bullex Smoke Generator 4000 User manual

Smoke
Generator
4000™
[ USer’S manUal
www.bUllex.com
20 Corporate Circle • Albany, NY 12203 USA
Toll Free: 1-888-428-5539 • 518-689-2023
© BullEx, Inc. All rights reserved.

WARNING
WARNING
WARNING
WARNING
WARNING
Read and understand operator’s
manual before using this machine.
Failure to follow operating instructions
could result in death or serious injury.
Improper use may result
in re or injury.
Read instructions/safety manual before
installing, operating or servicing.
Risk of electric shock.
Avoid contact with water. This Smoke
Generator is not water proof.
Wear respiratory protection
when prolonged exposure to training smoke
or exposure to dense concentrations of
training smoke is likely.
Do not use Smoke Generators near known
asthmatics or those with respiratory
illness. Use only in accordance with
applicable laws, codes and norms.

20 Corporate Circle
Albany, NY 12203 USA
www.bullex.com

TABLE OF CONTENTS
  
  
  6
 
 
 
 
 
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE

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Albany, NY 12203 USA
www.bullex.com
2
Smoke Generator
1. INTRODUCTION


BullEx Smoke Generators are industrial-grade, high volume smoke
machines designed primarily for reghter and emergency personnel
training. e Smoke Generator is driven by a microprocessor control
system that carefully regulates temperature, smoke volume and density.
A variety of smoke settings can be programmed with the user interface,
allowing you to adjust the timing and intensity of smoke for your
particular training needs. Most importantly, BullEx Smoke Generators
allow you to produce continuous smoke which is ideal for creating
realistic and intense training exercises.
To ensure premium smoke and unit longevity, BullEx Smoke Generators
are designed to be used with BullEx’s specially formulated, water based
Smoke Liquid. Using a BullEx Smoke Generator and BullEx Smoke
Liquid together will provide you with the highest quality smoke available.
is user manual describes how to properly operate and maintain the
Smoke Generator 4000™ for optimal performance.
NOTE
Using smoke liquid other than BullEx Smoke Liquid, including oil based
smoke liquid, may clog the uid lines and create a hazardous smoke output.
Use of smoke liquid other than BullEx Smoke Liquid will void the warranty.

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FOR YOUR SAFETY WARNING
1. Use respiratory protection when in
prolonged contact with smoke or when
dense concentration of smoke is present.
2. People with respiratory conditions or
asthma should avoid exposure to smoke.
3. Do NOT use this appliance without
reading the entire “User’s Manual.”
4. Do NOT alter this appliance in
any manner.
5. Always use this appliance on a hard,
level, non-combustible surface such as
concrete, rock or stone.
6. Only BullEx Smoke Liquid is
approved for use with this product.
7. Keep Smoke Liquid out of reach
of children. If Smoke Liquid comes into
contact with eyes, immediately rinse
with water.
8. Smoke Liquid spill can be removed
from most surfaces with clean water.
9. Smoke Liquid is not for human
consumption.
10. Use caution when operating in windy
conditions as smoke can travel (e.g.
do not use in proximity to roadways;
smoke may obscure trac conditions).
11. e outlet nozzle and face of this
appliance will become hot when in
operation. To avoid burns, do NOT
touch appliance until it has completely
cooled for at least 15 minutes.
12. Do NOT attempt to move or store
a Smoke Generator until it is
completely cooled.
13. is appliance should be thoroughly
inspected on a regular basis by trained
personnel.
14. Do NOT handle Smoke Generators
roughly. Should you drop or bang the
Smoke Generator, inspect thoroughly
before use.
15. Serious injury or damage to
property may occur if these guidelines
are not followed precisely.

Read and understand operator’s
manual before using this machine.
Failure to follow operating instructions
could result in death or serious injury.

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4
Smoke Generator
2. SPECIFICATIONS
Below is a summary of BullEx Smoke Generator capabilities and
technical information.

BullEx Smoke Generators are continuous generators that produce
high volumes of consistent training smoke. ey are specially developed
for reghter and industrial emergency response training.
e heating element is the core of the generator and is the key to producing
high quality smoke. A microprocessor continually monitors and adjusts
the smoke generating process. e volume of the smoke uid ow is
automatically checked and adjusted to provide optimal training conditions.
BullEx Smoke Generators are developed for long term use. All the
values are set electronically and new software developments can be
downloaded onto the processor at the BullEx factory.

Because BullEx Smoke Generators are continuous generators and the
quality of the smoke is regulated at all times, it is possible that the
amount of smoke production may increase or decrease periodically.
Proper temperature control is the most important aspect of BullEx
Smoke Generators. To ensure high quality smoke production, the
generator detects temperature uctuation and self-adjusts to maintain
a consistent temperature.
Water based smoke uids produce the safest training smoke but continued
exposure should be avoided. We recommend the use of a lter mask
A1/P2 when training involves high concentrations or continuous exposure.

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

• Electronictimer.
• Variableuser-selectedsmokequantityandduration.
• Built-inheatingelementswithsubstantivethermalconduction.
• Electronicfaultindicatorsprovidedonthedisplay.
• Fittedwithtwohandlesforeaseoftransport.
• Monitoringoftemperatureofoutercover.
• Heatingelementdirecttemperaturesensor.
• Twomechanicaltemperaturesensors.
• High-pressureindustrialvacuumpump.
• Asbestos-freeinsulation.
• Optional: Remote control with 15 ft. cable or wireless controller.
 
Supply Voltage 110–120V~60Hz14.5amps
Power Consumption Max. 1800W
Dimensions 12.5" x 19.25" x 7.5"
Weight 45 lbs.
Power Cord 10 ft.
Tank Capacity 5 litres/1.25 gallons
Consumption of litres/hr.
Smoke Liquid 'XULQJ
Continuous Run
Operating Temperature  30°Fto90°F
Max. Pressure 85 PSI
Smoke Production
4000 ft3/min of smoke to zero visibility at 3 ft.

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Smoke Generator
3. OVERVIEW OF THE SMOKE GENERATOR
Figure 1 is an image of the Smoke Generator’s user panel. It contains
eight interface buttons and an LCD display. Below is an explanation
of each button.

Smoke can be produced manually by pressing the SMOKE button.
Smoke is continually produced while the button is depressed.
If the system is running a program, the SMOKE button will temporarily
interrupt these pre-set functions. e Smoke Generator will produce
smoke for as long as the SMOKE button remains pressed down. Once
the button is released, the Smoke Generator will revert back to the
original program selected.

is operating mode is selected by pressing the CONT. button.
Smoke is produced continuously until the STOP button is pressed.
FIGURE 1: Smoke Generator 4000™ User Interface

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
is button begins the preset programs. Instructions for setting up
programs can be found in the “Using Your Smoke Generator” section.

Pressing the STOP button will cease all smoke production and/or running
programs and the Smoke Generator will automatically maintain the
heater core at optimum temperature.

ese buttons change the density of the smoke output and navigate menus.

is button brings up the Smoke Generators menu containing
programming options and settings.

is button is used to conrm settings and change menus.
>

20 Corporate Circle
Albany, NY 12203 USA
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8
Smoke Generator
 
is bar indicates the remaining Smoke Liquid in the tank.
b 
is number indicates the heater core temperature as a percentage.
Onehundredpercentindicates660°F/350°C.Whenoperating
normally,thesystemwillrangebetween96and103percent.
c 
is section displays the current activity status of the Smoke
Generator. In this image the machine is ready to produce smoke
but is not actively generating any, as shown by displaying “Ready.”
Duringwarmupitwilldisplay“Heating.”
FIGURE 2: Display Screen Close Up
b c

e


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 
is displays the smoke output as a percentage of the maximum
smoke output the system can produce. e density can be adjusted
with the UP and DOWN buttons.
e 
is section displays the current volume of smoke being produced
in cubic feet.
 
is section displays the power the Smoke Generator is receiving
asapercentageof120V.Whenusingalongextensioncordorbad
power source the percentage will drop, causing smoke output to
drop as well.
 
is section indicates which section of the wireless remote control
will operate this generator. Ais the top, Bis the bottom.

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Smoke Generator
4. USING YOUR SMOKE GENERATOR
Turn on the Smoke Generator with the on/o switch located at the
back of the unit. When the Smoke Generator is switched on, the heating
element will begin to warm up until it reaches the pre-set temperature.
Upon reaching the pre-set temperature, various optional settings are
available to adjust how the smoke is emitted from the machine.
As discussed, it is possible to begin making smoke as soon as the generator
is warmed up by pressing the SMOKE or CONT. buttons. It is also possible
to change the smoke output by adjusting the density using the UP and
DOWN buttons. Releasing the SMOKE button or pressing STOP will
cease smoke generation.
e RUN button will operate a preset program. is can be used to
conduct training without manually controlling the Smoke Generator.
FIGURE 1: Smoke Generator 4000™ User Interface

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
1. Press the MENU button one time to bring up the programming display
screen. Use the UP, DOWN and ENTER buttons to navigate this screen.
2. Pressing ENTER when the arrow is on the “Initial Delay” setting
(as seen in Figure 3) will allow you to set the amount of time before
the Smoke Generator begins creating smoke. Use the UP and
DOWNarrowstoselectthetimeinhours(H)andminutes(M)
and press ENTER to conrm it.
3. ere are two modes available, AUTO and TIMER.
Figure 3 displays the AUTO option which is “Room Size.”
FIGURE 3: Programming Display (AUTO)
FIGURE 4: Programming Display (TIMER)
4. Use the UP and DOWN buttons to navigate the cursor down to
“Room Size” and press ENTER to change the value. Room size
options include small, medium and large and the Smoke Generator
will, after waiting for the specied “Initial Delay” time, create
smoke until reaching its automatic shut-o level. Press ENTER
again to conrm the changed setting.
5. To use the TIMER settings use the UP and DOWN buttons to
move the arrow to “Mode” and press ENTER, then UP or DOWN to
change the value. When TIMER is selected the display will appear
as seen in Figure 4.
>

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Smoke Generator
6. Use the UP and DOWN buttons to navigate through the new options
and press ENTER to change them. e programmable options are:
a. “Smoke” — Sets the amount of time the machine will produce
smoke during the program operation.
b. “Pause” — Sets the amount of time between repeated
“Smoke” operations.
c. “Repeat” — Choose “On” to utilize the “Pause” time and
continuously run the program until STOP is pressed.
7. When nished selecting the program options, press MENU to return
to the standard display.
8. Press RUN to begin the designated program.

FIGURE 3: Programming Display (AUTO) FIGURE 5: Setup Display
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
e Smoke Generator oers additional menus that feature more
settings and options.
1. Press MENU to open the Programming Display, then use the UP
and DOWN buttons to select “Setup” in the bottom right corner.
Press ENTER to change to the Setup display seen below in Figure 5.
FIGURE 6: DMX Display
2. Use the UP and DOWN buttons to select “Power,” “Language,” or
“Restore Defaults” and press the ENTER button to change them.
Use the UP and DOWN buttons to select the desired setting and
press ENTER again to conrm.
3. e maximum power setting is 1800 watts. Lower settings can be
used to reduce power consumption if necessary, but will decrease
the smoke output.
4. Use the UP and DOWN buttons to select “DMX” in the bottom
right corner. Press ENTER to change to the DMX display seen
below in Figure 6.
>

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Smoke Generator
5. Press ENTER and use the UP and DOWN buttons to change the
DMX channel that the Smoke Generator will use.
a. is setting will likely only need to be changed if the generator
will be operated with a dimmer pack and multiple generators
will be controlled by the same pack.
6. Use the UP and DOWN buttons to select “RC” in the bottom right
corner. Press ENTER to change to the remote control display seen
in Figure 7.
7. is display is used to link remote controls to the Smoke Generator
and designate which buttons on the remote will operate the machine.
8. As seen at the right of Figure 7, a remote can operate two independent
Smoke Generators by selecting Aor Bon the “Buttons” option.
Each set of four buttons on the remote function the same as the
buttons on the Smoke Generator control panel, AUTO operates
the same way as RUN.
FIGURE 7: Remote Control Display and Remote Layout

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FIGURE 3: Programming Display (AUTO)
9. Use “Learn Remote” to key a remote to the Smoke Generator.
a. Press and hold ENTER while the cursor is on “Learn (or
“Recognize” on some models) Remote.”
b. e display will read “Learning.” While keeping the “Enter”
button depressed, press and release any button on the remote.
c. Release the ENTER button, the remote will now be paired with
the Smoke Generator.
d. Remotes can only be paired one at a time.
10. Use “Erase All” to remove all remotes paired with the
Smoke Generator.
a. Press ENTER while the cursor is on “Erase All.”
b. Press ENTER to conrm.
11. Use the UP and DOWN buttons to select “Program” in the bottom
right corner (Figure 7 ). Press ENTER to change to the Programming
display seen in Figure 3.
12. At any time pressing MENU will return to the standard display
screen seen in Figures 1 or 2.

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16
Smoke Generator
  
E1 When the generator is started the settings are No
read by the device. Error 1 indicates that the device
is unable to read the setting values.
E3 Heatingelement1hasbeenswitchedonbutthere No
is no feedback.
E4 Heatingelement2hasbeenswitchedonbutthere No
is no feedback.
E5 e uid level is too low. Yes
E6 e temperature of the heating element casing No
has risen above the maximum value.
E7 e temperature of the heating element itself No
has risen above the maximum value set.
E8 e temperature of the heating element has Yes
fallen below the minimum value set.
E9 Heatingelement1hasbeenswitchedobut No
it is still functional.
E10 Heatingelement2hasbeenswitchedobut No
it is still functional.
5. ERROR CODES
e Smoke Generator has the ability to display a variety of error codes
which can provide you with information if something is impeding the
optimal operation of the device. If one or more errors are detected,
no smoke will be produced. e error codes can be cleared from the
display by correcting the error. Errors are shown on the display below
the standard display as seen in Figure 8. If several errors are detected
at the same time, these will be shown sequentially at half-second
intervals. e error codes are dened below.

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www.bullex.com
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• Need Assistance? Call 1-888-428-5539 •

e smoke generator fails to work because the settings are invalid or cannot be read.
Correct operation cannot be guaranteed. is error message cannot be removed.
Factorycalibrationisneeded.
ere is a problem with heating element 1. is problem could be the drive circuitry,
feedbackcircuitry,oractualheatingelement.Factoryrepairisneeded.
ere is a problem with heating element 2. is problem could be the drive circuitry,
feedbackcircuitry,oractualheatingelement.Factoryrepairisneeded.
More uid needs to be added and the generator should then be restarted.
Wait until the temperature falls. is can take several minutes. If this error occurs
regularly, calibration or repair will be needed.
Wait until the temperature falls. is can take several minutes. If this error occurs
regularly, calibration or repair will be needed.
e temperature should come up to the required level very quickly. If it does not,
somethingmayneedtobecorrectedwiththeheatingelement.Factoryrepairisneeded.
ere is an error in the drive of heating element 1. Switch o the equipment
IMMEDIATELYtopreventoverheating.Factoryrepairsneeded.
ere is an error in the drive of heating element 2. Switch o the equipment
IMMEDIATELYtopreventoverheating.Factoryrepairsneeded.
FIGURE 8: Standard Display with Error Message

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18
Smoke Generator
6. SERVICE
e Smoke Generator has been designed to require minimal
maintenance and/or service.

Once per year, the Smoke Generator should be ushed with BullEx
Cleaning Solution, comprised of deionized water. e uid remaining
in the tank must rst be removed and then approximately 3 quarts of
Cleaning Solution should be ushed through the generator. e generator
should be run on the Continuous setting until the uid tank is empty.
Any solution left in the tank must be removed.
NOTE
 Using tap, ltered,
RO or even distilled water will damage your heating core.
BullEx oers economical maintenance packages to keep your generator
running at optimal levels. Please contact your sales representative for
more information.