Unit C6 Hastingwood Trading Estate 35 Harbet Road London N18 3HU Phone 020 8803 7400 FAX 020 8803 5060 email: office@gradav.co.uk HEAVY FOG GLACIATOR HEAVY FOG GLACIATOR Fluids Suitable for this system: CONNECTIONS REMOTE FUSE RATINGS The Heavy Fog Glaciator uses four fuses. They should be replaced with the value and type detailed below: DMX receiver low voltage 2AT Heavy Fog Fluid B2 Heavy Fog Fluid C3 1-GND, 2-12V OUT, 3-INPUT 1 INTERFACE 5 6 Power PCB 12AT 1 FOG 2 STANDBY 3 TIMER 4 FAN 5 SPECIAL 6 GND Compressor control relay 12AT Main input fuse 20AT Three of these fuses are located internally and should not be accessed without first disconnecting the power supply. 9 ON 1 2 3 4 5 6 7 8 9 10 11 12 1 2 4 8 16 32 64 128 256 SPECIAL 1 SPECIAL 2 SPECIAL 3 DMX ADDRESS 1 GND 2 COLD 3 HOT OUT FILTERS The Heavy Fog Glaciator uses a washable synthetic fibre filter in the air intake for the condenser unit (located at the top of the machine). This can be removed for cleaning by removing the ventilation grill above it (two M5 screws). Use the following guidelines for when to check the filter. Normal Conditions: Inspect and clean/replace every 250 hours Severe Conditions: Inspect and clean/replace every 150 hours DMX DATA INPUT NOTE! The JEM warranty will be void if any fluid other than JEM approved fluid is used. If other fluids are used there could be serious damage to the machine and the fluid may not have been tested for use in public areas. IN 17 HEAVY FOG GLACIATOR USER GUIDE HEAVY FOG GLACIATOR USER GUIDE SPECIFICATION HEAT EXCHANGER 2.5KW heater (240V) Wide bore steel vaporizing coil Ceramic thermal trip for over-temperature protection Electronic Temperature control using thermocouple FLUID SYSTEM Oscillating piston high pressure fluid pump Low fluid detection by electronic sensor 9.5L fluid containers (2.5 US Gal.) Maximum fluid consumption 120mL/minute REMOTE CONTROL OPTIONS DMX512 decoder: Required Channels = 2 Output is proportional for all levels above 12% Channels supported = 1 to 511 Valid start codes = 0 (dimmer data only) Full framing error detection implemented Analogue control via standard JEM Multifunction Contoller. Optional PLC interface for simple switching control of the system. CONTROL PANEL 2 x LED displays with 4 button keypad Output level control from 0 to 100% for Fog Timer range: Delay time (toF) 0 seconds - 90 seconds Run time (ton) 0 seconds - 90 seconds REFRIGERATION UNIT 2/3 HP compressor with thermostatic control Uses refrigerant R404A (0.850 Kg) OUTPUT CONNECTION Ducting adaptor to accept 150mm (6") flexible ducting POWER REQUIREMENTS Input voltage 200 - 250vac Input power (max) 3.1Kw Main fuse 20AT Frequency 50/60Hz dependant on model. USER GUIDE CONTENTS Introduction Features Safety Guidelines Machine Layout Commissioning The Machine Remote Control Options DMX Operation The Display Control Panel Functions The Timer Basic Operation The Fluid System Display Messages Basic Fault Finding Specification Connections Fuse Ratings Filter Maintenance 2 2 3 4 5 5 6 8 10 11 12 13 14 15 16 17 17 17 © 2000 Martin Professional A/S, Denmark. All rights reserved. No part of this manual may be reproduced, in any form or by any means, without permission in writing from Martin Professional A/S, Denmark. 16 1 HEAVY FOG GLACIATOR USER GUIDE HEAVY FOG GLACIATOR USER GUIDE INTRODUCTION The Heavy Fog Glaciator is the first of a new generation of JEM professional Heavy Fog machines, designed for touring and installation in a variety of applications. Provision has been made for easy integration into most common control systems currently used in the entertainment industry. As well as providing remote control options via DMX, the machine comes with a comprehensive control panel for local operation and display of operating parameters. The Heavy Fog effect is provided by cooling the smoke output from the main heat exchanger until it is at a temperature lower than the ambient in which the machine is operating. Air is added to the smoke, prior to cooling, from the fan mounted in the rear of the machine. This increases the volume of the effect and allows the output to be pushed through ducting. A fluid container with 9.5L capacity (2.5US Gal.) is provided for Heavy Fog fluid. To allow reliable unattended operation, the fluid level is monitored electronically, and the machine shut down if necessary. All machines come with robust carrying handles, and heavy duty braked castors. Fan Display dEn/oFF dEn/nor St StL Displayed when the Standby switch is set to OFF. Shows the current Density setting. Compressor is starting Compressor is stalled BASIC FAULT FINDING The Heavy Fog Glaciator is a complex machine and will require a competent service technician to repair any major faults. However, the following guide will allow the user to overcome the more common problems. SYMPTOM CAUSE CURE Allow time to reheat Add fluid Set standby to ON Check settings Allow time with DMX on Fit 120 ohm resistor No fog output when the Machine is not ready machine is fired using Fluid is below min level the Fog or Timer switch. Standby switch is OFF No fog output when using DMX to fire the machine. Incorrect DMX address Machine not ready No DMX termination FEATURES Tubeless condenser 9.5L fluid capacity Pump Ramping system for continuous operation All digital control system 2.5KW heat exchanger Accurate timer DMX512 interface (two channel) Remote interface. Optional PLC interface Non-volatile memory for user settings Electronic low fluid detection High pressure piston pump. LED displays for FOG and ICE controls. Fog and Density controls for easy set-up. Flu Lo is displayed on the Fog display Fluid level is below min Add more fluid Machine is not ready after 20 minutes heating time Fog disperses too quickly Standby switch is OFF Blown fuse on Power control PCB Set Standby ON Disconnect supply and replace fuse. Wrong grade of fluid Choose a longer lasting used for the application fluid (see front cover) Fan level too high Increase density setting (Reduces fan speed) 2 15 HEAVY FOG GLACIATOR USER GUIDE HEAVY FOG GLACIATOR USER GUIDE DISPLAY MESSAGES The following list shows the messages possible, and the context under which they are displayed. Only the messages available under normal operation are shown. Messages shown when using the menus, are detailed in other sections of this handbook. Fog Display Fog/oFF Fog/Err Displayed when the Standby switch is set to OFF, indicating that the machine can not be fired and the heaters are OFF. Shows that the Standby switch is ON but the heater is not on. This is an error condition and should not normally occur. Displayed when the heater is running but the machine is not ready. The machine is ready to fire using the Fog or Timer switches. Indicates that the fluid in the container is below the minimum level to operate the machine. Only visible when the machine has reached the ready state. The FOG switch is being used to fire the machine. The number displayed is the current Fog output level in the range 0 to 20 SAFETY GUIDELINES Always use JEM approved fluid in the container supplied with the machine. Do not bypass the fluid sensor, this could cause damage to the machine. Check the voltage is correct for use with the machine, the voltage setting is printed on the serial label. The machine must be operated in a horizontal position and should not be suspended overhead. Observe the warnings displayed on the machine (yellow labels). Do not remove the covers or attempt to repair a faulty machine, an authorized JEM dealer should be contacted in the event of a faulty machine. Always use smoke machines in well ventilated areas, over-use could affect sufferers of asthma or other chest conditions. Smoke machines can cause condensation to form. Floors and surfaces may become slippery and should be checked regularly. This machine is not waterproof, and should not be exposed to wet outdoor conditions. Do not spill fluid over the machine, if fluid is spilt clean with a damp cloth and contact an approved JEM dealer for advice. Refer servicing to qualified service personnel. Disconnect the machine from the power supply before removing any covers. Mains Cable Wiring Instructions Fog/Ht Fog/rdy FLu/Lo Fog/08 The Heavy Fog Glaciator is fitted with an un-terminated 16A cable. A suitable 16A connector should be used to connect to the supply system. To connect to US 208V supplies, the neutral conductor can be connected to the second phase of the 120V system, while phase 1 is connected to the Live pin. This equipment must be earthed. Brown = Live Blue = Neutral Green / Yellow = Earth 14 3 HEAVY FOG GLACIATOR USER GUIDE HEAVY FOG GLACIATOR USER GUIDE MACHINE LAYOUT HEAVY FOG OUTLET 9.5L FLUID CONTAINER THE FLUID SYSTEM The Heavy Fog Glaciator uses a 9.5L (2.5 US Gal.) container to give approximately 4.5 hours of continuous operation at full output. This will vary with power supply voltage, which will determine the maximum continuous output level. The machine control system uses a `Pump Ramping' technique to allow continuous operation with moderate input power requirements. When the output level is set to maximum, the machine will give maximum output until the heat exchanger has used its energy reserves. The control system will then override the output level setting and reduce the pump speed to match the output to the available input power. This ensures that the output will be continuous, although at a reduced level. Continuous operation gives rise to the possibility of pump damage if the machine runs out of fluid. This is overcome in the Heavy Fog Glaciator by using an electronic fluid sensing system, ensuring that the pump is shut down when the fluid level is too low. The Left-hand display will show a Lo Flu message to warn the user that the machine is shut down due to lack of fluid. Variations in pump performance due to supply frequency differences (50/60Hz), are compensated for automatically. Supply voltage changes will also affect the pump performance, and can be catered for by using the Supply Voltage menu (SuP) on the right-hand display unit. Using the Menu key, select the SuP menu and press enter. Now adjust the voltage to match the local power supply voltage (valid range is 200 - 250V). Press the enter key to store the new setting in non-volotile memory. The pumps will now run at the optimum level for the conditions. Remember that the type of fluid used will play a large part in determining the resulting effect. The list of fluids inside the front cover of this handbook shows the main fluids compatible with this machine. Choose a fluid suitable for the venue and type of effect you want to create. Generally, use the standard B2 fluid, but for longer lasting effects, contact a distributor for advice on using another fluid grade. CONDENSER AIR INLET POWER INLET DMX INPUT TOP VIEW CONTROL PANEL FAN AIR INLET HEAVY FOG OUTPUT FRONT VIEW 4 13 HEAVY FOG GLACIATOR USER GUIDE HEAVY FOG GLACIATOR USER GUIDE BASIC OPERATION The following instructions explain how to operate the basic functions of the machine. It is assumed that the machine is being started from cold. Starting with all the control panel switches OFF, and the display showing `OFF', go through the following sequence. Set the Standby switch to ON. Fog display shows FOG/Ht Ice display shows Den/nor Set the output to Fog = 8 Set the Ice switch to ON When the machine is ready (after approx. 20 minutes heat-up time) fog can be produced. Fog display shows FOG/Rdy Ice display shows Den/nor If starting the machine for the first time, or after the fluid has been changed, the pump may need to be primed. Do this by setting the Fog output to 15 and firing the machine for 10 seconds, or until fog is produced at the output. If the pumps have not primed after 20 seconds, there may be a problem with the fluid system. Refer to the Fault Finding section of the handbook for advice. Set the Fog switch to ON to produce continuous output of Heavy Fog. Fog display shows FOG/08 Ice display shows Den/nor Set the Timer switch to ON to produce timed output (read the Timer section to see how to configure the timer). Note that the Fog switch overrides the timer switch. Fog display shows ton/04,toff/03 etc Ice display shows Den/nor COMMISSIONING THE MACHINE Unpack the machine and look for any obvious signs of damage. Place the machine on a level surface and fit a container of JEM/Martin approved fluid into the fluid compartment. Fit the fluid line and cap to the container. Check the wiring instructions in the Safety Guidelines section of this handbook and connect the machine to the power supply. Set the power switch in the power inlet box to the ON position, and look for the start-up message on the displays. Set all the switches on the control panel to OFF and refer to the Basic Operation section of this handbook for information on how to use the main functions of ...