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HEATER PROBLEMS

Is power getting 

through 

the thermal trip?

(check 240V / 110V)

THERMAL TRIP 

FAULT – RESET / 

REPLACE

Is power getting to the 

thermal trip?

(check 240V / 110V)

See PCB 

PROBLEMS

Disconnect power and remove power 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

NO

NO

NO

NO

Summary of Contents for ZR12-DMX

Page 1: ......

Page 2: ...I use with my machine 6 What can my machine do 6 Specifications 7 Service of machines Tools and optional extras 9 Machine Overview 10 Opening The Machine 11 Inside The Machine 11 How To How To Change...

Page 3: ...ement 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...

Page 4: ...cal 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 Immu...

Page 5: ...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 t...

Page 6: ...esult of classical Jem design principles Electronic pump ramping provides continuous and even fog output Soft start electronics gives a low level of operating noise ideal for TV and theatre environmen...

Page 7: ...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 Typical Power and Current US model 110 V 60 Hz 1070 W 9 72 A 115 V 60 Hz 1169...

Page 8: ...ain fuse 220 240 V power 5 AT slow blow Main fuse 110 120 V power 10 AT slow blow Typical Power and Current US model 110 V 60 Hz 1070 W 9 72 A 115 V 60 Hz 1169 W 10 16 A 120 V 60 Hz 1273 W 10 61 A EU...

Page 9: ...ize 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 Seala...

Page 10: ...10 ZR12 MACHINE OVERVIEW The Outside ANALOGUE CONTROL 3 PIN DMX ANALOGUE LINK STATUS LIGHTS...

Page 11: ...10 M4x10 pozidrive TAPTITE screws from the outside of the machine and store safely 3 Lift off the lid The Inside PUMP MAINS INPUT EARTH POINT THERMOCOUPLE ANALOGUE LINK NOT REMOTE SOCKET MAINS INPUT H...

Page 12: ...connects the BRASS ASSEMBLY to the HEAT EXCHANGE and disconnect the fluid line from the pump 8 Undo the 4 screws that hold the HEAT EXCHANGER to the CHASSIS 9 Withdraw the NOZZLE of the heater through...

Page 13: ...ook the rear RUBBER MOUNT from the pump 9 Withdraw the pump from the front RUBBER MOUNT 10 Remove the PUMP from the machine 11 Remove the BRASS FITTING from the front of the PUMP REFITTING 12 Fit the...

Page 14: ...S from the 5 pin din sockets 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 REFITTIN...

Page 15: ...MPERATURE CALIBRATION POT until the RED HEATING LED FLASHES 8 IF YOU PRESS THE RAMP BUTTON IN THE LED SHOULD GO OUT AND COME BACK ON AGAIN WHEN YOU RELEASE THE BUTTON 9 Disconnect the CALIBRATION BOX...

Page 16: ...TION KIT HEAT EXCHANGE THERMAL TRIP ONLY 05041021 TRIP SWITCH ONLY HEAT EXCHANGE THERMAL TRIP Inc LOOM TRIP SWITCH INCLUDING LOOM CASEWORK CARRY HANDLE PLASTIC 19200050 PLASTIC CARRY HANDLE CASEWORK T...

Page 17: ...NLY 05041021 TRIP SWITCH ONLY HEAT EXCHANGE THERMAL TRIP Inc LOOM TRIP SWITCH INCLUDING LOOM CASEWORK CARRY HANDLE PLASTIC 19200050 PLASTIC CARRY HANDLE CASEWORK TOP LID 26561670 TOP LID CASEWORK MAIN...

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Page 22: ...THE DIN PLUG 5 TO TERMINAL OF SWITCH STRAIGHT TO SWITCH NOT DIODE ON BLUE WIRE PIN OUT DESCRIPTION 1 NOT USED 4 NOT USED 2 GND TO DMX CARD 3 TO SWITCH TERMINAL ZR12 DMX REMOTE CONTROL XLR PLUG PIN OUT...

Page 23: ...YELLOW BLUE WHITE ZR12 DMX REMOTE TEST SWITCH BACK OF SWITCH IN4007...

Page 24: ...0v INPUT NEEDS 1 5v TO HEAT AND 2v 10v PUMP SPEED WHEN MACHINES READY PIN OUT DESCRIPTION 1 GND WHEN MACHINES UP TO TEMPERATURE 4 GND WHEN MACHINES HEATING 2 GND 3 16v OUTPUT ZR12AL REMOTE CONTROL DIN...

Page 25: ...Drawn by GS 28 03 2006 ZR12AL REMOTE PCB PIN OUTS Drawing No 2011 2A 1 2 3 PIN 1 BLACK 2 BLUE 3 RED ZR12AL REMOTE PCB PIN OUTS...

Page 26: ...ully 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 o...

Page 27: ...ng 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...

Page 28: ...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...

Page 29: ...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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