JEM AF-2 Service Manual Download Page 2

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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

Service of machines:

Tools and optional extras

Machine Overview

Opening The Machine

Inside The Machine

How To…

How To Change A Fan

How To Change A PCB

Main PCB

DMX PCB

How To Change The Software

Spare Parts Lists:

Spare Parts 240V

Spare Parts 110V

Appendix:

Fuse Ratings

PCB Schematics

Summary of Contents for AF-2

Page 1: ......

Page 2: ...uid can I use with my machine 6 What can my machine do 6 Specifications 7 Service of machines Tools and optional extras 8 Machine Overview 9 Opening The Machine 10 Inside The Machine 10 How To How To Change A Fan 11 How To Change A PCB 13 Main PCB 13 DMX PCB 14 How To Change The Software 15 Spare Parts Lists Spare Parts 240V 16 Spare Parts 110V 16 Appendix Fuse Ratings 17 PCB Schematics 18 ...

Page 3: ...lement This is controlled by a J Type thermocouple fitted to the heat exchanger The temperature is determined by the calibration of the main control PCB Once the working temperature is reached the main control PCB will allow the pump to be operated and the machine will now be ready to run Haze machine principles The JEM ZR24 7 and Magnum Hazer work on the same smoke generation principles as the JE...

Page 4: ...ical appliances These standards reference the following European standards Emissions EN 55 022 B RF voltage and field strength EN 60 555 Harmonic current content EN 55 014 RF voltage discontinuous Immunity IEC 801 2 Electrostatic discharge to case IEC 801 4 Common mode fast transients These standards also meet the requirements of CISPR 22 JEM did not carry the CE mark on products that were produce...

Page 5: ...t hand side of the screen there are several different categories Click on SUPPORT This will bring you to the SMOKE USER SUPPORT page If you have a LOGIN NAME AND PASSWORD then press the LOGIN icon at the top of the page and enter your username and password into the relevant boxes If you do not have a LOGIN NAME you can still use the site just with limited access to information Select SMOKE from th...

Page 6: ...r standing It can be used alone or as part of a complete fog system by linking with other Jem machines using DMX The fan unit incorporates a very high quality scaled fan motor to withstand high condensation levels associated with close proximity to fog The AF 2 is constructed from mainly aluminium sheet for minimal weight without compromising ruggedness If you want extra protection for the AF 2 th...

Page 7: ...pin locking XLR DMX data 3 pin and 5 pin XLR sockets Power connection 3 pin IEC Electrical 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 6 3 AT slow blow Typical Power and Current US model 110 V 60 Hz 320 W 2 9 A 115 V 60 Hz 350 W 3 04 A 120 V 60 Hz 381 W 3 18 A EU model 220 V 50 Hz 206 W 0 9...

Page 8: ...size small and medium Wrenches 7mm 12mm x2 Pliers Needle Nose small Wire Cutters small Digital Multi Meter With ability to measure mV Additional Items recommended Cable Ties p n 13104000 Silicone Sealant JEM Calibration Box p n 92620005 Paper towels or other absorbent material Ammeter For measuring current draw of machine could be handheld or bench mounted Epsilon 5 Portable ISP Programmer p n 505...

Page 9: ...9 AF 2 MACHINE OVERVIEW The Outside 3 PIN DMX REMOTE INPUT SOCKET MAINS INPUT 5 PIN DMX ...

Page 10: ... FAN to a flat position 2 Remove the 10 screws from the BOTTOM PANEL of the machine and store safely 3 Lift off the ACCESS PANEL and disconnect the EARTH LOOM The Inside DMX PCB BEHIND PANEL EARTH POINT FAN OUTPUT MAINS INPUT CAPACITOR ...

Page 11: ...OOM and remove the COVER 4 Remove the FAN EARTH LOOM from the EARTH POINT THIN GREEN YELLOW 5 Remove the BLACK WIRE from the terminal block 6 Remove the BROWN WIRE from the terminal block 7 Remove the PURPLE WIRE from the terminal block 8 Remove the BLACK WIRE from its CRIMP 9 Remove the BROWN WIRE from its CRIMP 10 Remove the loom from the clip holding the loom to the chassis PURPLE BLACK BROWN ...

Page 12: ...Refitting Your New Fan 1 Feed the wires through the hole in the chassis 2 Secure the FAN using the 4 bolts and washers ensuring not to cross thread the inserts 3 Reconnect the EARTH LOOM to the EARTH POINT 4 Reconnect the BLACK BROWN AND PURPLE WIRES to their relevant place in the terminal block RECRIMP IF NECESSARY 5 Replace the BOTTOM COVER ENSURING TO RECONNECT THE EARTH LOOM 6 APPLY POWER TO T...

Page 13: ...e chassis 4 Disconnect the MAIN PCB WIRING LOOMS from the MAIN PCB Note orientation before removal 5 The MAIN PCB is mounted on 2 mounting posts which need to be squeezed to remove the PCB 6 Remove the PCB Refitting 7 Mount the PCB on the mounting posts 8 Replace the 2 screws that hold the PCB to the CHASSIS 9 Reconnect the MAIN PCB WIRING LOOMS Observe polarity 10 Check the operation of the unit ...

Page 14: ...R 3 Remove the 4 screws that hold the MOUNTING PLATE to the chassis 4 Move the MOUNTING PLATE to one side and gain access to the rear of the plate 5 Remove the screws holding the DMX PCB to the MOUNTING PLATE THROUGH XLR SOCKETS 6 Disconnect the wiring looms OBSERVE POLARITY 7 Remove the PCB ...

Page 15: ...SION which is available for free from our WEBSITE onto the EPSILON 5 PROGRAMMER 2 Disconnect the PROGRAMMER from your PC 3 Remove the BOTTOM COVER of the machine 4 Plug the 6 WAY HEADER into the AVR PORT on the MAIN PCB of the machine 5 Apply power to the machine 6 Check that the POWER LED on the PROGRAMMER comes on 7 On the PROGRAMMER press the NO button once to clear the fail indicator 8 Press t...

Page 16: ...XIAL OTHER FAN GUARD 05749022 FAN GUARD FAN MOUNT OTHER CAPACITOR 04030070 8uF CAPACITOR CHASSIS MOUNT OTHER HAND WHEEL 08132309 HANDWHEEL M8 OTHER WIRING LOOMS COMPLETE ALL WIRING LOOMS FOR MACHINE OTHER STICKERS COMPLETE ALL STICKERS LABELS FOR MACHINE 110V Part Description Spare Part Number Comments PCB MAIN 62020078 MAIN CONTROL PCB TESTED PCB DMX INTERFACE 62021035 PROGRAMMED AND TESTED PCB X...

Page 17: ...OUNT OTHER CAPACITOR 04030069 25uF CAPACITOR CHASSIS MOUNT OTHER HAND WHEEL 08132309 HANDWHEEL M8 OTHER WIRING LOOMS COMPLETE ALL WIRING LOOMS FOR MACHINE OTHER STICKERS COMPLETE ALL STICKERS LABELS FOR MACHINE APPENDIX Fuse Ratings Fuse 240V 110V Internal 5A 6 3A External 5A 6 3A ...

Page 18: ... CONTROL I P FAN 240V 110V MAIN CONTROL PCB GREEN BLUE BROWN BLACK BLUE BROWN CAPACITOR 8 0uF 240V GREEN BROWN 1 3 3 1 1 3 1 3 1 3 1 3 COMPANY PROJECT AF 2 WIRING DIAGRAM MARTIN MANUFACTURING UK PLC DRAWN J RAMONES REV DATE A 7 JUNE 2005 IEC CKET SO IEC FUSE LIVE NEUTRAL EARTH 5 0A 230V 6 3A 110v BLAC K BLUE BROWN 25uF 110V FS 1 5A 230V 6 3A 110V ...

Page 19: ...Material Date Rev Date Sign Scale AF 2 Touring Frame 15 06 05 General Dimensions xx xx 05 B M D C xx xx 05 Material Item No A4 1 8 Measurement without tolerance DS2768 M FIRST ANGLE PROJECTION 92620006 Remote Control Docking Point 772mm 30 38 745mm 29 33 ...

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Page 22: ...rol Pin outs 2 RED 16v 3 BLUE 0 10v 1 BLACK GND PIN OUT DESCRIPTION 1 3 2 1 GND 3 0 10v INPUT 1 5v WHEN HEATING 2v 10v PUMP SPEED WHEN MACHINES READY 2 16V AF2 REMOTE CONTROL PIN OUTS VIEWED FROM SOLDER SIDE OF THE REMOTE XLR Drawing No 2005 1A ...

Page 23: ...Drawn by GS 28 03 2006 AF2 REMOTE PCB PIN OUTS Drawing No 2005 2A 1 2 3 PIN 1 BLACK 2 BLUE 3 RED AF2 REMOTE PCB PIN OUTS ...

Page 24: ...fully heated and ready to run Check power and turn on See HEATER PROBLEMS Is the pump running See PUMP PROBLEMS Undo the brass fitting to the heater fluid line and run the machine Is fluid coming out of the brass fitting Pump seized Replace pump Heater is blocked Replace heater YES NO NO NO NO YES YES YES ...

Page 25: ...ing to the pump set to full power and check 240V 110V See PCB PROBLEMS Does piston seem to be moving Is fluid travelling through pump PUMP SEIZED REPLACE PUMP BLOCKED REPLACE Fault may be in fluid line heater NO YES YES YES NO NO ...

Page 26: ... loom from element connectors Is power getting to the heater check 240V 110V Measure across the elements for continuity and check for earth leaks Normal Ohms reading OPEN CIRCUIT HEATER REPLACE See PCB PROBLEMS Earth leakage See PCB PROBLEMS OPEN CIRCUIT HEATER REPLACE Is the heater heating Overheating CHECK CALIBRATION Check thermocouple OK REPLACE HEATER YES YES YES YES YES YES YES YES NO NO NO ...

Page 27: ...PCB PROBLEMS APART FROM THE OBVIOUS FUSES WIRING ETC PCB FAULT FINDING IS TOO IN DEPTH TO COVER HERE PLEASE REFER SERVICING REPAIR TO A QUALIFIED ENGINEER ...

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