Martin Magnum 850 Specifications

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Martin Magnum 850 Specifications | Manualzz

JEM Smoke Machine Training Program

An Introduction To Smoke Technology:

INDEX

Smoke Machine Markets

Smoke Machine Principles

CE Marking

Searching for information on the NET

Which fluid can I use with my machine?

What can my machine do?

Specifications

Service of machines:

Tools and optional extras

Machine Overview

Opening The Machine

Inside The Machine

How To…

How To Change A Heat Exchanger

How To Change A Pump

How To Change A PCB

Control PCB

Calibration

Spare Parts Lists:

Spare Parts 240V

Spare Parts 110V

Appendix:

Fuse Ratings

PCB Schematics

3

3

4

5

6

6

6

8

9

10

10

11

12

13

13

14

15

16

16

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2

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.

3

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

EN 60 555

RF voltage and field strength

Harmonic current content

EN 55 014 RF voltage (discontinuous)

Immunity:

IEC 801-2

IEC 801-4

Electrostatic discharge to case

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.

4

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.

5

X=NO

O=YES

Which fluid can I use with my machine?

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

MAGNUM 800 O O

What can my machine do?

O O O X X X

Dance clubs and discos the world over greatly appreciate this industry workhorse.

This reliable yet compact fog machine delivers a non-stop intense cover of fog for instant atmosphere generation – a must for any mobile DJ or small club.

Easy to operate with a convenient carrying handle and portable design, the Magnum 800 uses the same high technology standards found in the larger Magnum 2000.

The Magnum 800 is tough and rugged, the perfect fogger for small nightclubs, mobile DJs and bands. It is also a useful fogger for parties and celebrations.

Specifications:

X

Physical

Performance

Control and Programming

Fluid System

Construction

Installation

Connections

Length: 410 mm

Width: 165 mm

Height: 170 mm

Dry weight: 6.5 kg

Max. smoke output (approx.): 200 m

3

per minute

Max. operating time at full output (approx.): 38 mins

Operating time: Continuous, automatic level adjustment

Warm-up time: Approx. 7 minutes

Control options: Remote control (supplied) or DMX with optional DMX interface module

Remote control features: Instant or timer-controlled output, 0-100% adjustable output level

Fluid pump: Oscillating piston, high pressure

Onboard fluid capacity: 1 l

Max. fluid consumption at peak output: 50 ml per minute

Housing: Steel & aluminium

Heat exchanger: 750 W, direct thermal protection

Orientation: Floor (No Flying Kit Available)

Remote control: 5-pin DIN

Power connection: 3-pin IEC male socket

DMX (with optional DMX interface): 3-pin locking XLR

6

Electrical

Typical Power and Current

Thermal

Approvals

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): 10 AT (slow blow)

US model

110 V, 60 Hz: 820 W, 7.45 A

115 V, 60 Hz: 896 W, 7.79 A

120 V, 60 Hz: 975 W, 8.13 A

EU model

220 V, 50 Hz: 630 W, 2.86 A

230 V, 50 Hz: 689 W, 3.00 A

240 V, 50 Hz: 750 W, 3.12 A

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

Maximum ambient temperature (Ta max.): 40° C

Exterior surface temperature, steady state: 50° C

Max. nozzle temperature: 200° C

Accessories

Ordering Information

Service Info (internal only - do not publish)

EU safety: EN 50 081-1, EN 50 082-1

EU safety: EN 60 335-1 (1995)

Pro Smoke Studio (DX Mix) fluid, various sizes available

Pro Smoke Super (ZR Mix) fluid, various sizes available

Pro Smoke Super (Fragranced) fluid, various sizes available

Pro Smoke High Density (SP Mix) fluid, various sizes available

I-fog fluid, various sizes available

Ducting Kit (Including adapter and 5m of 4-inch (104mm) ducting): P/N 92625004

DMX Interface ZR12: P/N 92765015

Martin Magnum 800, 110 V: P/N 92220001

Martin Magnum 800, 240 V: P/N 92220000

Cooling time before service or maintenance: 15 minutes

Minimum clearance around air vents: 0.20 m

7

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

Wrenches

Flat tip, size small and medium

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

8

MAGNUM 800 MACHINE OVERVIEW

The Outside:

ANALOGUE

CONTROL

9

Opening The Machine:

1. DISCONNECT FROM MAINS SUPPLY.

2. Remove the 6 M4x10 pozidrive TAPTITE screws from the outside of the machine and store safely.

3. Lift off the lid.

The Inside:

HEAT

EXCHANGE

THERMAL TRIP

EARTH POINT

BRASS FITTINGS

PUMP

ELEMENTS

FLUID LINE

THERMOCOUPLE

MAINS INPUT

10

HOW TO….

REFER TO SCHEMATICS / DIAGRAMS IN THE APPENDIX FOR MORE DETAILS

How To Change A Heat Exchange:

1. Always try to change a HEAT EXCHANGE when it is cold as the exposed metal parts can be

VERY HOT.

2. DISCONNECT FROM MAINS SUPPLY.

3. Remove TOP COVER.

4. Disconnect the THERMOCOUPLE from the MAIN PCB.

5. Disconnect the HEAT EXCHANGE POWER WIRES from the terminals of the PCB.

6. Remove the negative (BLUE) wire from the heater.

7. Undo the brass nut that 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 the hole and remove the heat exchange from the chassis.

Refitting Your New Heater:

1. Replace heat exchange in chassis NOZZLE FIRST.

2. Screw the 4 screws back in through the bottom of the chassis

3. Replace the negative (BLUE) wire to the HEAT EXCHANGER ELEMENT.

4. Reconnect the HEATER POWER wires to the TERMINALS of the PCB.

5. Using a NEW OLIVE refit the COPPER FLUID LINE to the PUMP.

6. RECALIBRATE the temperature of the unit. (See Calibration Section)

11

How To Change A Pump:

1. DRAIN ALL FLUID FROM THE SYSTEM FIRST.

2. DISCONNECT FROM MAINS SUPPLY.

3. Remove TOP COVER.

4. Disconnect the POWER wires from the PUMP.

5. Disconnect the BLACK RUBBER FLUID LINE from the rear of the PUMP.

6. Move the fluid line out of the way. (BE CAREFUL OF FLUID COMING BACK DOWN THE

PIPE)

7. Disconnect the COPPER FLUID LINE from the front of the pump.

8. Unhook 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.

12

REFITTING:

12. Fit the BRASS FITTING to the front of the pump using a THREAD SEALANT COMPOUND.

13. Fit the new PUMP to the CHASSIS by inserting the front end first into the RUBBER MOUNT.

14. Hook the rear mount onto the back of the pump.

15. Reconnect the BLACK RUBBER PIPE.

16. Reconnect the POWER wires to the PUMPBROWN INSIDE / BLUE OUTSIDE.

17. Turn machine on and RE-PRIME the system.

18. Refit TOP COVER.

How To Change A PCB:

REFER TO SCHEMATICS / DIAGRAMS IN THE APPENDIX FOR MORE DETAILS

PCB

1. DISCONNECT FROM MAINS SUPPLY.

2. Remove TOP COVER.

3. Remove the 2 screws at the bottom of the PCB HEATSINK from INSIDE THE HEATER

COMPARTMENT.

4. Disconnect the PCB WIRING LOOMS from the PCB (Note orientation before removal).

5. Remove the 2 PLASTIC RIVETS from the 5-pin din socket.

13

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.

REFITTING:

8. Fit the HEATSINK to the PCB using the 2 screws/nuts adding THERMAL TRANSFER

PASTE underneath component Q6.

9. Fit new PCB to the mounting posts.

10. Insert the 2 PLASTIC RIVETS into the din socket.

11. Insert the 2 screws into the heatsink from the heater compartment.

12. Reconnect the PCB WIRING LOOMS (Observe polarity).

13. Refit the TOP COVER.

Calibration:

1. Set the JEM CALIBRATION BOX to the required mV setting (13.4mV).

2. Make sure the RAMP BUTTON on your CALIBRATION BOX (GREY) is OFF.

3. Remove the TOP COVER.

4. Disconnect the THERMOCOUPLE from the PCB.

5. Connect the RED TERMINAL of the CALIBRATION BOX to the POSITIVE (+)

THERMOCOUPLE connector of the PCB.

6. Connect the BLACK TERMINAL of the CALIBRATION BOX to the NEGATIVE (-)

THERMOCOUPLE connector of the PCB.

7. Turn the machine on and tweak the TEMPERATURE 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 from the THERMOCOUPLE connectors.

10. Replace the THERMOCOUPLE onto the DMX/PROGRAM PCB (PRE 11/06: YELLOW = +

BLUE = - / POST 11/06: BLACK = + WHITE = -)

11. Turn the machine on and check for current draw.

12. Let the machine heat up and check using a digital volt meter that the RED (HEATING) LED turns OFF at the correct point.

13. The GREEN (OK) LED should turn on about 1mV lower than the peak temperature setting.

(RED LED TURNING OFF)

14. TEMPERATURE CALIBRATION IS NOW COMPLETE.

14

OTHER

Part

PUMP

PCB

PCB

HEAT

EXCHANGE

HEAT

EXCHANGE

HEAT

EXCHANGE

HEAT

EXCHANGE

HEAT

EXCHANGE

HEAT

EXCHANGE

HEAT

EXCHANGE

CASEWORK

CASEWORK

CASEWORK

OTHER

OTHER

OTHER

OTHER

OTHER

Description

PUMP

MAIN

REMOTE

COMPLETE

BARE Inc BRASSWORK

BRASSWORK ONLY

SPARE PARTS LISTS

240V

Spare Part Number

05761003

62020005

62020008

26400630

26460030

CASEWORK

INSULATION

THERMAL TRIP ONLY

THERMAL TRIP Inc LOOM

CARRY HANDLE (PLASTIC)

TOP COVER

MAIN CHASSIS

BOTTLE

REMOTE CONTROL

FLUID LINE

MAINS SWITCH

WIRING LOOMS COMPLETE

STICKERS COMPLETE n/a

26520010

05041021

19200050

26560150

26560140

34300001

92765000

56220011

05523002

Comments

240V RED BODY (LARGE)

MAIN CONTROL PCB - TESTED

TESTED w/o BUTTON TOPS OR

KNOBS

COMPLETE BUILT UP HEAT

EXCHANGE c/w BRASS FITTINGS

BARE EXCHANGE (No insulation or casework) c/w BRASS FITTINGS

BRASS FITTINGS ONLY

CASEWORK AVAILABLE

SEPARATELY - CONTACT [email protected]

PRE CUT INSULATION KIT

TRIP SWITCH ONLY

TRIP SWITCH INCLUDING HARD

WIRED LOOM

PLASTIC CARRY HANDLE

TOP LID / COVER

MAIN CHASSIS - BARE

9.5L FLUID BOTTLE

COMPLETE REMOTE CONTROL

CLEAR FLUID LINE

MAINS ON/OFF SWITCH

ALL WIRING LOOMS FOR

MACHINE

ALL STICKERS / LABELS FOR

MACHINE

15

Part

PUMP

PCB

PCB

HEAT

EXCHANGE

HEAT

EXCHANGE

HEAT

EXCHANGE

HEAT

EXCHANGE

HEAT

EXCHANGE

HEAT

EXCHANGE

HEAT

EXCHANGE

CASEWORK

CASEWORK

CASEWORK

OTHER

OTHER

OTHER

OTHER

OTHER

OTHER

Fuse

Internal

Description

PUMP

MAIN

REMOTE

COMPLETE

BARE Inc BRASSWORK

BRASSWORK ONLY

110V

Spare Part Number

05761001

62020007

62020008

26400820

26460030

CASEWORK

INSULATION

THERMAL TRIP ONLY

THERMAL TRIP Inc LOOM

CARRY HANDLE (PLASTIC)

TOP COVER

MAIN CHASSIS

BOTTLE

REMOTE CONTROL

FLUID LINE

MAINS SWITCH

WIRING LOOMS COMPLETE n/a

26520010

05041021

19200050

26560150

26560140

34300001

92765000

56220011

05523002

STICKERS COMPLETE

240V

6.3A

APPENDIX

Fuse Ratings

110V

10A

Comments

110V BLACK BODY (LARGE)

110V MAIN CONTROL PCB -

TESTED

TESTED w/o BUTTON TOPS OR

KNOBS

COMPLETE BUILT UP HEAT

EXCHANGE c/w BRASS FITTINGS

BARE EXCHANGE (No insulation or casework) c/w BRASS FITTINGS

BRASS FITTINGS ONLY

CASEWORK AVAILABLE

SEPARATELY - CONTACT [email protected]

PRE CUT INSULATION KIT

TRIP SWITCH ONLY

TRIP SWITCH INCLUDING HARD

WIRED LOOM

PLASTIC CARRY HANDLE

TOP LID / COVER

MAIN CHASSIS - BARE

9.5L FLUID BOTTLE

COMPLETE REMOTE CONTROL

CLEAR FLUID LINE

MAINS ON/OFF SWITCH

ALL WIRING LOOMS FOR

MACHINE

ALL STICKERS / LABELS FOR

MACHINE

16

MAGNUM 800 REMOTE CONTROL DIN PLUG PIN OUTS

2

1

4

5

3

1 - YELLOW (READY).

4 - WHITE (HEAT).

2 - BLACK (GND).

5 - BLUE (0 - 10v)

3 - RED (+16v).

VIEWED FROM THE SOLDER SIDE

OF THE DIN PLUG

PIN OUT DESCRIPTION

1, GND WHEN MACHINES UP TO TEMPERATURE

4, GND WHEN MACHINES HEATING

2, GND

5, 0 - 10v INPUT, NEEDS 1.5v TO HEAT AND

2v -10v PUMP SPEED WHEN MACHINES READY

3 +16v OUTPUT

Magnum 800 Remote Plug Pin

Drawing No. 2000-1A

Drawn by : GS 28/03/2006

MAGNUM 800 REMOTE PCB PIN OUTS

1 2 3 4 5 6

PIN

1, Not Used

2, RED (+16v output)

3, BLUE (0-10v input)

4, BLACK (GND)

5, WHITE (Heat)

6, YELLOW (Ready)

Timer control

Timer LED

Ready LED

Heat LED

Fog button

Output Level Control

MAGNUM 800 REMOTE

PCB PIN OUTS

Drawing No. 2000-2A

Drawn by : GS 28/03/2006

NO OUTPUT

YES

Is the machine plugged in, turned on at the mains AND the power switch set to

ON?

NO

Is the machine fully heated and ready to run?

YES

NO

Check power and turn on

See HEATER PROBLEMS

Is the pump running?

NO

YES

See PUMP PROBLEMS

Undo the brass fitting to the heater / fluid line and run the machine.

Is fluid coming out of the brass fitting?

NO

YES

Heater is blocked – Replace heater

Pump seized – Replace pump

PUMP PROBLEMS

Is power getting to the pump?

(set to full power and check 240V / 110V)

YES

NO

See PCB PROBLEMS

Does piston seem to be moving?

YES

NO

PUMP SEIZED - REPLACE

Is fluid travelling through pump?

YES

NO

PUMP BLOCKED - REPLACE

Fault may be in fluid line / heater

HEATER PROBLEMS

YES

Is the heater heating?

NO

Overheating

YES

CHECK

CALIBRATION

YES

Check thermocouple

OK?

NO

Is power getting to the heater?

(check 240V / 110V)

NO

REPLACE

HEATER

YES

YES

Is power getting to the thermal trip?

(check 240V / 110V)

YES

Is power getting through the thermal trip?

(check 240V / 110V)

NO

NO

See PCB

PROBLEMS

THERMAL TRIP

FAULT – RESET /

REPLACE

Disconnect power and remove power loom from element connectors

Measure across the elements for continuity and check for earth leaks

Normal Ohms reading?

NO

YES

OPEN CIRCUIT

HEATER -

REPLACE

See PCB

PROBLEMS

YES

Earth leakage?

OPEN CIRCUIT

HEATER -

REPLACE

See PCB

PROBLEMS

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

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