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Publication No. SM 2547-1
Kodak
03/98
SERVICE MANUAL for the
KODAK EKTAPRO Slide Projector
Model 4020, 5020, 7020, 9020, (9020/CINE)
Model 9020
© Kodak AG, Stuttgart 1998 Kodak AG, Stuttgart I 03/98
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PLEASE NOTE
The information contained herein is based on the experience and knowledge relating to the subject matter gained by Kodak prior to publication. No patent license is granted by this information. Kodak reserves the right to change this information without notice, and makes no warranty, express or implied, with respect to this information. Kodak shall not be liable for any loss or damage, including consequential or special damages, resulting from the use of this information, even if loss or damage is caused by Kodak's negligence or other fault.
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TABLE OF CONTENTS
ELECTROSTATIC DISCHARGE ......................................................................................................... 1-1 Overview..................................................................................................................................... 1-1 Awareness .................................................................................................................................. 1-1 Action ......................................................................................................................................... 1-1 Every Day ................................................................................................................................... 1-2 During Maintenance and Repair ................................................................................................. 1-2 1. GENERAL INFORMATION .............................................................................................................. 1-3 Service Tools ...................................................................................................................................... 1-3 For Models 4020/5020/7020/9020 and 9020/CINE ............................................................................ 1-3 Safety Precaution................................................................................................................................ 1-4 Safety Check ...................................................................................................................................... 1-5 2. INTRODUCTION .............................................................................................................................. 2-1 Projector Models ................................................................................................................................. 2-2 EKTAPRO Model 4020............................................................................................................... 2-2 Features and Functions: ............................................................................................................. 2-2 EKTAPRO Model 4020............................................................................................................... 2-3 EKTAPRO Model 5020............................................................................................................... 2-4 Features and Functions: ............................................................................................................. 2-4 EKTAPRO Model 7020............................................................................................................... 2-5 Features and Functions: ............................................................................................................. 2-5 EKTAPRO Model 9020............................................................................................................... 2-6 Features and Functions: ............................................................................................................. 2-6 Overview .................................................................................................................................... 2-7 Accessories......................................................................................................................................... 2-8 DUAL LAMP MODULE............................................................................................................... 2-8 CABLE REMOTE ....................................................................................................................... 2-8
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CONDENSER KIT 4X4 (with CLIP)............................................................................................ 2-9 IR REMOTE System RA/LP (Laser Pointer) ............................................................................ 2-10 12/7-PIN MODULE ................................................................................................................... 2-10 LENS SUPPORT...................................................................................................................... 2-10 12/7-PIN ADAPTER CABLE..................................................................................................... 2-11 TWIN SOCKET ADAPTER....................................................................................................... 2-11 SLIDE SYNCHRONIZER ......................................................................................................... 2-12 LAMPS ..................................................................................................................................... 2-12 Specification...................................................................................................................................... 2-13 CONNECTORS ................................................................................................................................ 2-13 Remote SOCKET on Projector:................................................................................................ 2-13 P-Bus / RS 232 "IN".................................................................................................................. 2-14 P-Bus / RS 232 "OUT"............................................................................................................. 2-14 ACCESSORY SLOT................................................................................................................. 2-15 OEM ACCESSORIES ........................................................................................................................ 2-16 COPYWRITE............................................................................................................................ 2-16 SLIDE SYNCHRONIZER ADAPTER by KODAK AUSTRALIA................................................ 2-17 ADAPTER by MÜWO ............................................................................................................... 2-18 ADAPTERS by MAYER & ZELLER.......................................................................................... 2-19 ADDRESSES ..................................................................................................................................... 2-20 CONTROL SYSTEMS.............................................................................................................. 2-20 SOFTWARE for direct PC CONTROL...................................................................................... 2-21 RACKS ..................................................................................................................................... 2-21 EXTERNAL TIMER .................................................................................................................. 2-21 3. THEORY GUIDE .............................................................................................................................. 3-1 Block Diagram..................................................................................................................................... 3-1 Microcontroller Unit ............................................................................................................................. 3-3 Description of Functions ..................................................................................................................... 3-4
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Power Supply ............................................................................................................................. 3-4 The TRANSFORMER supplies the following voltages: .............................................................. 3-4 The POWER REGULATION PCB contains:............................................................................... 3-4 The output voltages and signal are:............................................................................................ 3-4 Switch On / Initialize Procedure.................................................................................................. 3-6 Slide Change Sequence ............................................................................................................. 3-7 Tray Motion................................................................................................................................. 3-8 Tray Motion Sequence: .............................................................................................................. 3-9 LAMP Control ........................................................................................................................... 3-11 a) Dual LAMP Operation .......................................................................................................... 3-11 b) Low/High LAMP Setting ....................................................................................................... 3-12 c) LAMP Protection................................................................................................................... 3-12 d) LAMP Voltage Control .......................................................................................................... 3-12 e) Lamp Dimming ..................................................................................................................... 3-13 Focus ........................................................................................................................................ 3-15 Auto focus................................................................................................................................. 3-16 P-BUS ..................................................................................................................................... 3-17 Command Structure ................................................................................................................. 3-18 Accessory slot .......................................................................................................................... 3-19 Remote Control ........................................................................................................................ 3-20 4. DISASSEMBLY/ASSEMBLY........................................................................................................... 4-1 UPPER HOUSING.............................................................................................................................. 4-1 BUTTONS and COVER PLATES ....................................................................................................... 4-2 Assembly .................................................................................................................................... 4-3 CENTER HOUSING ........................................................................................................................... 4-4 FAN, KEYBOARD PCB and TRAY MOTION PCB............................................................................. 4-8 BACK PANEL PCB........................................................................................................................... 4-10 TRANSFORMER, POWER SUPPLY PCB and BACK PLATE ASSEMBLY .................................... 4-11
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MECHANISM FRAME and LENS MOUNT....................................................................................... 4-12 LENS MOUNT .................................................................................................................................. 4-13 Model 4020/7020 ...................................................................................................................... 4-15 RETAINER AF ASSEMBLY.............................................................................................................. 4-16 Model 5020/9020 and 9020/CINE ............................................................................................ 4-16 MECHANISM FRAME ...................................................................................................................... 4-18 AUTO FOCUS PCB and FOCUS MOTOR....................................................................................... 4-21 Master Board PCB ............................................................................................................................ 4-22 Master Board PCB Connectors ................................................................................................ 4-23 MICROCONTROLLER ............................................................................................................. 4-24 LOWER HOUSING........................................................................................................................... 4-25 DUAL LAMP MODULE ..................................................................................................................... 4-26 DUAL LAMP MODULE............................................................................................................. 4-29 Lubrication ........................................................................................................................................ 4-30 5. DIAGNOSTICS ................................................................................................................................. 5-1 Diagnostic Overview EKTAPRO 4020/5020/7020/9020 and 9020/CINE ........................................... 5-1 Preparation ......................................................................................................................................... 5-3 Conditions:.................................................................................................................................. 5-3 No Function......................................................................................................................................... 5-4 Switch on Procedure Problems........................................................................................................... 5-9 Lamp Problems EP 4020/5020/7020/9020 and 9020/CINE ............................................................. 5-12 Mirror Position................................................................................................................................... 5-17 Brightness Test......................................................................................................................... 5-17 Switch On Procedure ........................................................................................................................ 5-18 Switch On Procedure complete - No Keyboard Function ................................................................. 5-19 No function with REMOTE CONTROL ............................................................................................. 5-20 IR Remote Control .................................................................................................................... 5-20 Cable Remote ................................................................................................................................... 5-23
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No Slide Transport forward/reverse and other projection problems ................................................. 5-24 Shutter Problems .............................................................................................................................. 5-35 Fan Problems.................................................................................................................................... 5-27 Slide Obstruction in Slide Tray.......................................................................................................... 5-29 Conditions for a correct transport cycle .................................................................................... 5-29 Wrong Transport Step by 80/140 SLIDE TRAY................................................................................ 5-30 No Focus Actuation........................................................................................................................... 5-32 No Standby Function ........................................................................................................................ 5-33 Communication Trouble 4010/5010/9010......................................................................................... 5-35 AUTO FOCUS 5020/9020 and 9020/CINE: No AUTO FOCUS Function......................................... 5-39 Accessory Slot 7020/9020 ................................................................................................................ 5-40 Malfunction of the 12/7 PIN Module.......................................................................................... 5-40 6. Projector Checking ......................................................................................................................... 6-1 Slide Transport Problems ................................................................................................................... 6-1 Slide jam (all models) ................................................................................................................. 6-2 CODER DISK ..................................................................................................................................... 6-2 7. MAINTENANCE ............................................................................................................................... 7-1 Maintenance Intervals......................................................................................................................... 7-1 Maintenance Procedure...................................................................................................................... 7-1 Cleaning.............................................................................................................................................. 7-1 Ultrasonic cleaning ..................................................................................................................... 7-2 Lubrication .......................................................................................................................................... 7-3
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ELECTROSTATIC DISCHARGE CAUTION
This equipment includes parts and assemblies sensitive to damage from electrostatic discharge. Use caution to prevent damage during all service procedures. Overview Electrostatic discharge (ESD) is a primary source of product downtime lost productivity costly repair.
While we cannot feel a static charge of less than 3,500 volts, as few as 30 volts can damage or destroy essential components in the electronic equipment. As technology advances, these components will be even more vulnerable to ESD destruction. Therefore, to maintain and increase productivity and profitability, you must observe ESD guidelines. Effective ESD control requires the following things. Awareness Everyone in your organization should be aware of ESD because partial ESD control is no ESD control at all. Everyone needs to remember that: Action Everyone from senior management to the evening security crew, must observe ESD guidelines. If you repair and maintain electronic equipment, always wear grounding straps and work at ESD protected sites. If you work around electronic equipment, keep static generators like plastic trash bags away from sensitive components. Observe ESD guidelines everyday. (See the following sections for special tips). Remember, effective ESD control is everyone's responsibility: ESD is a primary source of equipment failures and intermittent malfunctions. ESD affects productivity and profitability. ESD can be controlled.
-
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Every Day
1. Keep trash away from static-sensitive equipment. Plastic materials, such as trash can liners and plastic
foam cups, generate the static electricity that damages or destroys electronic components.
2. Look at the label. Static-sensitive components are marked with bright graphic labels. Follow the label
directions.
3. Spray the carpet. ESD that is generated when you walk over carpet is a major cause of component
destruction. In some cases, especially in low-humidity environments, you may need to periodically spray carpets with an anti-static spray that is available at local stores. During Maintenance and Repair
1. Wear a grounding strap when you work with static-sensitive components. Always make certain that the
clip is attached to a properly grounded, unpainted surface.
2. Use a portable grounding mat if you cannot repair components at an ESD-protected workstation.
(Kodak's Customer Equipment Services Division can help you in set up ESD-protected workstations.)
3 . Use protective packaging when you transport components from one area to another. Transparent
antistatic bags, available from a variety of manufacturers, shield the components from further damage.
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1. GENERAL INFORMATION Service Tools
Use the following tools to repair a KODAK EKTAPRO Slide Projector: TORX TORX TORX TORX Screw Screw Screw Screw Driver size Driver size Driver size Driver size 206 210 215 220
or TORX bits TL-3255
Logic Probe Oscilloscope Digital Multimeter
TTL/CMOS - only for checks on the AUTO FOCUS PCB. Voltage 5 to 240 V AC 0 to 50 V DC 1 to 100 mA DC Accuracy: 1% 0,1 to 2 A DC 0,1 to 5 A AC The multimeter should have RMS capability 1%
Current
Accuracy Fixture Tool 622 0454
For Models 4020/5020/7020/9020/9020/CINE PLCC Extractor Tool TL-4430 Service Computer 100% IBM compatible Hard disk CGA/EGA/VGA Monitor/Display 1 RS 232 Serial Interface 1 Centronics Printer Interface 1 720kB Floppy Disk Drive 1 9pin Serial Interface CORD Diagnostic Software: TL-4575
Ejector Microcontroller G 990 3250
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Safety Precaution
1. Do not operate or repair the projector without proper accessories. Add all COVERS before use to
prevent mechanical hazards and electrical shock.
2. Before operating the projector, check the VOLTAGE SELECTOR. Make sure that the correct line voltage
is selected.
3. Do not use a damaged POWER CORD. The damaged CORD can cause malfunctions and current
leakage or electrical shock.
4. If there is any abnormal noise, smell or smoke during operation, deenergize the projector immediately
and contact authorized personal for support.
5. Do not operate the projector in unsafe locations such as outdoors or in wet places. Do not allow liquids,
gaseous or solid-state materials to enter the projector.
6. When doing electrical measurements, use an isolation transformer or a leakage current detector in the
power line to avoid an electrical shock.
7. Use only original parts from the Parts List to repair the projector. 8. Make sure that the requirements of UL 122 - Splices and Connection - paragraph 13.10 and EN 60 950,
section 4.39 are observed. When replacing AC primary components, such as wires, sockets or capacitors , wrap the ends of the wire completely around the terminal before soldering.
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Safety Check
NOTE
Check the area around the repaired location. Make sure that parts and wires have been returned to the correct positions. Completely assemble the projector before doing an electrical safety test. The safety tests: Ground Continuity Test Insulation Resistance Test Equivalent Leakage Current Test Use a safety tester that measures all 3 tests at one time. Such a test device would be a Mini Tester 0701 N (Manufacturer:Gossen, Germany) or an equivalent device. Details for safety standards can be found in the regulations: IEC 380, 435, 950, UL 478, 1012. Prerequisites for measurements: The projector is energized FUSE with VOLTAGE SELECTOR insert COVERS in place LAMP MODULE installed
Test values for Mini Tester 0701N Interfaces Models 7020 and 9020 have an accessory slot. The 7/12pin module from Kodak is safety tested, and has approval from VDE and other institutions. If an OEM module is installed, inform the customer: the OEM is responsible for the safety and function of the module. the module is not part of the repair order. the specifications and safety warnings for the accessory in the slot are found in the "Operator's Manual". 1-5 03/98 Ground Continuity Test Insulation Resistance Test Equivalent Leakage Current .......< .......< .......< 300 mOHM = 0,5 OHM = 7 mA
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2. INTRODUCTION
The Kodak EKTAPRO Slide Projector series is a new family of Projectors that uses the latest mechanical and electronic technology. The Projector is modular designed, and equipped with a modern 1-chip MICROCONTROLLER, STEPPER MOTORS, optical sensors, and digital and analog circuits. All functions and displays are controlled by the MICROCONTROLLER software. Four models with different features and functions are available worldwide top 2 models can be attached to the old CAROUSEL and EKTAGRAPHIC family processors with optional ADAPTERS in the accessory slot. This new feature allows the future use of other equipment manufacturers Projector systems and accessories. The Models 4020, 5020, 7020 and 9020 are equipped with an RS 232 interface (P-Bus). This bus allows communication with a computer and multi Projector shows in a new way. The P-Bus can also be used for Service Diagnostics. The total amount of slide cycles for the models 7020 and 9020 can be read out with the Diagnostic Software TL-4575 ("SYSTEM REPORT" menu). The modular design, the LAMP MODULE and the accessory slot for special MODULE´s are needed to adapt the Projector to future applications. All models can be operated with 80 and 140 slide trays. Compliance with international safety regulations has been approved. All models are available in two versions: a) for 120/220/230/240 V, 50/60 Hz b) for 100/220V 50/60 Hz (Japan)
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Projector Models
EKTAPRO Model 4020
figure 2-1
Features and Functions: Line voltages Line frequency Power consumption Dual Lamp Module Extra Bright: : : : 120/220/230/240V or 100/220VAC can be select with an external VOLTAGE SELECTOR 50/60 Hz 380 W 35h EXR 82V/300 W 70h FHS 82V/300W 200h EXY 82V/250W approx. 0,9s (single step) approx. up to 3s (random access) Manual and electrically If the standby mode is activated the Keyboard will be disabled 75% light output Using an IR REMOTE CONTROL the keycode 550* will disable this function, enter of the same keycode enables this function again 80/140 slides After changing the switch position the Projector is running automatically through a initialization procedure
: : Slide change time : : Focus : Standby function : Economy LAMP setting : No SLIDE No LIGHT function: Slide Tray capability Slide Tray Switch : :
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EKTAPRO Model 4020
Adjustable Tray Motion : Tool PN 622 0454 has to used on Projectors from SN 85 xxx and above Two height adjustment feet are attached on the front side of the Projector LED continuously on Projector O.K. If the LED is blinking fast a slide jam occurs. In standby mode the LED is blinking short off and long on. If the LED is blinking continuously (on/off) a checksum error occurs (only during programming the processor) 8 pin mini DIN A single step will happen after pressing the "Forward" or the "Reverse" button less than 0.9s. Multiple steps will be done by pressing the "Forward" button more than 0.9s A run into the "Zero" position will immediately be done after press and hold the "Reverse" button until the Slide Tray is in "Zero" position After switching on the Projector the last used lamp will be selected (memory function). This memory function can be disabled by pressing the STANDBY button during switching on the projector Pressing both transport keys will enable the lamp to adjust the projector (green LED on the Backpanel is blinking). The Standby key will disable this function
Manual elevator mechanism : Indicator LED on front :
Remote SOCKET Slide change buttons
: :
Last Lamp used
:
Line up
:
NEW
In case of using a IR Remote Control single steps are possible independent how long the button is pressed. By pressing the "Reverse button" on the IR Remote Control random access is possible. To select the Slide Tray capacity (80 or 140 slides) a ball point pen or a small screwdriver has to be used. The Lamp Module has no longer a Heat Absorbing Glass installed. Due to the new mirror the light output is increased up to 30%.
NOTE
In case of changing the mirror take care of the type (see NEWSLETTER #4).
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EKTAPRO Model 5020
figure 2-2
Features and Functions:
All features and functions of Model 4020 Additional: AUTO FOCUS Timer : : Each slide will be focused, independent of the slide mount Slide change can be set from 1 up to 60 sec.
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EKTAPRO Model 7020
figure 2-3
Features and Functions:
All features and functions as Model 4020. Additional features:
Application Slot : Bus CONNECTORS (RS232) : Address Switch : Initializing procedure : High Light :
for Kodak and OEM ADAPTERS IN (female) and OUT (male) 16 addresses can be selected After power on the Projector the SLIDE LIFTER and the RING DRIVE will be checked, the LAMP and the FAN will be switched off 20% more light output, lamp life time approx. 30% reduced
NEW (only on Models 7020/9020)
If the parallel Mode "970*" is set on the IR Remote Control it is possible to toggle with "666*" between two projectors to control the focus functions. These functions are only visible on the screen.
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EKTAPRO Model 9020
figure 2-4
Features and Functions: This multi purpose Projector has all of the features of the EKTAPRO 7020. Additional features include: AUTO-ZERO function: : When the Projector senses an empty, gate the Projector automatically returns the tray to zero and begins the projection cycle again. This function can be deenergized. Slide change can be set from 1 up to 60 sec. Same as in EKTAPRO 5020 20% more light output, lamp life time approx. 30% reduced
Timer AUTO FOCUS High Light
: : :
NOTE (new Model EKTAPRO 920/CINE)
For special applications (cinema promotion) the Model EKTAPRO 920/CINE is available. This model has a build in memory function which knows the last projected slide after switching off the projector. Switching the projector on again the slide tray will run into that position after the initialization procedure. If the timer is switched on at that time a soft dissolve will be started immediately. New parts (NAMEPLATE and MICROCONTROLLER) see Illustrated parts list.
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Overview
Model FUNCTIONS/ACCESSORIES DUAL LAMP MODULE (Extra BRIGHT) TIMER AUTO-ZERO ADDRESS SWITCH APPLICATION SLOT AUTO FOCUS PRESENTATION BUS "IN" PRESENTATION BUS "OUT" RANDOM ACCESS EXTERNAL DIAGNOSTICS 4020 X X X X 5020 X X X X X X 7020 X X X X X X X 9020 X X X X X X X X X X
12/7-PIN MODULE SLIDE SYNCHRONIZER (1000Hz) TWIN SOCKET CABLE REMOTE IR REMOTE SYSTEM RA IR REMOTE SYSTEM RA/LP X = Standard Feature O = Accessory not possible
O O O O
O O O O
O O O O O O
O O O O O O
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Accessories
DUAL LAMP MODULE
CAT No. 718 4369
figure 2-5
CABLE REMOTE
CAT No. 712 1080
figure 2-6
6mm
3mm
HEAT ABSORBING GLASS with CLIP
(not installed in Model 3020) CAT No. 717 7140 (6mm thick) CAT No. 717 7157 (3mm thick) see NEWSLETTER #3/MAY/1996 page 5
HEAT ABSORBING GLASS
CLIP
figure 2-7
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CONDENSER KIT 4X4 (with CLIP)
CAT No. 714 4967
figure 2-8
IR REMOTE System RA (with Random Access) CAT No. 712 1072 complete with RECEIVER and TRANSMITTER
RECEIVER
figure 2-9
TRANSMITTER
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IR REMOTE System RA/LP (Laser Pointer)
CAT No. 712 1064 complete with RECEIVER
TRANSMITTER RECEIVER as use with IR REMOTE System RA.
figure 2-11
12/7-PIN MODULE
CAT No. 712 5875
Int. Ext.
figure 2-12
LENS SUPPORT
CAT No. 715 1335
figure 2-13
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12/7-PIN ADAPTER CABLE
CAT No. 712 5883
figure 2-14
TWIN SOCKET ADAPTER
CAT No. 712 5909 see NEWSLETTER #3/MAY/1996 page 7
B
C
figure 2-15
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SLIDE SYNCHRONIZER
CAT No. 712 5891 (not available)
see page 16 OEM ACCESSORIES
LAMPS
Catalog No. 145 2259 147 7678 145 2143 Description EXR 82V/300 W EHS 82V/300 W EXY 82V/250 W Lifetime life time about 35 hours life time about 70 hours life time about 200 hours
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Specification
Electrical Supply : : : : : : : : : : : : : : : : : 120/220/230/240 V or 100/220 V 50/60 Hz 380 W 310 x 355 x 145 mm max. (l/w/h) with tray and lens (12.2 x 14 x 5.7 in) 6300 g (13.9 lb) 24 x 36 mm (0.9 x 1.4 in) <0,8 s <3 s 50°C (104°F) max. above room temperature EXR 82V/300W 0.3 s 0°C to 40°C (32°F to 113°F) 20 to 85% r.H. approx. 700 l/min. (20,000 cuft/min.) VDE, UL , CSA 0° to 18° with internal elevation mechanism 30° max. allowed
Power Consumption Dimensions Weight Slide size Slide change time Slide search time Slide temperature LAMP (standard) Automatic LAMP change Operating temperature Humidity Air consumption Approvals Leveling
CONNECTORS
Remote SOCKET on Projector:
Type Mini DIN
7 8 5 4 2 1 (viewed from front ) 6 3
PIN No. 1 2 3 4 5 6 7 8
Signal 12 VDC Gnd Signal 1 (LSB) Signal 2 Signal 3 Signal 4 Signal 5 (MSB) Interrupt
12 V DC = average value between 7.2 and 14.5 V DC
figure 2-16
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P-Bus / RS 232 "IN"
PIN No. 1 2 3 4 5 6 7 8 9
Signal Connected to 4 and 6 Receive Data (RxD) Transmit Data (TxD) Connected to 1 and 6 Signal Ground Connected to 1 and 4 -
figure 2-17
P-Bus / RS 232 "OUT"
PIN No. 1 2 3 4 5 6 7 8 9
Signal Connected to 4 and 6 Transmit Data (TxD)v Receive Date (RxD) Connected to 1 and 6 Signal Ground Connected to 1 and 4 -
figure 2-18
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ACCESSORY SLOT
a 1 2 3 4 5 6 7 8 9 10
b 1 2 3 4 5 6 7 8 9 10
PIN No. a1 a2 a3 a4 a5 a6 a7 a8 a9 a 10 b1 b2 b3 b4 b5 b6 b7 b8 b9 b 10
Signal SDA (I2C Data) I2C_INT (Interrupt) SLOT_232_R, TTL Level not used SLOT_A SLOT_C not used 12V DC 200mA max. 34V DC 750mA max. 26V AC_N 750mA max. SLC (I2C Clock) PLL_DISS SLOT_232_T (TTL-Level) SLOT_DIS SLOT_B SL_DISS not used VSS 12 (Ground) VSS 34 (Ground) 26V AC_L
figure 2-19
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OEM ACCESSORIES
COPYRIGHT The adapter of this English company is only designed to use traditional AV cassette recorders. Cue pulses recorded on the tape trigger the interface unit to generate digital commands to advance the EKTAPRO Projector. It is an interesting feature that the adapter works either by plugging directly into the remote socket or works remotely by additional use of the EKTAPRO IR Receiver. In this case the system can simultaneously used with both the EKTAPRO IR Transmitter and the adapter. The adapter is powered by a 9 volt A PP3 battery. The illustration (figure 2-20) shows both possibilities to run the Projectors.
EKTAPRO IR Receiver
figure 2-20 IR-USE. The advantage is that the Adapter and Projector can be separated. In addition, the use of the EKTAPRO Remote Transmitter is possible without disconnecting the Adapter. CABLE USE If no IR receiver is available the Adapter can be plugged with the fixed installed cable to the remote socket.
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SLIDE SYNCHRONIZER ADAPTER by KODAK AUSTRALIA Kodak Australia offers an own solution of a slide synchronizer adapter. This unit is built in the IR Receiver housing and is therefor directly to be plugged onto the remote socket. A 6pin socket is built into the housing. The system supports most of traditional AV cassette recorders. The S-AV cable remote can also be used with the possibility to give transport commands and to focus. Speaker desk (lecterns) installations can be fully used. The system is able to switch the Projector into the standby mode (press forward and reverse button simultaneously) or run to the Projector to the zero position (press and hold down forward and reverse button).
NOTE
The S-AV Timer does not work on this adapter!
Speaker´s Desk Professional AV Cassette Recorder
EKTAPRO IR Receiver Housing with built in Slide Synchronizer Adapter
S-AV Remote Control
figure 2-21
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ADAPTER by MÜWO The German company offers a slide synchronizer adapter which is built into the EKTAPRO Cable Remote Control. A 6pin socket provides connection with external devices which are traditional AV cassette recorders, S-AV Timer and speaker desks. Even if any devices are connected, the remote still works.
Professional AV Cassette Recorder
Speaker´s Desk
EKTAPRO Remote Control with built in Slide Synchronizer Adapter
S-AV Timer
figure 2-22
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ADAPTERS by MAYER & ZELLER The Swiss company Mayer & Zeller offers a 1000 Hz adapter which comes along in a small black plastic box with a standard 6pin female receptacle and an integrated cable with the new 8pin male connector for the EKTAPRO Projectors. The adapter offers the possibility either to connect a traditional AV cassette recorder to advance the Projector or to connect the standard cable S-AV remote control or to use the cable already installed in the speakers desks. The adapter is also offered in a special version which also enables the control of the focus via the remote control (or speakers desks).
S-AV Cable Remote Control
Professional AV Cassette Recorder
figure 2-23
NOTE
The S-AV Timer cannot be used because of the lack of a support voltage . But Mayer & Zeller offers a special Timer for controlling the EKTAPRO Projectors. The timer is built into the EKTAPRO Cable Remote Control. This a quite sophisticated solution and an interesting offer for those who intend buying a cable remote. For further details contact the company.
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ADDRESSES
CONTROL SYSTEMS · ARION 701 South 7th Street Delano, MN 55328 USA Tel: (001) 612 972 3351 Fax: (001) 612 972 3524 Bässgen AV Technik GmbH Hauptstraße 58, 79104 Freiburg Germany Tel: (0049) 761 23953 Fax: (0049) 761 35042 Copyright Machines Limited 44/46 Sillwood Street Brighton, Sussex BNI 2PS UK Tel: (0044) 273 720 175 Fax: (0044) 273 321 150 Dataton AB Box 257 S-581 02 Linköping Schweden Tel: (0046) 131 14325 Fax: (0046) 131 38445 HEP Holland P.O.B. 33112, 3005 EC Rotterdam Niederlande Tel: (0043) 10 418 3689 Mechanische Weberei GmbH Neuhäuser Weg 2, 33175 Bad Lippspringe Germany Tel: (0049) 52 52270 Fax: (0049) 52 522 7201 Müwo electronic In den Maltwiesen 11, 72379 Hechingen-Stetten Germany Tel: (0049) 7471 15830 RMF Products Inc. P.O.B. 520, 1275 Paramount PKWY Batavia II, 60510 USA Tel: (001) 708 879 0020 Fax: (001) 708 879 6749 Stumpfl Rudigierstraße 8, A-4701 Bad Schallerbach Austria Tel: (0043) 7249 2811 Fax: (0043) 7249 2811 18 Zygo Systems Limited 48 Fallowfields Bicester Oxon OX67Qs UK Tel: (0044) 869 248 261 Fax: (0044) 869 248 260
·
·
·
· ·
· ·
·
·
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SOFTWARE for direct PC CONTROL · ARION 701 South 7th Street Delano, MN 55328 USA Tel: (001) 612 972 3351 Fax: (001) 612 972 3524 AVC Team Bieber Am Holling 3, 35649 Bischoffen Germany Tel: (0049) 6444 1027 Fax: (0049) 6444 8527 Martin Ballein Viktor Scheffel Straße 2, 74076 Heilbronn Germany Tel: (0049) 7131 165170 Fax: (0049) 7131 52470 Hilger & Bremen GbR Heinzenstraße 20, 52062 Aachen Germany Tel: (0049) 241 49797 Fax: (0049) 241 49787 Holidays Afloat Limited Schachterij 9920 Lovendegem Belgium Tel: (0032) 9372 8908 Fax: (0032) 9233 5609 Stumpfl Rudigierstraße 8, A-4701 Bad Schallerbach Austria Tel: (0043) 7249 2811 Fax: (0043) 7249 2811 18 Peter Ziegler Van Gogh Platz 6, 53844 Troisdorf Germany Tel: (0049) 2241 46143
·
·
·
·
·
·
RACKS · · Chief Manufacturing Inc. 14310 Ewing Avenue South Burnsville MN 55337 USA Roha Projektionstechnik Bruno Jacoby Weg 11, 70597 Stuttgart Germany Tel: (0049) 711 723 621 Fax: (0049) 711 23699
EXTERNAL TIMER · Mayer & Zeller Wettsteinallee 15, 4058 Basel Switzerland Tel: (0041) 61681 4343 Fax: (0041) 61681 3907 Müwo electronic In den Maltwiesen 11, 72379 Hechingen-Stetten Germany Tel: (0049) 7471 15830 Wintron GmbH Egilolfstraße 70, 70599 Stuttgart Germany Tel: (0049) 711 4567 258 Fax (0049) 711 4567 267
· ·
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3. THEORY GUIDE Block Diagram
All functions of the projector are controlled by the MICROCONTROLLER ( MC68HC016B with 16k ROM) on the MASTER PCB.
The controlling software is loaded in the 16k ROM of the MICROCONTROLLER for Models 4020 - 9020 and 9020/CINE.
Located around the MICROCONTROLLER on the MASTER PCB there are the inputs, outputs and drivers for the sensors, LAMP, MOTOR´s and other functions.
The block diagram (figure 3-1) shows all of the functions of Model 7020 and 9020.
All model is equipped with the same MASTER PCB´s.
MODEL 4020 5020 7020 9020 9020/CINE
MASTERBOARD LAYOUT No.7 LAYOUT No.7 LAYOUT No.7 LAYOUT No.7 LAYOUT No.7
MICROCONTROLLER Version 4.8 Version 4.8 Version 4.8 Version 4.8 Version 4.9
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MASTERBOARD Model 4020 - 9020 (9020/CINE)
Service Manual
M
Keyboard PCB Remote Socket Fan
Transformer
Line Switch Power and Lamp Regulation 5V DC 12V DC 26V DC 36V DC
MASTERBOARD
Back Panel PCB
Fuse
Dual Lamp Module
M
Mirror Motor
Mirror Driver
Software Lamp Control
MICRO CONTROLLER
Accessory Slot
figure 3-1
3-2
Autofocus PCB
M
Focus Motor Driver Driver
Focus Control
Tray Motion PCB Software Slide in Gatel Driver Input
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M
Shutter Solenoid Tray Motor
M
CAM Slide Lifter Gate Sensor Sensor Motor Tray Size
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Microcontroller Unit
The main device on the MASTER PCB is the 16-bit MICROCONTROLLER unit MC68HC05B16 from MOTORola for the models EKTAPRO 4020 - 9020 and 9029/CINE This MICROCONTROLLER has a microprocessor, timer, memory, analog/ digital converter and input/output ports on one chip. Compared to a standard processor, where for each item a peripheral IC is necessary. This MICROCONTROLLER with its on-chip software controls all functions of the projector plus peripheral circuits. The main features of the MICROCONTROLLER are: 24 bi-directional I/O lines 8 input-only lines serial communication interface system 8 channel A/D converter 15120 Bytes ROM (Models 4020 - 9020 and 9020/CINE) 2 channel timer
The following block diagram shows the internal MICROCONTROLLER functions.
PA0 PA1 PA2 PA3 PA4 PA5 PA6 PA7 PB0 PB1 PB2 PB3 PB4 PB5 PB6 PB7 PC0 PC1 PC2/ECLK PC3 PC4 PC5 PC6 PC7 TCMP1 TCMP2 TCAP1 TCAP2 RDI SCLK TDO PLMA D/A PLMB D/A
VPP1
Charge pump
496 bytes self check ROM
RESET IRQ OSC2 OSC1
COP watchdog
Oscillator ÷2 / ÷32
VDD VSS PD0/AN0 PD1/AN1 PD2/AN2 PD3/AN3 PD4/AN4 PD5/AN5 PD6/AN6 PD7/AN7 VRH VRL
M68C05 CPU 16-bit timer
PORT D
8-bit A/D converter
SCI
PLM
figure 3-2
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PORT C
352 bytes static RAM
PORT B
MC68HC05B16 (15120 bytesROM) Model 4020 - 9020 and 9020/CINE
PORT A
256 byte EEPROM
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Description of Functions
Power Supply
The PROJECTOR POWER SYSTEM consists of a · · · POWER INPUT ASSEMBLY with POWER ON/OFF SWITCH, PRIMARY FUSE HOLDER and VOLTAGE SELECTOR TRANSFORMER, SECONDARY FUSE HOLDER POWER REGULATION PCB
The TRANSFORMER supplies the following voltages: Primary voltage outputs: 92/81 VAC LAMP voltage for Models 4020 - 9020 and 9020/CINE (SOFTWARE CONTROLLED LAMP CURVE) Safety Extra Low Voltage outputs: 10 VAC for +5V DC and +12V DC 26 VAC for 36 VDC regulated and unregulated, The POWER REGULATION PCB contains: line EMI filter rectifiers and regulators Triac LAMP Software Control Circuits (Models 4020 - 9020 and 9020/CINE)
The output voltages and signal are: 36 VDC unstabilized (36 VDC_12P) 36 VDC capacitor- stabilized (36 VDC) 12 VDC unregulated 5 VDC regulated 26 VAC Zero_cross signal for slot interface for MOTOR´s, solenoid, fan for remote control and slot for logic and MICROCONTROLLER for accessory slot for synchronization of the dissolve feature
Details can be obtained from circuit diagrams and the following block diagram.
IMPORTANT
Connect all the equipment to the same same power line, otherwise phase shifting will bring up problems !
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Kodak AG, Stuttgart
Power Module
Power Regulation Board
L ) N )
Gray 120 91 82
Voltage Selector Black 240 Red 230 Switch White 220 Fuse 1.25A 10V
) Regulator
12V DC 5V DC
VSS
26V AC_FL
figure 3-3
Blue
Zero Cross Circuit
3-5
26V
Zero_Cross 36V DC_12P 36V DC
Regulator
15V DC
2A USA 2.8A
VSS
Economy Normal Triac Relay Triac Relay Lamp1 Lamp2 Neutral
Line Filter
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Switch On / Initialize Procedure
Projector Status:
START
Mechanic position is not known Projector is energized
The MICROCONTROLLER starts the initialization routine:
Microcontroller is active
Slide LIFT MOTOR On.Move LIFTER to Up Positon
-
load the look-up tables look at the accessory slot and projector address sets the ECONOMY LAMP RELAY to 82V completes a Hardware reset
SLIDE LIFT MOTOR rotates clockwise (max. of 805 steps = one SLIDE LIFTER cycle).
CAM Sensor Signal 0-1 No
Yes
Stop LIFT MOTOR Move Slide Tray about 3 Slides forward
If SENSOR SIGNAL changes from not actuated to actuated, the SLIDE LIFTER is in up position. Yes = Start tray MOTION. No = Begin a failure routine, after it has advanced 805 steps without sensor signal change. slide tray moves forward about 3,5 slides (with software version above 4.2). Details about tray motion can be obtain from page 3-9.
Yes
Zero Sensor actuated ?
If the ZERO SENSOR is not actuated, the tray reverses
No Reverse Slide Tray
No Zero Sensor actuated ?
Yes
If the ZERO SENSOR is not actuated, the slide tray continues to advance.
Stop Tray Motor
Slide LIFT MOTOR On Slide LIFTER to Down Positon
The SLIDE LIFT MOTOR moves clockwise.
CAM Sensor Signal 1-0 Yes Stop LIFT MOTOR
No
When the CAM SENSOR changes from actuated to not actuated, the LIFTER is in the down position.
Stop LIFT MOTOR
Slide in Gate Sensor actuated ?
No
Power LED Blinking
If the SLIDE IN GATE SENSOR is actuated, the SHUTTER opens.
Write the Failure into Memory
Yes
Open Shutter Autofocus On Projector Ready for Operation
Projector does not Operate
END
figure 3-4
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Slide Change Sequence
Projector Status: START
SLIDE LIFTER down SHUTTER is open SLIDE is in GATE LAMP is energized
Start:
"Forward"/"Reverse" BUTTON is pressed. Signal from: P-Bus, Remote Control or Timer
Close Shutter Switch Autofocus Off
The SHUTTER SOLENOID is deenergized.
max. 805 Steps of Slide Lift Motor
The SLIDE LIFT MOTOR rotates clockwise to move the SLIDE LIFTER up (max. 805 steps = one SLIDE LIFTER cycle). The SLIDE LIFTER is in the up position when the CAM SENSOR signal changes from not actuated to actuated. If no: If yes: the failure routine begins after 805 steps a without signal change. Starts the tray Motion. See page 3-10.
CAM Sensor Signal 0 - 1 ? Yes Slide Lift Motor off
No
Start Tray Motion Next slide position
For details see page 3-10.
Slide Lift Motor On
CAM Sensor Signal 1-0 ? Yes
No
No
Slide in Gate Sensor actuated ? Yes
The SLIDE LIFT MOTOR moves clockwise to move SLIDE LIFTER down. The MOTOR stops when signal changes from actuated to not actuated.
Slide Lift Motor off
Switch on Autofocus
Power LED blinking
Write Failure into Memory
Open Shutter
Projector does not operate
Yes
Timer activated ?
No
When a TIMER is in use, a slide advance forward is done each time after the selected interval is reached (Model´s 4020, 7020 external timer, Model 5020, 9020 and 9020/CINE internal timer).
End
figure 3-5
The slide is projected.
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Tray Motion
The STEPPER MOTOR is responsible for the slide tray movement. To move the tray one slide forward or reverse 47 steps are necessary in case a tray for 80 slides is used and 27 steps in case a tray for 140 slides is used. The tray movement is controlled by the TRAY MOTION CONTROL PCB. This PCB contains two optical sensors, one for the code wheel and one for the Zero Position Gear. This PCB is sending following feedback signals to the MICROCONTROLLER: Tray motion direction (forward or reverse) One pulse for each step of the STEPPER MOTOR Tray zero-position signal in case the tray is in the zero position
If the STEPPER MOTOR moves one step, a pulse will be send back from the TRY MOTION PCB to the MICROCONTROLLER after the step is done. If these pulses are missing, the MICROCONTROLLER assumes that the tray is not able move. The transport stops immediately. A failure code is written into memory, the projector do not operate, the power LED is blinking The projector must be deenergized. The jam must be cleared. As soon as the problem is solved, the projector should operate after switching on again.
Direction Tray Step Tray Zero
Tray Control PCB Zero-Pos. Sensor
Direction + Step Sensor
Slide Tray
figure 3-6
The DIRECTION + STEP SENSOR is a special optical device which generates two independent output signals: - step pulses (count signal for the MICROCONTROLLER to calculate the tray position) direction signal (low signal for forward steps and high signal for reverse steps)
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Tray Motion Sequence:
a) Go To Zero Position Projector Status: Signal from:
Zero Button
- Energized
- P-Bus (Model´s 4020 and 5020 input only) - Auto Zero (Model 9020 and 9020/CINE)
Close Shutter, Autofocus off, Move Slide LIFTER in up position
Shortest distance to Zero ?
The MICROCONTROLLER selects shortest distance to the zero position.
Tray Motor On Forward
Tray Motor ON Reverse
The TRAY MOTOR is energized.
More than 4 Step Signals missed ? No
Yes
The TRAY MOTION CONTROL delivers a step signal for each MOTOR step.
Transport Failure Power LED Blinking
The ZERO SENSOR delivers a signal if the position is reached
No Zero Sensor actuated ? Yes No
Failure:
Stop Tray Motor Slide LIFTER Down Write failure into Memory
A failure code is written into memory. The power LED is blinking.
Set Tray Position to Zero
Projector does not Operate
The position is reached. The TRAY POSITION in memory set to zero.
END
figure 3-7
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b) Go to next slide position
Start
Projector Status: Start action:
There is a slide in the gate and it is projected. The forward or reverse BUTTON is actuated or next slide is selected with RANDOM ACCESS.
See Slide Change Sequence, page 3-7.
Slide LIFTER Up
Next Slide Position ? forwards
reverse
RANDOM ACCESS:
The MICROCONTROLLER selects shortest distance to the next slide.
Tray Motor forward
Tray Motor reverse
The MICROCONTROLLER energizes the TRAY MOTOR for 47 steps (80 tray) or 27 (140 tray) for each slide.
More than 4 Step Signals missed ? No
Yes
The MICROCONTROLLER checks feedback from tray MOTION CONTROL CIRCUIT. If more than 4 feedback pulses are missed, exit to the failure routine.
Transport Failure
Power LED Blinking
No
requested Position reached ? Yes
No
For RANDOM ACCESS: The TRAY MOTOR ON until the position is reached.
Set Tray Position to next slide position
Write failure into Memory
For FORWARD/REVERSE BUTTONS: tray moves only for one slide slide is projected if transport button is still pressed, a slide is lifted up and the tray moves until button is released but stops at the ZERO POSITION.
Slide LIFTER down Slide projected
Projector inoperable
The MICROCONTROLLER sets the next position into memory. The SLIDE LIFTER Down procedure starts. For details, see Slide Change Sequence.
END
figure 3-8
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LAMP Control
a) Dual LAMP Operation All Models are equipped with a DUAL LAMP MODULE (Extra Bright). The POWER REGULATION PCB on all Models contains a LAMP current circuit that can detect if the active LAMP is on, indicated by a LED on the BACK PANEL. If a LAMP fails, the MICROCONTROLLER receives the LAMP_CURR signal from the POWER REGULATION PCB. It activates the MIRROR MOTOR and moves the MIRROR to the second LAMP position. Then the relay K1 is energized and second LAMP is energized. The MICROCONTROLLER also energizes the LED for the second LAMP. The LED's are located on the BACK PANEL. The Models 4020 - 9020 and 9020/CINE have a memory. This memory is storing the the current used lamp as long as the lamp is defective. That means the mirror of the DUAL LAMP MODULE do not change his position after a new lamp is inserted. This function can be disabled (see page 2-3). The characteristic of the lamp curve is no longer generated by a PLL circuit on the MASTERBOARD. Up to now it is stored in the Software LAMP Control memory and the TRIAC will be triggered from the MICROCONTROLLER.
91VAC 82VAC
Zero-Cross Circuit Relay Driver Relay Driver
Zero_Cross Economy Relay
M
Dual Lamp Modul
Lamp Current
Mirror Motor
Mirror Motor Driver
Lamp_curr
SOFTWARE TRIGGER
Software Lamp Control
Lamp Current Detection and Switch off
Dissolve Logic
DATA SYNC GND
Power Regulation Board
figure 3-9
Master Board
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L1
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b) LAMP setting Models 4020 - 9020 and 9020/CINE: a) Through the LAMP SWITCH or P-Bus The settings of the LAMP are change by using the LAMP dimming function through the TRIAC DISSOLVE LOGIC. The phase cut position for LOW is 75% of HIGH . The LAMP supply voltage is 91 VAC only. Resulting LAMP voltages: Standard: 82V RMS Economy : 72V RMS b) Via accessory slot External units that are connected to the accessory slot cannot use the Standard/Economy LAMP setting with phase cut. Therefore, the LAMP supply voltage is switched with the ECONOMY SIGNAL and a relay to 82 VAC. The functions of the STANDBY and Standard/Economy Buttons are disabled. c) LAMP Protection In the LAMP RETURN LINE on the POWER REGULATION PCB there is a small circuit that detects the actual LAMP current. LAMPS can explode when they reach the end of their life. The melting filament can create a short circuit with a high current. The high current is detected, and the LAMP is deenergized immediately by the TRIAC. This procedure prevents the LAMP from exploding, and protects the TRIAC.
d) LAMP Voltage Control All Models are equipped with a LAMP voltage regulation so that the LAMP voltage does not follow line voltage fluctuation. The 5V AC outlet of the POWER REGULATION PCB i used to create the VAC_Value signal on the MASTER PCB. This signal is fed to the MICROCONTROLLER (MC). The MC then selects a phase cut position of the LAMP voltage which results in a reasonable constant LAMP voltage. This function is disabled if an accessory is connected to the accessory slot. In this case the LAMP operates with 82 VAC.
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e) Lamp Dimming The LAMP DIMMING FUNCTION is installed in Model 4020 - 9020. It is used for dissolving for Economy and Standard LAMP settings. The main devices for dimming are the TRIAC, TRIAC CONTROL and Zero_Cross circuit on the POWER REGULATION PCB, the dissolve logic and the MICROCONTROLLER (MC) on the MASTER PCB. The TRIAC FUNCTION is controlled by the MICROCONTROLLER and its software, it works according to phase cut principals.
91VAC 82VAC
Zero-Cross Circuit Relay Driver Relay Driver
Zero_Cross Economy Relay
M
Dual Lamp Modul
Lamp Current
Mirror Motor
Mirror Motor Driver
Lamp_curr
SOFTWARE TRIGGER
Software Lamp Control
Lamp Current Detection and Switch off
Dissolve Logic
DATA SYNC GND
Power Regulation Board
figure 3-10
Master Board
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L1
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a) Lamp Voltage
The zero-cross circuit creates an impulse whenever the LAMP voltage crosses the zero line (LAMP voltage close to zero). See figure b. Therefore, every 10ms for 50Hz or 8,3ms for 60Hz a signal change occurs. This signal is sent to the DISSOLVE LOGIC on the MASTER PCB. The DISSOLVE LOGIC generates a clocksignal with 4096 pulses for the length of half a sine wave. This clock signal is triggered by the zero-cross signal. See figure c.
b) Zero-Cross Signal
Through