Inside a Fog Machine: How It Works and What to Do When It Clogs

by

Ever wondered what the inside of a fog machine looks like? While it might seem like a complex piece of tech, the core components are relatively simple. Fog machines are primarily made up of a heater core, pump, fluid reservoir, and control systems. Here’s a closer look inside and what you can do if your fog machine clogs.

How a Fog Machine Works:

  1. Heater Core and Heat Sink:
    • The heater core is the heart of the machine, where fog fluid is heated and vaporized into fog. It consists of a metal block (usually aluminum) designed to retain heat, with a thin copper or stainless-steel tube running through it. This tube is where the fog fluid is forced through, turning into vapor as it exits through the nozzle.
    • The heating element embedded in the block ensures the fog fluid reaches the temperature required to vaporize.
  2. Pump:
    • The pump pulls fog fluid from the reservoir and pushes it through the heating element. If the pump fails or the fluid lines clog, the machine won’t function properly.
  3. Coils or Straight Tubes:
    • The tubing inside the heater core can either be coiled or a straight shot. The design varies by model, but both styles serve the same purpose—heating and vaporizing the fluid. The coiled designs increase surface area for heating but also introduce more curves, which can become blocked more easily.
  4. Nozzle:
    • After the fluid is vaporized, it exits through a small nozzle, where blockages often occur.

What Happens When a Fog Machine Clogs:

Over time, fog fluid can leave behind residue, especially if the machine isn’t cleaned or flushed regularly. This residue clogs the narrow tubing inside the heater core, reducing or stopping the flow of fog.

Here’s how to troubleshoot and potentially fix the issue:

Fixing a Clogged Fog Machine:

  1. Backflushing with Compressed Air:
    • Disconnect the copper feed tube after the pump and use compressed air to blow backward through the system (from the nozzle side to the pump). This can often dislodge blockages, particularly near the nozzle where clogs tend to form.
  2. Cleaning with a Solution:
    • CLR (Calcium, Lime, Rust cleaner) or a vinegar solution can be used to dissolve buildup inside the tubes. Inject the solution with a syringe into the tubing (while disconnected from the rest of the machine), and let it sit for several hours or even days, depending on the severity of the clog.
    • Afterward, flush the system with distilled water to clear out the cleaner.
  3. Using a Wire:
    • For more stubborn blockages, use a thin wire like piano wire to carefully push through the tubing. A stiffer wire works best to avoid bending and bunching up in the tube. Be gentle to avoid damaging the tubing, but persistent enough to break through the clog.
  4. Drill Bit Method:
    • If the blockage is close to the nozzle, some users have had success using a long drill bit to carefully break through the clog from the nozzle side. Just be cautious to avoid damaging the heating element or the tubing inside.
  5. Frankenstein Method (Part Replacement):
    • If cleaning methods fail, you might consider replacing the clogged heater core with a working one from a used machine. This is an advanced repair and involves swapping out the internal components, but it can be a viable option, especially for higher-end fog machines with features like DMX control.

Preventing Future Clogs:

  1. Regular Maintenance:
    • Always flush your fog machine with distilled water after each season to remove residue. Let the machine dry completely before storage.
  2. Use High-Quality Fluid:
    • Using high-quality fog juice (like Froggy’s) can minimize residue buildup and clogs. Cheaper fluids tend to leave more deposits.
  3. Pump Care:
    • Ensure the pump runs properly and doesn’t run dry, as the fluid also helps cool and lubricate the pump.
  4. Store Properly:
    • Keep the machine in a dry, cool place to avoid corrosion, and use a protective solution like Pump Armor Fluid to protect the internals during storage.

Conclusion:

While fog machines might seem complex, their inner workings are relatively straightforward. If your machine is clogged, a combination of backflushing, using cleaning solutions, and manually dislodging the blockage can often get it running again. For more persistent issues, replacing parts from a similar machine could be the solution. Regular maintenance is key to preventing clogs and ensuring your fog machine delivers spooky fog year after year!

Leave a Comment