FM-ULTIMATE200D Service Manual - Techni-Lux
Contents
1. KT2 DMX unit underneath NOZZLE UNIT Nozzle unit assembled Compressed air inlet quck lock tube fitting Nozzle metal plate Access hole rubber gasket Nozzle body back part Fluid inlet tube fittings Nut Nozzle body front part Fluid tubes Fluid filter holder Fluid filter tube fittings Fluid filter Nozzle unit disassembled Fluid filter holder Nozzle metal plate Compressed air inlet tube fitting Fluid tube fittings Fluid filter Fluid tubes Access hole rubber gasket Nozzle body front part Nozzle body back part Nozzle body screws Fluid filter holder nuts Brass nozzles Brass nozzle rubber gaskets O ring sealing gasket Service manual Ultimate 200 std amp DMX NOTE For all service works described below always begin with the following precautions and preparations 1 Disconnect the machine from mains Disconnect DMX cables if equipped 2 Remove the screws that hold the cover plate Lift the cover off 3 Remove the two screws that hold the back plate Bend the back plate outward approx 2 5 cm 1 4 Depending on which part that is going to be serviced or replaced follow the relevant instructions below Connection disconnection of internal air tubes Ultimate hazers are equipped with super rapid quick lock tube fittings of the industrial type Connection and disconnection is done in a second without the need of tools The tube fittings are Polurethane PUR2. position 14 Put the air inlet frame back in place N POON E a TOOLS REQUIRED PH 2 Screwdriver TX 20 Screwdriver Flat pliers Cutting pliers SPARE PARTS REQUIRED 1 x DMX unit made for 120 or 240V 20 pcs wire stripes 2 5 mm 1 10 1 pce wire stripe 350 x 5 mm Appr 14 x 1 5 5 Replacing inlet amp outlet air tubes connected to the intercooler There are two tubes connected to the intercooler Tube between the compressor s air outlet and intercooler s inlet 1 Remove the old tube by releasing it from the compressor quick lock tube fitting and from the intercooler unscrew and release the tube clamp Be careful not to damage the intercooler s air inlet pipe made with copper when the old tube is removed 2 Ifnecessary clean the intercooler s air inlet pipe 3 Use anew Swefog original spare tube Place the tube clamp around the tube do not tighten it yet 4 Put the tube around the intercooler s inlet copper pipe To ensure an airtight connection approx 20 mm 0 8 of the copper pipe should be inside the tube 5 Connect the tube to the compressor s air outlet quick lock tube fitting Ensure an airtight connection 6 Place the tube clamp around the tube Tighten the clamp ensure an airtight connection Tube between the intercooler s outlet and compressed air filter 1 Remove the old tube by releasing it from the compressed air filter quick lock tub
3. OY oO Assembling new DMX unit 1 Assemble the intercooler to the DMX unit the work will be easier if the intercooler is put upside down Connect the brown wire to the override switch and connect the blue wire to the mains inlet s neutral N pin Place all wires coming out from the DMX unit through the wire hole Use 2 5 mm plastic wire stripes to fix the wires Place back the new DMX unit Place back the plastic frame between DMX unit and the machine s backplate Place and tighten all 5 screws that hold the DMX unit Connect the earth wire yellow green colour to the mains inlet s earth pin use a long pliers NOTE Wrong connection of the electrical wires may cause an electric shock and a serious personal injury If you do not have the experience and know how to connect electric wires contact an electrician Ensure that no electric wire is squeezed or close to a sharp edge 10 Check that the fan and compressor fan blades can rotate freely and that no cable is close to any of the fan blades 11 Put the air inlet filter back into the machine housing 12 Bend the back plate into a correct position put the 2 black screws behind the air inlet frame back in place 13 Place the long wire stripe that holds the capacitor in place put it through the left square hole in the DMX unit around the edge of the compressor plate see image below and tighten around the capacitor Ensure the capacitor is fixed in a correct
4. Swefog SERVICE MANUAL ULTIMATE 200 This manual is for 20 200 120 Ultimate 200 std 120V 60 Hz 20 200 240 Ultimate 200 std 240V 50 Hz 20 201 120 Ultimate 200 DMX 120V 60 Hz 20 201 240 Ultimate 200 DMX 240V 50 Hz REFER TO QUALIFIED PERSONNEL ONLY NOTE This service manual describes the most common service amp maintenance works The service and maintenance must be performed by personnel with great experience amp know how about haze machines in general and Swefog Ultimate series in particular Never modify or change anything inside the machine If any part is replaced always use Swefog original parts If not the manufacturer will not take any responsibility for safety performance and CE conformity Electrical works must be performed by personnel with national and international certificate of workmanship For information call Swefog HELPDESK Tel 46 590 122 50 122 00 Swefog technology group AB Fax 46 590 122 09 P O Box 106 stra V gen 6 e mail info swefog com 682 23 FILIPSTAD website www swefog com Sweden TABLE OF CONTENTS MACHINE COMPONENTS Compressor Unit Haze Unit SERVICE MANUAL ULTIMATE 200 STD amp DMX Connection Disconnection of internal air tubes COMPRESSOR UNIT 1 General Cleaning 2 Cleaning of intercooler intercooler fan amp air inlet frame 3 Replacing compressor air inlet filter 4 Replacing DMX unit if equipped 5 Replacing inlet amp outlet air tubes conne
5. aced Clean the surfaces between the back plate and the machine Put the back plate back and tighten all screws 6 Check all electrical parts like the fan motor mains connectors etc If any electrical part is oily or dirty check if it is possible to clean If not always replace with original spare parts only NOTE Never take unnecessary risks Risk of serious personal injury may occur if oily or dirty components are connected to mains 7 Clean all surfaces of the compressor Clean the compressor s fan blades there are two fans one in each end of the compressor 8 Check the compressor especially the middle grey part the electric motor wipe off dust and haze residues Clean all sides of the inner bottom part of the machine 10 Check all electrical parts like the intercooler fan the DMX electronics if equipped switches mains connectors etc If any electrical part is oily or dirty check if it is possible to clean If not always replace with original spare parts only NOTE Never take unnecessary risks Risk of serious personal injury may occur if oily or dirty components are connected to mains 11 Clean inside of the top cover Test and check all functions on your machine 12 Check for leakage dirt or dust inside the machine 13 Test and check all functions on your machine SYMBOLS Information on tools required to perform the service work Important information on the spare parts required before the
6. ade knife or a razor blade SPARE PARTS REQUIRED 1x tank unit
7. cted to the intercooler HAZE UNIT 1 General Cleaning 2 Check of condensed water in the compressed air filter 3 Cleaning of compressed air filter 4 Cleaning of nozzle unit 5 Replacing the electric motor of the output fan 6 Replacing the tank unit Oo WNW UM Machine Components Left side Use the images below to identify the parts inside Ultimate 300 When ordering spare parts please note some parts are sold as service kits Service kits Fan simplifies order of parts it also reduces the risk that any part needed for service is _ Air tube to nozzle forgotten Compressed air inlet quick lock tube fitting Fan motor Tank unit Intercooler inlet hot air Compressed air filter Intercooler outlet cool air Compressed air outlet Capacitor Air compressor Right side Air inlet frame Air inlet filter Mains inlet fuse amp mains switch image shows standard model DMX unit underneath XLR connectors DMX Mains inlet Mains neutral N pin Manual override switch Main switch Fan wires connected to mains outlet mains power to haze unit SERVICE KITS AVAILABLE Air filter service kit the kit includes 3 pcs of an air inlet filter cartridge Item no U23 KT1 Nozzle cleaning service kit includes 9 rubber gaskets for the small brass nozzles 1 O ring gasket for the nozzle body 1 access hole sealing gasket and 1 nozzle cleaning brush Item no U23
8. e fitting and from the intercooler unscrew and release the tube clamp 2 Use anew Swefog original spare tube Place the tube clamp around the tube do not tighten it yet 4 Put the tube around the intercooler s outlet copper pipe For a correct position of the tube approx 20 mm 0 8 of the copper pipe should be inside the tube 5 Connect the tube to the compressed air filter Ensure an airtight connection 6 Place the tube clamp around the tube Tighten the clamp ensure an airtight connection Ww 6 Check for condensed water in the compressed air filter The compressed air filter is the last filter that the compressed air passes before going through the nozzle The filter separates moisture from the compressed air While machine is operating the water will be removed from the air The water is stored in the filter cup Every time the machine is switched off a small valve in the bottom will open to let out the condensed water Check that everything is working OK and that no water is kept in the cup when the machine is switched off 7 Cleaning of the compressed air filter The filter cartridge is made with PE plastic or brass and be cleaned 1 Release the air inlet amp outlet nozzle tubes from the filter 2 Unscrew the transparent filter cup Remove the cup from the machine 3 Unscrew the filter cartridge 4 Disassemble the filter cartridge and put all parts in a cup with a light spirit for approx 1 h
9. if the nozzles are not assembled correct there is a risk of low haze output and a damaged compressor DRS ae ee ot 19 20 Pe Remove the air supply tube Remove the 4 screws that hold the nozzle plate Work the nozzle unit out of the tank Wipe the nozzle unit off with a cloth or paper Remove the 3 fluid tubes from the nozzle body Remove the 2 nuts from the back of the nozzle body Release the plate holding the fluid filter from the nozzle body Remove the 3 screws in front of the nozzle body Remove the front part of the nozzle body Remove the rubber gaskets from the brass nozzles Carefully clean the 3 brass nozzles by using a small brush like a toothbrush and an alcohol based cleaning liquid or spirit Check and clean the small output hole in the nozzle Do not leave any dust or dirt inside the nozzle Clean all sides of the nozzle do not leave any dirt Use compressed air to clean the small hole in the brass nozzle Clean the front part of the nozzle body clean the output holes from dirt Put the small brass nozzles back put them in the correct holes in the back part of the nozzle body NOTE Do not forget the rubber gaskets 3 pes for each brass nozzle Put the o ring gasket back Put the front part of the nozzle body back Ensure a correct position Assemble the 3 screws NOTE the upper screw is short the two lower screws are long Tighten each screw until there is no gap between the front and back
10. it If the electronics do not work properly it must be replaced 1 Loosen the 2 screws that hold the air inlet frame and remove the frame Loosen the 2 black screws behind the air inlet frame Bend the back plate outwards approx 25 mm 1 Work the air filter out of the machine Cut the plastic stripes around the black fan wires and the red capacitor wires Disconnect the fan wires from the fan Cut the plastic stripe around the capacitor that is attached to the DMX unit Lift the capacitor out of the machine do not disconnect the red wires Disconnect the air tubes from the intercooler at the compressor s outlet and compressed air filter s inlet 10 Loosen the 5 black screws that hold the DMX unit plate 11 Remove the plastic frame located between the DMX unit and the machine 12 Disconnect the earth wire connected to the mains inlet s earth pin 13 Cut all small black plastic stripes that keep all electrical wires together 14 Work the DMX unit out of the machine you may need to bend the backplate outwards approx 25mm 1 15 Cut the black plastic wires around the electric wires connected to the switches underneath the DMX unit 16 Disconnect the brown wire from the override switch and the blue wire from mains inlet 17 Remove the two screws that hold the intercooler and remove the intercooler 18 Clean all wires the plastic distance frame and clean the machine housing inside SON ponai Or
11. l Replace with a new fan motor of the same type and size NOTE Use Swefog original spare parts only Push the motor spindle through the rubber hole in the fan wheel Place the motor so that it fits into the bayonet holes on the fan housing Twist the motor approx 1 8 of a turn clockwise until the motor is in the right position Connect the fan cables Then bend the cable and connector 90 towards the electric coil Finally the fan wheel has to be adjusted Use a screwdriver and adjust the fan wheel until it rotates freely TOOLS REQUIRED PH 2 screwdriver Paper or a cloth 8 mm nut tightener TX 20 screwdriver A small brush i e a toothbrush Light spirit or alcohol based cleaning liquid and a cup for cleaning Compressed air 6 8 bars and an air blow gun SPARE PARTS REQUIRED 3x3 9 rubber gaskets for the small brass nozzles 1 O ring gasket 1 sealing gasket around the access hole in the tank included in the nozzle cleaning service kit item no U23 KT2 the above spare parts included in the U23 service kit available from your dealer TOOLS REQUIRED Voltage meter A screwdriver SPARE PARTS REQUIRED 1 x fan motor 120 or 240 V Adjust the fan wheel after the new motor is put in place Use a small screwdriver and bend the wheel to the left 10 Replacing the tank unit If the tank is damaged and there is a fluid leakage do NOT try to mend it The oil film from the ha
12. our NOTE Do NOT use strong spirits for risk of damaging the plastic parts 5 Clean the filter element from dirt with the use of compressed air 6 Clean amp dry all parts 7 Clean the rest of the filter amp filter cup with a light spirit and a cloth Make sure that no dirt or dust is left in the filter or filter cartridge 8 Put the filter cartridge back in place Ensure that the filter cartridge is tightened properly to the filter body 9 When the filter cartridge is fixed put the filter cup back in place Check the small valve at the bottom of the filter cup For correct operation check that the valve closes when the machine compressor is switched on and opens when it is switched off TOOLS REQUIRED 7 mm nut tightener A small screwdriver SPARE PARTS REQUIRED Original 10mm PUR tube for connection between compressor amp intercooler Original 10mm PUR tube for connection between intercooler amp compressed air filter TOOLS REQUIRED A small flashlight TOOLS REQUIRED Light spirit or alcohol based cleaning liquid in a cup Combination pliers A small flashlight for inspection 8 Cleaning of nozzle unit If your hazer seems to work normally but haze output is reduced the V TEC cracker nozzles may be clogged Ultimate 200 is equipped with the easyclean feature allowing for an easy and quick service of the nozzle unit NOTE It is very important to perform the cleaning work properly
13. parts of the nozzle body Then tighten each screw of a turn more Check the fluid filter If it seems to be dirty replace it with a new one Normally the fluid filter does not need to be replaced Check the fluid tubes between the fluid filter and the nozzle body If there is dirt inside the fluid filter see above and the tubes must be replaced Put each tube back in place Check the sealing gasket that is placed around the access hole on top of the tank between the tank and the nozzle plate Now your nozzle unit is as good as new Put it back through the hole in the tank Tighten all 4 screws NOTE Do NOT tighten too hard it may damage the sealing gasket Tighten each screw until there is no gap between the cover plate the gasket and the tank Then tighten 4 of a turn more 9 Replacing the electric motor of the output fan If the output fan is not working check as follows Use a voltage meter to ensure mains power is supplied to the fan If not check the problem If mains power is supplied and the fan still does not work check that the fan wheel can be rotated easily If so the motor must be replaced If not then check and solve the problem Disconnect from mains before proceeding the operation Disconnect the two fast on electric connectors underneath the motor The motor is fixed with a bayonet system twist the motor approx 1 8 of a turn anti clockwise When the motor is released pull it out from the fan whee
14. r inlet frame back in place 3 Replacing compressor air inlet filter SOE ae 10 11 Loosen the 2 screws that hold the air inlet frame and remove the frame Loosen the 2 black screws behind the air inlet frame Bend the back plate outwards approx 25 mm 1 Work the air filter out of the machine Open the filter cap twist it anti clockwise Remove the filter cartridge If necessary clean inside of the filter housing Use a cloth or paper and a light alcohol based cleaning liquid or spirit NOTE Don t let any dust or parts come into the air inlet tube connected to the filter housing the compressor may be damaged Replace the old cartridge with a new never re use an old cartridge for any reason original Swefog cartridge type SM L NOTE Place the filter cartridge in the filter cap first then screw the filter cap back in place Put the filter back in place inside the machine Tighten the two black screws at the back of the machine Put the air inlet frame back in place TOOLS REQUIRED PH 2 Screwdriver PZ 1 Screwdriver 8 mm nut tightener Compressed air 6 8 bars and an air blow gun Cloth or paper TOOLS REQUIRED Paper cleaning liquid SPARE PARTS REQUIRED 1 x Air inlet filter cartridge The above spare parts included in the U200 service kit available from your dealer 4 Replacing DMX unit if equipped See owner s manual for correct connection and setting of the DMX un
15. service work is started TOOLS REQUIRED Light spirit or an alcohol based cleaning liquid Paper or a cloth A small flashlight for inspection 2 Cleaning of the intercooler intercooler fan amp air inlet frame A regular cleaning and removal of dust clogging the intercooler is important to maintain good performance of your hazer The fan draws air through the intercooler and transfers heat from the compressed air out of the machine An intercooler clogged with dirt and dust will reduce cooling capacity the result is less haze output and an increased amount of moisture in the compressed air To clean the intercooler is easy and made in a few minutes NOTE NEVER use mechanical or sharp tools it may damage the thin aluminium plates inside the intercooler Use compressed air ONLY and blow off all dirt and dust MRA O E No Loosen the 2 screws that hold the air inlet frame and remove the frame Loosen the 2 black screws behind the air inlet frame Release the two inlet and outlet tubes from the quick lock tube fittings Bend the back plate outwards approx 25 mm 1 Use compressed air to blow air through the intercooler towards a cloth or a paper The dirt dust will come off from the intercooler Clean the fan Use paper or a cloth to clean the fan blades Clean the fan frame Work the back plate in place connect the two inlet and outlet tubes and tighten the two black screws at the back of the machine Put the ai
16. tubes All PUR tubes used in the Ultimate series are coloured light blue To disconnect a tube Pull the ring on the tube fitting towards the fitting while the tube is pulled out To connect a tube Just push the tube into the fitting the tube will be automatically locked Ensure the tube is locked NOTE Never replace a tube with a different type made with a divergent material or wrong size The tubes used in all Swefog machines are tested and approved to stand the temperature variations dust oily fluid residues and the tube size is calibrated 1 General cleaning The machine contains several fans and large amount of air goes through the machine during operation There will be residues of the haze inside the machine mixed with dust and dirt from the environment where it is used Regular cleaning service is necessary to keep your machine functioning like new The haze fluid is oil based and cannot be removed with water Always use a light alcohol based cleaning liquid or a domestic cleaning spirit and a cloth or paper for cleaning 1 Clean the top and the sides of the tank Carefully wipe off all dust from the fluid level window Make sure not to break the window Do not push hard against the window 2 Clean the fan the fan wheel inside and outside of the fan housing 3 Clean bottom of the machine Clean all surfaces 4 Clean all sides of the bottom facing the top cover 5 Remove the back plate where mains inlet is pl
17. ze fluid will make the use of glue or silicone impossible If the tank unit needs to be replaced proceed as follows 10 11 Disconnect the air supply tube connected to the nozzle unit Use a sharp knife or a razor blade to make a thin cut in the black sealing material at the front edge of the machine chassis see image Carefully bend the fan housing backwards to release the back edge of the tank Then release the front edge of the tank from the main fixture Lift the tank out of the machine Clean the machine housing especially the plate underneath the tank Remove any remaining black sealing material in front of the machine housing Clean the bended edge in the front of the machine chassis with an alcohol based liquid NOTE Clean the edge carefully if not properly cleaned the sealing material will not stick to the edge Put the new tank unit into the housing work the edge under the fan Ensure the front edge of the tank is put under the edge in front of the machine housing Use black polurethane rubber like sealing glue material and apply a 2 3 mm thick layer on the edge Silicone will not work Use a rounded piece of wood spatula to spread the sealing material Remove all waste glue with a spatula or a scrape Apply PUR glue between the machine housings front edge and the tank NEED HELP CONTACT OUR HELPDESK Tel 46 590 122 50 122 00 Fax 46 590 122 09 e mail info swefog com 10 TOOLS REQUIRED A cut bl
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