LION SG4000 User manual

SG4000™
SMOKE
GENERATOR
[ USER’S MANUAL
Original User Manual
Rev 101 06/21

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 FIRE OR INJURY.
Read instructions/safety manual before
installing, operating or servicing.

1. INTRODUCTION................................................................................................................. 2
2. SPECIFICATIONS............................................................................................................... 4
3. OVERVIEW OF THE SMOKE GENERATOR ........................................................................... 6
4. USING YOUR SMOKE GENERATOR .................................................................................. 10
5. ERROR CODES................................................................................................................ 16
6. SERVICE ......................................................................................................................... 18
7. IMPORTANT POINTS ....................................................................................................... 19
8. WARRANTY INFORMATION ............................................................................................. 20
9. CONTACT INFORMATION................................................................................................. 21
TABLE OF CONTENTS
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE
WWW.LIONPROTECTS.COM WWW.LIONPROTECTS.COM

SMOKE GENERATOR
2
WWW.LIONPROTECTS.COM
1. INTRODUCTION
Congratulations on the recent purchase of your new LION Smoke Generator.
LION Smoke Generators are industrial-grade, high volume smoke machines
designed primarily for reghter and emergency personnel training. The 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, LION 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, LION Smoke Generators are designed to
be used with LION’s specially formulated, water based Smoke Liquid. Using a LION
Smoke Generator and LION Smoke Liquid together will provide you with the highest
quality smoke available.
This user manual describes how to properly operate and maintain the SG4000™
Smoke Generator for optimal performance.
NOTE
Using smoke liquid other than LION Smoke Liquid, including oil based
smoke liquid, may clog the uid lines and create a hazardous smoke output.
Use of smoke liquid other than LION Smoke Liquid will void the warranty.

3
WWW.LIONPROTECTS.COM
FOR YOUR SAFETY
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 LION 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 trafc conditions).
11. The 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. This 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.
WARNING

SMOKE GENERATOR
4
WWW.LIONPROTECTS.COM
2. SPECIFICATIONS
Below is a summary of LION Smoke Generator capabilities and technical
information.
GENERAL
LION Smoke Generators are continuous generators that produce high volumes of
consistent training smoke. They are specially developed for reghter and industrial
emergency response training.
The 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. The volume of the smoke uid ow is
automatically checked and adjusted to
provide optimal training conditions.
LION 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 LION factory.
CONTINUOUS GENERATOR
Because LION 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 LION 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.

5
WWW.LIONPROTECTS.COM
SPECIAL FEATURES AND TECHNICAL SPECIFICATIONS
SPECIAL FEATURES
• 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. (4.6 m) cable or wireless controller.
TECHNICAL SPECIFICATIONS
Supply Voltage 115V Version: 115VAC 50-60Hz
230V Version: 230VAC 50-60Hz
Power Consumption 115V Version: Max 1800W
230V Version: Max 2000W
Dimensions 12.5" x 19.25" x 7.5" (32 x 49 x 19 cm)
Weight 45 lbs. (20.4 kg)
Power Cord 10 ft. (3.0 m)
Tank Capacity 5 litres/1.25 gallons
Consumption of Smoke
Liquid at Max. Power
3 litres/hr.
Operating Temperature 30°F to 90°F (-1°C to 32°C)
Max. Pressure 85 PSI (5.9 bar)
Smoke Production 4000 ft3(1219.2 m3) /min of smoke to zero
visibility at 3 ft. (0.9 m)

SMOKE GENERATOR
6
WWW.LIONPROTECTS.COM
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 (SMOKE ON DEMAND)
Smoke can be produced manually by pressing the SMOKE button. Smoke is
continually produced while the button is depressed.
As long as the heater has reached operating temperature BOOST will display on the
LCD screen and the smoke output will temporarily adjust to 140% density. This higher
density output will continue for up to 20 seconds before returning to normal output.
If the system is running a program, the SMOKE button will temporarily interrupt the
pre-set functions. Once the button is released, the smoke generator will revert back
to the original program selected.
CONT. (CONTINUOUS MODE)
This operating mode is selected by pressing the CONT. button. Smoke is produced
continuously until the STOP button is pressed.
FIGURE 1: SG4000™ SMOKE GENERATOR USER INTERFACE

7
WWW.LIONPROTECTS.COM
RUN
This button begins the preset programs. Instructions for setting up programs
can be found in the “Using Your Smoke Generator” section.
STOP
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.
UP AND DOWN
These buttons change the density of the smoke output and navigate menus.
MENU
This button brings up the Smoke Generator’s menu containing programming
options and settings.
ENTER
This button is used to conrm settings and change menus.
CONTINUES >

SMOKE GENERATOR
8
WWW.LIONPROTECTS.COM
AFLUID LEVEL SENSOR
This bar indicates the remaining Smoke Liquid in the tank.
BHEATER CORE TEMPERATURE
This 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.
CCURRENT OPERATING MODE
This 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
AB C
D
E
GF

9
WWW.LIONPROTECTS.COM
DDENSITY OF SMOKE OUTPUT
This displays the smoke output as a percentage of the maximum smoke
output the system can produce. The density can be adjusted with the UP and
DOWN buttons.
EVOLUME OF SMOKE PRODUCED
This section displays the current volume of smoke being produced in
cubic feet.
FSUPPLY POWER INDICATOR
This 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.
GREMOTE CONTROL SETTING
This section indicates which section of the wireless remote control will operate
this generator. Ais the top, Bis the bottom.

SMOKE GENERATOR
10
WWW.LIONPROTECTS.COM
4. USING YOUR SMOKE GENERATOR
Turn on the Smoke Generator with the on/off 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.
The RUN button will operate a preset program. This can be used to conduct
training without manually controlling the Smoke Generator.
FIGURE 1: SG4000™ SMOKE GENERATOR USER INTERFACE

11
WWW.LIONPROTECTS.COM
PROGRAMMING THE SMOKE GENERATOR
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. There 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-off 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.
CONTINUES >

SMOKE GENERATOR
12
WWW.LIONPROTECTS.COM
6. Use the UP and DOWN buttons to navigate through the new options and
press ENTER to change them. The 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
13
WWW.LIONPROTECTS.COM
OTHER SMOKE GENERATOR SETTINGS
The Smoke Generator offers 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. The 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.
CONTINUES >

SMOKE GENERATOR
14
WWW.LIONPROTECTS.COM
5. Press ENTER and use the UP and DOWN buttons to change the DMX channel
that the Smoke Generator will use.
a. This 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. This 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

15
WWW.LIONPROTECTS.COM
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. The 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.
13. On the standard display screen there will be a small icon appear in the upper
right corner any time a button is pressed on a paired remote as seen in Figure 8.
FIGURE 8: REMOTE CONNECTION ICON

SMOKE GENERATOR
16
WWW.LIONPROTECTS.COM
5. ERROR CODES
The 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. The 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 9. If several errors
are detected at the same time, these will be shown sequentially at half-second
intervals. The error codes are dened below.
Code Definition Heating Comments
E1 When the generator is
started, the settings are
read by the device.
Error 1 indicates that
the device is unable to
read the setting values.
No The smoke generator fails to
work because the settings are
invalid or cannot be read.
Correct operation cannot be
guaranteed. This error message
cannot be removed. Factory
calibration is needed.
E3 Heating element 1 has
been switched on but
there is no feedback.
No There is a problem with
heating element 1. This problem
could be the drive circuitry,
feedback circuitry, or actual
heating element. Factory
repair is needed.
E4 Heating element 2 has
been switched on but
there is no feedback.
No There is a problem with
heating element 2. This problem
could be the drive circuitry,
feedback circuitry, or actual
heating element. Factory
repair is needed.
E5 The uid level is too low. Yes More uid needs to be added
and the generator should then
be restarted.

17
WWW.LIONPROTECTS.COM
Code Definition Heating Comments
E6 The temperature of the
heating element casing
has risen above the
maximum value.
No Wait until the temperature
falls. This can take several
minutes. If this error occurs
regularly, calibration or repair
will be needed.
E7 The temperature of the
heating element itself
has risen above the
maximum value set.
No Wait until the temperature
falls. This can take several
minutes. If this error occurs
regularly, calibration or repair
will be needed.
E8 The temperature of
the heating element
has fallen below the
minimum value set.
Yes The 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.
E9 Heating element 1 has
been switched off but it
is still functional.
No There is an error in the drive of
heating element 1. Switch off
the equipment IMMEDIATELY
to prevent overheating. Factory
repairs needed.
E10 Heating element 2 has
been switched off but it
is still functional.
No There is an error in the drive of
heating element 2. Switch off
the equipment IMMEDIATELY
to prevent overheating. Factory
repairs needed.
FIGURE 9: STANDARD DISPLAY WITH ERROR MESSAGE

SMOKE GENERATOR
18
WWW.LIONPROTECTS.COM
6. SERVICE
The Smoke Generator has been designed to require minimal maintenance
and/or service.
ANNUAL MAINTENANCE
Once per year, the Smoke Generator should be ushed with LION Cleaning
Solution, comprised of deionized water. The uid remaining in the tank must rst
be removed and then approximately 3 quarts of Cleaning Solution should be ushed
through the generator. The generator should be run on the Continuous setting until the
uid tank is empty. Any solution left in the tank must be removed.
NOTE
Deionized water is NOT regular water. Using tap, ltered,
or even distilled water will damage your heating core.
LION offers economical maintenance packages to keep your generator running at
optimal levels. Please contact your sales representative for more information.
WATER
The Smoke Generator is water-resistant, not watertight. Some residual moisture
or incidental splashing should not cause damage, but use caution when using the
generator during reghter training sessions. Always ensure that the generator
does not get wet during training operations. Do NOT cover the equipment with a
tarpaulin. This may result in a hazardous situation due to built-up heat from the
generator that cannot dissipate. Smoke ducting kits are available and can be used
to put smoke into areas where hose lines are used.
Pay close attention to the weather when operating the equipment outside
to avoid
unnecessary exposure to water.
The warranty does not cover damage caused by
exposure to water.
MAIN POWER CORD
If the main power cord needs to be replaced, contact LION for assistance.
OPENING AND REPAIRING
The Smoke Generator may only be opened and repaired by qualied staff.