the ultimate jem low lying fog/smoke machine service manual
Contents
1. 9 o Z LL O LL 9 LL z 9 LL 2 LL Oo gt gt G 2 4 5 gt 5 te gt 5 4 E C o 21 EO d 3 c E O sS 2 lo Lg 2 D op p S s gt 52 5 9 aoe o gt 925 95 e xe 5 Sx 58 5 3 3 8 54 8 5 Suc EE 2t gt 62 25 Lr ges gt 5 lt Q lt 62. JEM LTD 16 15 PH2 PH3 gt ij tc S mi mi mi mi S N O luF 5 our S N O luF li 0 luF V x U o x V os x UV x2 m2 m2 R4 R9 RIS R20 gt ES S ES S ES 120R 120R 120R 120R ue i F J5 16 ee 5 gt aR gt gt gt FS2 HEATERI 5 54 HEATER2 FS6 HEATER3 a 87 HEATER4 2H 10A 10 mE 10A 104 o WE A 2 2 2 5 gt J1 PINI RAMP RESET n J1 PIN2 12V J1 PIN3 GND J1 CONTACTOR PHI g g g J1 PINS PUMP mtl R21 cs mtl R14 mtl R6 J1 PING PUMP CHANGEOVER N 91K 9IK EH our N 9IK our J1 PINT HEATER CONTACTOR V o X2 V 04 x2 V PA J1 PINS DEFROST VALVE EP J1 PINS HEATERS 3 amp 4 m m m2 J1 PINIO HEATERS 1 amp 2 J1 PIN11 HEAT FAN R19 RII R5 J1 PIN12 FREEZE FAN eu
3. FOG INPUT ENABLE 12V 12V Q3 Eun FOG READY RIS ENABLE SIGNAL LED3 IK R23 R25 BROWN RI R8 READY i 9 EFFECTS 1 6 T GREEN FOG GO SWI8 e N FOG OUTPUT LED4 LEDS 07 REFRIGERATION N R24 JAK REFRIGERATION CONTROLLER R2 R9 8 OFF F ON ON LED VE 2K2 680R 3 014 6 YELLOW YELLOW GREEN amp BROWN FOG 1 JACK R149 5 CONTROL i REFRIG OFF GND INPUT 47K REFRIG ON 12V ida LED Lu RED amp BROWN Ll RED amp BLACK LEDI GND CONTROLLER RS R7 ON T 2K2 GREEN DMX VE CONTROLLER RED 12V 7805 ON LED VE WHITE amp RED LED2 VOLTS ds TIMER R10 HEATING DK BLUE 02 3 60 12V 2 2 RED m I4 R3 T FH 4708 FH our 68K SMOKE HF 47 RIS R19 GND SIGNAL HEATING zz 220K 10K LT BLUE RED amp BLUE SIGNAL GND N RED DMX GND BLACK R4 TIMER amp Cr corneas 1 EFFECTS 22K FOG GO FOG GO N GND is R16 12 10K DMX FIRE mm 12V WHITE R30 R29 IK m 12 12V Hi 10K R31 c LED23 EH FREEZE E SMOKE HEAT FAN FAN FAIL DEFROST 20 R2
4. DRAWN BY CPW DATE 28 2 1997 TITLE HF6500 CONTROLLER PART3 DWG No CPW057REV LTD 12V LED10 R32 MP I R39 c R43 HORIZ 2 10K Lt 10K HORIZ SCAN 0 luF R40 SCAN GREEN D3 47K R36 12V R35 2M2 R45 10K 5 120R R33 R37 10K 4K7 1 2 8 14 1 Us 05 c7 ca S 14 D 4 9 B 13 100u
5. eap 2K2 2K2 CH our 1K LT lt GND GND DRAWN BY CPW DATE 10 12 1996 TITLE HF6500 HF2500 MOTHERBOARD PART3 DWG No CPW049 REV 1 HEATING m i 9 JEMLTD 11 RED 4 12V 12V R37 C45 R41 co Co ES 12V gt mams 10K 104 ee L L L L L L L PIN2 PIN7 24 Mod ND DK BLUE iur o o R44 46 C54 C44 C47 C49 C50 C51 52
6. E R46 HEATERS 10uF 4700uF 0 1uF 0 1uF O 1uF O 1uF 0 luF 0 1uF 0 1uF O 1uF J14 2 2K2 3 2 E PIN3 PINIO U3 9 12V LT BLUE Ec PINO i R42 SERVO 12V 12V gt GND ee 6500 RED HORIZ LOUVRE PAD4 HORIZ LOUVRE 112a 2500 6500 DMX R38 R47 R49 YELLOW amp ORANGE DMX GND lt GREY 120R R48 4K7 RED J8b PAD 10 PAD 10 IM gt GND J12b R43 WHITE DMX VE lt ORANGE amp IM R45 18 RED GREEN 4K7 J12c PADI PADI 6500 DMX VE lt Q ORANGE amp U3 R50 VERT LOUVRE 19 BLUE BLUE R39 6 8 ia 2K2 PAD3 VERTLOUVRE PAD2 PAD2 2K2 0 Q8 YELLOW amp ORANGE 9 BLUE J9a FTH READY gt SERVO GND B o WHITE BLOCK she R40 SENSOR GND PINII GNI IK BROWN 12V 12V GND IE ary 12V R62 C4 o 1uF UE FREEZE c28 bis 100K EJ FREEZE Lun FAN gt 0 1uF co R53 R55 LN PUMP FAN FAIL J13 10K 10K nn 4 4 PINI2 i 7 PINS PINS U3 R63 1 5 9 HEAT FAN E PUMP u gt O YELLOW 10 R51 390K VRAMP 13 5 FAIL _ 4 SIGNAL eS i 2 4K7 6 US C33 18 J14 R64 FREEZE 05 10 100uF GND PING IM i FAN SIGNAL WHITE ORANGE L R73 714 2 v R69 m 2K2 PIN9 zo 56K PINK 12V R56 220R R65 R66 GND Bv 680R 390K R70 R74 HEAT GND 100K FAN
7. 9 VRAMP O 1uF 12V 14 arr R57 R58 R60 R61 dos Us D 680R 6K8 6808 10K 4 _ 8 14 4 100K UA 702 gt R75 R76 9 3V3 7 MiB n VR5 SPARE 6500 4K7 1K I Us gt EVAPORATOR Ld 200K R67 114 L E 200K 15 SENSOR O 1uF 47R PINI L 2K2 CONDENSER GREY T GND R52 a R59 SENSOR m E gt A 220K 120R GND VR6 10K R72 R68 6K8 GND GND IK R54 22K GND DRAWN BY CPW DATE 10 12 1996 TITLE HF6500 HF2500 MOTHERBOARD PART2 DWG No CPW047 REV 1 REFRIG CONTROLLER LED ON LED VE PAD 9 PAD 5 RED amp GREENS BLACK BROWN OVER TEMP RELAY 2 SMOKE HF SIGNAL 14 2 RED amp 680R BLUE REFRIG OFF LED RAMP GENERATOR PAD 8 RED amp BROWN HEATER CONTACTOR J13 R4 PIN7 2M2 c20 100uF Q3 PUMP CHANGEOVER OVER TEMP J13 RELAY COM2 mE GND WIRED LINK 19 CONTACTOR R30 J13 PIN4 1K 2 STANDBY ON 104 5 GND J14 PUMP CHANGEOVER J14 PURPLE PIN2 GREEN 680R WHITE amp BLUE STANDBY RED Ame R35 RELAY N 12V 1K 20K 47K R28 02 N C2 01 1M HEAT FAN OVER TEMP RELAY FAIL J14 PIN4 WHITE Q1 CONTROLLER ON LED VE C3 PAD 7 15 6VREF Ji BLOCK WHITE amp O1uF PRESSURE LEDe SENSUR RED SWITCH OVERTEMP GND RED DRAWN BY CPW DATE 10 12 1996 TITLE OLD
8. 5 47R 1 5 706 7 9 7 18 202 2 gt A E 8 5 FS3 4mH 400W 4mH 400W FREEZE 4mH 400W zs WV z3 WV FAN zi WV 75V 5 4 6 4 6 4 6 Us U4 3021 3021 3021 m Ze M a 2 12V 12V 12V 1 2 J1 PINII pe 1 2 J1 PINI2 Sis 7 2 J1 PINS gt 2 gt RAMP RESET FREEZE PUMP 0 R24 R23 R22 FAN J1 PINI FAN x 470R 470R 470R 2 c13 08 7812 12V VAPOUR FAN D5 J1 PIN2 0 0 0 LINE gt m gt R25 x L3 R26 x R27 R28 n7 aw 91K 9IK 47R 120R n gt DI D3 0 FS9 FS10 PHI FSI Ju n2 800mA 4 4 4 4 ad da m gt EH HF HEATER ia DEFROST HF PUMP 4700uF 4700uF CONTACTOR CONTACTOR VALVE RLI RL2 RL3 A RLA i 2 D4 12 2 12V A 12 12 MOIRA T Kj J1 PIN3 J1 PIN4 J1 PIN7 J1 PINS UNES CHANGEOVER 06 D7 08 gt J1 PIN6 GND ES DRAWN BYCPW 15 12 1996 TITLE HF6500 TRIGGERBOARD DWG No CPW050 REV
9. lt gt o lt o lt lt o lt O lt gt v TX Ec TI Of pp TO PH PH3 sia 314 siz 32 112 J 9 Las Cas Transformer E m 5 8 L3 L2 tol va E eig Ti T 15v O P me 20VA LK4 so 5 REI LK16 08 09 LK LK8 D2 Di D6 IBS UR ERE Z 777777 722222222 7 22227727 77777 05 HERUY FOG TRIGGER BORRD I2 LUD TRIG JEM CO 18 g 5 B E T 5 8 8 5 T T 8 5 T T us d S 5 5 fs 2 R24 R23 R13 Ri 0111 MOLEX PIN OUTS Heater 1 Live Feed 10A Fuse Heater 2 Live Feed 10A Fuse Pin 1 Half wave output Pin 7 Defrost valve Pin 2 Heavy fog contactor Pin 8 Condensor fan Heater Live Input From Contactor Pin 3 Heater contactor Pin 9 Ground HF 6500 TRIGGER BOARD Pin 4 Heaters 1 amp 2 Pin 10 Pump change over Pin 5 12 volts Pin 11 Heaters amp 4 Pin 6 Pump Pin 12 Evaporator fan 6500 D M X WIRING 12345678910 E 1 BLACK FROM 2 YELLOW RED FROM 3 YELLOW BLUE FROM 4 PINK FROM P C B 5 WHITE FROM P C B 6 ORANGE FROM P C B 7 FROM P C B 8 FROM P C B 9 YELLOW FROM P C B 10 RED FROM DMX FUNCTIONS CHANNEL 1 COMPRESSOR ON 2 FLUID TANK CHANGE OVER 3 HORIZONTAL LOUVRE 4 VERTICAL LOUVRE 5 FIRE 6 NOT USED DATE 25 02 98 6500 DMX WIR
10. GND SWITCHES D R66 R68 120R 120R d T3 R65 7 N R67 x R80 MN E 3n3F 68K LEDI2 3n3F 68K LEDI3 2K2 WAVE SEA SE SE Eile GND YELLOW GND YELLOW GND EFFECTS EFFECTS FOG GO FOG GO 12V SE SE SWITCHES SWITCHES gt 0 R83 027 R86 R87 cos LED7 R92 TIMER V 47K jour EH 1000 TIMER 4 IK ON GREEN swi2 swi3 RED CLOUD WATERFALL C30 SE SE 0 luF ii d LED9 LEDS R94 VAM TIMER VAM TIMER IK N N ca i R85 REPEAT 4 7 R91 ihik ae i 10K YELLOW YELLOW IM 9 8 FOG GO 3 1 11 13 AL Q R90 D R70 R72 470K Q4 120R 120R 020 R69 7 amp Len R71 N al N R95 3n3F 68K LEDI4 3n3F 68K LEDIS iy 5 xot CLOUD WATERFALL Ul SE SE GND YELLOW GND YELLOW 12 men E 2 R96 EFFECTS EFFECTS a tke Ul Took FOG GO FOG GO GND 5 3 PUMP TIME R97 ji 470K LT 22K SWITCHES SWITCHES zm T 13 Ul 894 SWIS ii 5 10 VOLCANO CURTAIN x SE SE u4 14 gt VR2 5 ME 9 12 DELAY TIME 9 A13 A12 470K 3 1 13 T SW6 SW7 545 9 D7 TIMER TIMER TIMER R74 R76 ONCE REPEAT START 120R 120R 22 R73 E058 R75 M d S 68K LEDI6 3n3F 68K LEDI7 VOLCANO CURTAIN SE SE R84 R88 GND YELLOW GND YELLOW 47K 2K2 EFFECTS EFFECTS FOG GO FOG GO GND
11. 0 D A2 GND R105 R109 26m 10K Q4 2 A2 2 9 R112 as 2 7 15 IM GND U8 AT 93 R110 pe R102 2 6 16 EE 56K M 4 5 17 SET 7 u R Q AS Qs Bii os 3 4 18 D12 IM RIT m 7 6 6 GND D10 c32 C3 R107 12 3 19 D13 pono LT 220 99 AT Q1 14 7 25 quo GND 33 15 24 17 TR R106 i 10K 12 3 9 1 10 23 22 A 22 Hs AH G SE E 12 2 20 GND AD 12 26 ANG GND AI3 14 GND LTD DRAWN BY CPW DATE 3 3 1997 TITLE HF6500 CONTROLLER PART4 DWG No CPW058REV 12V SE SE SWITCHES SWITCHES 12V R79 EFFECTS 12V R78 15K FOG 60 810 Dec A 220K R81 WAVE SEA 47K an SE s R82 010 3 IK R77 C3 4 E 712 ae m 47R 0 1uF SE 10 un 2r 3 1 13 9 12
12. 650 2500 MOTHERBOARD PARTI DWG No 078 REV 1 12V 12V 12V 12V R116 R128 R115 22K d 6VREF 12V 2M2 AL ii 39 R131 R132 C40 our 100K Er 13 9 8 D AL un 4 10 SER Hm 6 R133 09 ae 100K 22uF IM 10 s SETTING FOG 4 CONTROL E R129 vis GND EH 3 5VREF 22K E VERT LOUVRE L _ L YELLOW amp GND GND GND BLUE 12V 12V 12V R120 R119 IK SUREE 2M2 RI35 RI38 5 012 0 47K 2 10 D A2 E ze 100K al m 100K RM Ly 12 R136 R139 09 d 100K 56K 7 o FOG Br CONTROL PEN NS
13. LED 10 RED BLUE SMOKE H F SIGNAL 11 PINK FREEZE FAN FAIL 12 ORANGE PUMP SIGNAL 13 PURPLE STANDBY ON 14 GREY DMX GROUND 15 BROWN READY SIGNAL 16 BLACK DEFROST VALVE SIGNAL 17 YELLOW FREEZE FAN FAIL 18 GREEN PUMP CHANGEOVER 19 LT BLUE GROUND GND 20 BLUE 12VOLTS 21 WHITE HEAT FAN FAIL 22 RED HEATING SIGNAL 10 SERVICE AND MAINTENANCE Internal view of the machine Section 1 Internal view of machine For an internal view of the machine you must Unscrew all 28 screws on the outside of the machine This includes the side panels Remove the two nylon caps and nuts on the front cover and push the fluid tanks down into the machine Line up the 2 ducting clips on the front cover so they are flat and pull the lid forward The rear lid will slide off backwards Ensure the controller has had its joystick removed before this is done Section 2 view off Electronics door Looking towards the front from the rear of the machine on your left hand side of the machine you will see a filtered side panel Unscrew all 6 six screws from around the edges and remove the panel There you will see a slide out electronics door pull towards you for a view of the electronics On the electronics door you will see a Mother PCB a Trigger PCB and 2 Contactor Section 3 Replacing the Trigger PCB After following section 2 Remove all crimps on the board Unscrew the second Triac in from the left of t
14. Replace compressor capacitor Reset and try again if trip re activates check filters are clean and machine isn t in an enclosed space reset and run again if trips again reset and check machine for gas when running high pressure side 200psi low pressure side 30 psi 516 of R22 in machine If less check for leaks If O K check compressor for faults Replace Freeze fan and solenoid switch fail lights on Evaporator fan motor failure Jammed fan wheel Evaporator fan fuse blown Solenoid failure Evaporator coil sensor faulty Mag valve sensor faulty Replace motor Rectify Replace fuse No 8 on trigger PCB Replace coil Replace sensor Replace sensor Heavy fog smoke rising Evaporator fan speed to high Faulty thermostatic expansion valve Restriction in refrigeration circuit Solenoid valve jammed open Drier blocked Lack of refrigerant Fan voltage on low speed should be 75 85 volts check this on mother PCB Replace then purge and recharge Check pipe work for ice build up at any one point and clear by applying heat Clear or replace Replace Check for leaks seal vacuum purge and recharge Fault finding guide Timer malfunction Damp or faulty switch Repair or replace Erratic special effects Excess voltage drop in control cable Damp controller Faulty power supply Try different controller or use shorter control cable Condenser fan ru
15. ele c36 GND oar 3 5VREF our dme HORIZ LOUVRE SEINE L YELLOW amp GND GND RED 12V R145 FOG CONTROL 4 12V 13 12V 12V Mud 12V 12 10K 2 1 m R148 O FREEZE FAN SIGNAL 12 R122 22 oF FT PINK 3K 126 R 5 R147 1 bos T DMX CABLE 6VREF 22K un his VR7 2M2 elim Ms R142 px Ls U12 OUTPUT ii 2K 12 22 luF 2 FOR PINK 3 4 12V YELLOW amp BLUE 14 22K BEN R146 ORANGE e D A3 YELLOW amp RED Hen ND 10 8 7 P 3 5 R123 2M2 R124 B 13 R127 R140 CUT id 2M2 Uo 2 2 alt 100K 100K 12 4 DMXFAN Q D14 CON 38 SPEED m R141 R143 R144 3 5VREF our PINK 100K 68K 100K GND GND GND GND JEM LTD DRAWN BY CPW DATE 3 3 1997 TITLE HF6500 CONTROLLER PARTS DWG No CPWO059 REV 3 5VREF 12V 12 R98 R103 20K R101 IK 1 2M2 R100 2M2 16 45V 1 9 R104 QE LL D A i 10K i ji R108 in Q2 VPP m INP 0 8K2 RII 6 9 12 3 Al
16. ensuring the joints are staggered Place heat shrink over the red wire connections Solder new sensor to the existing red wires Pull heat shrink over the connections and Heat shrink Place some Heat sink past on the copper outlet pipe from the coil Place the new sensor on top of it and tiewrapp Ensuring you do not break the sensor SERVICE AND MAINTENANCE Section 7 Replacing a servo board After following section 1 and only removing the front cover 1 The servo boxes are on either side of the machine at the front 2 Remove the four 4 screws holding the servo box in place Disconnect the louver arm connector Pull the box towards you This will give you a view of the servo PCB inside the box Disconnect the wires Unscrew the four 4 screws on the bottom of the box that hold the servo PCB in place Remove the PCB Replace with new PCB If the metal arm connections on the bottom of the PCB are not attached to the new PCB then disconnect the metal connections from the old PCB and fix to the new PCB 10 When connecting line the pot up on the bottom of the board so that it is at half way through a turn This will give a central point on the louver when 1n fire mode 11 Reverse procedure from No 7 Section 8 Replacing the vapour fan After following section 1 and removing the front cover only Remove earth from the fan 2 Cut up the heat shrink until you can see were the wir
17. 2 nae FLUID FAIL YELLOW VALVE FAIL 22K 2K2 YELLOW LED22 WHITE BLACK T HF FLUID LEDI8 LEDI9 R26 ij ig YELLOW FREEZE DMX REFRIG ON 47K ari FAIL FAN FAIL ORANGE gt 4 10 14 RED RED D2 010 RII Ke R12 R13 Au LED20 B sw4 9 1 6 1K6 th 1 6 839 DEFROST CONTROLLER REFRIGERATION PUMP VALVE FAIL OFF EH LL R27 R28 CHANGEOVER RED 47K 220K GREEN DMX HF DMX SMOKE LED21 100uF FLUID Om R14 COMPRESSOR STANDBY ON 5 GND YELLOW GREEN 1 6 FAIL PURPLE SIGNAL RED RED amp BLUE sw2 SW3 SW16 5117 CONTROLLER ds COMPRESSOR ph ai REFRIGERATION HEAVY SMOKE FAIL FOG WHITE amp BLUE GND GND GND DRAWN BY CPW DATE 27 2 1997 TITLE HF6500 CONTROLLER PARTI DWG No CPW0SSREV 1
18. E 60RPM 2208 Ul ORANGE D3 O 4 47R 12 AW 390K 12V i C4 R5 R7 VRI R9 InF 680R 22K 4K7 Di SERVO GND WHITE POT SHAFT LINKED TO MOTOR SHAFT DRAWN BY CPW DATE 7 3 1997 TITLE HF6500 SERVO BOARD DWG No CPW060 REV JEM LTD DEFROST VALVE 8 C40 12V n o 0 c37 s 12 100uF 82 iy Co R88 12 09 2M2 V R93 VOUT cas R86 01 GND IT 10K 0 9 7 4 T 1 R89 R92 U2 17 Ul 10K 47K m R94 EST D8 D9 2 150K Ai 10K D7 196 10uF a v2 C39 12V uua GND 10uF 12V R97 R77 ME R84 6808 V R79 12V 12V 12K R83 GND o Y R85 220K v4 c9 0 luF 0 luF 200K R80 33 lt d VI 6VREF IK i M 13 02 DEFROST Ul 10 4 16 J14 SOLENOID PIN8 E SENSOR BLACK v3 R81 R95 L c36 R91 L
19. F HORIZ SPEED 12 5 VR3 D4 SCAN 100K R41 HORIZ n 13 47K CK SCAN GND U 12 ARC GND 470K ES R34 C8 R38 R42 R44 0 7 R46 10K 560K 47K 68K 2M2 12 HIP GND SETTING A HORIZONTAL JOYSTICK POT R59 R60 ME 100K 22K DMX HORIZ GND LOUVRE YELLOW amp o BLUE 12V R61 100K VR8 HORIZONTAL ADJUSTMENT 10K GND 12V lt 12 RAT cis C3 R54 856 51 9 M LEDII p 10K 0 luF IK 0 luF 10K VERT VERT SCAN SCAN VRI D5 GREEN VERTICAL ADJUSTMENT RSI VR6 R50 10K 2M2 VERT 10K R58 R62 d SCAN T R48 120R 100K GND SPEED 10K 14 100K 13 6 14 4 05 05 DMX VERT gt S v 14 Ai 10 5 EL 5 LOUVRE 100uF 5 Ov D6 VRS YELLOW amp 12 SETTING VERT 3 1 7 RED CK SCAN ur 3 VERTICAL 52 ARC GND y ne 06 JOYSTICK R49 R55 R57 4 7 POT R53 R63 R64 10K 100uF 47K 3n3F 68K 10K 560K 5 100K 2K GND GND DRAWN BY CPW DATE 28 2 1997 TITLE HF6500 CONTROLLER PART2 DWG No CPWOS6REV
20. ING DRAWN BY J MARSHALL 1 ORANGE BLUE FROM SOCAPEX 2 GREEN BLUE FROM SOCAPEX 3 GREY FROM SOCAPEX
21. THE ULTIMATE LOW LYING FOG SMOKE MACHINE 650 SERVICE MANUAL PLEASE READ THESE INSTRUCTION CAREFULLY JEM SMOKE PLC Version 1 0 990127 6500 SERVICE MANUAL CONTENTS 1 beat res SUO EHE Paetus 2 n 3 Safety and wiring Cui pia re HAERES 4 Safety and wiring off machines E Pia 3 Fault Guide cereo etre pd debct sre ud etie ek 6 7 8 9 Fault finding guide amp 22 pin socapex guide 2 2 10 Service and maintenance CH Eu EUR 11 12 13 14 15 16 DMX 512 Optio eere EC a o ER ERE Ua E ERREUR 17 Part number tas x o thea dU ERE In a eiut 18 Heavy Fog 6500 mother wiring 22 19 Heavy Fog 6500 trigger wiring 2 20 M tec 21 Heavy Fog 6500 Features and Specifications The Heavy Fog 6500 is a dual purpose machine it can deliver Smoke or Low lying fog at continuous output 24 hours a day 7 days a week 365 days of the year A series of vertical and horizontal louvers at the front of the
22. ecific smoke or heavy fog tanks 27 Never attempt to do any work on the machine if it isn t described in the manual Consult your supplier for advice on the JEM Heavy fog 6500 Safety Wiring of the machine Because the machine in most cases will be wired to a 3 phase supply a voltage of 415volts A C will exist across each set of phases therefore great care must be taken when working on live apparatus ELECTRICITY KILLS Under no circumstances should anyone without sound electrical knowledge be permitted to work on this machine while connected to a live electrical feed U K AND EUROPEAN WIRING IF THE MACHINE The U K European model operates on 220 240 volts and may be operated on a single 220 240 volt phase however this causes a substantial current draw so it is much more desirable to use three separate phases to provide better load distribution The machine will benefit and run much more smoothly U S A WIRING IF THE MACHINE The wiring connection is different in the U S In the U S 2 x 110volt phases legs are used to obtain 208 volts however the same cautions apply To obtain a voltage of 208 volts from two 110 volt legs connect all live feeds Hots together on one leg and the neutral Blue wire on the other leg This will give you 208 volts Note in this situation the supply neutral is not used To those unfamiliar with use if multiple electrical phases known as Legs in the USA this action may seem strange but is commo
23. es join cut the wires at this point 3 Remove all the heat shrink from of the cable 4 Remove all the silicone from around the vapor fan 5 Remove the two 2 bolts holding the vapor fan in place 6 Remove the vapor fan 7 Replace with new vapor fan 8 To the existing wires sleeve with new heat shrink 9 Around the edge of the new vapor fan once in place seal with silicone sealant 10 Join the wires together by soldering ensuring there is heat shrink over the brown and blue wire joints 11 LIaot chveiel tha nnnnantinana and ranlana tha SERVICE AND MAINTENANCE Section 9 Replacing the block After following section 1 taking off only the front cover make sure the machine is turned off If you have the old style block the heating elements will only be coming out of the block 1 in length and there will be heat resistant wire attached to them The new blocks have 7 of elements coming out of the block and are attached to the wires with crimps Remove the fluid tanks on both sides of the machine Remove the two screws that hold the sensor access plate in place and remove plate Remove the four 4 screws that hold the sensor retaining plate in place Remove the sensors do not cut the wires these sensors are fragile Drill out the six 6 1 16 rivets that hold the vapor fan plate in place above the block and place plate on top of machine do not cut the wires to the fan Remove the bracket that
24. he board Unscrew all four 4 nylocs in the corners of the board Pull out the molex connector Remove the board Reverse the procedure to replace the board N B Trigger board connections are as follows PRE MAY 1997 JEM HEAVY FOG V1 0 N 15 1 2 3 4 5 6 7 8 9 0 11 12 13 14 POST MAY 1997 LVD_TRIG PCB N 15 1 2 3 4 5 7 6 8 9 10 11 12 13 14 The above connections are from right to left 11 SERVICE AND MAINTENANCE Section 4 Replacing the Mother PCB After following section 2 Remove all wires on the board Making note of the connections Remove all four 4 nyloc in the corners of the board Pull the board forwards to reveal the back of the board 10 Remove all soldered wire connections on the back of the motherboard by de soldering them making a note of the connections 11 Remove the board 12 Replace with new board 13 Reverse procedure to replace the board Section 5 Replacing a Contactor After following section 2 Remove all wires on the contactor you are replacing making note were they were removed from Remove the two 2 nuts and bolts holding the contactor in place Remove the contactor Replace contactor and Reverse procedure After following section 1 and removing only the back panel Cut wires as close to the red condenser sensor as possible Remove all silicone from around the old sensor and remove sensor Strip the existing Red wires back about 3mm
25. holds the block in place this will have an earth connection on it 7 Atthe back of the block there is an 8 way dispersal cone try to pull this off if no luck cut it off 8 Depending on type of block cut through or pull off the wires connected to the block elements 9 Undo all the 4mm nuts that connect the fluid inlet pipes to the block 10 Now you can remove the block by pulling the block in it s casing up towards you 11 Replace with new block ensuring that it has all the correct fittings on it and the fluid inlet pipes are bent in the right direction the 8way dispersal cone cannot be fitted until the block is in place You may have to cut the block shroud as shown in diagram 1 for the new block to fit 12 Once in place bend all 8 elements down 90 degrees 13 Place heat shrink over all 8 elements 3 of 12 6mm heat shrink 14 Cut 2 0 6 8mm heatshrink and place it over the wires that will connect to the block elements pushing it to the top of the wires 15 Cut 8 x 9 of glass fibre insulation and push it over all 8 of the wires that will connect to the elements 16 If not already connected fit all the wires with 2 5 crimps blue 17 Push the crimps one at a time onto the elements Ensure that the Brown wires are at the bottom and the blue wires are on the top 18 Once crimps are connected pull down over the crimp connection the heat shrink and shrink on with a heat gun Pull up over the whole element the Glass fibre i
26. ide Yellow Red broken No variable smoke Worn or damaged slider Replace output at all control Smoke output stuck on minimum Broken volts supply to slider Reconnect wires on slider ensuring secure Machine cannot be Socapex line 5 Green Brown Repair turned on or off using broken Standby or on buttons Mains LED is dim Machine works by pressing the heavy fog button only to start Machine stays in Socapex line 7 White Red Repair standby mode broken Smoke LED will not Socapex line 8 Red Brown Repair light and difficulty broken selecting heavy fog function Heavy fog LED will not Socapex line 9 Red Black Repair light broken Machine will not switch Socapex line 10 Red Blue Repair from Heavy fog to smoke or vice versa machine is stuck in smoke mode broken Fault finding guide Problem Front evaporator fan will not respond to demand for smoke or heavy fog Probable cause Socapex line 11 Pink broken or 4066 chip next to pink wire blown Cure Repair connection or replace chip No smoke or heavy fog but front fan still controllable with slider when smoke or heavy fog is in demand Socapex line 12 Orange broken or 4066 chip next to pink wire blown NOTE 4066 chip can be damaged by plugging in the controller with the power already switched on Repair connection or replace chip Standby mains on Smoke only w
27. machine controlled by a jot stick mounted on the controller will direct the low lying fog wherever it is required further more the controller has a pre programmed louver movement to reproduce scenic effects such as Sea Wave Cloud Waterfall Curtain and volcano The on board 19 rack mounted controller can be removed and mounted remotely or if preferred the machine can be controlled via a lighting desk using either the 0 10v input connection through a Mono Jack plug and the 512 DMX card Via a 5 pin XLR plus a slave socket to link the machines together Specifications Power requirements 220v 240v 50hz 3 phase 20 amps per phase 208v 60hz 60 amp Single phase Heaters 10kw Fan speed 0 3000rpm 1 2 amps Smoke output 1250mc per minute H F output 500 square maters per minute Pumps 2 x Piston pumps 0 7amps each Fluid capacity 2 x 5 integral tanks Fluid types 1 B2 C3 and Dimensions 1170 x 760 x 715mm Weight 210kg Safety Always connect to the correct mains power supply Always use genuine JEM fog fluid Always disconnect from the mains before attempting to start work on the JEM H F 6500 Do not suspend the machine above peoples heads Do not stand directly at the front of the machine when firing Do not block the airflow vent at the back of the machine Clean the machines filters out once a month Always install in a well ventilated area Ensure correct fluid is placed into sp
28. n in the commercial field and normal practice As always make sure that the earth ground wire in the USA is properly connected NEVER operate this machine without the earth ground wire connected Safety Wiring of the machine N B THIS APPLIANCE MUST BE EARTHED Wiring of Plug BROWN PHASE 1 240V 3 PHASE BLACK PHASE 2 BLACK PHASE 3 BLUE NEUTRAL GREEN YELLOW EARTH 208V SINGLE PHASE BLACK PHASE 1 BLUE PHASE2 GREEN YELLOW EARTH Fault finding guide Problem Heater Fan and compressor fail LED s on Probable Cause Condenser fan fuse blown Condenser fan motor faulty Fan blade jammed Insufficient air flow to the machine Low gas charge Condenser coil air outlet blocked or restricted at rear of machine Cure Replace Fuse No7 Replace Re align Clear restriction Re site machine Check for leaks purge and re charge Clear restriction and or re site machine Red LED on motherboard flashing Overheat sensor circuit activated faulty sensor on block O S Triac or Opto on Trigger board Replace Sensor Or Sensors Replace Triacs or Opto s No s 1 2 6 and 7 Heavy fog button pressed but does not activate after normal delay period Phase down Contactor 1 faulty Faulty capacitor Pressure switch tripped Compressor internal thermal overload trip activated Check mains supply voltage Repair or replace Contactor 1
29. ns at full speed on switch on Broken sensor Wire broken or disconnected on mother PCB Replace red sensor on condenser coil Repair or re connect wire No heavy fog output or no smoke output Earlier models only Tank empty Air leak in pump or fluid line Faulty pump Pump fuse blown Blocked change over valve Change over fuse blown Change over valve faulty Faulty switch or broken LED Refill Locate and reseal Replace Replace fuse No s 5 and 6 Clean and test Replace fuse No 5 Replace or modify to current spec using two separate pumps Repair or replace High current draw Refrigerant overcharge Tight compressor Compressor electrical problem Discharge valve leak Internal compressor leak Purge and recharge Run in for a few hours Wiring problem Check and correct Re seal Replace compressor Low current draw Low refrigerant charge Water in system Check for leaks and re seal Purge evacuate and re gas Servo faulty no servo action at all Faulty servomotor or wiring Repair or replace Block heats up O K but no heating LED on controller Socapex line 22 Red broken Repair Fault finding guide Problem Probable cause Cure Heat fan LED amp Socapex line21 White Repair Compressor fan fail Broken LED lights on Servo appears faulty Socapex line 3 Repair Smoke blows low on Yellow Blue or 4 floor or to one s
30. nsulation now pull over the glass fibre insulation the last piece of heat shrink at the bottom so that 12 is on the heat shrink and 1 is over the wire now shrink on using the heat gun 19 Spiral wrap the wires 20 Connect all the fluid pipe inlets back to the block 2 Replace the vapor fan by riveting it back into place 22 Reconnect the bracket the holds the block in place along with the earth tag 23 Refit the 8 way dispersal cone 24 Refit the sensors reversing procedures 4 3 and 2 25 Refit the tanks 26 Test to ensure all is working refit the cover Blue Heavy fog 6500 controller White to Slider Green e Orange ink Blue to slider Red to Slider Pi 9 gt e Link 0 10v Jack Socket Blue Purple Red Blue Red Brown White Red Green Brown Red Link to pump switch Red Black Light Blue Brown White Yellow Black White Blue LTD SERVO VE Hy RED E 2 el C R2 R6 4 47008 H 820R EH AKT in E 10 n 390K R3 R8 VERT LOUVRE 220R 220R ORANGE C3 C5 0 InF 6 E LH 12 HORIZ LOUVR
31. orks No heavy fog Stuck in standby from switch on Socapex line 13 Purple broken Repair Machine will not go into ready mode although heating LED goes of and front nozzle is hot Socapex line 15 Brown broken Repair No operation of solenoid switch fail Led or compressor fail LED Socapex line 16 Black broken Repair No operation of freeze fan fail and compressor fail LED s Socapex line 17 Yellow broken Repair Smoke delivered when heavy fog is required heavy fog LED is light Socapex line 18 Green broken Repair Heavy fog LED only lights up on controller total failure of all controls but compressor starts up Socapex line 19 Light Blue broken Repair Fault finding guide Problem Probable cause Cure Mains on LED only Socapex line 20 Dark Blue Repair lights up on controller broken Total failure of all controls but pumps run Machine has failed but Socapex line 6 White Blue Repair there are no lights broken controller 22 pin Socapex wiring table Pin Colour Function ORANGE BLUE DMX VOLTS 2 ORANGE GREEN DMX VOLTS 3 YELLOW BLUE VERTICAL LOUVER 4 YELLOW RED HORIZONTAL LOUVER 5 GREEN GROWN CONTROLLER LED VE 6 WHITE BLUE COMPRESSOR FAIL 7 WHITE RED CONTROLLER ON LED VE 8 RED BROWN REFRIGERATION OFF LED 9 RED BLACK REFRIGERATION ON
Download Pdf Manuals
Related Search