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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. 

 

Smoke machine principles: 

 
All JEM / Martin 

conventional

 smoke machines utilise the same technology: 

 

In Brief: 

 

When the 

run button

 on the 

remote

 is pressed, 

smoke fluid

 is pumped from a removable 

container

 

 

situated within the machine via the flexible fluid pipe into an 

oscillating piston pump

The 

fluid

 passes through the 

pump

 and enters the 

heat exchanger

 were the 

fluid is vaporised

 and 

 

exits as thick, white 

smoke

 
 
The 

heat exchanger

 is comprised of a 

heating element

 and a 

coil

 of copper or steel tubing between 3 and 6 

metres in length. This is cast into a mass of 

aluminium

 
The 

heat exchanger

 is heated via the 

heating element

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 JEM  /  Martin 
smoke machines. 
The only difference is the smoke output on a hazer exits into a 

metal chamber

 where there is a 

fan

 creating a 

fast moving air stream

. This air stream 

disperses

 the smoke output and creates the 

haze

 
Again the principles are identical to that of a 

conventional

 smoke machine. 

There is a 

pump, heat exchange, PCBs

 and 

onboard controls

. The major difference is the 

air chamber

radial fan

 is used with this system. It is used to allow the exiting smoke to have the 

maximum dispersal

As with several of the smoke machines, the haze machine has a 

low fluid shut off

 system. This is an 

electronic temperature control device

 that measures the 

temperature

 of the 

heat exchange

 over a short 

period. If the 

temperature

 has not changed but the unit has been 

pumping

; the unit will assume that the 

system has 

run out of fluid

 and shut down. 

This prevents the system from running dry and burning out 

the pump. 
 
 
 
 
 

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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