LeMaitre G300 User manual

lemaitrefx.com
G300 Operations Manual
v. 06.10.05

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

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The G300 is a Microprocessor Controlled, Water Base Fog and Haze generating system.
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).
1
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.
Introduction
Microprocessor Control
Water Base Fog Technology

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M.S.D.S. available at www.lemaitrefx.com
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.
Warning

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Model: G300 Continuous Flow Fog / Haze
Micro-Processor Control Management
Type: Water Base Fog/Haze generating system
Size: 610 x 210 x 295 mm.
23 7/8”x11 7/16”x10 1/2” High (Incl. Handle)
Weight: 24 Kilos , 52 Lbs.
Power Rating: 110 Volt A.C.50/60 Hz 18 Amps
240 Volt A.C.50/60 Hz 9 Amps
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
3
Technical Specifications
G300 Illustration

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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 proce-
dure. 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.
4
Operating Procedure

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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’ - No timer or time display
‘1-SH’ - Single issues upon Fog activation
’00:10' - Timer selection in 10 second steps
’05:00' - to 5 Minutes, then 30 second steps
’20:00' - to 20 Minutes.
The ‘Duration’ control ( time of actual fog issue ) allows the following selection:
’00.02' - Timer selection in 2 second steps
’00.30' - to 30 Seconds then 30 second steps
’08.00' - 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.
5

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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 com-
mences 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.
6
Note:
Note:
Note:

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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 Me-
tres.(100 Feet).
It is not recommended to plug/unplug the handset while the machine is still pow-
ered up. If this should occur, there is a possibility that the display will produce non read-
able characters if transmission is broken mid stream of a display update.
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.
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)
Analog 0-10V Control
7
Remote and External Control Features
Analog 0-10V Control
0-10V Control Pin Assignment

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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 ‘up-
stream’ 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.
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.
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.
8
Linking Switch Setting Options
G300/ Haze - Mode Changing
Machine to Machine Linking

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It is important to note that the ‘user’ will be responsible for ensuring that the ma-
chine 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 re-
adjustment 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.
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 - LIVE
BLUE or WHITE - NEUTRAL
YELLOW/GREEN - GROUND
Always ensure that the G300 is properly grounded and that the supply is in accord-
ance with the specifications on the back panel of the machine.
9
Electrical Connections

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The casing of the G300 is steel with a powder paint coating. To clean simply wash with mild
soap and warm water.
Periodically check to ensure that the fluid pick up filter screen is in place and clean from
debris.
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.
10
Maintenance
Exterior:
Fluid Pick Up:
Heat Exchanger

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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

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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.
G300 Steamer/ Air Purge Control List

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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 com-
pletely 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.
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 G300’s 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 .
LSG/ G300 Operating ProcedureS

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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.
Note:

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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 “Director’s Choice”. It hangs in the
air 2 - 3 times longer than the “Director’s 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.
Directors’s 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.
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.
Recommended Fluids
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.
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.
Never use Neutron Haze Fluid in your G300!

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Warranty: All warranty is one year parts and labour unless specified and is on
manufacturer defect only. Abuse or poor maintenance is not ac-
cepted. 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 eco-
nomical means available. Should you require the item express-re-
turned, then you are responsible for any difference in freight cost.
Return Policy: 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.
Warning: 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 equip-
ment owners manual for proper use.
Warranty

lemaitrefx.com 17
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.
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Safety Precautions
Accessories

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Typical G300 Flow Rates in cc (ml.)/second
Flow
Setting
Flow
Setting
Fog Haze Fog Haze
1 0.3 0.05 17
20.0618
30.0819
40.1220 1.0
5.50.25 21 1.0
622 1.25
723 1.25
824 1.5
925 1.5
10 0.6 0.5 26 2.0
11 27 2.5 2.0
12 0.6 28 3.0 N/A
13 29 4.0 N/A
14 30 5.0 N/A
15 0.8 31 6.0 N/A
16 0.8
G300 Flow Rates
Notes