JEM Smoke Machine Training Program INDEX An Introduction To Smoke Technology: Smoke Machine Markets Smoke Machine Principles CE Marking Searching for information on the NET Which fluid can I use with my machine? What can my machine do? Specifications 3 3 4 5 6 6 6 Service of machines: Tools and optional extras Machine Overview Opening The Machine Inside The Machine 8 9 10 10 How To… How To Change A Heat Exchanger How To Change A Pump How To Change A PCB Control PCB Calibration 11 12 13 13 14 Spare Par
AN INTRODUCTION TO SMOKE TECHNOLOGY Smoke Machine Markets Jem / Martin smoke machines are categorised into 2 ranges: The Professional and the Club / DJ range. If a product is branded as a “Martin” product this is aimed at the Club / DJ market. All products branded as a “JEM” product are classed as Professional and are aimed at the higher end touring / installation market. All JEM / Martin Smoke products can be used across both of the different markets without any compromise of performance or features.
CE mark All products that are produced by JEM / Martin carry the CE Certification. These products meet the requirements of the following EC Standards and as such, comply with the EMC (Electromagnetic Compatibility) and LVD (Low Voltage Directives), directives of the European Community: EN 50 081-1 1992 Generic Emission Standard for domestic and light Industrial environments. EN 50 082-1 1992 Generic Immunity Standard for domestic and light Industrial environments.
Searching for information on the INTERNET If you require information with regards to JEM / Martin Smoke, Haze and Heavy Fog products an ideal place to start is the Internet. Martin has a dedicated team of staff who are constantly monitoring and updating the information that is placed onto the INTERNET. This is to ensure that the best possible service is being given to not just dealers and end users but also to internal staff. Locating information is simple: First go to: www.jemsmoke.
Which fluid can I use with my machine? X=NO O=YES MAGNUM 800 Pro-Smoke Studio DX Mix Pro-Smoke Super ZR Mix Pro-Smoke Highdensity SP Mix O O O I-Fog Reg. DJ Fluid O Party Pack O X Pro Haze X Heavy Fog Fluid B2 Mix Heavy Fog Fluid C3 Mix X X What can my machine do? Dance clubs and discos the world over greatly appreciate this industry workhorse.
Electrical Typical Power and Current Thermal AC power (EU models): 220-240 V nominal, 50 Hz AC power (US models): 110-120 V nominal, 60 Hz Main fuse (220-240 V power): 5 AT (slow blow) Main fuse (110-120 V power): 10 AT (slow blow) US model 110 V, 60 Hz: 820 W, 7.45 A 115 V, 60 Hz: 896 W, 7.79 A 120 V, 60 Hz: 975 W, 8.13 A EU model 220 V, 50 Hz: 630 W, 2.86 A 230 V, 50 Hz: 689 W, 3.00 A 240 V, 50 Hz: 750 W, 3.12 A Measurements made at nominal voltage. Allow for a deviation of +/- 10%.
SERVICE OF MACHINES TOOLS AND THINGS: For successful servicing of a machine you will need some basic tools which are in good working order and the right size for the job. Other tools / equipment are available for specific jobs but in most cases these are not needed for general service.
MAGNUM 800 MACHINE OVERVIEW The Outside: ANALOGUE CONTROL 9
Opening The Machine: 1. DISCONNECT FROM MAINS SUPPLY. 2. Remove the 6 M4x10 pozidrive TAPTITE screws from the outside of the machine and store safely. 3. Lift off the lid.
HOW TO…. REFER TO SCHEMATICS / DIAGRAMS IN THE APPENDIX FOR MORE DETAILS How To Change A Heat Exchange: 1. Always try to change a HEAT EXCHANGE when it is cold as the exposed metal parts can be VERY HOT. 2. DISCONNECT FROM MAINS SUPPLY. 3. Remove TOP COVER. 4. Disconnect the THERMOCOUPLE from the MAIN PCB. 5. Disconnect the HEAT EXCHANGE POWER WIRES from the terminals of the PCB. 6. Remove the negative (BLUE) wire from the heater. 7.
How To Change A Pump: 1. 2. 3. 4. 5. 6. DRAIN ALL FLUID FROM THE SYSTEM FIRST. DISCONNECT FROM MAINS SUPPLY. Remove TOP COVER. Disconnect the POWER wires from the PUMP. Disconnect the BLACK RUBBER FLUID LINE from the rear of the PUMP. Move the fluid line out of the way. (BE CAREFUL OF FLUID COMING BACK DOWN THE PIPE) 7. Disconnect the COPPER FLUID LINE from the front of the pump. 8. 9. 10. 11. Unhook the rear RUBBER MOUNT from the pump. Withdraw the pump from the front RUBBER MOUNT.
REFITTING: 12. 13. 14. 15. 16. 17. 18. Fit the BRASS FITTING to the front of the pump using a THREAD SEALANT COMPOUND. Fit the new PUMP to the CHASSIS by inserting the front end first into the RUBBER MOUNT. Hook the rear mount onto the back of the pump. Reconnect the BLACK RUBBER PIPE. Reconnect the POWER wires to the PUMP – BROWN INSIDE / BLUE OUTSIDE. Turn machine on and RE-PRIME the system. Refit TOP COVER. How To Change A PCB: REFER TO SCHEMATICS / DIAGRAMS IN THE APPENDIX FOR MORE DETAILS PCB 1.
6. The PCB is mounted on 2 mounting posts which will need to be squeezed to remove the pcb. 7. Remove the HEATSINK from the PCB by removing the 2 screws/nuts/washers. REFITTING: 8. Fit the HEATSINK to the PCB using the 2 screws/nuts adding THERMAL TRANSFER PASTE underneath component Q6. 9. Fit new PCB to the mounting posts. 10. Insert the 2 PLASTIC RIVETS into the din socket. 11. Insert the 2 screws into the heatsink from the heater compartment. 12. Reconnect the PCB WIRING LOOMS (Observe polarity). 13.
SPARE PARTS LISTS 240V Part PUMP PCB Description PUMP MAIN Spare Part Number 05761003 62020005 PCB HEAT EXCHANGE HEAT EXCHANGE HEAT EXCHANGE REMOTE 62020008 COMPLETE Comments 240V RED BODY (LARGE) MAIN CONTROL PCB - TESTED TESTED w/o BUTTON TOPS OR KNOBS COMPLETE BUILT UP HEAT EXCHANGE c/w BRASS FITTINGS BARE EXCHANGE (No insulation or casework) c/w BRASS FITTINGS BARE Inc BRASSWORK 26400630 BRASSWORK ONLY 26460030 CASEWORK n/a BRASS FITTINGS ONLY CASEWORK AVAILABLE SEPARATELY - CONTACT jemser
110V Part PUMP Description PUMP Spare Part Number 05761001 PCB MAIN 62020007 PCB HEAT EXCHANGE HEAT EXCHANGE HEAT EXCHANGE REMOTE 62020008 Comments 110V BLACK BODY (LARGE) 110V MAIN CONTROL PCB TESTED TESTED w/o BUTTON TOPS OR KNOBS COMPLETE BUILT UP HEAT EXCHANGE c/w BRASS FITTINGS BARE EXCHANGE (No insulation or casework) c/w BRASS FITTINGS COMPLETE BARE Inc BRASSWORK 26400820 BRASSWORK ONLY 26460030 CASEWORK n/a BRASS FITTINGS ONLY CASEWORK AVAILABLE SEPARATELY - CONTACT jemservice@martin
MAGNUM 800 REMOTE CONTROL DIN PLUG PIN OUTS 2 4 1 - YELLOW (READY). 5 4 - WHITE (HEAT). 3 1 2 - BLACK (GND). 5 - BLUE (0 - 10v) 3 - RED (+16v). VIEWED FROM THE SOLDER SIDE OF THE DIN PLUG PIN OUT DESCRIPTION 1, GND WHEN MACHINES UP TO TEMPERATURE 4, GND WHEN MACHINES HEATING 2, GND 5, 0 - 10v INPUT, NEEDS 1.5v TO HEAT AND 2v -10v PUMP SPEED WHEN MACHINES READY 3 +16v OUTPUT Magnum 800 Remote Plug Pin Drawing No.
MAGNUM 800 REMOTE PCB PIN OUTS 1 2 3 4 5 6 PIN 1, Not Used 2, RED (+16v output) 3, BLUE (0-10v input) 4, BLACK (GND) 5, WHITE (Heat) 6, YELLOW (Ready) Timer control Timer LED Ready LED Fog button Heat LED Output Level Control MAGNUM 800 REMOTE PCB PIN OUTS Drawing No.
NO OUTPUT YES Is the machine fully heated and ready to run? Is the machine plugged in, turned on at the mains AND the power switch set to ON? NO Check power and turn on NO See HEATER PROBLEMS YES Is the pump running? NO See PUMP PROBLEMS YES Undo the brass fitting to the heater / fluid line and run the machine.
PUMP PROBLEMS Is power getting to the pump? (set to full power and check 240V / 110V) NO See PCB PROBLEMS YES Does piston seem to be moving? NO PUMP SEIZED - REPLACE YES Is fluid travelling through pump? NO PUMP BLOCKED - REPLACE YES Fault may be in fluid line / heater
HEATER PROBLEMS YES NO Is the heater heating? Overheating YES YES Check thermocouple OK? CHECK CALIBRATION NO Is power getting to the heater? (check 240V / 110V) REPLACE HEATER NO YES See PCB PROBLEMS Is power getting to the thermal trip? (check 240V / 110V) NO YES YES Is power getting through the thermal trip? (check 240V / 110V) THERMAL TRIP FAULT – RESET / REPLACE NO Disconnect power and remove power loom from element connectors Measure across the elements for continuity and check fo
PCB PROBLEMS APART FROM THE OBVIOUS FUSES / WIRING ETC.
