JEM AF-2 Service Manual

2

JEM Smoke Machine Training Program

INDEX

An Introduction To Smoke Technology:

Smoke Machine Markets 3

Smoke Machine Principles 3 CE Marking 4 Searching for information on the NET 5 Which fluid 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

3

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. A 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.

4

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. EN 60 335-1 1995 Safety of household and similar electrical 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 produced prior to 1995.

These products can be identified by either the DIN/XLR socket on the rear or top of the unit or the Mains PCB: If the unit has a 5 pin DIN or a 4 pin XLR without the CE text on the rear, the unit is classed as NON-CE. If the PCB has a 12 pin Molex connector fitted to it, this is classed as a NON-CE unit.

5

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.com Here you will find information on all of our current range of products including news, bulletins,

specifications and even videos of machines in action.

To access support information:

On the left 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 the menu on the left hand side. Go to the PRODUCTS MENU and choose the PRODUCT you require information on. Now go to the CATEGORY menu and select which piece of information you require (parts,manuals, etc) Once you have done this press the SEARCH icon. All of the information relevant to the product you have chosen will now be displayed. A LOGIN is required for access to TECHNICIAN and DISTRIBUTOR SUPPORT areas. Please direct all inquires regarding access to your national distributor.

6

Which fluid can I use with my machine?

X=NO O=YES

Pro-Smoke Studio DX Mix

Pro-Smoke Super ZR Mix

Pro-Smoke Highdensity SP Mix

I-Fog

Reg. DJ Fluid

Party Pack

Pro Haze

Heavy Fog Fluid B2 Mix

Heavy Fog Fluid C3 Mix

AF-1 X X X X X X X X X

What can my machine do?

The AF-2 is a compact but powerful fan designed with clubs, studios, theatres and touring applications in mind. The AF-2 features DMX input as standard and can be installed on a ceiling, in a truss or can be floor 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 the accessory Touring Frame is available. This at the same time acts as a floor stand, and adds the ability to mount the remote control.

An analogue remote control is provided enabling variable output and timer control of fan speed allowing you to adjust to every situation.

7

Specifications:

Physical

Width: 682 mm Height: 707 mm Depth: 318 mm Dry weight: 17 kg

Performance

Maximum airflow: 6500 m3 per hour Fan speed: 0-1380 rpm

Control and Programming

Control options: Remote control (supplied) or on-board DMX Remote control features: Instant or timer-controlled output, 0-100% adjustable output level

Timer Range: Delay 2-18 secs (X1), 16-144 secs (X8) / Run Time 2-18 secs (X1), 16-144 secs (X8)

DMX channels: 1 Protocol: USITT DMX512/1990

Construction

Housing: Steel & aluminium

Installation

Orientation: Any

Connections

Remote control: 3-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, 0.93 A 230 V, 50 Hz: 225 W, 0.98 A 240 V, 50 Hz: 245 W, 1.02 A

Measurements made at nominal voltage. Allow for a deviation of +/- 10%.

Approvals

EU safety: EN 50 081-1, EN 50 082-1 EU safety: EN 60 335-1 (1995)

US safety: UL Std. 507

Accessories

AF-2 Touring Frame: P/N 92620006

Ordering Information

Jem AF-2 Fan, 110 V: P/N 92615400 Jem AF-2 Fan, 240 V: P/N 92615300

8

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.

Equipment needed:

Screwdrivers Pozidrive, size 1 and 2 Flat tip, 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 50502004) Common Sense!!

WARNING – MAINS VOLTAGE

DISCONNECT FROM MAINS SUPPLY

BEFORE REMOVING COVERS

AND SERVICING THIS MACHINE

PROCEED WITH EXTREME CAUTION

9

AF-2 MACHINE OVERVIEW

The Outside:

3

PIN DMX

REMOTE INPUT

SOCKET

MAINS INPUT

5 PIN DMX

10

Opening The Machine:

1. Move the 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

11

HOW TO….

REFER TO SCHEMATICS / DIAGRAMS IN THE APPENDIX FOR MORE DETAILS

How To Change A Fan:

1. DISCONNECT FROM MAINS SUPPLY.

2. Move to a flat position and remove BOTTOM COVER.

3. Disconnect the EARTH LOOM 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

12

11. Undo and remove the 4 bolts and washers that hold the fan to the chassis. (OBSERVE ORDER

OF WASHERS)

12. Withdraw the fan from the chassis pulling the LOOM and GROMMET through the hole at the same time.

13. Remove the FAN from the chassis and place on your workbench.

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 THE MACHINE AND TEST THE FAN OPERATION.

BOLT

GROMMET

PURPLE

BLACK

BROWN

13

How To Change A PCB: REFER TO SCHEMATICS / DIAGRAMS IN THE APPENDIX FOR MORE DETAILS

Main PCB

1. DISCONNECT FROM MAINS SUPPLY.

2. Move to a flat position and remove BOTTOM COVER.

3. Remove the 2 screws that hold the PCB to the 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.

11. Refit the TOP COVER.

14

DMX PCB

1. DISCONNECT FROM MAINS SUPPLY.

2. Move to a flat position and remove BOTTOM COVER.

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.

15

Refitting:

8. Fit new DMX PCB to the MOUNTING PLATE using the screws through the XLR sockets.

9. Ensure that the RED LED lines up with the hole in the chassis.

10. Reconnect the DMX PCB WIRING LOOMS (Observe polarity).

11. Check the operation of the unit and adjust if necessary.

12. Refit the

13. Refit the TOP COVER.

How To Upgrade The Software:

1. Using the SOFTWARE provided with the EPSILON 5 PROGRAMMER upload the latest

SOFTWARE VERSION (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 the 'YES' button.

9. Wait for the 'BUSY' LED to go out.

10. When the PROGRAMMER shows 'PASS', press 'NO', and then disconnect the machine

from power.

11. Unplug the PROGRAMMER.

12. Apply power to the machine and check the operation of the machine.

16

SPARE PARTS LISTS

240V

Part Description Spare Part Number Comments PCB MAIN 62020079 MAIN CONTROL PCB - TESTED PCB DMX INTERFACE 62021035 PROGRAMMED AND TESTED

PCB XLR INTERFACE 62021021

5 PIN XLR MALE / FEMALE BOARD

PCB REMOTE 62020508

TESTED w/o BUTTON TOPS OR

KNOBS CASEWORK TOP PANEL 26566670 TOP PANEL - BARE CASEWORK BOTTOM PANEL 26566680 BOTTOM PANEL - BARE CASEWORK FRONT SPINNING 26566590 FRONT CHASSIS RING CASEWORK REAR SPINNING 26566600 REAR CHASSIS RING CASEWORK FRONT GRILL DISC 26566740 FRONT GRILL DISC CASEWORK MAIN CHASSIS 26566650 MAIN CHASSIS - BARE CASEWORK HANGING PLATE 26566690 HANGING PLATE CASEWORK HANGING BRACKET 26562551 HANGING BRACKET OTHER REMOTE CONTROL 92765013 COMPLETE REMOTE CONTROL

OTHER MAINS SOCKET 05247205

MAINS SOCKET (IEC) c/w FUSE

HOLDER OTHER FAN 05731211 240V FAN AC AXIAL 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 XLR INTERFACE 62021021

5 PIN XLR MALE / FEMALE

BOARD PCB REMOTE 62020508

TESTED w/o BUTTON TOPS OR

KNOBS CASEWORK TOP PANEL 26566670 TOP PANEL - BARE CASEWORK BOTTOM PANEL 26566680 BOTTOM PANEL - BARE CASEWORK FRONT SPINNING 26566590 FRONT CHASSIS RING CASEWORK REAR SPINNING 26566600 REAR CHASSIS RING CASEWORK FRONT GRILL DISC 26566740 FRONT GRILL DISC CASEWORK MAIN CHASSIS 26566650 MAIN CHASSIS - BARE CASEWORK HANGING PLATE 26566690 HANGING PLATE CASEWORK HANGING BRACKET 26562551 HANGING BRACKET OTHER REMOTE CONTROL 92765013 COMPLETE REMOTE CONTROL

OTHER MAINS SOCKET 05247205

MAINS SOCKET (IEC) c/w FUSE

HOLDER

17

OTHER FAN 05731212 110V FAN AC AXIAL OTHER FAN GUARD 05749022 FAN GUARD (FAN MOUNT)

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

1

2

3

LN

FAN OUTPUT

MAINS I/P

N

L

FS 1

TX 1

PL 1

PL 2

PL 4

PL 3

JP 1

JP 4

JP 3

JP 2

PL 3

PL 1

SW 1

DMX RECIEVER PCB (3 PIN XLR)

PCB 5 PIN XLR

REMOTE CONTROL I/P

FAN : 240V @

110V @

MAIN CONTROL PCB

GREEN

BLUE

BROWN

BLACK

BLUE

BROWN

CAPACITOR:

8.0uF@240V

GREEN

BROWN

1

3

1

3

1

31

3

COMPANY

PROJECT

AF 2 WIRING DIAGRAM

MARTIN MANUFACTURING UK PLC

DRAWN

J RAMONES

REV/DATE

A. 7-JUNE-2005

IEC CKETSO

IEC FUSE:

LIVE NEUTRAL

EARTH

5.0A @ 230V

6.3A @ 110v

BLACK

BLUE

BROWN

25uF@110V

FS 1:5A@230V

6.3A@110V

339mm

[13.35"]

Martin

Product

Description

Item No.

Sign.

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"]

Drawn by : GS 28/03/2006

JEM AF2 Remote control 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

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

NO OUTPUT

Is the machine

plugged in, turned on

at the mains AND the

power switch set to

ON?

Is the

machine 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

YES

PUMP PROBLEMS

Is power getting 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

NO

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

NO

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