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Cold spark machines are a popular choice for event professionals and venue owners to uplift weddings, live concerts, and parties with dynamic sprays of sparks. Also known as cold spark fountains, these machines create cold sparks that are safe for indoor and outdoor setups and create instant captivating effects in diverse environments. Unlike the hazards of pyrotechnics, these cold sparks transform events and occasions to the next level. In a common scenario, the well-heated spark fountain creates a whistle sound, shows the ready LED sign, and, when triggered, bursts bright sparks. If those sparks do not work properly, there are three things that you should check: Make sure to turn on the power button, use the DMX or remote control, and load the machine with fresh powder.
These cold spark machines usually operate without hassle, but like other machines, if there is a lag in the machine, professional users should know about basic troubleshooting. This guide will help you understand the basic methods to troubleshoot the cold spark machines to stay prepped up for the events and avoid any performance issues.
Below are the key causes of powder clogging that can disrupt the functioning of cold spark machines:
As the cold spark machines operate with titanium or titanium-zirconium granules, it is important to keep them moisture-free. If the spark powder gets exposed to moisture, it will clump and create operational issues. In addition, it is important to keep the cold spark machine protected from rain and humid environments and avoid storing it outdoors at night.
Failure to follow these instructions properly can hamper the operation of the spark machine, making the spark powder jam or clog. Therefore, users need to take care to store the spark powder in a dry area to make it work at its optimal level.
Moreover, humidity in the air can make the warranty on a spark machine void and null.
Field-Fix Tips:
Clear the Tube: It is advised to clean the machine by using the built-in clear powder cycle that usually runs for 20 to 30 seconds after each event. A remote or DMX command button is available to perform this task in many machines. In a scenario, if the sparks stop midway through a stage performance, users need to shut down the machine safely and carefully draw out any jammed clumps. Usually, the professionals put the unit into an inverted position to dump hardened powder and smoothly run the clear cycle again.
Replace the Spark Powder: If you find clumps that do not loosen up, then it is important to dump out the old powder entirely. We recommend using a clean, dry batch of powder from a trusted supplier. If low-quality powders are used or the wrong powder is selected, the cold spark machine may malfunction. For example, adding aluminum powder to a unit designed for titanium dust creates smoke and leaves unburnt residue. Therefore, we recommend using the manufacturer-recommended powder, as most machines utilize a titanium/zirconium mix.
Check Hopper and Lid: Users need to close the hopper cover before they initiate firing from the cold spark machine. If any user tries to fire the spark with a lid open, it can be risky. Loose powder may spill, clog the heater, or sparks may ignite outside the machine. Therefore, before the start of an event, the professional users should clean the nozzle and remove leftover powder that could possibly block the effect of sparks.
Prevent moisture: It is recommended to store the spark powder in sealed bags that should be placed in a moisture-free environment. Usually, it is suggested not to use the machine in a rainy or snowy environment and to keep it totally dry. If the powder gets moistened, it is advised to replace it with a fresh batch or rotate the machine to keep the powder dry and ready to use.
The machine's power lights, whether LED or normal, illuminate properly, but the fan does not produce any noise. In such a scenario, either the fan doesn’t spin or it stutters, without any sparks shooting out. In some cases, there is visibility of an error light or code on the machine (see below).
The fan (blower) is usually the main point of failure. Either it is jammed, a fuse has blown, or the switches don't work. Many spark machines are equipped with a tip-over sensor. If the machine tips over approximately 45°, it automatically shuts off the fan, which is generally regarded as a safety feature. There can be electrical problems, like a defective fuse or motor burnout, that can cause the fan to stop working.
Check Tilt Sensor: It is important to position the spark machine on a flat surface. If the machine’s tip-over safety is initiated, which is often termed an E06 fault, it is recommended to put off the machine, turn it upright, and start again.
Look for Error Codes: Many machines flash an error code on LCDs or LEDs. For example, an E04 error means that the fan has some issue. In some cases, if debris falls into the nozzle, it can disrupt the functioning of the fan. The user needs to turn off the power, remove obstructions, and then restart. The machine typically uses a 5–6A automotive fuse, and if it burns, the only solution is to replace it.
Inspect the Fan: If you are comfortable with machines, it is suggested that you open the housing of the cold spark machine with its power off for accurate inspection. Here, the main concern is to notice if the fan blades spin freely. If there is metal dust or burn marks, an immediate step should be taken to clean it. A quick spray of compressed air can be of tremendous help. However, if there is a strong smell of burning from the fan motor or if the fan does not spin when powered on, it may need to be replaced. If you use a spilled blob of clumped granules, the fan motor may stop working after a while.
Ensure proper control mode: Make sure the machine is not in remote-only mode if you're using DMX, and vice versa. Any error in setting the DMX address or wrong channel can turn the fan off. Here users need to read the manual. Spark machines typically utilize two DMX channels, with the first channel facilitating fan operation and the second channel boosting spark intensity. Some units are equipped with either a wireless handheld start or an RFID start. It helps make sure that those systems are working or removed so they don’t override the fan.
The cold spark machine powers up with lights/LED on, the fan may run, but there is no spark effect. The heater may not be heating up, or the powder might not be igniting.
Possible causes include the following:
In models like spark packs, there is a need for an RFID or code scan to enable shot time; if this process is not completed, the machine may not run.
Check Powder Feed: Firstly, there should be powder in the hopper and accurately poured into the feeding chamber. A machine with inadequate spark powder doesn’t function properly.
Watch Indicator Lights: In the majority of cold spark machines, a green signal shows up when the heater has reached optimal temperature. There are SparkOne models that depict the flash sign that means ready to fire and a solid signal that implies heating or vice versa. Check the temperature readings on your machine if it has one. Anytime the system doesn't reach the right temperature, the heating coil might not be working right.
Error Codes/Sensor errors: If the machine is equipped with an LCD, it may indicate an error like E01/E02 for heating issues. In one scenario, one manual’s fault chart depicts E04, which means the blower is not working, and E06, an error that implies anti-tilt, while E01/E02 refer to the heating failure issues. If you observe a heating fault, then immediately shut it down, let it cool, and then restart.
DMX Remote Conflict: When you are using DMX, make certain the first channel that controls heat is at maximum value. In certain units, DMX channel 1 is used as a safety interlock. A Facebook conversation, for instance, talked about how some Sparkular-style machines won't fire until channel 1 is fully up. Therefore, it is important to verify your lighting console or controller is conforming to the right values.
Manual Reset: Try shutting the machine completely off and restarting it. In case your machine provides manual or wireless mode, try switching it. Occasionally a simple reboot process can smooth out any small sensor or temperature glitches.
The cold spark machine powers on but does not respond to your lighting console or remote control. Alternatively, it might fire at an incorrect time.
Possible causes of this issue are the following:
Verify DMX addressing: There are usually 2 DMX channels in each cold spark machine. In Sparkular cold spark machines, channel 1 is used for fan settings, and channel 2 is dedicated to spark settings. Therefore, users are required to look at the DIP switches or menu address; they must match the console. Treating it as a 1-channel fixture or leaving it at address 001 when your show is patched differently is a common mistake.
Check connections: Users must check the XLR cables along with their in/out chain. Fixtures can go out of operation if you plug a DMX cable in the wrong way or into a power socket. It is critical to check that the unit's DMX in port is connected to the console's out port and the out port daisy-chains to the next unit if there are multiple units. Addition of a DMX terminator on the last unit supports the stabilization of the signals.
Status LEDs: Many controllers have a DMX status that is reflected on the LED. On the Sparkula model, a flashing DMX LED means there is a signal, while an off LED means there is none. On the SparkOne console, a solid DMX LED means communication is fine, and an absence of light means failure. Looking out for these indicators is crucial. Investigate wiring or addressing if the DMX LED is dark or flashing strangely.
Interference from Other Modes: If your cold spark machine is controlled by a handheld wireless remote or a memory card slot, you need to remove those or disable local mode during a DMX show. It is a common occurrence to have a wireless card inserted that can sometimes override DMX control. One quick tip from the field is to run the machine in the DMX mode only or remove the RF card after programming.
Software Patching: A few designers said that generic fixtures might need to be properly defined in lighting software. One user of Resolume said that a cold spark can be controlled like any other effect because it has two channels: fan and intensity. If you are opting for GrandMA or Hog, it is important to check whether your virtual fixture type aligns with the real channels and values.
The common points of concern are when the sparks appear weak, short, or mostly smoke/dust. There is a presence of lots of white powder falling out rather than having the flying sparks.
Usually, the problem arises from using an inaccurate type of powder or choosing a low-quality one. There are powders like fine magnesium that burn in an uneven manner. Also, if the powder is stored in a moist condition, it can degrade over a period of time.
Use Recommended Powder: Each cold spark machine arrives with a manual that guides users on choosing the type and quality to use. Use of non-branded powders may not give optimal results. If you recently changed the powders, it is recommended to use the old brand. For instance, a tech found out that the machine was made for "titanium composite" (Ti+Zr) powder. He used plain Mg and got a lot of residue. Finding the right mix of Ti and Zr was the solution, and it burnt cleanly.
Check Powder Grain Size: The outdoor-rated cold spark machines work optimally with coarser “large” granules for bigger sparks. In indoor environments, the machines use a finer "medium/small" mix. Using an inappropriate size of granules can lead to either overfeeding or underfeeding, which negatively impacts the machine's performance. Therefore, it is highly recommended to label your bags and refill accordingly.
Rotate Stock: In all scenarios, you should not use old stock. It is recommended to always keep a fresh stock and rotate it by date. It is better to discard stock that is wet or clumpy. Powder that is wet and packed down will make your output dull.
Inspect for Contamination: If you are using another event’s powder or refill, make sure it’s not mixed with confetti, metal bits, or other powders. There are maximum chances of contaminants clogging or even sparking unpredictably.
If you notice a gradual decline in the performance of the cold spark machine in the form of sparks not as high or bright, the blower slowing, or the machine overheating. There can be occasions of machines shutting down after short runs or requiring longer preheating.
There are various reasons behind this performance lag:
Cold spark machines usually witness an abrasive metal dust every time they fire, which can easily settle over the sensors, fan grills, and electronics.
Clean the Dust Net and Vents: User manuals clearly state the cleaning of the fan’s dust filter or dust net. If dust blocks airflow, this can make the entire unit overheat. In such a case, shut down the machine, remove any external mesh or grill, and then blow out or vacuum the dust. At the same time, it is important to avoid using any liquid cleaners for cleaning the dust nets and vents. Small brushes or canned air can be used in tight spaces.
Wipe the Exterior: It is always recommended to opt for a dry microfiber cloth to wipe away any settled powder. It is critical to ensure gentle wiping of the housing to avoid scratches. Cleaning the outside makes it less likely that dust will get inside. Moreover, when the appearance of machines looks good and clean, it adds to the durability of the units.
Flush the Internals: Check the manual to see if there is a provision for a bottom port or drainage hole in your machine. A healthy practice is to run the machine on clean” mode after each use. This mode helps to blow out residual granules from the barrel. If you see sparks that aren't even or glowing bits that are falling, turn off the power and take off the nozzle to physically get rid of any fused lumps.
Limit Continuous Use: Cold spark machines typically have a 30-second burst rating. Do not run them at full speed for more than one minute straight. Between bursts, give your machine an adequate time to rest and cool down. It helps to boost the performance with ease.
Schedule Regular Checks: Before and after each event, give the unit a full checkup. If it doesn't void the warranty, open it up and look for loose wires or scorch marks on the heating element. It is advised to replace any brittle hoses or worn-out cables. Additionally, make sure to regularly inspect the fuse and fan motor for signs of wear. Having a decent 5–10 minutes to clean can help to prevent major failures on the next gig.
No power at all? We recommend checking the mains power and fuse. If it's not working, try another outlet.
Power on, fan silent, no spark: In such a scenario, it is important to examine the tilt sensor (set upright), inspect it properly, replace the fuse, and remove all the obstructions in the fan and nozzle. Let it cool and restart.
Power on, fan running, no spark: It is important to check if the powder is fully loaded and there are no clumps in it. If the heating light is off, the sensor or heating element is broken. Make sure to set DMX channel 1 for heat to a high temperature or switch to the manual trigger. Identify the error codes (e.g., E01 or E04), and if this error appears, immediately take the guidance from the manual.
Sparks fire weakly or sputter: It is advised to run the clear cycle to clear any blockages. For optimal performance on a cold spark machine, use a fresh and high-quality batch of spark powder. Also, ensure the hopper lid is fully secured and dry.
DMX issues: Ensure the machine’s DMX address and channel mode are fully aligned. If there is a problem, switch the cables, choose a different DMX port, and watch the DMX status LED. To find the source of the problem, you can disconnect DMX and test with the local trigger if necessary.
If problems still continue despite accurate adherence to troubleshooting guidelines, or if you intend to bring your cold spark machine to regular usage, it is recommended to opt for a newer version that is more performance-driven and can sustain frequent usage. Industry experts recommend a professional-grade cold spark system for credible performance. One popular choice is the Rasha Professional AllSparx Cold Spark Machine, highly preferred by DJs and coordinators mainly for its reliable and consistent performance. Built to higher standards with a stronger fan motor and better seals, the Rasha Professional AllSparx Cold Spark Machine comes with quality powder, making it ready for immediate use during busy events. Even the best machines require maintenance, but a top-tier model is designed to endure heavy use and minimize downtime.
To conclude, identifying the exact problem and fixing it with the steps above will keep your cold spark fountains working as they should. Always have a spare fuse, fresh powder, or even a second unit ready for big events, and make sure your machine is clean, dry, and full of the right powder.
Ensure your machine is plugged in and turned on. Switch to a different plug or breaker if needed. Thoroughly check the fuse and immediately replace it if it is blown. Usually machines use a 10A fuse for optimal outcomes. Identify whether the control mode is remote or DMX. For a remote, put in a new battery and point it at the unit. For DMX, check the cables and channel. Make sure there is sufficient spark powder in the hopper, as if there is no powder, it results in no sparking.
Switch off and unplug the machine, and make sure to remove any old powder.
Check that the powder pathway is clear. It is recommended to use a small brush or compressed air to smoothly get rid of the buildup from the feed tube and fan area.
Ensure the fan spins easily. To make sure the powder is flowing right, add new, dry powder and test with a short spark.
Always replace the fuse with a fix. It is important to check whether the powder is loaded, as running empty can lead to an overload. Regular maintenance includes checking the fan and motor for debris and cleaning them. Always ensure replacing the fuse with the proper rating as clearly specified by the manufacturer, for example, 10A for a 600W unit. If the issue persists, have a qualified technician inspect the machine.
Yes. These machines are designed to produce no open flame or significant smoke. The sparks come out at a temperature of about 64°C, which is not hot enough to burn. However, it is recommended you keep a safe distance that is roughly 5–6 feet, which is 1.5–2 meters away from the audience. In addition, there should be strict adherence to all safety guidelines described in the manual.
It mainly depends on the model that you are using. Many machines usually give 20–30 second bursts, yielding about 10–20 bursts per pack. There are high-end machines, the Rasha AllSparx, that can run almost continuously—up to 30 minutes on a single refill. To determine the exact run time of your machine, read its specifications.
After each use, it is recommended to clean out any leftover powder and wipe down the interior using a microfiber cloth.
Ensure your spark powder is well placed and sealed in its container to avoid moisture.
Frequently opt for a test by firing the unit with no powder to burn off any residue.
Replacement of fuses and batteries and regular inspection of all parts regularly are suggested according to the user manual.
