JEM HEAVY FOG GLACIATOR (01) PDF MANUAL


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PDF Content Summary: Martin Professional A/S,Olof Palmes Allé 18, DK-8200,Aarhus N Phone: +45 87 40 00 00 Internet: martin.dk USER GUIDE VERSION 1.1 Heavy Fog Glaciator

Fluids Suitable for this system: Heavy Fog Fluid B2 Heavy Fog Fluid C3 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. HEAVY FOG GLACIATOR CONNECTIONS REMOTE 1-GND, 2-12V OUT, 3-INPUT INTERFACE1 FOG 2 STANDBY 3 TIMER 4 FAN 5 SPECIAL 6 GND DMXADDRESS 165 9 1 GND 2 COLD 3 HOT ON 112234485166327648128 9256 10SPECIAL 1 11SPECIAL 2 12 SPECIAL 3 OUT INPUT DMXDATA IN HEAVY FOG GLACIATOR 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 Power PCB 12AT 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. 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 17

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. 16 HEAVY FOG GLACIATOR USER GUIDE USER GUIDE CONTENTS Introduction 2 Features 2 Safety Guidelines 3 Machine Layout 4 Commissioning The Machine 5 Remote Control Options 5 DMX Operation 6 The Display 8 Control Panel Functions 10 The Timer 11 Basic Operation 12 The Fluid System 13 Display Messages 14 Basic Fault Finding 15 Specification 16 Connections 17 Fuse Ratings 17 Filter Maintenance 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. 1

USER HEAVY FOG GLACIATOR 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. FEATURES Tubeless condenser 9.5L fluid capacity Pump Ramping system for continuous operation All digital control system 2.5KW heat exchanger DMX512 interface (two channel) Optional PLC interface Non-volatile memory for user settings 2 Electronic low fluid detection High pressure piston pump. LED displays for FOG and ICE controls. Fog and Density controls for easy set-up. Accurate timer Remote interface. HEAVY FOG GLACIATOR USER GUIDEFan Display dEn/oFF Displayed when the Standby switch is set to OFF. dEn/nor Shows the current Density setting. StCompressor is starting StLCompressor 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 No fog output when the machine is fired using the Fog or Timer switch. Machine is not ready after 20 minutes heating time Fog disperses too quickly 15 Machine is not ready Allow time to reheat Fluid is below min level Add fluid Standby switch is OFF Set standby to ON No fog output when using DMX to fire the machine. Incorrect DMX address Machine not ready No DMX termination Flu Lo is displayed on Fluid level is below min Add more fluid the Fog display Check settings Allow time with DMX on Fit 120 ohm resistor Standby switch is OFF Blown fuse on Power control PCB Set Standby ON Disconnect supply and replace fuse. Wrong grade of fluid used for the application Fan level too high Choose a longer lasting fluid (see front cover) Increase density setting (Reduces fan speed)

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 Displayed when the Standby switch is set to OFF, indicating that the machine can not be fired and the heaters are OFF. Fog/Err 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 Fog/Ht ready. The machine is ready to fire using the Fog or Timer Fog/rdy switches. Indicates that the fluid in the container is below the minimum FLu/Lo 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 Fog/08 number displayed is the current Fog output level in the range 0 to 20 14 HEAVY FOG GLACIATOR USER GUIDE 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 autho- rized 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 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 Brown = Live Blue = Neutral Green / Yellow = Earth 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. 3

MACHINE HEAVY FOG GLACIATOR USER GUIDE LAYOUT4 HEAVY FOG OUTLET 9.5L FLUID CONTAINER CONDENSER AIR INLET POWER INLET TOP VIEW DMX INPUT CONTROL PANEL FAN AIR INLET HEAVY FOG OUTPUT FRONT VIEW HEAVY FOG GLACIATOR USER GUIDETHE 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. 13

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 12 HEAVY FOG GLACIATOR USER GUIDECOMMISSIONING 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 the machine. Read the before using the machine. 5 Safety Guidelines REMOTE CONTROL OPTIONS The Heavy Fog Glaciator provides the user with 3 ways to implement a remote control on the machine. The main control panel is fixed and can not be removed for remote operation. All the remote interfaces are located on the panel adjacent to the control panel. The options are: DMX 512 Digital Interface . The interface uses the two XLR 3 connectors marked DMX on the interface panel, and uses the usual DMX electrical standards (RS 485). The inputs are protected against overvoltage and an ouput connector is provided to allow multidrop operation of the link. Remote Interface . The remote interface uses an XLR 3 connector to allow a standard JEM remote to fire the machine. Full proportional control of the Fog output can be achieved, but the Density level must be set on the control panel. PLC Interface . This connection is an option available to installers who wish to control the machine using the ouputs from a standard Programable Logic Controller (PLC). When the interface PCB is fitted, 12/24v DC control signals can be used to switch the Fog, Standby, Timer and Ice functions. The output levels and timer settings must be made using the control panel. HEAVY FOG GLACIATOR USER GUIDE DMX OPERATION The machine may be operated using the industry standard DMX 512 digital control protocol. This allows the control of the fog system to be easily integrated with the lighting system in most installations. DMX may be used without changing any of the settings on the main control panel. When the system detects a valid DMX data stream on the input, the control will default to the DMX system levels. Any attempts to control the machine from the control panel will have no effect until the DMX signal is removed. The displays will show the current input values for Fog and Density. To ensure correct operation of the displays, the standby switch should be set to the ON position when using DMX. The machine requires two channels, with the address of the first channel set on the DIP switch. The channels control the FOG and Density settings in the following manner. Channel 1FOG output level 0 - 32 zero output (dead-band) 33 - 255 proportional output level control Implemented in 20 discrete steps Channel 2Compressor switching and Density setting 0 - 32 Compressor off 33 - 65 Low (Lo) density 66 - 98 Normal (Nor) density 99 - High (Hi) density The system implements true proportional control of the fog output rather than the simple switching functions found on other equipment. The output levels of FOG and FAN are linked during DMX operation via the Density setting. The DMX base address can be set to any channel in the range 1 - 511 using the DIP switches. The channel number must first be decoded into binary format before being set into the switches. 6 HEAVY FOG GLACIATOR USER GUIDEICE: Setting this switch to ON, will start the compressor (displays ‘St’ while starting). If the compressor fails to start within 10 seconds, the display will show ‘StL’ and the compressor will be shut down. This function is independent of the status of the STANDBY switch. THE TIMER The timer system is implemented in software using the machine’s main control PCB. As such, the timing is crystal controlled and will be of good accuracy when compared to the usual analogue timers commonly found on fog machines. The timer is enabled by setting the Timer switch on the control panel to ON. Pressing the Timer switch will cause the timer to start from the beginning of the ON period and run through to the end of the OFF period, the cycle will then repeat until the Timer switch is set to OFF. The timer will only function when the Standby switch is set to ON and the machine is ready (RdY). Switching the Timer to OFF at any time during the cycle will halt the operation. While the timer is running, the left-hand display will show the elapsed time in seconds. The display will alternate between the period name (ton/toF) and the elapsed time in seconds. To set the time periods, use the Menu key on the left-hand display to set the ‘ton’ menu as current. Press the Enter key to see the current value for the On Time (ton), and make adjustments using the Up/Down keys. Now press enter to store the value and use the menu key to select the Off Time (toF) menu. Adjust the value as for the On Time, and then enable the Timer switch on the control panel to test the settings. The current Fog and Density levels will be used by the timer system when in the ON period. 11

HEAVY FOG GLACIATOR USER GUIDE CONTROL PANEL FUNTIONS The control panel provides a means to enable the various functions that control the Fog and Fan operation. The switches have a maintained action, and are used to set the operating mode of the machine. The settings for Fog and Density levels are made using the LED display keypad. The Lo,Nor & Hi density settings are used to relate the fan speed to the current level of fog output. Use Lo density when using ducting to get maximum thrust from the fan , and use Hi density to create a very dense effect (although with reduced volume). The ramping control system may overide the density setting if required. The layout of the control panel is shown in the following drawing. 0 0 1 1 TIMER FAN 0 0 1 1 FOG STANDBY The switches are used to set the operating mode of the machine and are used individually or in combination. The functions available are explained below.FOG : Gives Fog and Fan output at the levels currently set using the display system. The machine must be Ready before fog can be produced. STANDBY : The standby switch brings the machine into operating mode and will start the heater. This switch must be ON to use the Fog switch or the Timer. When Standby is OFF, the machine will display OFF on both displays. With standby ON, and the machine ready, Rdy will be on the Fog display. TIMER : When the machine is Ready, (at operating temperature), the timer switch will start the timer running using the settings from the display. 10 HEAVY FOG GLACIATOR USER GUIDEThe machine uses a ‘pump ramping’ technique to allow continuous operation. This means that transmitting DMX 100% will cause the machine to run at full output until the temperature falls and the output is automatically reduced. The output will remain at this level until the DMX signal is reduced, or the fluid is exhausted. There is no possibility of damage, since the electronic fluid level sensor will shut the machine down. The fan output level is affected by the ramping system via the Density setting. The onboard timer functions are not accessable via the DMX system. Any timing of the output must be done using the programming capabilities of the DMX console being used to control the system. The binary weighting of the DIP switches is shown on the panel next to the switches. 7

HEAVY FOG GLACIATOR USER GUIDE THE DISPLAY Two LED displays are used in the Heavy Fog Glaciator to show status and control information. The left display shows all information for the fog generation functions of the machine, whilst the right display shows the information for the Ice functions. Located below each display are 4 function keys that can be used to control the display and the settings on the machine. The functions of the keys are shown in the following drawing. MENU ENTER UP KEY DOWN KEY KEY KEY The message displayed will depend on the operating mode of the machine at the time. However, pressing the menu key at any time will cause the display to go into the edit mode, allowing the operating parameters to be adjusted. After approximately 5 seconds since the last keystroke, the display will leave the edit mode and revert to displaying the current status information. Pressing the menu key will display the current menu function, whilst pressing and holding will scroll through the available menus. All keys work the same way, and can be operated with single keystrokes or held down to force the display to scroll through the available options/values. The scrolling function comes into operation 1 second after the key is pressed. When the user has set the required menu function, pressing the enter key will display the current value associated with that menu item. The user can now use the UP/DOWN keys to move through the available options/values either by single keystrokes or by scrolling. 8 HEAVY FOG GLACIATOR USER GUIDETo store the new value into non-volaile memory, the enter key must be pressed before moving on to another menu or leaving the edit mode. When not in edit mode, the display will show information appropriate to the current operating mode. To do this, the display will alternate between two messages. The duration of the first message is typically 1 second, whilst the second message will be visible for 2 seconds. Some messages are compounded together to form one message, eg FLu/Lo indicating low fluid in the fluid container. As an example, when the STANDBY switch on the control panel is set to OFF (0), the display will alternate between FOG and OFF. For more information about the messages to expect, see the sections covering the different control functions on the machine, eg ‘THE TIMER’. The section entitled ‘DISPLAY MESSAGES’ contains a complete list of the messages and the circumstances under which they are displayed. The menus available on each display and the functions they perform are as follows: Fog Display Fog Sets the current Fog output level in the range 0 to 20. Ton Sets the ON time of the Timer in the range 0 to 90 (seconds). ToF Sets the OFF time of the Timer in the range 0 to 90 (seconds). Ice Display Den Sets the output density level (Lo,Nor,Hi). SuP Sets the supply voltage in the range 200 to 250v. Ice Displays current system temperatures. The software that controls the displays and the other functions of the machine is stored in ‘Flash’ memory on the DMX receiver PCB. As new features become available, this program code can be updated by using the Martin Uploader programming device for the AVR microprocessor. 9


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