is pressed Models 2270 and 2280 i Failure to drive in Fast For WARD or brake in REWIND Models 2270 and 2280 j Failure to REWIND or brake in FAST FORWARD k Failure to brake in REWIND Models 2210 2220 and 2220L m No interlock on main lever in FAST modes Film Handling and Picture Troubles NOTE Test Film must be in good condition a Noisy film handling in film gate 68 INSTA LOAD XL 2200 SERIES Capacitor C18 open Relay K5 defective Model 2280 Relay K6 defective Model 2270 Solenoid SO3 defective Relay K1 defective Switch S3 defective Switch S6 defective Fast Forward clutch actuator cap not engaging clutch spring properly Fast Forward drive belt tension incorrect Solenoid SO1 defective Solenoid 502 defective Relay K1 defective Switch S3 defective Switch S5 defective Rewind clutch actuator cap not engaging clutch spring properly Feed sprocket clutch positive drive roll pin missing Rewind brake cable off
90. main shaft worm gear and the take up gear with a clean dry cloth or toothbrush DO NOT USE SOLVENTS ON THESE GEARS AS THEY WILL CRAZE OR CRACK 9 Grasp the take up gear and attempt to move it up and down If noticeable movement is detected the rear main casting bearing is worn and must be replaced Remove the rear sprocket and take up gear press the old bearing out and a new bearing in and reassemble the sprocket and take up gear 10 Lubricate the worm gear and take up gear with DC 44 grease 39479 P9 applied with a brush onto the teeth Installation of Blue or GREEN Take Up Clutch Liner 1 Butt the two ends of the liner against the key inside the take up gear 2 Form a slight belly in the liner opposite the key and push the liner into the take up gear 3 Push out on the belly formed in step 2 and tne liner will snap into correct position inside the gear Note The liner may appear to be too long How ever it is not DO NOT CUT THE LINER TO MAKE IT SHORTER Take Up Clutch Arm Servicing 1 On projectors without the FAST FORWARD option it is necessary to disassemble and thoroughly clean the take up pulley and brake spring 2 Use a cotton swab saturated with Teresso Instrument Oil 39479 P8 to clean the pulley oilite bearing DO NOT IMMERSE THE BEARING IN SOLVENT 3 Replace the brake spring and brake spring hub if deformed or scored 4 Lubricate the brake spring hub with four small drops of Ter
91. ned with instrument oil N 75 Roller end play should be 002 to 005 Sprockets Wipe with clean dry cloth Cloth may be moistened with alcohol if necessary Reel Arm Pulleys Clean grooves With cotton swabs moistened with alcohol or chlorothene Wipe flat surfaces with clean rag moistened with alcohol or chlorothene Sound Drum Clean grease and dirt from general area with alcohol Moisten cotton swab with alcohol and clean Photo diode and back edge of Sound Drum Sound Optic Moisten cotton swab with lens cleaner or alcohol and clean upper and lower lenses Motor Pulley and Main Shaft Pulley Clean drive surfaces with clean rag moistened with alcohol or chlorothene Shutter Wipe all visible surfaces of Shutter and Cam Assembly using a cloth dampened with chlorothene or alcohol Safety Shutter Wipe all visible Surfaces of Safety Shutter using a cloth dampened with chloro thene or alcohol Lexan Gears Main Drive Shaft Worm Gears Film Feed Clutch Gear and Takeup Clutch Gear DO NOT clean Lexan Gears with ANY solvent Wipe clean with clean dry cloth or remove excess dirty grease with toothbrush INSTA LOAD XL 2200 SERIES A CLEANING and LUBRICATION Some Useful Cleaning tools Be sure to use correct lubricant as specified by the lube charts and instructions Improper lubricant can cause damage Clean the front of the projector thoroughly Stubborn dirt may be remove
92. noid 503 but the solenoid does not operate since its terminal 5 is MOTOR DRIVE AND MODE LOGIC CIRCUITS not connected to line NEUTRAL These circuits are basically the same in all 2200 projectors This discussion covers the 2270 model since it contains all options except the Gemini 300 arc lamp When working with a different model omit the circuits which do not apply Swinger FJ of S2 connects the NEUTRAL side of the line to the yellow wire of the Main Drive Motor run winding and also to the Rewind Solenoid SO 1 Ter minal 2 Current flows through the run winding and the winding of Relay K3 operating the relay to connect LIVE power through its contacts to the black wire of the Main Drive Motor start winding The white A FORWARD PROJECT 2270 MODELS wire of the start winding is connected through capac itor C 17 to the NEUTRAL side of the line com Power is supplied to all the projector circuits by pleting the start circuit and causing the Main Drive operating the Main Power Switch 814 to ON Motor to run the projector in the Forward mode With the Forward button depressed and the Main Control Lever in the Project mode Main Control The Rewind Solenoid SO 1 does not operate since the i i u GA d to the Switch contact S2C is closed feed the LIVE NEUTRAL side of the line is also connecte side of the ete JA a pe other side of the solenoid coil terminal 1 through open contacts of Relay K3 and
93. one Control to its maximum right hand position Set the Volume Control for comfortable listening Run the projector Forward and adjust the BUZZ adjusting nut until no sound is heard or until the high and low frequencies are heard with equal volume There is a Buzz Track included as part of the Jiffy Test Film SMPTE P16 PP w FINAL PERFORMANCE TEST Place a Jiffy Test Film in the projector and check for proper operation Replace the covers and clean 2 23 INSTA LOAD XL 2200 SERIES 16mm LUBRICATION KEY GO Inst OiLN 75 D2 D4 Dow Corning DC 44 V1 Vischem No 352 Grease V2 Versalube G 322 Grease B Bearing Surface Or Pivot F Interface Figure 3 46 PREVENTIVE MAINTENANCE LUBRICATION POINT DIAGRAM INSTA LOAD XL 2200 SERIES VI B V2 B 60 20 GP G0 ID 16 mm Lubrication Key 60 1D Dow Corning DC 44 Dow Corning Damp Extreme Pressure Lube No Flourosilicone FS 1290 Instrument Oil 75 Glyptal 7526 Blue B Vischem No 352 Grease Versalube G 322 Grease Bearing Surface or ivot vi Interface Teeth ee X Drops VI B G0 ID D4 B Figure 3 47 OVERHAUL MAINTENANCE LUBRICATIO
94. oop reset gear when the projector is in the LOAD position Q DRIVE MOTOR BELT REQUIREMENT Reinstall the motor to the projector Hook the take up tension gage to the motor drive belt as shown in the illustration and pull down on the gage Sight along an imaginary line which touches the botton of the motor pulley and main shaft pulley while pulling down on the tension gage When the top of the gage wire touches this line the gage should read 7 to 10 ounces 2 18 er 7 TO 10 OUNCES 200 TO 285 GRAMS S INSTA LOAD XL 2200 SERIES DRIVE MOTOR BELT ADJUSTMENT Back the lock nut away from the motor plate and adjust the belt tension nut for correct tension Turn it counterclockwise to increase belt tension and clockwise to decrease tension Tighten the lock nut securely against the motor plate when adjustment is completed R REWIND BRAKE REQUIREMENTS Before attempting any take up or lift off adjustments check the operation of the rewind brake on models without Fast Forward Move the Master Control Lever to LOAD Viewed from the motor side of the projector the Helenes take up reel arm belt should move freely in a counter clockwise direction but bind or grip in a clockwise direction The feed and rewind arm belt should move freely in both directions Manually operate the rewind solenoid The take up reel arm belt should move freely in both directions and the feed and rewind
95. op of the Lensholder Rod Boss of the main casting Slide the Spring 45 and the Lensholder onto the Lens holder Rod and push the Lensholder in until the screw hole is visable toward the back edge of the access slot for Screw 44 Slowly move the Master Control Lever toward LOAD while observing the Lensholder Link When the hole in the Link just starts to become visible insert the end of Screw 44 into the hole It will be very helpful to hold the serew with a Holding type screwdriver LENSHOLDER LINK 31 Figure 3 1 REMOVAL AND REASSEMBLY OF LENSHOLDER 5 10 3 2 INSTA LOAD XL 2200 SERIES Continue to move the Master Control Lever slowly toward LOAD until the hole in the link lines up with the hole in the Lensholder and start the Screw 44 into the hole in the Lensholder While tightening the Screw 44 make sure the over size hole in the link slips over the shoulder on the Screw 44 so the Lensholder does not bind during operation Tighten the Screw 44 securely Replace the Front Sprocket 10 and the Film Strip per 8 Adjust Setscrew 46 to provide 002 to 010 clearence between the Setscrew and the main hous ing throughout the total Lensholder travel Removal of Front Clutches Remove the Film Stripper 8 the C Ring 11 and the Front Sprocket 10 Remove the Spring 14 being very careful not to allow the Pin 16 to slip out of the Arbor 15 and drop into the
96. own on the upper end of the clutch arm causing the arm to pivot and push up on the lower portion This forces the pulley against the clutch liner which is inside the clutch gear More weight placed on the reel arm causes more downward pressure on the roll pin and upper end of the clutch arm resulting in more upward pressure of the pulley against the clutch liner This results in more friction between the clutch liner and the pulley producing more take up drive Thus when the film take up reel gets heavier because it is taking on more film it causes greater force between the clutch pulley and liner resulting in the increased torque needed to drive the CLUTCH PuLLE heavier reel BLAS SPRING PRESSURE UPWARD PRESSURE eS FILM T U TENSION ADJUSTING NUT LIFT OFF OR DRIVE CONTACT ADJUSTING NUTS BRACKET Figure 14 16 INSTA LOAD XL 2200 SERIES FLYWHEEL DRIVE SYSTEM When the projector is operated in the Reverse mode the friction of the film traveling over the sound drum is not sufficient to drive the sound drum This causes increased drag on the film resulting in the loss of the lower loop with a consequent increase in noise in the film gate area The flywheel drive system eliminates this problem by driving the fly wheel in reverse to reduce the drag on the film and maintain the lower loop The Flywheel Drive mechanism is driven by a gear mounted on the main shaft In the forward modes the
97. pulleys Wrong rewind brake cable length Take up clutch pulley worn Take up clutch brake spring worn or dirty Solenoid 502 defective Interlock link uncoupled or de formed Claw protrusion or stroke out of adjustment Pressure shoe out of adjustment Emulsion buildup on pressure shoe and aperture plate REMEDY Replace Capacitor C18 Replace Relay K5 Replace Relay K6 Replace Solenoid 503 Replace Relay K1 Replace Switch S3 Replace Switch S6 Check cap spring engagement Replace actuator cap or spring as necessary Adjust drive belt tension Replace Solenoid SO1 Replace Solenoid SO2 Replace Relay K1 Replace Switch 83 Replace Switch 55 Check cap spring engagement Replace actuator cap or spring as necessary Replace feed sprocket clutch gear Reassemble brake cable Adjust brake cable Replace take up clutch pulley Clean or replace brake spring Replace Solenoid SO2 Reassemble or reform Adjust protrusion and or stroke Adjust pressure shoe Clean pressure shoe and aper ture plate INSTA LOAD XL 2200 SERIES TROUBLE CAUSE Film Handling and Picture Troubles Continued a Noisy film handling in film gate Continued b Film scratch c Film damage at feed sprocket Claw arm pins worn or damaged Dirty film Aperture plate or pressure shoe dirty Film path rollers stuck Supply reel arm pulley binding No end play in feed sprocket Sprocket defective
98. r s discretion 20 Press the STOP button Move the Master Control Lever to the LOAD position and thread a jiffy test film SMPTE P16 PP onto the projector 21 Move the Master Control Lever to the PROJECT position 22 Check for proper threading by manually rotating the manual advance knob and checking the film movement through the projector 23 Press the FORWARD button and observe that film moves smoothly through the projector and is gathered on the take up reel 24 Move the tone control and listen for a change in piteh 25 Advance the volume control momentarily to a loud listening level Check for case rattle or buzz 26 Follow directions on jiffy test film 27 Rewind jiffy test film when test is complete 28 Check Elevation 29 Check Loop Restorer PARA INSTA LOAD XL 2200 SERIES SECTION IH DISASSEMBLY and REASSEMBLY ADJUSTMENTS TITLE SECTION III SERVICE PROCEDURES REMOVAL OF LENSHOLDER REASSEMBLY OF LENS HOLDER REMOVAL OF FRONT CLUTCHES REASSEMBLY OF FRONT CLUTCHES REMOVAL OF TAKE UP CLUTCH Installation of Blue or Green Take Up Clutch Liner Take Up Clutch Arm Servicing TAKE UP CLUTCH REASSEMBLY REMOVAL OF TAKE UP SPROCKET and GEAR REASSEMBLY OF TAKE UP GEAR and SPROCKET SPRING LOADING TIP REMOVAL OF AUTOMATIC LOOP RESET ASSEMBLY REASSEMBLY OF AUTOMATIC LOOP RESET ASSEMBLY REMOVAL OF MAIN SHAFT REASSEMBLY OF MAIN SHAFT REMOVAL OF CLAW ARM REASSEMBLY OF CLAW ARM Claw Arm Adjustment Claw
99. rocket hole at the top of its stroke as it is from the outside edge of the sprocket hole at the bottom of its stroke Figure 3 22 Loosen Screw 14 and adjust the Bushing 8 Figure 3 21 so these two distances are equal Remove the film from the projector after proper Framing and Side Clear ance are established ae APERTURE MAIN CASTING DISTANCE A After the Gauge Target has been moved into the Aperture continue turning the Inching Knob clockwise so the Claw Arm Pins withdraw at the bottom of the stroke and raise to the top of the stroke STOP turning the Inching Knob when the Pins reenter the sprocket holes BEFORE they start moving down The Shutter Blade will be even with the bottom edge of the Aperture Note If you go too far go back to Step 3 and repeat Turn the Lamp on and project an image at least 8 wide a wide angle lens will help achieve this width at a shorter projection distance raise the elevation approximately 1 this will get you set up in case the Stroke is in need of adjustment and draw a reference line the full width of the Target on the bottom step Figure 3 23 PROJECTED IMAGE ean TOP CLA PIN AT top et 2 DRAW OF STROKE t APERTURE PLATE REFERENCE LINE CEAVSLOF 1 SHUTTER JUST BELOW APERTURE CLEARANCE PIN AT BOTTOM IE PIN ENTERS STOP UNDER PIN OF STROKE j j REQUIREM DISTANCE DISTANCE B VIEWED FROM BEHIND Figure 3 22 SIDE CL
100. s the ground from the base of Q4 allowing Q4 to conduct while the button is being pressed The resulting drop in voltage at the collector of Q4 is coupled to the base of Q5 cutting Q5 and Q6 off and releasing the Relay K4 The contacts of Q4 open to disconnect the speakers from the output amplifier and mute switch clicks THE POWER SUPPLY The 40 volts AC from the secondary of the Lamp Amplifier Transformer T1 is rectified by Full Wave Bridge Rectifier D1 to produce 54 volts DC which is centertapped to produce a positive and negative 27 volts DC The positive 27 volts feeds the current regulator circuit Q3 and Z3 and the relay portion of the muting circuit K4 as well as the main amplifier and microphone preamplifier The negative 27 volts is used for the driver and power amplifier stages of the main amplifier Z2 and Q2 Current regulation is accomplished by transistor Q3 and regulator chip Z3 This regulated current is required to keep the exciter lamp brilliance constant and prevent any variations in sound which would occur if the brightness of the exciter lamp were to vary When the DC voltage to the circuit increases because of the line voltage increase the DC output current from the emitter of the transistor tries to increase However since the base is held ata constant voltage by the regulator chip Z3 any attemped increase in emitter voltage is recognized as an increase in reverse bias causin
101. screw as though tightening This will force the nylon plug out of the hole Be careful to prevent the plug from falling into the projector Remove the setscrew Insert a NEW NYLON PLUG 38162 P1 and start the setscrew into the threads After cleaning the top and bottom lenses of the optic insert it in the projector and tighten the set screw until it is held in place but can be turned and moved up and down easily Be careful to prevent the optic from dropping onto the sound drum as this may damage the bottom lens Note You may find it more convenient to replace the nylon plug and setscrew with a new NYLON Tip Setscrew 45209 P1 2 22 INSTA LOAD XL 2200 SERIES Run the projector in Forward and focus the Sound Optics Cartridge by moving it up or down while rotating it back and forth until both requirements of Step e above are met Tighten setscrew VERY tight when adjustments are complete Note 1 Use of Tool T 43680 G1 might make focusing of the Sound Optic more convenient To use the tool attach the ring portion to the optic and clamp the adjusting rod portion to the lamp house platform of the main casting Note 2 No attempt should be made to remove the lens elements If difficulty is encountered meeting the above requirements and the Sound Optic is suspected replace the entire cartridge V2 BUZZ ADJUSTMENT Thread a continuous loop of BUZZ track film SMPTE P16 BT 45191 G3 in projector and set the T
102. se Run the projector forward with film Move the carrier to obtain quietest operation and steadiest picture These two requirements will generally occur simultaneously Reverse project Readjust if necessary for quiet steady operation Recheck b above Tighten the carrier Move the control lever up and down several times to be sure that the pressure shoe Seats properly and recheck with film P AUTOMATIC LOOP RESET SERVICING Move the Master Control Lever to LOAD By hand rotate loop reset gear clockwise about 90 and hold 2 17 INSTA LOAD XL 2200 SERIES Push the lower spring loaded arm down and examine the raised lip on the eccentric stud Replace the gear if this lip is worn While the loop reset arm is disassembled check the gear latch tab for burrs If a burr is found replace the arm AUTOMATIC LOOP RESET ECCENTRIC ADJUSTMENT When the Master Control Lever is in the LOAD position the cradle in the end of the arm link should trap the loop reset arm eccentric so the arm is neither forced up by the cradle nor able to be pushed up with the cradle in place This would result in the release of the engagement of the gear latch tab with the raised lip on the loop reset gear eccentric causing continuous recy cling of the loop reset mechanism in the fast modes of operation Loosen the setscrew in the eccentric and rotate it to fit into the cradle of the master control lever without releasing the l
103. ssible to adjust the lift off setting the double nuts on the bottom of the take up clutch threaded rod Turn these nuts up 1 2 turn PROJECTION LENS Clean and replace the projection lens Make sure the lens is positioned so the antitheft screw is flush with the lensholder casting If this screw is not seated properly the lensholder cover cannot be assembled properly and the projector will not handle film v BUZZ AND SOUND OPTIC FOCUSING a SMPTE P16 BT Buzz Track film 45191 G3 is used to adjust the lateral position of the front pressure roller with respect to the sound drum b SMPTE P16 SF A 7000 Hz sound focusing film Telex 45191 G2 or SMPTE P16 SF B 5000 Hz sound focusing film Telex 45191 G1 is used to adjust the focusing of the sound optic and the azimuth of the sound optic c These two adjustments are interdependent If difficulty is experienced in making either of these adjustments check the other one and adjust it as necessary v1 SOUND OPTIC FOCUSING ADJUSTMENT a Cut two strips of 7000 Hz sound focusing film about 40 long SMPTE P16 SF A P N 45191 G2 b Splice them together to form a closed loop with the emulsion side of one strip on the outside circum ference of the loop and the emulsion side of the other strip on the inside circumference of the closed loop 6 Thread this loop in the projector and adjust the Tone Control to its maximum right hand position d Connect an AC Voltmeter across the spe
104. switch S2A to mute the sound in the Fast Mode Con tact F1B connects the line NEUTRAL to the Rewind Solenoid SO 1 Terminal 1 The Solenoid operates because its other end Terminal 2 is connected to line LIVE through switch S2FJ Relay K3 and Switches S2C and S14 With the Rewind Solenoid operated the Rewind Clutch is locked into direct drive to transport film rapidly through the projector in the reverse direction INSTA LOAD XL 2200 SERIES lig Ih m K3 amt E oe N K pa n 3 m ot s2 GAN PANJ war 7 GH paa Ne 7 Z ma aa Por ul ne er Las m ssar M LL H 370 VAC Air PRON KT Tv ike 2 2 kar za Ao Blatt 2 Kr Pr 73 3 7 2 m sa wl FRAME GROUND h IS na d ETE aes ME y T Pi CE see 640678 1 ge H eee Aer Menn of ke SE Hi 5 Te 02 ee S fa A H E EA D5 ee Figure 20 Rewind 2270 Initially On When film is transported rapidly In Path through the projector it must not be possible to raise the Master Control Lever to the Project mode and close the mechanism tightly on the film or else the film would be damaged A Fast mode interlock system is used to prevent this from happening This interlock system is activated and held by Relay K2 and Interlock Solenoid 5
105. t to make clear ance for removal of the Claw Arm 13 Remove two Nuts 9 and Washers 10 and 11 Loosen the two Setscrews 14 and 19 and remove the Bushing 8 the Washer 17 and the Pivot 18 Note Wipe the Pivot 17 and the Bushing 18 with a Clean dry rag DO NOT clean these two parts with solvent Grasp the Claw Arm 13 and pull toward you be ing careful not to lose the Spring 15 or Pin 12 or damage the Claw Arm Pins Unhook the Spring 15 and remove the Pin 12 INSTA LOAD XL 2200 SERIES Q Reassembly of Claw Arm to Projector 11 Make sure Pin 12 is trapped in place by Spring Note Extreme care should be exercised during this procedure to insure that the pins on the Claw Arm are not allowed to hit the aperture plate or any other part of the projector causing damage to them 15 12 Perform all Claw Arm Adjustments Side Clearance Pull down Stroke Framing and Pin Protrusion Claw Arm Adjustments 1 Apply DC 44 grease 39479 P9 to the Pin 12 and stick the Pin in place on the Claw Arm 13 Side Clearance making sure the notch lines up with the hole in Puli down Stroke the Claw Arm 13 Note These two adjustments are interdependent and 2 Apply DC 44 grease to Rod 1 threads must be adjusted at the same time If either one is adjusted the other must be checked and 3 Hook Spring 15 onto the Claw Arm 13 and in adjusted as necessary until requirements for sert the Cl
106. the loop reset gear mounting shaft as shown Insert a dental pick through the small hole next to the hub of the Loop Reset Gear 11 and push the Kick Spring 12 out of the way so the gear can be pushed onto its shaft Secure the gear with the E Ring 10 251 7 1 Slide the Pinion 8 into the oilite bearing of the Pivot 9 and assemble the Pulley 7 allowing for 001 to 007 end play Tighten Set Screws 5 Slide the Arm Complete 4 into its mounting hole in the main casting and secure it in place with the E Ring 3 A set of surgical hemostats are very helpful for holding this E Ring during installation Replace the sound drum Flywheel 2 Move the Master Control Lever to the LOAD position and observe that the cradle in the end of the arm link traps the Loop Reset Arm Eccentric so the Reset Arm is neither forced up by the cradle nor able to be pushed up with the cradle in place Figure 3 18 Loosen the Set Screw in the Eccentric and rotate it to fit into the cradle of the Master Control Lever without releasing the Loop Reset Gear with the Master Control Lever in the LOAD position Removal of Main Shaft Ref Figure 3 19 Unhook the top of the Claw Arm Spring from the 5 Framing Arm and make sure all tension is off the Claw Arm before proceeding with these in structions Throughout this procedure be ex tremely careful of the Claw Arm Pins Figure 3 20 Loosen both Set Screws 14 in the Pul
107. the steel hub which is secured to and turns with the main shaft and the brass cylinder of the safety shutter SAFETY SHUTTER SERVICING Replenish the DC 200 Viscous fluid 200 Centistoke 39479 P17 each time preventive maintenance or overhaul is performed by standing the projector on its nose and applying two or three drops in the small crack between the steel hub and the sealing washer Turn the main shaft while rocking the safety shutter back and forth to WICK the fluid down into the shutter Run the projector for several seconds to distribute the fluid inside the brass cylinder Repeat the procedure two or three times to com pletely fill the reservoir INSTA LOAD XL 2200 SERIES M SHUTTER AND CAM OPERATION The shutter and cam are locked together and require no timing The cam moves the claw arm up and down stroke and in and out of the film sprocket holes protrusion Up and down movement occurs as the cam fol lower on the front of the claw arm follows the radial round surface of the cam In and out movement occurs as the cam follower Button see arrow on the back of the claw arm follows the axial surface wobble plate of the cam The pivot lower right is used to adjust stroke and repositioning of the shutter and cam assembly on the main shaft is what determines protrusion Tools required for adjusting stroke and protrusion are a Protrusion Gage G10 38000 Left b Pivot Adjusting
108. to 007 for the Sprocket In DE DEN order to correctly check the end play of the Sprocket the front sprocket clutch Shaft must be prevented from moving since it has its own 18 Hold the Actuator Caps 6 and 7 in place and assemble the Solenoid Package 3 with three ir J Screws 4 making sure to insert the interlock end play of 001 to 005 link wire into the slot in the bottom of the 15 Assemble the Film Stripper 8 Interlock Solenoid Paddle 3 3 INSTA LOAD XL 2200 SERIES E Removal of Take Up Clutch 1 Remove the motor and motor mounting plate to expose the take up clutch for servicing 2 Inits normal position the roll pin which holds the upper end of the clutch arm to the reel arm shaft is difficult to remove 3 Remove the reel arm belt and place a block of wood under the arm as shown to hold it in a ver tical position 4 Drive the roll pin out with a 3 32 2 5mm pin punch 5 Remove the upper end of the clutch arm from the reel shaft Remove the reel arm Clean the shaft and casting hole and relubricate with G E Versilube G 3221 39479 P14 6 Pull the clutch hub pulley out of the take up gear and push down on it to compress the bias spring and allow the hook of the rod to rise up in the slot Figure 3 6 PUSH DOWN ON BIAS SPRING INSTA LOAD XL 2200 SERIES 7 As soon as the hook clears the slot the clutch arm can be swung out and lifted up off the rod 8 Clean the
109. ts from the top side of the pulley In the case of the take up belt the con trol lever should be in the LOAD position G SOUND DRUM AREA SERVICING Look gt ALL SINGER INSTA LOAD PROJECTORS use a BSW 7 volt exciter amp 200 MA OG vers Lamps having a darkened envelope around the filament cause reduced sound output Try a new exciter lamp first if the projector has poor or low sound Driver Trainer Projectors are serious ly affected by exciter lamps with low light output Thoroughly clean the sound drum area CLEAN SHAFT Remove the flywheel and the sound drum Thoroughly clean the sound drum shaft the inside of the sound drum and the back edge of the sound drum 2 9 INSTA LOAD XL 2200 SERIES Soak a cotton swab with Teresso Instrument Oil 39479 P8 and clean the oilite bearing in the sound drum support Moisten a cotton swab with Alcohol and clean the photo diode in the sound support Gl FILM DAMPENER ARM ADJUSTMENTS If the dampener arm doesn t drop in 3 to 5 seconds DO NOT BEND THE DAMPENER ARM SPRING Remove the dampener arm roller and spring note orientation of spring Remove the dampener arm Disassemble the Dampener Arm and wipe the dampening fluid off the arm hub and aluminum cup Apply 2 or 3 drops of very heavy DC 200 200 000 Centistoke dampening fluid 39479 P 5 in an even coat on the hub and reassemble the aluminum cup to the arm Wipe a
110. tween the two windings which causes the motor to run in reverse The Rewind Solenoid 801 operates since the LIVE side of the line is connected to its terminal 2 from S2FJ and the NEUTRAL side of the line is con nected to its terminal 1 through S5 and 53 INSTA LOAD XL 2200 SERIES The operated Rewind Solenoid locks the Rewind Clutch in direct drive so it can drive the supply reel to take up film in reverse The Rewind Clutch is driven by the Feed Sprocket Clutch which is not locked into direct drive because solenoid 02 is not operated The Feed Sprocket Clutch slips to provide the proper Reverse take up tension and prevent film damage in the front sprocket Switch S2A mutes the sound by opening the exciter lamp circuit so the exciter lamp goes out FAST FORWARD 2270 MODELS Power is supplied to all the projector circuits by operating the Main Power Switch S14 to ON With the Forward button depressed the Master Control Lever in the Fast mode and the Main Power Switch ON switches 52A S2B S2C 82D and S14 are closed The movable contacts C are connected to the normally open N O contacts on switches 83 85 and S6 Switch S9 may be in the Hi or Lo position Switch S2FJ is connected to terminal 9 and S2GH is connected to terminal 7 Relay K3 is operated ctosing its normally open contacts The LIVE side of the line is connected to the black wire of the
111. ubricant Keystone Carbon Co St Mary s Pa 39479P8 2 oz Instrument Oil Teresso Oil No N 75 Humble Oil amp Refining Co New York N Y N 39479P9 2 02 DC 44 Light Consistency Silicone Grease Dow Corning Corp Midland Mich 39479P15 202 Vischem No 352 Ultra Chem Inc Wilmington Del 39479 P4 1 2 oz FS 1290 Fluorosilicone Grease Dow Corning Corp Midland Mich 39479P14 2 og Versalube G 322L General Electric 39490P1 3 oz 7526 Blue Glyptal General Electric Co Schenectady N Y N 75 39479P16 4 02 Extreme Pressure Lube No 3 39490P2 3 oz 1276 Clear Glyptal General Electric Co Schenectady N Y 39479 P17 1 2 oz DC 350 Dampening Fluid Used on Insta Load safety shutter P N 42994 G2 Replaces 39479 P13 DC 200 200CS 8101 5 Silicone Compound General Cement Electronic Co Rockford Ill No 59 Loctite Screw Lock Loctite Corp Newington Conn Saree sess 3 oz EC 880 Minnesota Mining amp Manufacturing Co St Paul Minn 45191 G3 12 ft PH22 57 Buzz Track Film P16BT een m e PH22 43 3000 cps Film 45191 G7 PH22 45 400 Cycle Test Film 45191 G2 12 ft PH22 42 7000 cps Film P16SFA 45191 G6 12 ft 16 3 mm Registration Test Film Reg 16 39490P4 8 oz Glyptal Thinner 1511M Chlorothene Dow Chemical Co Midland Mich 39490P12 4 02 Tan Paint 39490P13 4 02 Brown Paint INSTA LOAD XL 2200 SERIES SECTION III DISASSEMBLY AN
112. urned off LIVE AC power is removed from the Main Drive Motor M1 Relays K1 K2 and K3 and Rewind Solenoid 501 Relays K1 and K3 and Rewind Solenoid S01 release Relay K2 remains operated for to 5 seconds while C18 discharges through it The contacts of Relay K2 continue to apply LIVE AC power to the interlock circuit and now also to the Fast Forward Solenoid S03 through the N C contacts of Relay KJB The Interlock Solenoid S02 remains operated for 3 to 5 seconds preventing the Master Control Lever from being raised before the film comes to a complete stop The Fast Forward Solenoid S03 operates to lock the Fast Forward Clutch in direct drive braking the rear reel and stopping fast film movement through the projector After 3 to 5 seconds Capacitor C18 discharges sufficiently so Relay K2 releases and removes power from this entire circuit causing the Fast Forward Solenoid S03 and Interlock Solenoid 502 to release thus restoring the circuit to its rest condition INSTA LOAD XL 2200 SERIES End gov EMS 24 Ian E Pea 83 RT er 3 Lg NTE Nu nee 4 pe w h MAT RAS ras mn ma a sa a Jeon s ar ial 370 VAC ee pet LT pins at wee rez Ir i 4 eee az si 277 sz a p Pya ren x lu FRAME GROUND
113. wraps around the arbor of the Clutched Gear 3 When the projector runs in any forward mode the clutch gear rotates in a clockwise direction as viewed from the back of the projector pushing the tail of the spring to clamp it tightly around the arbor so the Clutched Gear 3 is directly driven by the clutch gear through the clamping action of the spring The drive of the worm gear on the main shaft is thus directly connected to the Rewind and Fast Forward clutches Figure 4 27 amp 32 through the clutch gear 14 clutch spring 6 and clutched gear 3 Since the Rewind Clutch is not locked in direct drive in any forward mode it does not drive the supply reel Film is pulled from the supply reel by the feed sprocket which is fastened to the shaft of the Clutch Gear 14 The Fast Forward Clutch also slips and does not drive the take up reel REVERSE Figure 3 When the projector runs in reverse the notch N in the clutch gear 14 moves in a counterclockwise dir ection moving the tail of the clutch spring 6 to open the spring coil and allow the spring to slip on the arbor of the clutched gear 3 This provides a clutched drive to the Rewind Clutch which is locked in direct drive in both reverse and rewind This is necessary so the Rewind Clutch will drive the supply reel in reverse only as fast as film is supplied to it from the feed sprocket FAST FORWARD Figure 4 In the Fast Forward mode the Feed Sprocket Clut
114. z ar EYE mo r I HE GE at T Pa s r 640678 342 3 a AMP SCHEWATIC n ME i oo TALZ a y 3 Fi i sje E nA oh s s 302 ti k 3 BRAKE 1 ae ow c 18 n o A Stout DISCHARGING PR Ivot py F I bl als T ra Figure 22 Stop Rewind 2270 Model E AUDIO AMPLIFIER The Audio Amplifier in the 2200 series projectors is a basic operational amplifier type providing excellent linearity with high gain For the purpose of our discus ion we have chosen the amplifier used in the 2270 models since it contains all the options available If the projector you are servicing in another model simply omit the circuitry which does not apply The 2200 series amplifier is made up of four basic sections 1 The Main Amplifier 2 The Microphone Preamplifier 3 The Muting Circuit 4 The Power Supply INSTA LOAD XL 2200 SERIES AS MIC PRE AUR 40 DB Gam AL Binet ART FAT Rie Pe Y BOARD ASSEMBLY AMPLIFIER PRE AMP Nese PROUT 98 BEST OMT un r 2s pa A phy re dd 39 ya nar By Abeta r Figure 23 TY asi SARR ACK 7 TONE AND VOLUME CONTROL ASSY Az vaLUME DRIVER AND POWER AMP 2V REG s ner 25 Watt Amplifier Schematic I POWER SUPPLY 2270 Model

Telex 2200 Service Manual

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