Swefog Duramax intellahazer 1k8 User manual

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IMPORTANT!
Read all cautions and warnings prior to assembly, mounting and operating
this equipment.
IMPORTANT !
Priére de lire toutes les précautions et les avertissements avant
l’assemblage, le montage et de faire fonctionner cet équipement.
WICHTIG !
Lesen Sie alle Warnungen sorgfältig bevor Sie das Gerät zusammenbauen,
installieren und benutzen.
¡IMPORTANTE!
Por favor, lea todas las precaucionas y las advertencias antes de ensamblar,
montar y opera reste equipo.
IMPORTANTI!
Leggere tutti gli avvertenti prima di montare e usare questo apparecchio.
Manufactured by:
SWEFOG TECHNOLOGY GROUP AB
Industrivägen 15
SE-682 33 FILIPSTAD, Sweden
Tel: [phone]
e-mail: [email protected]
internet: www.swefog.com

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HOW TO USE THIS GUIDE 4
1. INTRODUCTION 5
1.1 The Swefog Duramax intellahazer 1k8 5
1.2 Haze capacity 6
1.3 Some technical information 6
1.4 Intelligent Soft Start 6
1.5 About smoke fluid 7
2. UNPACKING 7
3. SAFETY PRECAUTIONS 8
4. CE-CONFORMITY 10
5. INSTALLATION & PRECAUTIONS 10
6. WIRING & CONNECTORS 17
6.1 Mains connection 17
6.2 DMX connection 17
6.3 DIN Remote 0-10V analogue connector 18
7. OPERATION 18
7.1 Technology 18
7.2 Control panel & display 19
7.2.1 Fan speed 20
7.3 Operation mode 20
7.3.1 DMX mode 21
7.3.2 Manual mode 22
7.3.3 Timer mode 22
7.3.4 A.S.O.C. –Advanced Sequence Operating Control 23
7.3.5 Remote / 0-10V mode 25
7.3.6 Fluid sensor ON or OFF 25
7.3.7 Switch OFF 26
7.4 MMS –Mode Memo System 26
7.5 LFS II –Low fluid sensing 27
7.6 Mechanical overheating protection 27
7.7 Ducting system 28
7.8 Flying installation 28
7.9 Error messages 28
8. SERVICE, MAINTENANCE & REPAIR 29
8.1 Software 29
9. TROUBLESHOOTING 30
10. Warranty 31
TABLE OF CONTENTS:

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For your safety, it is important that you read this manual thoroughly before you operate
the Duramax intellahazer 1k8.
This manual describes how to unpack, set up and operate the machine. It also lists
important safety precautions and contains a separate service & maintenance manual for
technical support.
In this manual you will find the following symbols:
The owner’s manual contains important safety precautions and
information on how to use your machine. Always read the owner’s manual before using
the machine!
This manual and updates can also be downloaded as PDF-files from the internet:
www.swefog.com
CAUTION: This symbol appears adjacent to caution
messages. Not heeding these messages could result in
minor personal injury and/or damage to equipment.
WARNING: This symbol appears adjacent to warning
messages. Not heeding these messages could result in
serious personal injury.
How to use this guide:

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The Duramax intellahazer 1k8 is a high output fog generator. Due to the very precise output
control and the integrated fan, the machine can be used for many purposes.
High output, up to 2,800m³ haze per minute.
Continuous operation at all levels.
Precise output control, 1 –100%, adjustable in 99 steps.
Solid, wide bore machined aluminium heat exchanger.
Able to handle all kinds of Swefog water based haze & smoke fluids.
High output radial fan turbine.
Industrial air pump.
Full R.I.S.C. microprocessor control. Software upgradeable.
Integrated dual “wave-guides” for easy redirection of haze.
We hope that you will be fully satisfied with the performance of your Duramax intellahazer 1k8.
To keep your machine functioning like new for its entire life, it is important to follow the
instructions in this manual and to perform regular maintenance of the machine.
For the best results, use only original water based Swefog smoke or haze fluid in the machine.
Use of any other fluid will void the warranty.
1.1 The Swefog Duramax intellahazer 1k8:
The Duramax intellahazer 1k8 is a professional haze generator, with a high output capacity,
powerful enough to fill large stages with haze. Without any need of settings or other
adjustments, the machine can be used with all kinds of water based fluids in Swefog’s
“Neutral Pro” series, supplied in bag-in-box (BiB) fluid containers.
This makes the Duramax 1k8 versatile, as the user can choose the most suitable fluid for every
venue; for normal use, light haze fluid (Neutral Pro XTR) is recommended, and a crystal-clear
extremely light haze is created. If a high output is required (i.e. for filling outdoor stages or
arenas), a medium density haze fluid (Neutral Pro MD) or even a high density smoke fluid
(Neutral Pro HD) can be used; this will maximize the output of the Duramax intellahazer 1k8.
NOTE: The Duramax intellahazer 1k8 is an advanced haze generator, and is NOT compatible
with other fluids than Swefog Neutral Pro. Other fluids will void the warranty and sooner or
later damage internal components.
The Duramax intellahazer 1k8 uses the newly developed BiB (bag-in-box) technique. This
allows the machine to be stored and/or shipped in any position, even upside down, without the
risk of fluid leakage. It also allows for very long storage time without risk of degradation of the
fluid.
We recommend that you have some experience with smoke appliances to use the Duramax 1k8,
but you don’t have to be an engineer to handle it. Just read this manual to understand your
machine and get started!
1. INTRODUCTION:

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1.2 Haze capacity
In all modes, the Duramax 1k8 can produce haze, fog or smoke (depending on fluid used)
continuously, without interruption for re-heating.
The output is never reduced, as the powerful heat exchanger is able to produce the selected
volume of haze at all times, even at full (100%) output.
1.3 Some technical information:
Very simplified, a haze machine contains a heat exchanger block, a fluid pump, a fan, an air
pump and an electronic control module, ECM. The heater block contains a pipe system, an
electric heater and metal, which works like a “battery” for storage of heat. The electronic
module controls the temperature in the heater block and the pump speed. When haze is
produced, the fluid pump starts to pump haze fluid mixed with air into the heater. Due to the
very high temperature in the heater block, the fluid will vaporize to a white haze. When the fluid
vaporizes, it consumes a lot of energy, which will cause the temperature in the heater block to
sink. Unlike most competing hazers, the Duramax 1k8 contains an oversized heat exchanger,
powerful enough to maintain its working temperature at all times, even at full output. The
Duramax 1k8 never needs to reduce output (pump speed) or stop for re-heating.
Most haze generators work with the same basic design. The difference between a high
performance generator and low-cost / mainstream products is the choice of internal components,
electronic control, user friendliness etc. Swefog Duramax 1k8 is made with the use of industrial
quality components, long-life heaters and non-compromise electronics. Most custom-made
components are precision-built in Sweden: other standard components are mostly of west
European origin. The end result is a high performance haze processor with detail quality which
sets Swefog as an industry benchmark.
1.4 Intelligent Soft Start:
To maximize performance and safety, your Duramax intellahazer 1k8 is equipped with an
advanced silent soft start system. Silent soft start is used to reduce “spitting” of unvaporized
fluid during the initial burst of haze generation. The silent soft start electronics gradually powers
the pump.
At output setting above 80%, the Duramax 1k8 will run pumps at 80% during the first 10
seconds. When 10 seconds have elapsed, the electronics will increase the pump speed to the
selected output level. At selected outputs below 80%, the pump will always start at selected
output, without soft start.
Please note: If the temperature is too low to generate haze, the pump will not start (READY
indicator is off). This is a fully automatic system, controlled by the processor, and cannot (and
should not) be disabled or modified by the user.

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1.5 About smoke fluid
Most water based smoke or haze fluids contain glycols. The glycols in the mixture create the
white particles that we recognize as smoke or haze. Three things are very important to keep in
mind regarding fluids and fog machines:
The water must be de-ionized. If the water contains minerals like calcium, salt etc;
the pipes of the heat exchanger will first be coated causing poor output, and
eventually they will clog completely, and your machine will be damaged. The pipes
cannot be cleaned.
The glycol used in the mixture has to be very clean. If not, it may clog the heat
exchanger, and most important of all, if the glycol is not 100% pure, it may be
hazardous to health, as it will contain a few fractions of unknown substances that
may be dangerous to inhale when heated.
There are also many low-cost fluids available, manufactured from water and
chemicals with unknown purity. Your fog generator will probably, work with most
of them for a limited period of time, but as always: You get what you pay for.
Swefog smoke and haze fluids are based on pure, de-ionized Swedish water which
is de-mineralized in an industrial laboratory, and absolutely free from minerals. It
contains selected glycols of pharmaceutical (medical) quality only –the finest and
most pure glycol available. The fluid is mixed and bottled in our factory, which
guarantees full protection quality control, and a clean fluid of the highest quality.
We strongly recommend that you use original fluids because the Duramax smoke
processor is a fine instrument and should be used with the original Swefog fluids it
was developed for. Other fluids may be designed for a different vaporizing (heater)
temperature or contain other chemicals and/or a different mix between water and
glycols. Fluids from other manufacturers may work fine with their own fog
machines, but if used in a Swefog fog / haze generator it may cause problems with
wet or toxic smoke. A clogged heater block can be replaced. Personal injuries may
be permanent. Always remember, you are responsible if the wrong type of fluid has
been used.
Using Swefog original fluids, you will be 100% sure the smoke produced by your
machine is non-toxic and safe, for both you and your machine.
The Duramax intellahazer 1k8 package contains one carton:
One machine.
One case (if supplied).
One manual.
PLEASE NOTE: Machine comes WITHOUT main supply cable. Duramax 1k8 is equipped with
POWERCON mains connector, and you need a mains cable with a compatible POWERCON
female connector.
Save the cartons and packing material for future use. If the machine needs to be transported, ship
placed on a small pallet preferably in the original box, and use straps to fix it to the pallet.
2. UNPACKING:

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Smoke residues and fluid spillage may be dangerous. A slippery surface can cause
serious personal injury! ALWAYS check surfaces before, during and after the use of the
machine.
Do NOT install this machine directly above an audience.
Do NOT point the discharge directly towards an audience.
Make sure the area in which this product is to be used is well ventilated.
Do NOT operate near flammable materials or fire.
Do NOT place hands or face near heat exchanger or output during operation. NOTE:
There might be puffs of smoke from the output pipe when machine is not operating.
Do NOT expose to rain or moisture.
Connect to mains outlet with earth. Use a cable with earth. Check for correct voltage
and/or mains frequency (see machine label). NEVER use the machine with wrong mains
voltage or frequency.
NOTE: The condensation of the smoke makes floors, stairs and other surfaces slippery.
Do NOT point the discharge towards cool or hard surfaces like wood, plastics, glass or
metal. If the machine is frequently used, or used for a long time, check surfaces
frequently.
3. SAFETY PRECAUTIONS:

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Use Swefog water based fluid only. Other fluids may damage the machine, cause
residues inside and outside the machine, or cause toxic or odorous smoke. USE OF ANY
OTHER FLUID WILL VOID THE WARRANTY.
The fluid contains glycol. If it condensates, glycol may cause some types of paint to get
wet. It may also affect other materials or surfaces. It may cause unprotected metal
surfaces to corrode. Do not point the discharge directly to a painted or sensitive surface.
NEVER mix or dilute the fluid. NEVER refill bag-in-box containers.
NEVER heat the fluid. Use room-temperature fluid only.
Use responsible concentrations of fog to create atmospheric effects.
NOT for residential use.
Operate in room temperature only.
NEVER cover vents or air inlets on the machine housing.
Service internal parts ONLY if you have the know-how and experience to perform the
service correctly. If not, please contact a Swefog service centre or the manufacturer.
NOTE: Incorrect service works and/or the use of non-original spare parts will void the
warranty.
NEVER change parts or details inside, use original spare parts only!
NOTE: If there is –for any reason –a fluid leakage or spillage, wipe off fluid spillage.
DO NOT use the machine until it is mended.
NOTE: The smoke may cause residues on mirrors, lenses and similar components. Keep
away from equipment with fan ventilation.
Must be handled by personnel with adequate experience with smoke appliances.
Operating the machine with an empty fluid tank will damage the pumps. Normally, the
automatic pump shutdown system will disable the pumps when the fluid is empty.

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4. CE-CONFORMITY (230V models only):
We, Swefog, declare that the appliance described in this manual
conforms to the EEC machine directive. Complete documents
may be required from Swefog.
5. INSTALLATION & PRECAUTIONS:
Fog outlet
Wave guides
Bag-in-box fluid
compartment
Keypad / display
DMX in/out,
DIN 0-10V
Analogue control
input
PowerCon mains
inlet
Fluid line
connector
Bag-in-box ejector
Droplet cloth
collector
Fan air inlet
Fluid connector
Spring holder clip

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This machine uses bag-in-box (BiB) fluid containers. Compared with a standard plastic canister, BiB
containers contain an oxygen barrier, preventing air to transfer through the material. The advantages
are excellent product life time, and a completely sealed container.
There are three good reasons to use BiB containers :
1. Leak-proof system. Correct handled, the BiB container is a 100% sealed system, with no
openings or no need to let air into the container while fluid is consumed. The machine with
fluid can be stored or shipped in any position without risk of leaking. The bag and the mating
fluid connector on machine both are equipped with automatic valves that closes the fluid line
if connector is removed.
2. The fluid does not age when consumption has started. The oxygen barrier will not transport
oxygen through the material. Since no oxygen is let into the fluid, it will keep same freshness
during the whole consumption cycle. Bag collapses flat while fluid is consumed, ensuring all
fluid is consumed.
3. The container will fit into compatible machines only. Water based fluids will fit into water
based machines, oil based fluids will not fit, and are compatible with oil based machines only.
This prevents user from using incorrect type of fog fluid.
The bag is extremely strong, and correct handled it will not leak. However, it is sensitive for rips or
scratches, and fluid will leak out if bag is punctured.
If bag is always kept inside its carton, it is safe. Ensure no part of bag is protruding outside carton, it
may easily be scratched and start to leak.
How to open and prepare the BiB container:
Check the label on fluid BiB corrugated box how to open box and positioning the fluid
connector correct.
Knock out, remove round cardboard

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Bend out flap toward non-perforated edge
Pull connector through opening outside box
Arrange connector on circular cutaway

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Push flap over connector to fixate
Insert container into fluid compartment

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Correct position of BiB fluid connector: Ensure the edges of connector goes between the
sheet metal rails, so it is supported in both directions, push & pull.
IMPORTANT –WARNINGS: No part of the plastic bag must protrude outside box, or
around the connector. If any part of bag protrudes, it will easily be ripped or scratched,
which will immediately cause serious leakage from the fluid container.

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Ensure connector is correct positioned in the support rail
Push box all the way in.
Connect fluid line by pulling the ring on machine female connector backwards about 3
mm, push black tube connector towards container until it ‘clicks’ in correct position.
Release ring and pull to ensure a correct locking of connector. NOTE: Incorrect
connection may cause leakage.

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Replacement of fluid container: Disconnect fluid connector, remaining drops of fluid can
be shaken off, using the orange cellulose cloth pad. Replace pad when necessary. While
containers are changed, place connector in the spring holder on right hand side.
Container is released by pushing the spring actuated bracket.

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6.1 Mains connection:
The standard mains connector for Duramax 1k8 is a Neutric PowerCon, approved for both
115V 60 Hz (USA / Canada) and 230V 50 Hz (Europe).
Duramax 1k8 is equipped with a MALE 20 Amp. power inlet connector type NAC3MPA.
Connect a mains cable (not supplied) equipped with a FEMALE connector, type
NAC3MPA.
NOTE: NEVER disconnect the PowerCon plug during load. Always switch machine off,
unplug the mains plug first, then unplug / remove the PowerCon connected to the machine.
6.2 DMX Connection:
6. WIRING & CONNECTORS:
Onboard XLR connectors:
MALE: Data IN for receiving data.
FEMALE: Data OUT for transmitting data.
Use a 5-pin female XLR for DMX input.
Pin 1 = 0V (earth)
Pin 2 = signal –(negative)
Pin 3 = signal + (positive)

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6.3 DIN Remote / 0-10V analogue connector:
DIN 41 524 pinout:
Pinout: 1: Not used 2: Ground 3: Fan speed 4: Haze output 5: +12V output for use with Swefog
remote controls ONLY. NOT for use with a light desk, other remote controls or any other purpose. Do
not link or short circuit any pins, it may damage the electronics. If an external voltage source is
connected for control (i.e. older types of light desks 0-10V), NEVER exceed 12V DC between earth
and pin 3/4. See chapter 7.3.5 “Remote / 0-10V mode” for further information.
7.1 Technology:
The Duramax intellahazer 1k8 is a high performance haze generator system. All internal
components are controlled by the microprocessor for safe operation. At start up from cold, the
machine will perform the operation below before it is ready to generate haze. Once ready, it can
produce haze as long as there is power and fluid:
NOTE: This machine uses the mains frequency sine wave (50 Hz for 230V models, 60 Hz for
115V models) for controlling electro-mechanical components inside, and timer functions.
Heating cycle: The machine starts to warm up the heat exchanger.
At a certain temperature, the fan starts to idle at its lowest speed, 10%. The fan always runs
when this machine is on and ready.
At another certain temperature, the air pump starts (may cause a few smoke puffs when
remaining fluid from last operation is forced through the heat exchanger).
When it is ready to produce fog / haze, the green “ready” indicator is on.
Never run the machine with the case removed. Duramax 1k8 uses several internal mechanical
parts that rotates, are hot, electrical and starts automatically.
7. OPERATION:

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7.2 Control panel & display:
All settings & programming are made with the use of the control panel and the
alphanumerical display.
SWITCH ON: Plug the Duramax intellahazer 1k8 into a power socket with the appropriate
voltage.
NOTE: The machine consumes 1,800 Watts = 8 Amps at 230V & 15 Amps at 120V.
Auto-ON: If the machine has been disconnected from mains, it will automatically switch ON
when the plug is connected to a mains socket. The RED “POWER” LED indicator is on.
From Standby mode (RED “POWER” indicator is flashing slowly): Press and hold the “OK”
switch for approx. 7 seconds until the “POWER” LED indicator is on permanent and display /
keypad lights up.
The Duramax 1k8 will require approximately 7 minutes to heat to minimum operation
temperature, and approximately 9 minutes to heat to its highest temperature. At certain
temperatures, the fan and air pump will start automatically.
POWER INDICATOR:
No indication: The machine is disconnected from mains.
RED flashing slowly (about 1 blink / second): Standby mode (sleeping).
RED on permanent: Power ON.
READY INDICATOR:
Until the GREEN “ready” indicator starts to flash, the pumps are unable to run.
A flashing Ready indicator indicates that the machine is able to produce haze, but the machine is
still heating and is not yet at its full capacity.
The indicator is permanent on at highest temperature. This indicates maximum haze capacity.

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The indicator will start to flash during operation. This is normal, and indicates the machine is
re-heating. Once heated up fully, Duramax 1k8 will not have reduced output due to low
temperature.
TIMER INDICATOR:
YELLOW: Timer or A.S.O.C. program is in operation.
At timer, A.S.O.C, DMX & 0-10V modes, machine may start and stop automatically!
SMOKE ON INDICATOR:
RED: indicates fog production is on. NOTE: at low output settings, there might be up to 20
seconds between fog bursts. Please keep away from fog output at all times.
7.2.1 Fan speed (applies to all operation modes below):
To achieve quiet operation and economical use, the Duramax 1k8 fan always idles at lowest
speed (10%) when no haze is generated (smoke OFF). At smoke ON, the fan runs at selected
speed. The speed can be selected in two ways:
TRUE SPEED: At fan speed levels from 11% and up, the fan runs with the speed selected.
The fan output level is indicated in the display.
AUTO: Fan speed is proportional to haze output, i.e. low haze output = low fan speed, high haze
output = high fan speed. AUTO mode is automatically selected at fan output levels from 10%
and below.
7.3 Operation mode:
Press MODE switch to select how to operate the machine: DMX / Manual / Timer / A.S.O.C.
/ Remote 0-10V / Fluid sensor ON or OFF / Switch off.
Op mode DMXCh: 001
Op mode DMX Ch: 001 Op mode MANUAL
Op mode MANUAL
Time:00:00 smoke
Fluid sensorON
Fluid sensor ON
SWITCH OFF? (OK)
SWITCH OFF? (OK)
P 0% FAN 0%
P 0% FAN 0% >P 0% FAN 0%
>P 0% FAN 0%
>P 0% FAN 0%
(press OK to set)
(press OK to set)
1.
2.
6. 5.7.
Press MODE to select how
to control the machine.
4.
Op mode REMOTE
P 0% FAN 0%
Op mode REMOTE
P 0% FAN 0%
Seq. 1
>P 0% FAN 0%
Seq. 1
>P 0% FAN 0%
Time:00:00 smoke
>P 0% FAN 0%
3.
7.3.1 DMX mode:
Select DMX mode to control the machine from a DMX light desk.
1. INTRODUCTION