G300 Operations Manual

v. 06.10.05 lemaitrefx.com
Please Read Carefully Before Operating Table of Contents
Page 1 Page 2 Page 3 Page 4 Page 7 Page 8 Page 9 Page 10 Page 11 Page 12 Page 13 Page 15 Page 16 Page 17 Page 18
Introduction Warnings Technical Specifications Operating Procedure Remote and External Control Features; Analog 0-10V Control Linking Switch Setting Options; G300/ Haze - Mode Changing; Machine to Machine Linking Electrical Connections Maintenance G300 Industrial Hose Option G300 Steamer/ Air Purge Control List LSG/ G300 Operating Procedure Recommended Fluids Warranty Safety Precautions; Accessories G300 Flow Rates

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Introduction
The G300 is a Microprocessor Controlled, Water Base Fog and Haze generating system.

Microprocessor Control

The Microprocessor is responsible for the following control elements Monitoring the heat exchanger temperature. Driving the heater within the heat-exchanger in a proportional power mode. Driving the fluid pump units in a pulse mode, relating fluid flow to temperature Accepting and manipulating data from the Flow, Duration and Interval controls. Accepting data from the Smoke Switch. Accepting data from the 0-10 volt inputs. Sending and receiving data relating to machine/machine linking. Monitoring the heater and pump power switching devices. Monitoring the voltage supply. Determining the mains frequency. Determining the main mode of operation and adjusting the required parameters. Monitoring the 31 step mode adjustment preset for parameter offsets. Monitoring the display preset to allow one of three display modes. Sending display information relating to FlowRate, Duration Time, Interval Time, Ready Status, Heater Status, temperature ( if selected) and mode step (if selected).
Water Base Fog Technology
Water Base Fog technology is achieved by pumping a Glycol/Water mixture through a Heat exchanger. The heat exchanger has been heated to the point where at the fog fluid mixture will vaporize. The fluids own vaporization forces the hot mixture out of the output nozzle where, when it mixes with the ambient air, it forms an opaque aerosol (fog). The fog is made up of tiny droplets of glycol that form around the small particles in the air. The suspended droplets reflect the light, which is why fog will take on the colour of the light illuminating it.

Warning

Important Safety Instructions: Do not touch or place hands, expose skins, within 50 cm. of discharge nozzle.
Important Safety Instructions: Do not remove the outer case until power has been disconnected from the machine.
Important Safety Instructions: Persons suffering from asthma or allergenic sensitivity may experience irritation, discomfort, or allergic symptoms when exposed to fog effects.
Important Safety Instructions: Ensure that this unit is grounded at all times. Failure to do so may result in serious injury.
Important Safety Instructions: Never use alternative fluids. Toxicity free output is your responsibility.
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Technical Specifications

Model: G300 Continuous Flow Fog / Haze Micro-Processor Control Management Water Base Fog/Haze generating system 610 x 210 x 295 mm. 23 7/8x11 7/16x10 1/2 High (Incl. Handle) 24 Kilos , 52 Lbs. 110 Volt A.C.50/60 Hz 240 Volt A.C.50/60 Hz 18 Amps 9 Amps
Type: Size: Weight: Power Rating: Facilities:
Selectable Haze or Hi-Power G300 Mode Detachable Digital Display Remote 0-10 Volt Fog/Flow Control Fog/Flow Digital Machine Linking Flow /Fog/Data Accept Switches

G300 Illustration

Operating Procedure
1) The G300 must only be connected to a mains supply capable of sustaining at least 18 Amps, and be adequately Grounded. The supply should be clean and free of interference. 2) The Power to the G300 should be controlled by the illuminated Mains Power switch located on the rear panel. 3) Shortly after switching ON, the digital display on the remote panel will show a 50H or 60H. This is an automatic line frequency check which allows highly accurate timing features. 4) The Display unit will now start flashing HAZE. This is a default setting. If Regular Haze fluid is to be used, then the machine should be allowed to continue without interruption. If the Hi-Power G300 mode of operation is required where fog fluid will be used, then at this time of display flashing, the button marked G300 MODE should be kept depressed. The display will change to read G300, until such time as this mode is recorded, and the machine continues in its start up procedure. The button can then be released. For those machines equipped with a G300 MODE keyswitch please refer to key card for proper keyswitch position.

Should Haze mode be selected when the machine has been operating in the G300 mode, then it is possible that time will be required to allow the machine to adjust to the Haze characteristics. This will be indicated by a flashing C code in the Heat-Flash window of the remote control.
5) The Remote Display will now enter its standard phase. This indicates the Heating power, the Flow rate setting, and the Ready status. At this stage the flow rate may be adjusted freely between minimum and maximum settings. (Upon entering a ready to operate phase the maximum allowable flow rate will be automatically adjusted based on the energy available. ) 6) The Timer controls are of an auto-display option, and will display immediately upon being adjusted, or if set to any position apart from the Interval being Off will display approximately every 10 seconds.
The Interval control ( time between repeating fog issues ), allows the following selection: OFF 1-SH 00:10' 05:00' 20:00' No timer or time display Single issues upon Fog activation Timer selection in 10 second steps to 5 Minutes, then 30 second steps to 20 Minutes.
The Duration control ( time of actual fog issue ) allows the following selection: 00.02' 00.30' 08.00' Timer selection in 2 second steps to 30 Seconds then 30 second steps to 8 Minutes.
Note that when the automatic display of the timer settings occurs, the Interval time will have a central colon (:) whereas the Duration time will have a central point (.) displayed. 7) As the machine heats up to its operating temperature, if the flow setting has been set to maximum, there will be a point when this will readjust to a much lower value. It is at this point that the machine has reached its lowest ready point. A flashing H or G will appear in the Ready Flash window, indicating that the machine is now ready at its minimum level. The machine can in fact be operated at this point, or further time allowed for maximum issue capabilities. If the machine is allowed further time, then the Flow rate will be seen to increase in its allowable maximum setting until position 31 is reached.
At this time, or shortly afterwards, the Heat Flash indicator bars on the Remote handset will reduce from 3 bars to 2, and then 1 and finally no bars, as the heater switches off. When settled, the Heat Flash indicator will indicate the power being used in maintaining the working temperature. Since proportional control is used, this will vary upon the operating environment. 8) The machine may now be operated fully as desired with due attention to all prevailing safety regulations.

FLUID REPLACEMENT

Replacing fluid does not require any attention to priming conditions. The G300 uses a unique system of fluid pumping which allows fluid system replenishment without requiring special settings of flow control. HAZE FLOW CONTROL
The machine will change the characteristics of the Flow Rate settings when Haze mode is in effect. This allows very short burst issues up to 5 seconds apart to be selected just by the Flow Rate control when at its lowest on setting. ( 0 is actually no flow, which can be useful if only a single channel 0 -10v control is available). This decreases to every 4,3,2, and 1 seconds, after which point normal flow control commences as the flow rate is increased. This feature allows instant Hazing to be instigated by employing a high flow setting, then allowing replenishment of loss by means of a low output, high velocity haze issue.
AUTOMATIC and CONTINUAL FLOW CONTROL
The G300 employs an extremely high accuracy thermal monitoring system. Combining this with Micro-Processor control and a highly stable Patented Heat Exchanger, allows a self management system to automatically adjust the flow rate for maximum conditions at any temperature. This means that regardless of energy availability, a continual flow setting is automatic. If the initial flow setting is high, then this will be decreased as flow continues, until such time as a stable situation is attained.
Remote and External Control Features
The standard Remote Handset may be removed from the machine, and operated effectively away from the issue site. The maximum recommended cable length is 30 Metres.(100 Feet). It is not recommended to plug/unplug the handset while the machine is still powered up. If this should occur, there is a possibility that the display will produce non readable characters if transmission is broken mid stream of a display update.

Analog 0-10V Control

The rear panel of the machine is fitted with a 4 Pin XLR connector which will allow the connection of two 0 - 10 volt lines. One line is of a switching characteristic for the activation of fog, simulating the Smoke On switch, while the second line is for analog control of the Flow Rate. Both lines can be used simultaneously for complete control, or either can be used individually. In the case of the Flow Rate line being used alone, the Smoke On switch will be required to be set in the On position, and a definite 0 volt condition available from the controller to switch the fog output off. No special selection of rear panel control switches is required for this mode of operation.

0-10V Control Pin Assignment
The Pin Assignment for the connector port labeled 0-10 v Control are as follows: Pin 1 Common Pin 2 Smoke On 0- 10V Pin 3 Flow 0- 10 V Pin 4 (Not used)
Linking Switch Setting Options
If it is required for a machine to accept Flow Rate data from an upstream unit, then the Flow Accept switch on this machine must be active. If it is required for a machine to accept the Smoke On switch data from an upstream unit, then the Smoke Accept switch on this machine must be active. If it is required to control the next downstream machine with the timer control of the local machine then the Send Timer switch must be active. Using these various switching options will allow flexibility in a link up pattern, and enable individual machine setup without the need to break the linking path.
G300/ Haze - Mode Changing
The two modes of operation that can be performed by the G300 machine are unique in their operating characteristics. They allow distinctly different fluid types to be used for a wide range of effects. As stated repeatedly throughout this operations manual, Hazing type fluid should not be used in the Hi-Power G300 Fog Mode. Although actual machine damage will not result, long term performance will suffer as a result. Changing modes of operation is effected at the point of switch on, and re-selection of the Hi-Power Fog mode at the time of Fluid replacement.
Machine to Machine Linking
This facility is available for the purpose of multi-machine control. The rear panel of the machine is fitted with two 5 Pin XLR connectors for daisy chaining any number of machines. Three selector switches above the Remote panel control various available options. Please note that the protocol of the communication is exclusive to the G300. Linking cable should be of high quality screened data type. Communication is dealt with via opto-coupled links, which will isolate ground potential, but it should be remembered that if the cable is grounded at both ends, then any ground voltage difference could convert to high current paths between machines via this screen.
It is important to note that the user will be responsible for ensuring that the machine is in the correct mode for the prevailing fluid type. All that is required is a brief machine switch Off then back On again. In the example given i.e. from Hi-Power G300 mode to HAZE mode, a readjustment period will be required for the machine to settle to the Hazing characteristics. ( Indicated by a flashing C in the heater flash window of the digital display.) To allow a quicker change over from G300 to Haze, operate the machine with normal fluid to the point of continuous flow, switch the machine off, replace the fluid with the Hazing type, switch back on, and all will be well.

Electrical Connections

The G300 must only be connected to a suitable electricity supply line. This supply line must support a suitable earth line. The following colour codes are employed in the electrical connection. BROWN or BLACK BLUE or WHITE LIVE NEUTRAL GROUND

YELLOW/GREEN

Always ensure that the G300 is properly grounded and that the supply is in accordance with the specifications on the back panel of the machine.

Maintenance

Exterior: The casing of the G300 is steel with a powder paint coating. To clean simply wash with mild soap and warm water. Fluid Pick Up: Periodically check to ensure that the fluid pick up filter screen is in place and clean from debris. Heat Exchanger Using high quality Le Maitre fluid should result in a long heat exchanger life however we recommend that our EZ Kleen Preventative Maintenance fluid be run through the fog machine on a regular basis - every month for about 5 - 10 minutes, depending on how heavily the G300 is used; to help prevent blockages.
G300 Industrial Hose Option
1. Remove G300 cover and existing fluid assembly 2. Drill hole in front control panel to accept key switch Figure 1. Solder wires from G300 mode button to Pins 1 and 3 on key switch (be careful not to over-heat the switch). 3. Take the long end of the black hose and feed up through the existing hole Figure 2. (from inside out) Be sure to use the hole plug provided to permit the hose clamp from protruding through the hole. 4. Slide on the strain relief and insert the brass filter Figure 3. To adjust the depth of the hose simply loosen nut A and slide up or down the hose and retighten. Be careful not to pinch off the flow of fluid. 5. Make all conncetions to the pumps using gear clamps provided and replace lid. Note: A dry hose can take between 45 - 60 seconds to prime. This is normal because of the inside diameter of the hose.

Figure 1

Figure 2

Figure 3

G300 Steamer/ Air Purge Control List
A- Air pressure Gauge: This is used as a visual aid to help in setting the air pressure used in the steam simulation/ air purge effect. B- Air Pressure Control: This is used to control the velocity of the steam/ air purge effect, with the setting being displayed on the Air Pressure Gauge in p.s.i (pounds per square inch). C- Air Input: This quick coupler connector is used as the input for the compressed air, and is an industrial interchange 1/4 body. D- Continuous Air Over Ride: This switch is used if continuous air output is desired. If show control air is used, this switch must be in the off position. E- G300 Mode Control (Key Switch): The G300 is a dual operational machine which operates in Haze (H) mode or Fog (G) mode. For the purpose of steam simulation, the fog (G) mode is used ONLY. Fog (G) mode is activated when the key is in the horizontal position. F- Show Control Smoke On (Terminals): These show control terminals control the fog ON or OFF. These are dry contact controls, where the contacts are open or closed. G- Interval Control: Controls the interval between fog bursts. If show control is used the interval setting must be 0. H- Duration Control: Controls the duration of fog bursts. If show control is used the duration setting must be 0. I- Smoke Flow Control: Controls the density of the steam effect and fog volume J- Show Control Air On (Terminals): These show control terminals control the air ON or OFF. If Show Control is used the continuous Air Over Ride switch must be in the OFF position. These are dry contact controls, where the contacts are open or closed.

Some experimenting is necessary to achieve each desired effect. A few points to keep in mind are the air pressure will determine the velocity of the effect, while the flow control of the fog machine will determine the density of the effect. When using the air option as a fog purge, enough time must be allowed for the air to completely purge the heat exchanger of fog and fog fluid. Remember on the next fog cue enough time must be allowed for the fog fluid to fill the heat exchanger and exit out the nozzle.
LSG/ G300 Operating ProcedureS
1.) Place the G300 directly against the foam ring input of the LSG. Proper alignment can be observed by shining a flashlight into the 12" exit of the LSG and noting the G300 output nozzle is centered in the LSG input. 2.) Connect the blue Twist lock connector into Custom port on the rear panel of the G300. (Available on G300s with LSG option.) 3.) Power up the G300 by turning on the Mains switch. Note that the G300 is in Fog mode, which is indicated by a flashing 'G ' on the remote display. 4.) Adjust remote interval control fully clockwise, until 'DEL' appears on the display. 5.) Adjust remote duration control until desired delay is achieved. This delay allows the liquid CO2 to purge the supply hose of CO2 gases ensuring only liquid is available for optimum cooling. The recommended formula for calculating delay time is 1 sec. for every three feet of supply hose. 6.) Adjust the remote flow rate to desired fog output level. It is recommended to start at '16' and adjust accordingly. The maximum recommended flow is :LSG High Flow rate is twenty. LSG Low Flow rate is twenty-five.
7.) The second connection to be made is the CO2 supply hose. This is connected to the liquid port of the CO2 supply. A washer is necessary to prevent leaks and are available from your gas supplier. 8.) A LSG Low requires a 350 Lb. Low Pressure Dewar. You must connect the supply hose to the Liquid output of the dewar. This is usually clearly indicated on the dewar outputs. The dewar pressure as indicated on the pressure gauge must read between 300 - 340 psi to operate the LSG, this is achieved by opening the pressure builder valve at least one hour in advance of use. A LSG High requires high pressure CO2 bottle. These are normally available in 20 or 50 lb. sizes. For ease of use it is recommended that bottles with liquid siphon tubes be used. If these are unavailable simply invert the bottle to obtain a liquid supply. 9.) Tighten the CO2 supply fitting snug with appropriate wrench. 10.) When the G300 Fog machine is up to operating temperature, activate the 'Smoke' button on the remote control. The CO2 will be activated, after the appropriate delay time passes smoke issue will start. Verify cool temperature output waving your hand in the outlet fog,and feeling for cool temperature.
Controlling the LSG with DMX
When controlling your G300/LSG with a G300 DMX Interface, the delay feature for purging the supply hose is not available. We recommend using the DMX/LSG interface to control the LSG, this will allow full delay flexibility between the G300 and LSG.

Recommended Fluids

Directorss Choice Fog Fluid: This fluid has been our long standing blend. It is a clean, white, practically odourless fog. It is used for many applications where a cloud of fog is required with a medium hang time. Pro Beam (Long Lasting) Fog Fluid: We have had many compliments on our fog fluid but many of our customers would like it to hang longer so we introduced the Long Lasting Fluid. It is still odourless but a little less white than our Directors Choice. It hangs in the air 2 - 3 times longer than the Directors Choice. Quick Dissipating Fog Fluid: We have been mixing this for some time for our special effects people working in the movies. We have decided that there are many other applications for this fluid. When using this in the LSX or LSG, you will find it works very well if you are having problems with the smoke rising too quickly. It has also been used for quick burst-of-steam effects, nitrogen bursts, etc. It will dissipate at about twice the rate of the Molecular Fluid. Extra Quick Dissipating Fog Fluid: It is very similar to the Quick Dissipating but dissipates at about twice the rate of the Quick Dissipating. Molecular Fog Fluid: The Molecular Fluid was originally designed for use in the LSG and LSX, however, many other applications were found very quickly. It is clean, white, thick fog, practically odourless and dissipates as it begins to warm. Maxi Fog Fluid: Maxi Fog Fluid was developed for our high volume users requiring an excellent balance of price and performance without compromise. Regular Haze Fluid: The Regular Haze Fluid is a water based formula, and gives a quicker result with less operation time of the G300. Ideal for medium size rooms and cutting down on operational costs. EZ Kleen Preventative Maintenance Fluid: EZ Kleen is used as a preventative maintenance measure to ensure longer heat exchanger life. It is easy to use and should be used on a regular basis to prevent blockage of your heat exchanger that frequently happens to fog and haze machines.
Never use Neutron Haze Fluid in your G300!
All of our Fog & Haze Fluids are water based and leave NO residue. The G300 must always be in Haze Mode when using Haze Fluids. Permanent damage will occur if Haze Fluid is used in the Power Fog Industrial for any length of time. lemaitrefx.com

Warranty

Warranty: All warranty is one year parts and labour unless specified and is on manufacturer defect only. Abuse or poor maintenance is not accepted. Le Maitre fluids must always be used. Any trace of other fluids will automatically void ALL warranties. Accept no substitutions as there are no exceptions to this rule. Proof of purchase or proof of sale must always accompany any warranty returns. An RA (return authorization) number must be noted on the outside of any box returned to our facilities. Any packages without a clearly marked RA number will not be accepted by our receiving department. Freight on warranty items are freight prepaid to our facility and we will prepay freight back to your facility after repair, by the most economical means available. Should you require the item express-returned, then you are responsible for any difference in freight cost. Return of any product must be done within 30 days of purchase. The package must be returned freight prepaid and the RA number clearly marked on the outside of the box. A restocking charge of up to 25% may be levied. Only credits are issued to the dealers account. Any product not returned within 30 days is considered purchased. Le Maitre Special Effects Inc. considers all it's product to be safe for use in the application it was intended. Le Maitre Special Effects takes no responsibility for misuse or incorrect use. Always refer to equipment owners manual for proper use.

Return Policy:

Warning:

Safety Precautions

1. Ensure that operation of the machine is supervised by suitably trained and authorised personnel. 2. Do not modify the machine or use a machine which has been damaged in any way. 3. Allow sufficient air circulation around the machine at all times. 4. Protect the G300 from direct weather effects and wet locations. 5. Only use fluids recommended by the Manufacturer. 6. Do not continue to produce Fog output in an enclosed area when visibility is reduced below 50cm. 7. Avoid direct Fog output continuously at persons, structure or objects within close prox imity of the discharge nozzle. 8. Ensure that adequate exhausting arrangements are available in the event of an emergency. 9. Do not place hands, or exposed skin within the first 50cm of the discharge nozzle at any time during fog production.

Accessories

Model CLF 2782 CLF 2777 CLF 2778 CLF 2776 CLF 2780 CLF 2785 CLF 2787 CLF 2824 CLF 2832 Description G300 with Steam (Air) Option G300 with LSG Option G300 with 20Litre Pail Option GVolt Fog & Haze Machine 4" Ducting Hose Adapter Optional DMX Interface G300 Hanging Bracket Flight Case For G300 Machine Flight Case For G300 Machine with 4" Casters 25' G300 Remote Cable 50' G300 Remote Cable 100' G300 Remote Cable
CLF 2770 CLF 2771 CLF 2773

G300 Flow Rates

Typical G300 Flow Rates in cc (ml.)/second
Flow Setting Flow Setting

Fog 0.8 0.6.5 0.3

Haze 0.05 0.06 0.08 0.12 0.0.27 0.31 0.8
1.0 1.0 1.25 1.25 1.5 1.5 2.0 2.5 3.0 4.0 5.0 6.0 2.0 N/A N/A N/A N/A