Kinoton FP30A Operating Manual

Operating Manual
FP 30 A Projector
DIGITAL CINEMA
FILM TECHNOLOGY
STUDIO TECHNOLOGY
CUSTOMIZED SOLUTIONS
360° DISPLAY SYSTEMS
FP 30 A
Preface
Dear customer,
this operating manual will help you get acquainted with the projector and to make use of
its possible applications in accordance with the requirements.
This operating manual includes important hints for a safe, proper, correct and economic
operation.
It will also help you to avoid danger, to reduce failures and to increase life and reliability
of the projector.
This operating manual includes useful hints for proprietor and personnel obligations.
It does not substitute, but supports, a thorough training period.
We confirm that the information given in this manual is true and correct to the best of
our knowledge and belief. However, notwithstanding all best care and attention, techni-
cal inaccuracies and typographical errors cannot be fully excluded.
As far as we did not assure explicitly and written form any special characteristics and
suitability of a product for a certain intended purpose, the statement in this manual are
generally without obligation.
All descriptions, illustrations and technical data comply with the technical status of the
product at the date of printing of this manual. Any modifications are subject to change
without prior notice due to ongoing further development.
FP 30 A
Imprint
All rights reserved
© Copyright by KINOTON GmbH,
Industriestraße 20a
Germany - 8 21 10 Germering
Printed in Germany, Issue May 2011
This operating manual – even in extracts – may only be reprinted or otherwise copied
with special, written permission from KINOTON GmbH.
Editor responsible for the contents: KINOTON GmbH
Editing and layout: Carmen Auer - KINOTON GmbH
Hints / Own Notes

FP 30 A
Contents
1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1.1 General Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.2 Dangers when Working with the Projector . . . . . . . . . . . . . . . . . . . . . . 1
1.1.3 Intended Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1.4 Guarantee and Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Explanations of Symbols and Notes . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Special Hazard Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.3.1 Electric Power Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.2 Lamphouse Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.2.1 Broken Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Contents
1.3.2.2 UV Radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.2.3 High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.3 Mechanical Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Preventing Projector Damage . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.6 Protective Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.6.1 Main Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.6.2 IR Reflex Film Break Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.6.3 Film Stripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Issue: 04/2011 i
FP 30 A
2 Transportation and Installation / Mounting . . . . . . . . . . 9
2.1 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Delivery or Equipment Variations . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3.1 Place of Installation, Place of Operation . . . . . . . . . . . . . . . . . . . . . . . 10
2.3.2 Important Hints for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3.3 Additional Installation Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4.1 Filling with Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4.2 Installing and Connecting the Lamphouse Components . . . . . . . . . . 14
2.4.3 Connecting the Water Cooling (option) . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4.4 Projector Terminal Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4.5 Connecting to the Non-Rewind System . . . . . . . . . . . . . . . . . . . . . . . 15
3 Function and Components . . . . . . . . . . . . . . . . . . . . . . 17
3.1 Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.1.1 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.1.2 Projection Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2 Film Gate and Film Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.2.1 Film Pressure Skate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2.2 The Dowser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2.3 Single Aperture Plates (only with manual lens turret or lens holder) . 21
3.2.4 Aperture Changer (option, only with electronic lens turret) . . . . . . . . . 21
3.2.4.1 Drive and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.2.4.2 Format Change with Three Lenses . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.2.4.3 Format Change with Two Lenses Turret . . . . . . . . . . . . . . . . . . . . . . 22
3.2.4.4 Changing the Format Combination . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
ii Issue: 04/2011
FP 30 A
3.2.5 Lens Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2.6 Lens Turret (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.2.6.1 Manual Lens Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.2.6.2 Electronically Controlled Lens Change (option) . . . . . . . . . . . . . . . . . 25
3.2.7 Focusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2.7.1 Manual Focusing with Lens Turret / Lens Holder . . . . . . . . . . . . . . . . 26
3.2.7.2 Electronic Focusing with Lens Turret (option) . . . . . . . . . . . . . . . . . . 26
3.2.7.3 Electronically Controlled Lens Holder Focusing (option) . . . . . . . . . . 26
3.2.8 Rotating Shutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.2.9 Intermittent Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2.10 Framing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2.11 Constant Speed Sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3 Reverse-Scan Sound Device . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.3.1 Analog Reverse-Scan Sound Device (non-upgradeable) . . . . . . . . . . 30
Contents
3.3.2 Reverse-Scan Sound Device Analog and optional DOLBY Digital
(upgradeable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.3.2.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.3.3 Sound Tracks on the Films . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4 SDDS Reader / DTS Reader (option) . . . . . . . . . . . . . . . . . . . 32
3.5 Film Cleaner (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.6 Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.6.1 Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.6.2 Intermittent Movement

(also called a Maltese Cross or a Geneva Movement) . . . . . . . . . . . . 34
3.6.3 Friction Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.6.3.1 Take-Off Friction (non-driven) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.6.3.2 Take-Up Friction (driven) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.6.3.3 Reel Shaft on Change Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.7 Electronic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.7.1 Main Control / Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.7.2 LED Power Supply Board for the Reverse-Scan Sound Device . . . . . 36
Issue: 04/2011 iii

FP 30 A
4 Operating Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1 Main Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.2 Projector Operating Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.3 Remote Control Panels (option) . . . . . . . . . . . . . . . . . . . . . . . . 38

4.3.1 “BWR” Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.3.2 Auditorium Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5 Operation, Threading and Troubleshooting . . . . . . . . 41
5.1 Switch On and Start the Projector . . . . . . . . . . . . . . . . . . . . . . 41
5.2 Stop and Switch Off Projector . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.3 Threading for Projection Operation . . . . . . . . . . . . . . . . . . . . . 42
5.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.4.1 General Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.4.2 Projector Troubleshooting Chart (Type 1 errors) . . . . . . . . . . . . . . . . 43
5.4.3 Projector Troubleshooting Chart (Type 2 errors) . . . . . . . . . . . . . . . . 43
5.4.4 Analog Sound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.4.5 Digital Sound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6 Cleaning / Maintenance / Repair . . . . . . . . . . . . . . . . . 47
6.1 General Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.3.1 Drain and Refill Oil (Kinoton type 3672 oil): . . . . . . . . . . . . . . . . . . . . 50
6.3.2 Changing the Intermittent Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
iv Issue: 04/2011
FP 30 A
6.4 Repair and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

6.4.1 Changing the Pilot Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.4.2 Adjusting the Film Pressure Skate . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.4.3 Adjusting the Height of the Film Pressure Skate . . . . . . . . . . . . . . . . 52
6.4.4 Changing the 35 mm Film Runner Strips . . . . . . . . . . . . . . . . . . . . . . 53
6.4.5 Adjusting the Lens Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.4.6 Changing a Constant Speed Sprocket / Pad Shoe . . . . . . . . . . . . . . 54
6.4.7 Adjusting the Tension of the Pad Shoe Spring . . . . . . . . . . . . . . . . . . 55
6.4.8 Adjusting the Distance between Pad Shoe and Sprocket . . . . . . . . . 55
6.4.9 Adjusting the IR Reflex Film Break Sensor . . . . . . . . . . . . . . . . . . . . . 55
6.4.10 Changing and Lubricating the Felt Disk of the Mechanical Friction . . 56
6.4.11 Adjusting the Mechanical Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.4.12 Tension the Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Contents
7 Parts and Wearing Parts . . . . . . . . . . . . . . . . . . . . . . . . 59
7.1 Parts for the Film Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.2 Parts for the Feed/Bottom Sprocket . . . . . . . . . . . . . . . . . . . . . 59
7.3 Parts for Guide Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.4 Other Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.5 Parts for Motors and Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.6 Film Spools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.7 Interchangeable Flanges with Friction Shafts . . . . . . . . . . . . . 64
7.8 Parts for Electronics and Controls . . . . . . . . . . . . . . . . . . . . . . 64
7.9 35 mm Apertures for Aperture Changer . . . . . . . . . . . . . . . . . . 65
7.10 Single Apertures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.11 Adapter Rings for 35 mm Lenses . . . . . . . . . . . . . . . . . . . . . . . 66
Issue: 04/2011 v
FP 30 A
8 Technical Data, Circuit Diagrams and

Plans of Terminal Connections . . . . . . . . . . . . . . . . . . 67
8.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

8.1.1 Projector Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
8.1.2 Reverse-Scan Sound Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
8.2 Terminal Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

8.2.1 Projector Terminal Strip for Automation and Remote Control . . . . . . 68
8.2.2 Sound Output on 8-pole Terminal Strip . . . . . . . . . . . . . . . . . . . . . . . 69
8.3 Wiring Schemes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

8.3.1 FP 30 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
8.3.2 Lamphouse (230 V mains connection) . . . . . . . . . . . . . . . . . . . . . . . . 71
8.3.3 Lamphouse (120 V mains connection) . . . . . . . . . . . . . . . . . . . . . . . . 72
vi Issue: 04/2011
FP 25/30/50 D / FP 10/20/30/50 A
1 Safety
1.1 Safety Notes
1.1.1 General Hints

»» Read this operating manual before operating the projector.
»» This operating manual is to be kept with the projector at all times.
»» For safe and trouble free operation of the projector a good working knowledge of
basic safety regulations and the projector’s correct use is required.
»» This operating manual contains the most important instructions for running the projec-
tor safely.
»» This operating manual must be read and understood by all persons working with the
projector, with particular emphasis on all aspects regarding safety.
»» In addition, all valid regulations and measures concerning accident prevention must
be observed.
»» The owner is responsible to assure that all persons who work with and / or operate
Safety Instructions
the projector are familiar with safe operating practices and accident prevention tech-
niques and have a complete working knowledge of the projector and all additional
machines and components of the system.
»» Those persons who work with the projector are responsible:
- to observe safe operating practices and accident prevention techniques
- to have read and fully understand the safety chapter and the warnings within this
operating manual.
»» The place on which the projector will be installed must be even, solid and clean.
»» Installation and basic adjustment must always be carried out by trained service
personnel.
1.1.2 Dangers when Working with the Projector

Projectors are constructed according to the latest engineering and state-of-the art safety
standards. The projector is only to be used for its intended purpose and is only used
when functioning absolutely perfectly.
Serious danger may result from improper use of the projector, causing injury to the user
or a third person, or damage may be done to the projector or other items in the vicinity.
Faults that could adversely affect safety must be rectified immediately.
The projector must not be used until any faults are rectified.
Issue: 04/2011 1
FP 25/30/50 D / FP 10/20/30/50 A
1.1.3 Intended Purpose

The projector is suitable to reproduce 35 mm film images and sound.
Any other or further use is not classified as an “intended purpose”. KINOTON cannot be
held liable for any damage resulting from different or extended operation.
As part of the “intended purpose” these tasks must be performed:
»» Observing all instructions and warnings contained in this manual
»» Inspecting the equipment for damage and correct function
»» Implementation of maintenance and repair work.
1.1.4 Guarantee and Liability

By reference KINOTON’s “General Terms of Business” apply. They are available to the
customer on conclusion of sale at the latest.
Guarantee and liability claims for damage to persons and property are invalid if due to
one of the following causes:
»» Improper use of the projector
»» Improper assembly, commissioning, operating and maintenance of the projector
»» Operation the projector with defective and / or non-functioning safety and protection
devices
»» Activating the lamphouse via the rectifier and not via the projector
»» Disregarding of the instructions in the manual concerning transportation, storage,
assembly, commissioning, operation and maintenance
»» Modification of the projector without written authorisation from the manufacturer
»» Connecting to power other than as specified
»» Failure to monitor and/or replace parts subject to wear and tear
»» Improper repairs
»» Emergencies due to influence from outside bodies or force majeure.
2 Issue: 04/2011
FP 25/30/50 D / FP 10/20/30/50 A
1.2 Explanations of Symbols and Notes

Throughout this manual you will find the following symbols:
DANGER
This symbol indicates an imminent threat of danger to life and personal health.
Disregarding this warning can result in serious personal injuries or highly dangerous
injuries.
Warning uv radiation
This symbol warns from UV radiation and that eye and skin protection during installation
and servicing must be put on.
ATTENTION
This symbol indicates a possibly dangerous situation. Disregarding this warning can
result in small personal injuries or damage to projector.
Safety Instructions
XX NOTE
This symbol indicates where notes, user tips and useful information can be found.
They serve to help use the projector to its fullest.
Always wear face protection when changing the xenon lamp.
Always wear protection gloves when changing the xenon lamp.
Always wear protection jacket (Kevlar) when changing the xenon lamp.
Issue: 04/2011 3
FP 25/30/50 D / FP 10/20/30/50 A
1.3 Special Hazard Points
1.3.1 Electric Power Hazards
DANGER
SS The access to power supply must always be kept closed. Only authorized service
personnel may access this area.
SS Installation according to the local electrical code and regulations an work on the
electrical supply conductors or circuits must only be done by qualified technical
personnel.
SS This projector should be operated from an AC power source. Ensure that the mains
voltage and capacity matches the projector electrical ratings. Do not defeat the pur-
pose of the grounding.
SS Do not allow anything to rest on the power cable and do not locate the projector
where persons will walk on the cable.
SS Do not operate the projector with a damaged cable or if the projector has been
dropped or damaged - until it has been checked for operation by a qualified service
technician.
SS Position the cable so that it will not be tripped over, pulled, or contact hot surfaces.
SS If an extension cable is necessary, a cable with a current rating at least equal to that
of the projector should be used to avoid overheating of the cable.
SS Do not use an accessory attachment which is not recommended by the manufac-
turer.
SS The rectifier must be exclusively enabled from projector only.
SS The 4060 DC ignition unit is directly supplied via the rectifier. Therefore the lamp
can be ignited by switching on the rectifier itself. Igniting the lamp by switching on
the rectifier at open lamphouse can cause serious injuries and damages to the lam-
phouse and projector.
SS The safety devices in the lamphouse (door switches and air flow switch) must not be
deactivated. Safe service work on open lamphouse is possible with functional safety
devices only, because rectifier and mains power will be switched off.
4 Issue: 04/2011
FP 25/30/50 D / FP 10/20/30/50 A
1.3.2 Lamphouse Hazards
1.3.2.1 Broken Glass

In cold condition the xenon lamp has an inner pressure of about 8 to 10 bar (145 psi)
and in hot condition of about 30 bar (435 psi). When a xenon lamp bursts, broken glass
can cause suffer injury to face, eyes and arteries. Therefore it is absolutely necessary to
wear protection with open lamphouse.
DANGER of explosion
SS Never bypass a door switch.
SS Only work on open lamphouse and with xenon bulb with face protection (shield),
neck protection and safety gloves which reach to the elbow.
If the xenon lamp explodes you can suffer injury to face, eyes and arteries.
SS Dispose of the xenon bulb: Before removing xenon lamp put protective cover
around it, pack xenon bulb in original package and give it back to your supplier.
SS Only insert the new xenon bulb in protective cover. Remove cover after mounting
the xenon bulb.
Safety Instructions
1.3.2.2 UV Radiation
Warning uv radiation
SS Operate projector with a closed lamphouse only.
SS Use UV radiation eye and skin protection during adjustment of the lamp and conver-
gence.
SS If you do some adjustments with an open lamphouse (look through visual hole), you
have to use visual protection which blocks the ultraviolet radiation.
Never look into light of a xenon lamp without protective glasses!
1.3.2.3 High Voltage
DANGER
Ignite xenon lamp in closed lamphouse only.
1.3.3 Mechanical Danger
DANGER
SS Do not work around the machine with long loose hair, or loose clothing such as
scarves or ties, they may get trapped in the drive mechanism and pull you in.
SS Only open shutter housing when projector is standing still with power disconnected.
If the projector is running with covers open be careful and do not touch the rotating
shutter or other moving parts. Serious cuts can result.
SS Do not put your fingers between the film track and film pressure skate or between
sprockets and pad shoes.
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FP 25/30/50 D / FP 10/20/30/50 A
1.4 Preventing Projector Damage
Attention
UU Always switch off main switch, before cleaning the projector housing. To keep the
cabinet looking brand-new, periodically clean it with a soft cloth. Stubborn stains
may be removed with a cloth lightly dampened with mild detergent solution. Never
use strong solvents, such as thinner or benzine or abrasive cleaners, since these
will damage the cabinet surface.
UU To ensure the highest optical performance and resolution, the projector lenses are
specially treated with an anti-reflective coating. Therefore, avoid touching the coated
lens surface.
To remove dust on the lens, use a soft dry cloth (Cleaning set from Kinoton).
Do not use a damp cloth, detergent solutions or thinner.
1.5 Service
Attention
UU Do not attempt to service this projector yourself. Refer all projector servicing to a
qualified Kinoton service center.
UU When replacement parts are required, be sure the service technician has used
original replacement parts or authorized replacement parts which have the
same characteristics as the original parts. Unauthorized substitutions may result in
degraded performance and reliability, fire, electric shock or others hazards.
Unauthorized substitutions may void warranty.
UU Upon completion of any service or repairs to this projector, ask the service techni-
cian to perform safety checks to determine that the projector is in proper operation
condition.
UU Xenon compact arc lamps are under high pressure. The lamp must be handled with
great care. They may explode if dropped or mishandled. Whenever the protective
cover is removed from the lamp, authorized protective clothing must be worn.
Copyright
Copyright of this manual remains in possession of KINOTON.
This manual is intended for the user and its staff only.
It contains regulations and operating notes that must not be copied, reproduced or
otherwise transmitted, in whole or in part.
Infringement of copyright laws may lead to prosecution. Due to ongoing development,
design details, features and specifications are subject to change without notice.
6 Issue: 04/2011
FP 30 A
1.6 Protective Devices

All existing safety devices must be checked regularly
1.6.1 Main Switch

In case of an emergency, you can switch off the projector using the main switch (under
the projector door). Push the switch to position “0”. The red lamp in the switch turns off.
1.6.2 IR Reflex Film Break Sensor

The film break sensor (arrow) switches off the projector when no film is passing the sen-
sor (e. g. at a film break). In this case the projector will be stopped.
Safety Instructions
XX NOTE
If your projector is equipped with an automation system the film break sensor can
trigger a run of events.
1.6.3 Film Stripper
The film stripper (arrow) prevents film from winding around the sprocket after a film
break or loss of a tape fixing has happened.
Film strippers are attached to all sprockets.
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FP 30 A
8 Issue: 04/2011
FP 30 A
2 Transportation and Installation / Mounting
2.1 Transportation
Delivery by a forwarding agent, train, ship or aircraft
»» The projector is mounted (without lamp house and film reel) on a pallet and secured
with screws.
»» With delivery to countries over-seas the projector secured on the pallet is packed in a
wooden crate.
»» The accessories are packed into a box or into the wooden crate too.
»» Weight (gross): about 240 kg (5600 lb)
Storage
If the projector is stored for a longer time:
»» Only store in dry rooms.
Installation / Mounting
»» Choose a suitable protective cover or leave projector in the original cover.
XX note
Although most parts are delivered with a protective cover, you have to clean the
projector and its components before the first start.
2.2 Delivery or Equipment Variations

»» Projector FP 30 A
»» Lamphouse
- up to 2000 W
- up to 7000 W
»» Reverse-scan sound device
- only analog, not upgradeable to Dolby Digital
- optical stereo analog, upgradeable to Dolby Digital
- optical stereo analog and Dolby Digital (option)
»» Lens holder
- electronic focusing control (option)
»» Lens turret (option)
- 2 lenses and manual lens change
- 2 lenses and automatic lens and aperture change
- 3 lenses and manual lens change
- 3 lenses automatic lens and aperture change
»» Remote unit
- focusing control (option)
- framing control (option)
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FP 30 A
»» Water cooling system (from 4000 W lamp capacity on)

»» Electronic friction drives (option) for film spools up to 4,000 m
»» Roller set for using with a rewind system (option)
»» Automation system (option)
- DMP 1 Digital Matrix Programmer
- CCA3 Cue Code Automation
- SA2 Sequence Cinema Automation
- EMK 1 Electronic Automation System
»» Pedestals
»» Reader for DOLBY / DTS / SDDS (option)
»» Control panel BWR (option)
»» Auditorium control panel (option)
»» Film cleaner (option)
»» Operating manuals
2.3 Installation
ATTENTION
UU The projector will be delivered completely wired and factory tested.
UU Only use suitable hoisting machines (crane, fork-lift).
UU Do not use unit parts as climbing aid.
UU The electrical connections have to be in accordance with local regulations and be
installed professionally.
UU All installation should only be carried out by Kinoton service.
2.3.1 Place of Installation, Place of Operation

»» The place on which the unit will be installed must be even, solid and clean.
»» The figure on the next page shows the projector’s dimensions.
»» Requirements of the projection room:
- humidity: 40 to 60 %
- temperature: 15 to 25° C
- maximum sea level: 2000 m
10 Issue: 04/2011
FP 30 A
2.3.2 Important Hints for Installation

Projector Dimensions
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FP 30 A
2.3.3 Additional Installation Hints
ATTENTION
UU The 162 PE lines have to be high-flexible to derive the high-frequency ignition
voltage.
UU Do not use the wires in the lamphouse cable to connect the additional dowser.
Lay the dowser connection in the lamphouse tube as short as possible.
UU If you install an old building projector remove all not used old cables, wires and lines
under the projector.
UU If possible the heat exchanger must not have more than 10 m distance to the
projector and the refrigerating set must not have more than 15 m distance to the
heat exchanger. If the environment temperature is high and the wires are long, the
hose is to be isolated because of condensation.
UU The cooling water temperature has to be more than 15° C, to avoid a precipitation of
condensed water on the film gate and the front gate.
12 Issue: 04/2011
FP 30 A
2.4 Mounting
2.4.1 Filling with Oil
XX note
Use only Kinoton type 3672 oil.
4
3
 Intermittent movement
(Maltese cross)
 Oil gauge glass with oil level rings

2 (red and green)
 Oil gauge cap

1
 Vent hose
 Oil hose
5
Procedure to fill with oil

• Open the projector head housing.
• Remove the oil gauge cap . If there is not a small vent hole in the cap, pierce it with
a pin.
• Add oil through the hose using a funnel or squeeze container. The oil level must be
between the red and green rings .
• While filling, turn the mechanism slowly, by hand, so that any air bubbles can
escape. Turn the framing knob between the left and right stops several times to
distribute the oil. If necessary add more oil.
• Put on the cap on the oil gauge and hang the hose back in the clip. Do not put the
shipping cap on the hose; throw it away.
XX note
ZZ The quantity of oil to fill the movement is about 6.8 fl. oz (200 ml).
ZZ Do not overfill the intermittent.
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FP 30 A
2.4.2 Installing and Connecting the Lamphouse Components
XX note
ZZ Connecting the lamphouse should be carried out by service personnel.
ZZ The installation and adjustment of the xenon bulb and the adjustment of the intensity
of currents is described in the lamphouse manual.
ZZ The mirror should only be installed and adjusted by trained service personnel.
The reflector should only be changed and adjusted roughly by the projectionist in
case of need, therefore see lamphouse manual.
ZZ You will find the lamphouse connecting plan in chapter 8.3.
2.4.3 Connecting the Water Cooling (option)
ATTENTION
UU A water flow of 2 to 3 l/min is needed to get a water temperature of 18° C ± 2° C
(64° F ± 10° F).
UU The water temperature should not be less than 16° C, otherwise water can con-
dense on pipes, cables and film running components and finally results in damage
of the film material. At bad conditions dropping water can damage the electronics.
UU If possible the heat exchanger must not have more than 10 m distance to projector
and refrigerating set must not have more than 15 m distance to heat exchanger.
If environment temperature is high and wires are long, the hose is to be isolated
because of condensation water.
UU At bad climatic conditions (high temperature, high humidity) condensation can also
occur above 16° C - in this case please check the projector.
• Connect the inlet and outlet tubes of the

water cooling system to the connecting
pieces in the projector.
XX note
You will find the description of the water
cooling unit in the corresponding operating
manual.
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FP 30 A
2.4.4 Projector Terminal Strip

The projector terminal strip is mounted
in the bottom of the projector.
XX note
ZZ The projector will be delivered ready wired.
ZZ Plans of terminal connections, see chapter 8.2.1.
2.4.5 Connecting to the Non-Rewind System

• Connect the 4-pole cable from the non-rewind system to the FPA-81-01 main board
in the projector which is behind the operating panel.
Connect:
brown wire to RUN
white wire to RUN
Connect:
yellow wire to 0V
green wire to RISS
XX note
ZZ The installation of the non-rewind system is described in “ST 200 M / MT 600/2000”
or “FT 3M” operating manual.
ZZ The roller set for the film run between the projector and the non-rewind system
should not be mounted until the projector has its final position to the screen.
XX note
See also wiring scheme in chapter 8.3.1.
ATTENTION
Installing the non-rewind system’s connection should only be carried out by service
personnel.
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FP 30 A
16 Issue: 04/2011
FP 30 A
3 Function and Components

The FP 30 A projector is suitable to reproduce 35 mm film and sound formats in small,
medium and large cinemas.
»» The film is transported through projector from the top to the bottom.
The intermittent sprocket is driven from the Maltese cross which is driven via the
synchronous drive from the main drive motor.
»» The projector is normally equipped with mechanical friction drives.
The lower take-up friction is driven via a chain by the main drive motor.
»» The film can also be guided via a set of guide rollers to and from the non-rewind
system.
»» A film break sensor recognizes an available film. If a film break has happened the
projector motor is stopped and the dowser is closed.
»» Depending on requirement an automation system can be built in the projector door.
»» The lenses can be stored in a lens holder or optionally in a lens turret (two-folded or
three-folded).
»» If the projector is equipped with a remote controlled lens turret which changes the
lenses electronically an aperture changer put in simultaneously the corresponding
aperture.
Components
»» The projector can be equipped with a universal lamphouse (1000 to 2000 W or
2000 to 7000 W).
»» The reverse-scan sound device is mounted on the projector head., It is suitable to
reproduce analog sound and optionally digital sound DOLBY SR·D.
»» Furthermore the projector can be equipped with a DTS or a SDDS reader (Sony).
Both readers can be attached on an extension arm at the top of the projector.
Issue: 04/2011 17
FP 30 A
3.1 Components Overview

 Projector housing with door
Á Take-off friction (option)
Â Lamphouse
2
Ã Shutter housing and film gate
1 Ä Lens turret (option)
Å Reverse-scan sound device

3 4 5 Æ operating panel
 Take-up friction (option)

6
7  Pedestals (adjustable)
8 3.1.1 Housing
The projection equipment, sound
devices, friction drives or/and set
of guide rollers are attached on the
housing.
The drives, the motors, the whole
electrical equipment and the auto-
9
mation systems are mounted in the
projector housing.
3.1.2 Projection Components Overview

 Feed sprocket
1
Á Shutter housing
Â Film gate
2
Ã Intermittent sprocket
3
6 Ä Bottom / holdback sprocket
Å Lens turret (option)

4 Æ Reverse-scan sound device
8
 Framing knob
5  Film pressure adjusting knob

7
9
18 Issue: 04/2011
FP 30 A
3.2 Film Gate and Film Track

In the film gate the film is positioned precisely. By adjusting the film pressure skate
you can optimize the picture steadiness.
After threading the film, close the film track with the film pressure skate to guide the
film. The four ceramic rollers guide the film laterally.
 Shutter housing
1
Á Film gate
3
Â Film runner strips (2)
2 Ã Ceramics roller (4)
Ä Film pressure skate
Å Intermittent sprocket
4 Æ Aperture changer (option)
Film Gate Components

7
5
3.2.1 Film Pressure Skate

For smooth and silent film running it is very important that the pressure of the film
skate is adjusted accurately.
XX note
ZZ Adjusting the film pressure skate, see chapter 6.4.2.
ZZ Adjusting the height of the film pressure skate, see chapter 6.4.3.
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FP 30 A
3.2.2 The Dowser

The dowser opens or closes the path of xenon light to the film gate.
5
4
5 3
1
1
2
2
 Dowser
Á Dowser rotation solenoid
Â Light baffle
Ã Rotary shutter
Ä Film gate with water cooling unit or fire protection plate
ATTENTION
If the dowser does not close while the projector is stopped, the film will burn.
20 Issue: 04/2011
FP 30 A
3.2.3 Single Aperture Plates (only with manual lens turret or lens holder)
Push the single aperture plate into the film gate until the stop is reached and the
aperture plate snaps into position.
3.2.4 Aperture Changer (option, only with electronic lens turret)

The aperture changer is suitable for automatically changing the aperture when the
corresponding format key has been pressed. Simultaneously the lens is changed too.
 Aperture changer
1
Á Aperture
Â Drive pin (with knurled nut installed)
• Push the aperture into the film gate and

place the aperture changer drive pin
into the hole on the aperture. Tighten

the knurled nut on the drive pin.
3
 Hole for drive pin

2 3 4
Á 1:1.66 aperture
1 Â 1:1.85 aperture
Ã 1:2.39 aperture
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FP 30 A
3.2.4.1 Drive and Control
 Aperture changer motor
Á Aperture changer drive
Â Aperture changer/lens turret

control board
3
3.2.4.2 Format Change with Three Lenses
• Push , or on the operating panel.

$
$The aperture changer places the selected aperture into the film gate and the
matching lens in position.
3.2.4.3 Format Change with Two Lenses Turret
• Push or .
$ the lens turret is equipped with two lenses and the aperture has three openings
$If
you can select any two of the three aperture openings to work with the two lenses.
For example for some shows the format change could be between CS (Cinema-
Scope) and WS (1:1.85) and for other shows the format change could be between
WS (1:1.85) and NS (1:1.33).
The following format combinations are available:
- format combination Á and Â or
- format combination Â and Ã or 2 3 4
- format combination Á and Ã
1
22 Issue: 04/2011
FP 30 A
3.2.4.4 Changing the Format Combination
• The “select” function is activated by holding the control closed more than
2 seconds.
$
$The turret will not rotate. The turret solenoid makes a clattering sound which means
that a new format combination has been selected.
$
$The format combination changes to the next combination, for example:
- from Á and Â to Â and Ã.
If you activate the “Select” input again the format combination will be changed
again, for example:
- from Â and Ã to Á and Ã and so forth. After the “Select” input was selected three
times, the combinations repeat.
XX note
Check your selection and push WS (flat) or CS (scope) button. The turret turns to the
selected lens and the aperture changer changes to the selected aperture.
XX Hint

Make a note which shows you which aperture combination is chosen after how many
times he SELECT button was pushed.
XX note
ZZ Changing the aperture changes the lens too, see also lens turret, chapter 3.2.6.2.
ZZ If the projector is equipped with an aperture changer do not push single aperture
plates into the slit, because there is no stop and lock device for that aperture plate.
3.2.5 Lens Holder

• Loosen the clamping screw (black
arrow) for inserting a lens and then
tighten the screw again.
• For focusing turn the focusing
adjusting knob (white arrow).
XX note
Adjusting the lens holder, see chapter 6.4.5.
Issue: 04/2011 23
FP 30 A
3.2.6 Lens Turret (option)

3.2.6.1 Manual Lens Change
 Lens tubes
5 Á Lens in lens tube
3
Â Handle (arresting pin)
Ã Focusing knob (manual)

4
Ä Position lever for moving the lens
turret away from the gate
1 2
• Loosen the knurled screws.

• Push the lenses into the lens tubes.
The tubes are labelled CS (1:2.40), WS (1:1.85) or NS (1:1.33).
• Precisely focus each lens in its tube without adjusting the focus knob.
• Fasten them with the knurled screws.
XX note
Some lenses may require rings to support the rear section; these are available from
Kinoton.
• For easy film threading flip the position lever - the lens turret will move away from
the film gate.
Make sure to put the lever fully back in position before projecting!
• To rotate a lens into position, pull out the handle and turn the lens turret to the
desired position. Let handle drop – lens turret is positioned.
XX note
It is possible to set the handle so it remains up so that the turret can continuously
rotate. This position is not used for normal operation.
24 Issue: 04/2011
FP 30 A
3.2.6.2 Electronically Controlled Lens Change (option)

The electronically controlled lens turret is suitable to change the lens automatically
when the corresponding format key has been pressed. Simultaneously the applicable
aperture is changed too.
 Lens tubes with lenses
Á Latching solenoid
2 Â Sensor board (covered)
5
3
Ã Manual focusing
4
Ä Position lever for moving the
lens turret away from the gate
1
• To select a lens, push one of the
format buttons.

$
$The light barrier on the sensor
1 board senses the position of the
corresponding
coding plate (one coding plate for
one lens).
$
$The lens turret will stop at that
position and be magnetically
latched.
Drive and Control

The lens turret/aperture changer control board (arrow, right figure) activates the turret
motor (arrow, left figure), which changes the lens via a toothed belt.
XX note
ZZ When changing the lens the aperture is changed too (see also chapter 3.2.4).
ZZ Initializing the EE-PROM should be only carried out by experts.
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FP 30 A
3.2.7 Focusing
To adjust the focus for a sharp picture on the screen, you have to move horizontally
the whole lens turret or lens holder. This operation can be done manually or electroni-
cally controlled.
3.2.7.1 Manual Focusing with Lens Turret / Lens Holder

• Turn the focusing knob (arrows) to move the lens turret or the lens holder.
3.2.7.2 Electronic Focusing with Lens Turret (option)

Pushing the focusing buttons triggers the control board (placed over the aperture
changer/lens turret board or separate over the focus motor) to activate the turret
motor (placed over the lens turret motor or separate), which shifts the lens turret via a
toothed belt driving a threaded shaft.
XX note
Electronic focusing can only be carried out with open dowser.
3.2.7.3 Electronically Controlled Lens Holder Focusing (option)

When operating the focus controls, the focus motor rotates a shaft with a eccentric
segment at the end. That eccentric is located between the focus shaft and the lens
holder and thus shifts the lens holder fore and aft as it rotates.
XX note
Electronic focusing is only carried out with open dowser.
26 Issue: 04/2011
FP 30 A
3.2.8 Rotating Shutter

The rotating shutter interrupts the projection light once during the film transport and
once during the picture standstill. (48 interruptions a second at 24 pictures a second).
The shutter is mounted on a shaft which is driven from the intermittent movement via
a fibre gear.
2
1

4
 Shutter (1-blade)
Á Shutter shaft
Â Fibre gear and drive unit
Ã Intermittent sprocket drive
Ä Synchronous gear for main drive motor
DANGER
Only remove or replace the shutter housing when the projector is off.
If you have to work on the projector while it is running be very careful not to touch the
rotating shutter. Serious cuts can result.
XX note
The shutter is factory-set. Nevertheless, if necessary only trained service personnel is
allowed to adjust the shutter timing.
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FP 30 A
3.2.9 Intermittent Sprocket

The intermittent sprocket (arrow) is a
very precise sprocket.
It transports the film step by step
through the film gate.
The intermittent sprocket is driven via
the intermittent sprocket drive by the
main drive motor.
XX note
The sprocket is factory-set.
All adjustment must only be carried
out by experts.
3.2.10 Framing
There is an adjustment to move the frame up and down because the picture must be
positioned correctly in the film gate.
The framing control should be kept
in mid-position to allow correction
in either direction. There are white
position reference dots on the knob
and projector for your convenience.
These may not align exactly.
The intermittent sprocket and Maltese
cross shafts have opposing splines
and are connected with a bushing.
When sliding the bushing (by turn-
ing the framing knob and the framing
shaft) the sprocket will rotate relative
to the Maltese cross. With this action
the adjustment of the shutter will not
be changed.
Manual Framing
• Adjust the framing position by
turning the framing knob (arrow).
• Turning the framing knob to the
right => frame moves upwards
• Turning the framing knob to the left
=> frame moves downwards
Electronic Framing (option)

When pushing the framing buttons
the motor slides the framing bush-
ing via a chain and the sprocket will
rotate relative to the Maltese cross.
28 Issue: 04/2011
FP 30 A
3.2.11 Constant Speed Sprockets

Sprockets are designed to transport the film continuously. The teeth of the sprocket
engage the perforations of the film. Both sprockets provide for equal loops before and
after the film gate.
6
5
2
4 1
3
3
1
5
2

 Feed sprocket / bottom or holdback sprocket
Á Pad shoe with handle
Â Ring nut with spring
Ã Film stripper
Ä Guide roller
 Hand wheel
• The feed sprocket (left figure) pulls the film from the take-off friction or platter to the
film gate.
• The bottom sprocket (right figure) pulls the film out of the sound head and feeds it
to the take-up friction or platter.
• The pad shoe holds the film on the sprocket.
• The film stripper prevents broken film from being wound up around the sprocket.
• With the handle you can open the pad shoe to thread the film.
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FP 30 A
Operating a Pad Shoe Gently

The pad shoe has a brass bearing tube which pivots on the pad shoe shaft, and is
positioned with a ring nut and a spring.
To avoid damaging the pad shoe and causing the brass tube to revolve within the pad
shoe, the pad shoe must be handled gently.
Follow these points:
• Do not slam the pad shoe closed.
• Only open the pad shoe as far as the stop pin.
• Do not open the pad shoe too far - over the stop pin - the spring will break and the
brass tube will be damaged.
XX note
ZZ Changing a constant speed sprocket and a pad shoe and adjusting the pad shoe
spring, see chapter 6.4.2.
ZZ Adjusting the distance between the pad shoe and the sprocket, see chapter 6.4.8.
ZZ Adjusting the film break sensor, see chapter 6.4.9.
3.3 Reverse-Scan Sound Device

Reverse-scan sound devices scan the sound track (analog and optional DOLBY
digital) on the film by means of red LEDs.
3.3.1 Analog Reverse-Scan Sound Device (non-upgradeable)
 LED holder with LED

2 Á Sound drum
Â Sound pressure roller

1 4 5 Ã Analog sound optics
3 Ä P.C. board with solar cell
XX note
A non-upgradeable analog reader will not accept cue detectors.
30 Issue: 04/2011
FP 30 A
3.3.2 Reverse-Scan Sound Device Analog and optional DOLBY Digital (upgradeable)
The Reverse-Scan Sound Device contains an analog sound reader and optionally a
Dolby digital reader.
XX note

ZZ An only analog sound device is upgradeable with DOLBY digital.
ZZ The reverse scan sound head is delivered factory checked and adjusted.
ZZ Optional cue sensors for reading metal foil tapes can be mounted in the reverse
scan sound device.
3.3.2.1 Components
2
1
4 5
3
4
 LED holder with optional second digital LED
Á Sound drum
Â Sound pressure roller
Ã Analog (upper) and optional digital (lower) sound optics
Ä P.C. board with solar cell (analog)
 P.C. board with CCD-unit (digital)
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FP 30 A
3.3.3 Sound Tracks on the Films

The analog sound is printed as two wavy
lines on the film.
The height of the amplitude signifies loud-
ness, frequency signifies pitch.
The Dolby digital sound information
(DOLBY SR·D) is encoded between the
perforations.
The DTS digital sound information is
encoded between the picture and the
analog sound track.
The SDDS information is encoded on the
edges of the film.
DTS
SDDS DOLBY Analog
SRD
3.4 SDDS Reader / DTS Reader (option)

Optionally a DTS Reader and/or SDDS Reader can be attached to special holders on
the projector for reading the corresponding sound track on the film.
3.5 Film Cleaner (option)

Optionally the projector can be equipped with a film cleaner.
32 Issue: 04/2011
FP 30 A
3.6 Drives
XX note
ZZ In this chapter you will get an overview of the drive components.
ZZ All work on drives should be only carried out by experts.
6 7  Main drive motor
 Synchronous gear on motor shaft
 Toothed belt between the

synchronous gears
5 4  Synchronous gear on
intermittent movement shaft
 Intermittent movement
8
 Fibre gear:
drives shutter and sprockets
3
 Chain to upper/feed sprocket
Components
shaft & cog
1 2
 Chain
9
 Lower/holdback sprocket
shaft & cog
 Chain to take-up friction

10
shaft & cog
3.6.1 Main Drive

Via gears the following shafts are driven by the main drive motor :
»» Intermittent movement  via a synchronous drive Á + 
»» Feed sprocket
»» Bottom sprocket 
»» Shutter 
»» Take-up friction shaft
A drive with two synchronous gears is necessary to synchronize the motor speed and
the maltese cross speed. Therefore different drives are available for different frequen-
cies (50 or 60 Hz) of voltage.
XX note
Tension the chains, see chapter 6.4.12.
Issue: 04/2011 33
FP 30 A
3.6.2 Intermittent Movement (also called a Maltese Cross or a Geneva Movement)

To pull the film down one picture at a time the intermittent sprocket has to move the
film ahead by four sprocket teeth (¼ of a complete rotation):
A motor rotates the cam continuously. During each rotation the cam’s pin engages
one of the slots in the starwheel and pulls it ¼ turn. As soon as the pin leaves the
slot, the outer surface of the cam engages the curved surface of the starwheel which
prevents the starwheel from turning until the pin engages the next slot.
During this time the film is held still in film gate and is able to project the picture.
Intermittent
Sprocket
Star wheel
Cam
Pin
The intermittent movement is in a closed oil bath.
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3.6.3 Friction Drives

The friction is a shaft, which is driven with a constant turning moment. The take-off
friction is not necessary to be driven, because the take-up friction - which is driven by
the main drive motor - pulls the film from the upper take-off shaft.
Generally the spring pushes the driving disk and the felt disk  against a fitted disk.
The more the pressure onto the felt disk the more is the braking effect.
3.6.3.1 Take-Off Friction (non-driven)

This “take-off clutch” provokes that a cer-
tain traction force is necessary to wind off
the film. This friction prevents spinning of
the film spool in case the projector sud-
denly stops which would cause film clutter
– in the worst case the film material could
be damaged or even break.
3.6.3.2 Take-Up Friction (driven)

As it is with the take-off friction where the
Components
braking force is regulated the film tension
can be controlled by the take-up friction.
• Is it too strong, it brings too much
tension to the sprocket which can lead to
perforation damages.
• Is it too weak the film will be wound too
loose. This can lead to film damages dur-
ing rewinding (scratches, etc.).
XX note
ZZ Depending on friction (from 600 up to 2000 meters) the film tension has to be
adapted.
ZZ The film tension is inversely proportional to the reel diameter:
The film tension is less, when the reel diameter is large (beginning of take-off
friction).
ZZ Changing and oiling the felt disk of the friction is described in chapter 6.4.10.
ZZ Adjusting the mechanical friction, see chapter 6.4.11.
3.6.3.3 Reel Shaft on Change Flange

The reel shaft is attached with a changeable
flange. To change the flange loosen the 3 Al-
len screws (arrows) and change the flange.
To fix a film spool/reel you have either to close
the lock bar or the screw on a knurled nut.
Issue: 04/2011 35
FP 30 A
3.7 Electronic Components
XX note
ZZ In this chapter you will get an overview of the electronic components, which are
mounted in the projector.
ZZ All work on electronic parts should be carried out by experts.
3.7.1 Main Control / Interface Board
XX note
ZZ Plan of terminal connections, see
chapter 8.3. Main control board
ZZ Wiring scheme, see chapter 8.3.1.
Capacitors
3.7.2 LED Power Supply Board for the Reverse-Scan Sound Device
The LED board can be designed for
supplying the analog sound LED only or
for supplying also the digital sound LED. 24 V Power LED Power
supply unit supply unit
The LED board is powered via the projector
by 24 V.
36 Issue: 04/2011
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4 Operating Elements
4.1 Main Switch

Main switch in position I:
Current transfer is switched on => the switch lights up red.
Main switch in position 0:
Current transfer is switched off => the switch is off.
4.2 Projector Operating Panel
XX note
The operating panel buttons can differ corresponding to a remote control unit or lens
turret with 2 or 3 lenses.
Standard buttons:
Operating Elements
Projector STOP
Projector START
Dowser CLOSE
Dowser OPEN
Optional buttons remote controlled with lens turret / aperture changer:
Format CS Format WS
Format SELECT
Format NS (for 3-folded lens turret) (for 2-folded lens turret)
Issue: 04/2011 37
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4.3 Remote Control Panels (option)
BWR Control Panel
Auditorium Panels
4.3.1 “BWR” Control Panel
House light ON Stage light ON Focusing + (option)
House light HALF Stage light STOP Focusing - (option)
Dowser OPEN
House light STOP Stage light OFF
Dowser CLOSE
House light OFF CS format
Masking format 1 WS format Frame UP
Masking format 2 NS format Frame DOWN
Masking format CS Curtain OPEN Projector START

AUTO
START
Auto START Curtain STOP Projector STOP
Curtain CLOSE
38 Issue: 04/2011
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4.3.2 Auditorium Panel
House light ON Stage light ON Focusing + (option)
House light HALF Stage light STOP Focusing - (option)
House light STOP Stage light OFF Frame UP
House light OFF Frame DOWN

AUTO
START
Auto START Projector START Projector STOP
XX note
ZZ The standard auditorium panel I is equipped with a keyboard (4 x 4 buttons) and a
potentiometer to set the sound level.
ZZ The standard auditorium panel II is equipped with 2 keyboards (each 4 x 4 buttons)
and a potentiometer to set the sound level.
Operating Elements
ZZ The RP4 auditorium panel is equipped with a keyboard (4 x 4 buttons) and the RP 4
remote panel for EMK 1 control.
Issue: 04/2011 39
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40 Issue: 04/2011
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5 Operation, Threading and Troubleshooting
5.1 Switch On and Start the Projector
• Switch on the external power supply for the performance room.
• Switch on the main switch (position “I”).

$
$The switch illuminates red.
• Thread the film (see chapter 5.3).
• Push the projector .

$
$The projector is running, ventilation is on, xenon lamp is on.
• If necessary push , to open the dowser after the start leader has run through.
Operation and Threading

5.2 Stop and Switch Off Projector
• To stop projector manually push and close dowser by pushing .

$
$The dowser closes, the xenon lamp turns off, the projector stops and the ventilation is
on (if temperature is more than 60° C).
• Switch off the main switch (position “0”).

$
$The key lamp gets off.
• Switch off the external power supply for the performance room.
XX note
ZZ If you have an emergency stop, push the main switch (position “0”), to cut the
power.
ZZ If the film is run through the projector stops due to the film break sensor.
Issue: 04/2011 41
FP 30 A
5.3 Threading for Projection Operation

from take-off • Put the full reel on the upper reel
friction shaft or prepare the platter system.
• Open the sprocket pad shoe.
- Thread the film in the feed
Feed sprocket sprocket
(all perforations engaged in
Film sprocket teeth).
Gate - Close the pad shoe.
• Thread the film in the film gate.
- Close the film pressure skate.
- One whole frame must be
Intermittent centred vertically in front of
sprocket the aperture opening.
There is a small light inside the
Rev-Scan aperture to assist in centring.
Bottom sprocket Sound - Assure the film is centred
Device horizontally between the
ceramic discs.
to take-up friction
A film loop of about 4 frames - 16 perforations (35 mm film) must be left both just
above and just below the gate! If the loops are too big the film will touch station-
ary parts and be scratched. If the loops are too small the film may break, the im-
age may jump, or the sound may warble.
• Thread the film through the guide rollers to the sound head (35 mm film) and then to
the bottom sprocket. The sound pressure roller may be lifted to ease threading.
• Open the sprocket pad shoe.
- Thread the film in the holdback/bottom sprocket (all perforations engaged in
sprocket teeth).
- Close the pad shoe.
- Verify the loop below the gate is still OK.
• Wind-up the film several times around the take-up reel or lead film to “take-up” level
of platter system.
XX note
ZZ When operating the projector with the handwheel, do not jerk (quickly twist) the
handwheel; instead start its rotation gently and smoothly. Abusing the handwheel
can break teeth from the lower CSS shaft’s fibre cog.
ZZ If a DTS reader is installed the film has run from the top of the spool - spool turns
right.
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5.4 Troubleshooting
5.4.1 General Hints

Even though we produce high quality, reliable equipment, there still can be problems
due to incorrect operation, poor maintenance, incorrect procedures etc.
This chapter has information about some common problems and about solving those
problems. It is not possible to cover all possible problems in an operating manual; we
suggest each owner develops a relationship with a competent cinema service provider.
XX note
ZZ Items marked (service) usually require experienced service technicians.
ZZ Basically there are two types of errors:
- Type 1 errors: projector won’t run/stops immediately
- Type 2 errors: errors which do not stop projector
5.4.2 Projector Troubleshooting Chart (Type 1 errors)

Error Cause Solution
Troubleshooting
Nothing works - main power is not available - check fuses or circuit breakers
- loose main power connection - check main power connections
- 24 V DC supply failed - change (service)
- 24 V DC fuse on main terminal blown - change
Motor runs, pilot - fuse blown on LED power supply - check all, replace if blown
lamp is on, sound- board
head LED won’t lit
5.4.3 Projector Troubleshooting Chart (Type 2 errors)

Noisy operation - film is threaded incorrectly - thread correctly
- chains and/or gears are worn - change
- outboard intermittent bearing worn - change (service)
- intermittent movement is worn [rare] - change (service)
Rollers don’t turn - poor cleaning - clean regularly with alcohol
- roller worn or damaged - change
Film break when - frictions are not adjusted correctly - adjust
starting the film run - friction shafts are running dry - lubricate with Cardan oil
Oil leak - wrong oil - use Kinoton 3672 oil
- too much oil - reduce oil quantity
- oil tube / vent is blocked - clean oil tube / vent
- seals are defective [clean unit with - replace seals (service)
alcohol; find leak’s source]
Foam in oil gauge - wrong oil - use Kinoton 3672 oil
glass - too little oil - fill oil
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Picture moves - ceramic discs are blocked or dirty - remove and clean
horizontally - ceramic discs are worn [rare] - change
(waves)
Picture moves - skate pressure isn’t adjusted - adjust
vertically (jumps) correctly
- skate height isn’t adjusted correctly - adjust
- film print defective [test film] - get new print
- skate is worn - change
- intermittent sprocket damaged - change (service)
- framing bushing defective - change (service)
- intermittent movement defective - change (service)
[rare]
Perforation - skate pressure is too strong - adjust
damage in direction - intermittent or upper/feed sprocket - change the worn sprocket(s)
of travel teeth have worn
Perforation - take-up friction is too strong - adjust

damage against - lower/holdback sprocket teeth - change the worn sprocket
moving direction have worn
Perforation side - sprocket teeth are damaged - change sprocket
damage - pad shoe is damaged - change pad shoe
- film gate position is not correct [rare] - adjust
Scratches on film - film loop is too large - thread film correctly
- emulsion particles / dirt on rollers - clean
- rollers, skate, and/or film runner - change the worn or defective
strips are defective or worn part
Picture blurring - shutter is not adjusted correctly - adjust (service)
- skate pressure too low - increase pressure
Soft image - dirt on lens elements - properly lens clean front
and rear
Unable to stay in - excessive heat from xenon lamp - decrease xenon current and/
focus or use IR heat filter
- replace damaged IR heat filter
- make sure light is properly
distributed (no “hot spot”)
Misframed image - incorrect threading - thread properly
- misframed splices - re-make specific bad splice
Automatic - aperture or operating arm was - do not force automatic

aperture registers moved by hand aperture.
imprecisely If mechanism has been
damaged, see service infor-
mation on reducing play.
- operating arm tube has been - clean well with alcohol
lubricated Do not lubricate the operating
arm tube.
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5.4.4 Analog Sound

No sound / some - sound processor failure - check plugs and power; call service
channels missing - amplifier failure - check if sound track is threaded on
the correct side
- speaker failure - check / replace exciter lamp
(standard sound) or red LEDs (rev.
scan sound)
- sound device is defective - check all equipment for blown
fuses / tripped circuit breakers
Sound out of sync - lower loop wrong size - thread correctly
with picture - wrong threading path - thread correctly
Loss of high fre- - dirty sound optics - clean with lens cleaner and Q-tip
quencies - sound optics focused poorly - adjust sound optics’ focus (service)
Garbled sound - scanning drum jammed - remove blockage; change or oil
bearings
- sound pressure roller loose - adjust tension (service)
Hissing sounds - scratches on sound track - replace print
Troubleshooting
- dirt on sound track - clean
- defective sound electronics - check and replace (service)
5.4.5 Digital Sound

No sound - check the following [also see - use film for digital playback
the “no sound / some - switch on digital sound processor
channels missing” section of - switch correct processor mode
“Analog Sound”, above.] - load disk loaded correctly and check
the right disk is in place [DTS only]
- thread film correctly
Sound out of sync - loops wrong size - thread correctly
with picture - wrong threading path - thread correctly
Poor digital sound - improper tension - re-thread
- dirt on lens - remove dust using compressed air
- dirt on digital sound track - clean digital soundtrack
- scratches on digital track - replace print
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46 Issue: 04/2011
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6 Cleaning / Maintenance / Repair
6.1 General Hints
ATTENTION
UU Any work on the electric supply wiring must be carried out by electricians.
UU Make sure that nobody starts the projector while you are working on it.
For all maintenance, cleaning and repair you must disconnect the projector from its
power supply (switch off the main switch).
UU All adjustments must be carried out by experts.
Because of using many maintenance-free parts, the consumption of material and the
expenditure of time for maintenance work and repair are reduced to a minimum.
The necessary maintenance and cleaning work may be performed by the projector’s
operators. This work has to be carried out regularly and carefully. See the following lists
Cleaning and Maintenance

regarding the schedule for this work.
6.2 Cleaning
XX note
The film print should not be used oily or dirty with antiblocking agents, but always clean
and dry.
After each show
Component What is to do?

film path / aperture Clean with a soft toothbrush or cloth / Blow out with air
sprockets / pad shoe pressure.
Daily

film path / aperture Clean with a soft toothbrush or cloth / Blow out with air
sprockets / pad shoe pressure.
lens Clean with a lens cleaning brush.
ATTENTION
UU Using air pressure can make problems, because the dirt will not be absorbed but
pressed into bushings and optics.
UU Never use sharp objects to remove particles from film path.
Issue: 04/2011 47
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Every 2 weeks

ceramics roller Remove the ceramics rollers and then remove the dirt in the
holes by using air pressure. Clean the ceramics roller with a
alcohol moisturized cloth.
Every 3 months

film break sensor Clean the film break sensor with a soft cloth.
main drive motor / fan Blow out the dust with pressurized air.
guide rollers Clean the guide rollers and roller shafts with alcohol.
spool shafts Lubricate with Esso universal oil.
Every 6 months

shutter / Clean the shutter housing with pressurized air.
shutter housing Clean shutter edges with a soft toothbrush.
lens turret (if existing) Clean the coding plates and the sensors on the sensor board
with a Q-tip moisturized with Isopropyl or Isopropanol.
ATTENTION
Do not blow with pressurized air into the rotor - particles can be blown into the rotor and
block the rotation.
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6.3 Maintenance
Daily

intermittent movement Check oil level => oil level must be between the red and the
green ring, if necessary refill oil, see chapter 6.3.2.
Every 3 months

lens holder Lubricate the lens holder guidance with Cardan oil,
type 8657
fibre gear / Lubricate with Kinoton EL 4854 grease.
shutter shaft worm
chains Lubricate with Esso universal oil.
aperture changer Clean the part of the shaft above the film path with a cloth,
(if installed) and the threaded part of the shaft (inside the back cover) with
Maintenance and Repair

a brush. After cleaning lubricate the threaded part of the shaft
with Klübertex BEM 43-132 or Esso universal oil.
Do not lubricate the brass tube/non threaded parts of shaft!
Every 6 months

Reverse-scan sound Check O-rings on sound pressure roller.
device Check all rollers, whether they run easily.
Annually
sound reproducer Lubricate the pressure roller ball bearings with a drop of
Cardan oil, type 8657. Do not use any other lubricant!
Lubricate the sound drum shaft with 1 drop of Esso
universal oil.
XX note
ZZ Cardan oil is very pasty therefore the ball bearings will be retarded for a proper film
run. By getting move the guide roller with one finger, the roller has to stop at last
after a half of turn. Otherwise you have to clean the bearing and then fill it with
Cardan oil.
ZZ You must not use any oil or grease!
water cooling (if existing) Empty and clean and refill coolant. Check whether pump
and refrigeration system are sealed and working properly.
Issue: 04/2011 49
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6.3.1 Drain and Refill Oil (Kinoton type 3672 oil):

»» after 50 operating hours after the first running
»» after 500 total operating hours or after a quarter of year
»» after every 4000 operating hours or once in a year, whichever comes first
6.3.2 Changing the Intermittent Oil

Procedure to change oil (Use Kinoton type 3672 oil only.):
• Remove the oil gauge cap and remove hose from clip. Move open end of hose down
into empty container. Let the oil drain out completely. Add oil through the hose. The
oil level must be between the red and green ring.
• During filling, turn the mechanism slowly, by hand, so that any air bubbles can
escape. Several times turn the framing knob alternately between the left and right
stops to distribute the oil. If necessary add more oil.
• Put the cap on the oil gauge and hang the hose back in the clip. There should be a
vent hole in the oil gauge cap. There must not be any cap on the hose.
XX note
ZZ The quantity of oil to fill the movement is about 6.8 fl. oz (200 ml).
ZZ Do not overfill the intermittent.
6.4 Repair and Adjustments
6.4.1 Changing the Pilot Lamp
ATTENTION
Before opening the shutter housing, wait until
the shutter stands still!
• Remove the shutter housing.

• Put the screw driver behind the lamp
socket and lift the lamp out of the socket.
• Push the new pilot lamp into the socket
and close shutter housing.
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6.4.2 Adjusting the Film Pressure Skate

The correct adjustment of the film pressure skate is mandatory in order to run the film
easefully and steady-going and with minor wear and tear of projector and film copy.
Repair and Adjustments

• Reduce the skate pressure by turning the adjusting knob (arrow) such that the picture
begins to shake vertically on the screen.
$
$The projector running noise becomes louder and more unsteady.
• Increase the skate pressure until the running noise becomes quietly and steadily and
the picture steadiness is correctly.
XX note
ZZ Only tighten the film pressure skate as much as is absolutely necessary!
ZZ Pressure too low: The picture shakes on the projecting screen.
ZZ Pressure too high: The sprocket teeth, film perforations, film pressure skate
and runner strips will wear excessively and film emulsion
will be left in the gate
ZZ The necessary pressure of the skate depends on the used film material.
It is recommended to check the skate pressure again, after splices have run through
the film gate and also after the film material has been changed.
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6.4.3 Adjusting the Height of the Film Pressure Skate

The film pressure skate has to be adjusted so that it rides perfectly on the film gate and
the intermittent sprocket.
• Loosen the setscrew (black arrow).

• Insert 2 superimposed film layers into the film gate.
• Screw the ball pin (white arrow) out or in to the desired length - the skate should just
not be moved vertically. You can use an Allen wrench in the holes of the ball pin to
rotate it.
$
$Without any film layers in the film gate the skate must have clear tolerance.
• When the adjustment is adjusted correctly fasten the setscrew again.
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6.4.4 Changing the 35 mm Film Runner Strips

• Loosen the knurled fastening screws and remove the old runner strips and insert the
new runner strips.
$
$They must lay in parallel to the vertical film gate edges.
The small spring-suspended ceramic rollers must have a free clearance.
$
$The seat is correct, if the conic ending running strips are lying lightly on the sprocket
without touching the teeth, so that a perfect film run even with splices is assured in
both directions.
• Tighten the knurled screws.
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6.4.5 Adjusting the Lens Holder

• For setting up lenses, set scale in the
mid-position.
• Loosen the clamping screw (arrow)
and push the lens into the holder until
picture is sharp (basic adjustment).
• Tighten the clamping screw again.
• Repeat the adjustment for each lens
without turning the focus knob.
• To adjust the picture focus finally turn the knob slightly as required.
6.4.6 Changing a Constant Speed Sprocket / Pad Shoe

• Loosen the locking nut (black arrow)
and the adjusting nut (white arrow) of
the pad shoe with the special tool –
the spring will relax.
• Pull the pad shoe from its shaft.
• Loosen the film stripper setscrews
(two black arrows) and remove the film
stripper.
• Turn the sprocket locking screw (on
sprocket surface) anticlockwise five to
six turns to loosen the sprocket.
• Pull the sprocket from its shaft.
XX note
If the teeth of sprocket are worn on one
side only, you can turn it and use the
other side (not with combined sprockets). Otherwise you must replace the sprocket.
• Install the sprocket onto the shaft with a slight counter-pressure on the belt wheel in
the projector.
• Tighten the locking screw on the sprocket again.
XX note
The sprocket end play should be between .0004” (0.01 mm) and .001” (0.03 mm).
• Put on the film stripper again and fasten the 2 stripper setscrews in a way that it does
not touch the sprocket surface.
• Grease the pad shoe shaft with Cardan oil and then put the pad shoe onto the shaft.
• Place the torsion spring in the hole of spring cage and place the whole assembly in
pad shoe again.
XX note
Be sure that spring end is placed exactly in hole of pad shoe.
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6.4.7 Adjusting the Tension of the Pad Shoe Spring

• Loosen the locking screw (black arrow) with an Allen key.
• Adjust the tension of the spring by turning the adjusting ring (white arrow) clockwise
with a special tool.
$
$The pad shoe pressure should be (measured on pad shoe with a spring scale):
- 450 g ± 50 g at open condition and
- 150 g to 250 g at closed condition.
• After adjustment lock the spring by tightening the locking screw (black arrow) again.
6.4.8 Adjusting the Distance between Pad Shoe and Sprocket

• Turn the adjusting screw (arrow) until
a gap of 2 film layers is generated
between the sprocket and the pad
shoe.
• After adjustment paint-lock the

adjusting screw.
6.4.9 Adjusting the IR Reflex Film Break Sensor

Position the sensor (arrow) in a way that it “looks” vertically towards the film surface.
The sensor’s view must be perpendicular to the film.
• To adjust the sensitivity of the sensor
thread a film and turn the plastic screw
(arrow) with a screw driver until the red
LED (adjusting aid) blinks.
• Then turn the screw until the LED surely
lights steadily.
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6.4.10 Changing and Lubricating the Felt Disk of the Mechanical Friction
• Remove the knurled nut, the spring, the friction plate and the felt disk on the friction
shaft (black arrows).
• Once in a year the felt disk should be put in a Cardan oil bath. If the felt disk is worn
(surface is hardened) it has to be changed and oiled.
• Mount the friction again.
• Thread a film and adjust the friction (see next chapter).
6.4.11 Adjusting the Mechanical Friction

Via the knurled nut (white arrows) the spring tension can be adjusted and therefore the
pressure against the friction disk to the felt disk. Adjusting the frictions is necessary if
the felt disk was replaced.
Adjusting the take-off friction:

• Put a full film spool onto the take-off friction shaft.
Thread the film and run the projector.
• Stop the projector - the film should not build a loop, otherwise the friction is adjusted
with too small pressure.
• Turn the knurled nut clockwise to increase the pressure onto the felt disk.
Adjusting the take-up friction:

• The take-up film spool has to be nearly full, then stop the projector - the film should
not build a loop.
• If necessary adjust:
- Right turn of the knurled nut => spring increases the pressure
- Left turn of the knurled nut => spring decreases the pressure
XX note
ZZ Depending on the film reel length the film tension has to be adapted.
ZZ The film tension is inversely proportional to the reel diameter:
The film tension is less, when the reel diameter is large (beginning of take-off fric-
tion)
56 Issue: 04/2011
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6.4.12 Tension the Chains
XX note
The chains must not be taut, but they must not
flap during the movement. The chain should be
tension in a way that a distance of about 1 cm
remains, when the chain is pressed towards the
bottom sprocket (arrow).
• Open the projector head rear cover.

• Remove the chain case by loosening
the 2 Allen screws (arrow) and then
Cleaning / Maintenance / Repair

remove the hexagonal rod nuts.
Upper Chain
• Loosen the feed sprocket
assembly by turning the Allen
screw from the projector front side.
• Slide the assembly vertically until the
chain is tension correctly.
• Then fasten the Allen screw again.
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Lower Chain
• Loosen the centre Allen locking
screw on the eccentric gear (arrow)
and move the eccentric gear until the
chain tension is correct.
• Tighten the lock screw again.
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7 Parts and Wearing Parts
7.1 Parts for the Film Gate

Part Figure Order Number
Film runner strips, white 1A 5322 463 10021
Film runner strips, Novotex brown 1B 5322 463 10023
Knurled screw for fastening the film runner strips 1C 5322 505 10336
Ceramics roller 1D 5322 532 50362
Film pressure skate, black 1E 1000 463 17019
Film pressure skate, brown (longlife) 1F 5322 463 10019
7.2 Parts for the Feed/Bottom Sprocket

Film stripper 2A 1000 604 57008
Pad shoe 2B / 3B 5322 525 30003
Parts and Wearing Parts

Nut for pad shoe 2C / 3C 5322 462 50027
Spring for pad shoe 2D 5322 492 40001
Handwheel for bottom sprocket 3D 1000 413 47005
7.3 Parts for Guide Rollers

Big guide roller Ø 34 mm 4A 1000 525 37042
Cap 4B 5322 462 70374
Small guide roller Ø 20 mm 4C 1000 525 67054
Cap 4D 5322 462 70373
7.4 Other Parts

Knurled screw for shutter housing 5A 5322 505 10192
Focusing adjusting knob 5B 1000 413 37001
Film pressure skate adjusting knob 5C 1000 413 37001
Framing adjusting knob 5D 5322 413 10007
Knurled screw for fastening the lens (M 4 x 8) 5E 1000 502 17004
Film cleaner 0040 060 0048X
Esso universal oil EL 4805, 100 ml 1000 390 27008
Issue: 04/2011 59
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Figure 1 Fig. 1A Fig. 1B
1A
1C
1E
1D
Fig. 1E Fig. 1F
Fig. 1C
Fig. 1D
60 Issue: 04/2011
FP 30 A
Figure 2 Fig. 2A
2A
2C
2B
Fig. 2B + 3B

Figure 3
3D
Fig. 2C + 3C
3C
3B
Fig. 3D Fig. 2D
Issue: 04/2011 61
FP 30 A
Figure 4 Fig. 4A
4A + 4B
Fig. 4B
4C +4D
Fig. 4C
Figure 5 Fig. 4D
5A
5B
5E
5D
5C
62 Issue: 04/2011
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7.5 Parts for Motors and Drives

Oil hose 6 5322 530 20236
Oil gauche glass 7 5322 532 70114
Knurled nut M8 8A 1000 505 17006
Spring for Kinoton friction 8B 5322 492 50064
Felt disk for Kinoton friction 8C 1000 532 57007
Projector oil 3672/00, 1 L 1000 390 27006
Figure 6 Figure 7

Figure 8 Fig. 8A Fig. 8B
8C
Fig. 8C
8B
8A
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7.6 Film Spools

Part Code number
Film spool Ø 9 mm, 600 m film 0040 060 00050
Film spool Ø 12.7 mm, 1800 m film 0040 060 00765
Film spool Ø 12.7 mm, 2000 m film 0040 060 00770
7.7 Interchangeable Flanges with Friction Shafts

Part Code number
change flange, shaft Ø 12.7 mm (USA), 35 mm film 1000 535 77035
change flange, shaft Ø 12.7 mm (USA), 35 mm film, quick change 1000 535 77067
Kodak core adapter for Ø 12.7 mm (USA) 1000 705 37013
change flange, shaft Ø 12.7 mm, 35 mm, lock nut 1000 535 77039
change flange, shaft Ø 12.7 mm, 35 mm, lock nut, quick change 1000 535 77068
change flange, shaft Ø 12.7 mm, 35 mm, locking bar 1000 535 77024
change flange, shaft Ø 12.7 mm, 35 mm, locking bar 1000 535 77066
quick change
Kodak core adapter for Ø 12.7 mm 1000 705 37014
change flange, shaft Ø 9 mm, 35 mm, cross bar 1000 535 77025
change flange, shaft Ø 9 mm, 35 mm, cross bar 1000 535 77040
quick change
Kodak core adapter for Ø 9 mm 1000 705 37014
change flange, shaft Ø 5/16”, 35 mm, cross bar 1000 535 77027
change flange, shaft Ø 5/16”, 35 mm, cross bar, 1000 535 77063
quick change
Kodak core adapter for Ø 5/16” 1000 705 37016
change flange, shaft Ø 9 mm, 35 mm film 1000 535 77034
with reel platter and lock nut
change flange, shaft Ø 9 mm, 35 mm film 1000 535 77065
with reel platter and lock nut, quick change
change flange, shaft Ø 9 mm, 35 mm, lock nut 1000 535 77033
change flange, shaft Ø 9 mm, 35 mm film, lock nut, quick change 1000 535 77064
7.8 Parts for Electronics and Controls

Part Code number
Pilot lamp, 24 V / 3 W 0040 120 00059
Key lamp 1000 134 87005
Fuse 6.3 AT 4822 253 30031
64 Issue: 04/2011
FP 30 A
7.9 35 mm Apertures for Aperture Changer

Part Code Number
Triple aperture shaped 1000 451 17012
Triple aperture for filing 1000 451 17016
Hole aperture to adjust the frame center 1000 451 17017
Triple aperture dimension smaller than specified 1000 451 17020
Hole aperture for filing 1000 451 17022
7.10 Single Apertures

Part Code Number
Single aperture complete CS 2.35:1 5322 451 10009
Single aperture complete NS 1.37:1 5322 451 10011
Single aperture complete 1.85:1 5322 451 10012
Single hole aperture complete 5322 451 10013

Single aperture for silent movies 1000 451 17014
Single aperture complete Super 35 mm 1000 451 17015
Single aperture finished size 1:1.37 1000 451 17023
Single aperture S35/1:2.39 1000 451 17029
Single aperture CS+1:1.66 1000 451 17031
Single aperture S35/1.1.85 1000 451 17032
Single aperture S35/CS 1000 451 17033
Issue: 04/2011 65
FP 30 A
7.11 Adapter Rings for 35 mm Lenses

Part Code Number
Adapter ring 1 for ISCO Cinemascope Ultra-Star 55 / 60 0070 410 00003
Adapter ring 2 for Schneider Super-Cinelux 50 / 52,5 / 55 / 57.5 / 60ISCO 0070 410 00018
Ultra-Star HD 42 / 45 / 48 / 50 / 55 / 60 / 65 / 70 / 75 / 80 / 85 / 90 / 95ISCO
Ultra-MC 35 / 45 / 50 / 55 / 60 / 65 / 70 / 75 / 80 / 85 / 90ISCO
Cinemascope Ultra-Star 50
Adapter ring 3 Schneider Super-Cinelux 28 / 30 / 32.5 0070 410 00015
Adapter ring 4 Schneider Super-Cinelux 42.5 / 45 / 47.5 0070 410 00017
Adapter ring 5 Schneider Super-Cinelux 35 / 37.5 / 40 0070 410 00016
Adapter ring 6 ISCO Cinemascope Ultra-Star HD 29 / 32 / 35 / 38 / 40 0070 410 00001
Adapter ring 7 ISCO Cinemascope Ultra-Star HD 95 / 100 0070 410 00002
Adapter ring 8 Schneider Super-Cinelux 2 / 90 0070 410 00019
Adapter ring 9 ISCO Ultra-Star-Plus 2.1 37.5/ 40/ 45 0070 410 00013
Adapter ring 10 ISCO Ultra-Star-CS 0070 410 00014
Adapter ring 11 Schneider Super-Cinelux 2/ 95 0070 410 00009
Adapter ring 70.6 / 62.5 0070 410 00010
66 Issue: 04/2011
FP 30 A
8 Technical Data, Circuit Diagrams and

Plans of Terminal Connections
8.1 Technical Data
8.1.1 Projector Data
Name Film Projector

Type FP 30 A
Machine No. See data plate on housing.
Connecting Data
Power supply 120 V / 230 V
Technical Data / Terminal Connection

Frequency 50 Hz / 60 Hz
Pre-fuse 6.3 A
Power max. 500 W (without lamphouse)
Power and Operating Data
Nominal rotary frequency of main drive motor 1500 rpm

Power of main drive motor 100 VA
Sizes and Weights
Components Sizes Weight

Projector 424 mm x 750 mm x 2340 mm approx. 140 kg
Film spools 600 m / 1800 m / 2000 m / 4000 m
Friction shafts Ø 9 mm or Ø 12.7 mm or 5/16”
Apertures 1:1.37 / 1:1.66 / 1:2.35
Framing ± ½ picture manual or automatic
8.1.2 Reverse-Scan Sound Device
Connecting Data
Power supply 24 V =
Frequency 50 Hz / 60 Hz
Power max. 6W
Power and Operating Data
Frequency response analog: 30 Hz - 16 kHz ± 1 dB

digital: 20 Hz - 20 kHz ± 0.5 dB
Wow and flutter ≤ 0.1%
Issue: 04/2011 67
FP 30 A
8.2 Terminal Connection
8.2.1 Projector Terminal Strip for Automation and Remote Control
No. Projector inside Wire Color

1 + 24 V red
2 - 24 V blue
3 START forwards (2) white
4 GND/COM blue
5 STOP (3) purple
6 dowser OPEN yellow
7 GND/COM blue
8 dowser CLOSE green
9 GND/COM blue
10 lens turret NS white/green
11 lens turret WS grey/purple
12 lens turret CS brown/green
13 framing DOWN green/white
14 GND/COM blue
15 framing UP blue/white
16 sensor black
17 RUN brown
18 RUN grey
19 RUN (2) red/brown
20 RUN (2) yellow/brown
21 film break violet
22 NC
23 NC
24 NC
25 NC
PE protect. conduct., ground
68 Issue: 04/2011
FP 30 A
8.2.2 Sound Output on 8-pole Terminal Strip
Solar cell connection

Shield
Sound output left - (yellow)
Sound output left + (brown)
Sound output right - (white)
Sound output right + (green)
Wiring Schemes
Issue: 04/2011 69
70
8.3
8.3.1
4
1
FP 30 A
K5
4
1 K6 K7
Dow2 60A
Run3
Run3
Run2
Run2
FT-3M MT/UT 600/2000 Dow2 60B
Dow3 Xe3a
FP 30 A
Dow3 Xe3b
22Ω/25°
1
4
1 K1
- +
RUN
RUN
RUN
FT-3M/ST200E
Wiring Schemes
0V
Film Break - + - +
Ton
12
Mot1
Pilot K3-10
Mot1
Pilot lamp - + Motor
Mains K3-9 Mot2
+24V Mot2
Dowser STOP START PTC 15
K3-8
Dows. Cap2
+ - + - 12uF 15uF
NS K3-7
7 Cap1
Mot3
K3-6
- +
LED-Netzteil LED8101 ~ ~ Mot3
- -
~
+
~
+ N
- + - +
PE
PX
WS L 60A/60B
122
- + 122LH Lamphouse
+
+
122 Xenon
-
-
L1
18,6VA
- + Xenon N
Ringkerntrafo - +
122 PE
+ - + -
CS
122GL
0.6A
0 T
10V
+ + 115V~ X2
0.6A
10V 15V 0 115
K3 1
J2
+ + 230V~
- + X3 CLOSE OPEN
J1 0.3A
+ +
~ ~
10V 15V 115
X1
0
+ -
Rectifier
Power Supply Unit 24V/5A
-
-
- +
L1
Power Supply Unit 24V/2.5A
+
+
L2
+
+
L3
~
~
+
+
K2 N
-
-
~
~
24V
K4 PE
+ 0V 15
Filmtheater- und Studiotechnik
1 6 1
0V
0V
0V
BH
GM
+24V
+24V
1 1
WS
STOP 2
RISS
NS
CS
COM
STOP 3
STOP 1
X_CLOSE
X_OPEN
START2
START1
+15V 0V -15V LED2+ LED2- LED1+ LED1- En- En+ GND/PE A C ~ AC ~
br
gr
bl
ye
gn
vio
wt
rs
CS
WS
NS
+15V
0V
-15V
LED1-
LED1+
LED2-
LED2+ wt
En
En
AC~
GND/PE
AC~
N
L1
GND/PE
+24V
0V
Com.
0V
+24V
MSK8103 Netz
CAT.655
Reverse scan N
Si6,3Atr
L1
PE
Issue: 04/2011
FP 30 A
8.3.2 Lamphouse (230 V mains connection)
M1 Lamp fan
M2 Fan motor
H Hour counter
Ignition Unit 4060 DC
SK1 Main switch
SK2 Ignition button
SK3 SK4 Door switches
SK5 Airflow switch
bn
re.
re.
2
6
SK6 Thermal switch
+
Ignite
SK6
A Ammeter
4
8
wt
L Xenon lamp
H
E
6
NW Shunt 60 mA
M1
vi
SK2
gr
M2
L
W A A V
bk
bl
700 30-45 37 19
-
bn
1000 30-55 50 20
bl
1600 45-70 65 22
Wiring Schemes
2000 50-85 70 29
115/250V
2500 70-100 90 28
0
Filter
Re.
3A
3000 60-110 100 30

Lamphouse
4000 80-150 135 30

1
~230V
5000 100-150 140 35

6500 80-160 160 41
7000 120-165 160 43
bk
shunt ab 2KW
SK4
Lampenhaus
SK5
Light Dowser
NW
A
( OPTION )
SK3
T6;3A
Si1
Interference
( OPTION )
Ring core
+24V
AUTO/MAN.
=0V
MAG: GL P R O Y. INPUT
SK1
- 122A 122 60B 6 0 A 20 40 60

+
ye-gn
Terminal Strip
8µF
wt
bk
bk
bk
bl
bn
Input
+
122A
122B
60A
-
60B
122
PE 4 0
20
60
N
L
Rectifier
Mains
~230V
Terminal Strip
60A
60B
122
122
at dowser ON
Projector
at start
at start
Rectifier
+24V
Issue: 04/2011 71
FP 30 A
8.3.3 Lamphouse (120 V mains connection)
M1 Lamp fan
M2 Fan motor
H Hour counter
SK1 Main switch
Ignition Unit 4060 DC SK2 Ignition button
SK3 SK4 Door switches
SK5 Airflow switch

bn
re.
re.
2
SK6 Thermal switch

+
Ignite
SK6
A Ammeter
wt
L Xenon lamp
H
E
6
NW Shunt 60 mA
M1
vi
SK2
gr
M2
L
W A A V
bk
bl
700 30-45 37 19
-
1000 30-55 50 20
bn
bl
1600 45-70 65 22
2000 50-85 70 29
2500 70-100 90 28
115/250V
3000 60-110 100 30

Filter
Re.
3A
Lamphouse
4000 80-150 135 30

1
~230V
5000 100-150 140 35

6500 80-160 160 41
7000 120-165 160 43
Shunt from 2kW on
sw
SK4
SK5
Light Dowser
NW
A
( OPTION )
SK3
T6;3A
Si1
Interference
( OPTION )
~230V
VT035
Ring core
+24V
~110V
AUTO/MAN.
=0V
MAG: GL P R O Y. INPUT
SK1
- 122A 122 60B 6 0 A 20 40 60

Terminal Strip
+
ye-gn
8µF
wt
wt
bk
bk
bl
bn
Input
+
122A
122B
60A
-
60B
122
40
20
60
PE
Gleichrichter
L
Rectifier
Terminal Strip
Mains
~110V
60A
60B
122
122
at dowser ON
Projector
at start
at start
Rectifier
+24V
72 Issue: 04/2011
EC Declaration of Conformity
Company name Kinoton GmbH

Address: Industriestr. 20a, D-82110 Germering
Machine designation: Cinema Projector

Machine type: FP 30 A
Maschine serial number: KAD0101
Relevant EC stipulations:
Machine regulation 2006/42/EG

Low Voltage regulation 2006/95/EG
EMC regulation 2004/108/EG
Standards:
if need be harmonized standards EN 61000-6-1, EN 61000-6-2
EN 55022/A1, EN 55022
if need be national standards
and technical specifications
the above-named machine is developed, constructed and manufactured in

accordance with above-listed EC regulations and in sole responsibility of
Company: Kinoton GMbH
Industriestr. 20a
Germany 82110 Germering
Place, date: Germering, 11. 01. 2010
Signature:
Prename, name: Herbert Zipfel
Function: Production Manager

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Operating Manual

Printed in Germany, Issue May 2011

Hints / Own Notes

1.1 Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1.2 Dangers when Working with the Projector . . . . . . . . . . . . . . . . . . . . . . 1

1.1.3 Intended Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.1.4 Guarantee and Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2 Explanations of Symbols and Notes . . . . . . . . . . . . . . . . . . . . . . 3

1.3 Special Hazard Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.3.2 Lamphouse Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.3.2.1 Broken Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.3.2.3 High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.3.3 Mechanical Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.4 Preventing Projector Damage . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.6 Protective Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.6.2 IR Reflex Film Break Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.6.3 Film Stripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 Transportation and Installation / Mounting . . . . . . . . . . 9

2.2 Delivery or Equipment Variations . . . . . . . . . . . . . . . . . . . . . . . . 9

2.3.2 Important Hints for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.3.3 Additional Installation Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.4.2 Installing and Connecting the Lamphouse Components . . . . . . . . . . 14

2.4.3 Connecting the Water Cooling (option) . . . . . . . . . . . . . . . . . . . . . . . . 14

2.4.4 Projector Terminal Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.4.5 Connecting to the Non-Rewind System . . . . . . . . . . . . . . . . . . . . . . . 15

3 Function and Components . . . . . . . . . . . . . . . . . . . . . . 17

3.1 Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.1.2 Projection Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.2 Film Gate and Film Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.2.2 The Dowser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.2.4 Aperture Changer (option, only with electronic lens turret) . . . . . . . . . 21

3.2.4.1 Drive and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.2.4.2 Format Change with Three Lenses . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.2.4.3 Format Change with Two Lenses Turret . . . . . . . . . . . . . . . . . . . . . . 22

3.2.4.4 Changing the Format Combination . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.2.5 Lens Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.2.6 Lens Turret (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.2.6.1 Manual Lens Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.2.6.2 Electronically Controlled Lens Change (option) . . . . . . . . . . . . . . . . . 25

3.2.7.1 Manual Focusing with Lens Turret / Lens Holder . . . . . . . . . . . . . . . . 26

3.2.7.2 Electronic Focusing with Lens Turret (option) . . . . . . . . . . . . . . . . . . 26

3.2.7.3 Electronically Controlled Lens Holder Focusing (option) . . . . . . . . . . 26

3.2.8 Rotating Shutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.2.9 Intermittent Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.2.11 Constant Speed Sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.3 Reverse-Scan Sound Device . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.3.3 Sound Tracks on the Films . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.4 SDDS Reader / DTS Reader (option) . . . . . . . . . . . . . . . . . . . 32

3.5 Film Cleaner (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.6.2 Intermittent Movement

3.6.3 Friction Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.6.3.1 Take-Off Friction (non-driven) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.6.3.2 Take-Up Friction (driven) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.6.3.3 Reel Shaft on Change Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.7 Electronic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Issue: 04/2011 iii

4.1 Main Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4.2 Projector Operating Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4.3 Remote Control Panels (option) . . . . . . . . . . . . . . . . . . . . . . . . 38

4.3.2 Auditorium Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39