INTRODUCTION

Today's smoke generator is a technical, state-of-the-art,

combination mechanical and electronic instrument, and certain

precautions must be followed in its handling and storage. The

electronic console must be stored in a heated warehouse or laboratory

environment when not in actual operation. The electrical inter-

connect cables should be stored either in the generator storage

comparmnents 'or with the console. The smoke generator traile: can

be stored outdoors but it is preferable to store it in a warehouse

or garage. If the trailer is stored outdoors, the stack transmisso-

meter. section m-t have a waterproof cover. A tarpaulin covering

the entire generator may be used, but care must be taken to avoid

putting stress on the stack fans or the transmissometer elect-ical

connections.

The generator is durably designed for field use and portability.

However, like all things mechanical, the generator sometimes will

break down. In this event, a supply of spare parts is the best

solution. If no spare parts are available, some of the field

procedures in this guide may enable the class to proceed.

The operation of the generator should be entrusted only to

individuals who will treat it with the proper respect. Improper

operation or handling is the cause of most problems encountered with

a smoke generator. Attempting to "force" the generator and over-

heating the combustion chamber or the vaporizer can cause Rermanent

internal distortion, and result in unstable smoke production

and/or reduced opacity capability. Once severely damaged, a major

overhaul is usually required to correct the problem. Even the

simple act of placing a watergroof cover over the console if it

rains during a certification run can save hours of frustration and

"down time" and should not be overlooked.

The electrical lines and fuel lines should all be handled

wit? care. Damaged lines or improper connections can result in

unstable performance and cause considerable frustration to operator

and participants alike. The valves on the control console are

metering valves not shut-off valves and should never be closed

extremely tight.

Last, but by no means least, each of the systems discussed

in this guide require a reasonable warm-up time prior to routine

operation. Overlooking this fact can cause unnecessary problems

with the generator and delays in conducting a smoke school.

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TROUBLE SHOOTING

The modern smoke generator has several "component systems"

combined into a single unit. Together they provide the capability

of producing black and white mnoke plumes in opacities from zero to

one hundred percent. They also have the ability to reliably measure

and record the opacities of these plumes as produced. It is

impractical to attempt discussing all the systems at the same time.

The most logical approach as used below is to deal with each system

individually. The systems to be discussed and the order in which

they will be presented are as follows:

Electrical power supplyFans and BlawerElectronics - Transmissometer, Recorder, etc.Fuel Delivery systemBlack Smoke systemWhite Smoke system.

ELECTRICAL POWER SUPPLY

Problem

No electricity to console.

Possible Cause & Remedy

1.

2.

3.

4 .

Check to see if console isplugged in.

Check electric cord connectionsto see that they are firmly made.

Check ground fault interruptorsand/or circuit breakers.

Check connectors on extensioncords to see that they are ingood condition.

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Problem (Continued) Possible Cause & Remedy (continued)

5.

6.

Electricity reaches consolebut not other ccunponents.

1.

2 .

3.

4 .

5 .

Electricity reaches console 1.and components but voltageis low.

2.

Check for cuts or breaks inextension cord and power supplycord.

Use VOM meter to measure eachsection at its junction with thenext to isolate problem.

Check switches to see that theyare turned on.

Check the fuses in the console.

Check the electrical interconnectcords for proper and tighthook up.

Check the electrical interconnectcords for damaged or broken spots.

Check systematically through thesystem with a VOM meter to seeif problem can be isolated.

Check electrical supply foradequacy at source - if inadequatefind another source.

If source is adequate but vcltagedrops before reaching console 'usea larger guage wire or a shorterextension cord or both.

FANS AND BLOWER

Stack fans not running. 1. Is main power switch on console'turned on?

2. Is fan switch, if present, turnedon?

3. Have electr ical interconnectcords been properly hooked up andtightened?

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Problem (continued)

Stack fan running but notup to speed.

Possible Cause & Remedy (continued)

4.

5.

6.

7.

1.

2 .

3.

4.

Main blower or induced draft i.fan blower not running.

2.

3.

4.

Check for broken or damagedwires where exposed.

Check for physical damage orobstructions - bent housing,lodged sticks or twigs, waspnests, etc.

Check to see if fans can be rotatedby hand without dragging on housing.

If fan turns freely by hand, andsufficient power is reaching fanmotor and fan will not run aburned out motor is indicated.Replace fa.

Check to see if it is dragginson housing or is othe-rwiseobstructed.

Check electrical connections.

Check to see if fan rotates freelyby hand - if not and fan is notdragging bad bearings are indicatedreplace fan.

Use VOM meter to see if voltageis adequate. If not see lowvoltage procedures under electricalsupply section.

Check console to see that mainpower switch and main blowerswitch are both turned on.

Check electrical interconnectlines for tightness and forpossible damage.

Use VOM meter to check foradequate electrical supply tomotor.

Check supply connections atmotor to verify good contacts.

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Problem (continued) Possible Cause L Remedy (continued)

5. If adeguate electrical supplyis reaching motor some typeof internal short is indicated -have motor repaired or replace.

Blower running but not up to 1. Check for external damage orspeed. shaking loose which might cause

misalignment of motor and blower.

2. Use VOM meter to see if voltageis adeguate. If not see lowvoltage procedures under electricalsupply section.

ELECTRONICS - TPANSMISSOKETER & RECORDER

The transmissometer is composed of a light source and a

photocell with interconnect lines to transmit power to the light

source and the signal from the photocell. The signal from the

photocell goes to the ten-turn pots on the console and then to the

recorder. The signal is then simply converted to the input to

the drive mechanisms of the recorder. This produces the response

of the recorder indicator. If there is a digital component in

the readout system an inverter for the signal from the photocell

will also be included.

If a problem exists and the operator has determined by

checkout that the problem is internal to the recorder DO NOT- -

ATTEMPT REPAIRS. Substitute an alternate recorder or readout

device for a check or expediency or contact the generator manrfactnrez .

Repairs to the recorder should be attempted only by the generator

manufacturer or by an instrument service company.

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Problem Possible Cause & Remedv

NO readout fromtransmissometer

1.

2.

3.

4.

5 .

6.

7 .

a.

9.

Check electric power supply cordto verify that it is properlyconnected.

Check all appropriate switchesto see that they are turned on -main power, transmissometer,recorder, etc.

Check for blown fuses on theconsole.

Check electrical interconnectlines to ensure proper andtight connections.

Check light source for a burnedout bulb.

Check recorder to verify thatit is set on 10 millivolts.

Check for possible physicalobstructions between lightsource and photocell.

Check interconnect lines verycarefully for a possible brokenwire.

If generator has been exposed torain or other wetness checkjunction boxes for moistureand possible shorts.

10. If light source is not burnedout but appears dim: a) checkvoltage to light source witha VOM meter, b) replace lightsource with a stronger (brighterbulb.

11. Using a sensitive digital VOMmeter check the output of thephotocell.

12. If photocell outgut is adequatecheck the output from the tenturn pot. This will check thepe- i-cocnance of the pot.

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Problem (continued)

Readout is jittery 1.

Possible Cause & Remedy (continued)

13. If the output from the pot isadequate, a problem with therecorder is indicated.

14. If the problem is in the recorderand cannot be corrected by externaladjustments , contact the generatormanufacturer. A digital voltmeter may be substitutedtemporarily in an emergencysituation.

2.

3.

4 .

5 .

6.

7 .

a.

9.

Check all interconnect lines fortight connections.

Check interconnect lines forpossibly damaged wires.

Check to see if equipment has hadsufficient warm-up time.

Check possibility of ambientlight reaching photocell.

Check power supply to lightsource for prooer voltage andfluctuations with a VOM meter.

Check power supply to readoutdevice for proper vcltage witha VOM meter.

Check input connections at therecorder for a dampening capacitor.If there is not one present installone rated between 150 ME and250 MF. Be sure to keep thepositive and negative polescorrectly aligned.

Check the junction boxes on thetrailer for a possible loosewrre or snort.

Check recorder to verify that itis operating on 10 MV range.

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Problem (continued)

Readout is stable but notadequate for a span.

Unable to adjust readout.

Possible Cause & Re..edv (continued)

1.

2.

3.

1.

2.

3.

4 .

Check the recorder to ensureit is operating at 10 millivolts.

Check the light source forproper voltage and light intensity.If voltage is correct but lightappears dim, replace light sourcewith a stronger (brighter) bulb.

Check the Dhotocell for aging ordeterioration. This is normallya gradual process rather than anabrupt change. This can bestbe accomplished by use of asensitive digital VOM meter.

Check the recorder to ensure itis operating at 10 millivolts.

Check the adjustment of both10 turn pots to ensure that oneis not over-riding the other.

Check connection at pots toensure their integrity.

Check the pots for damage or wearand replace as necessary.

FUEL DELIVERY SYSTEN

The fuel delivery system of the modern smoke generator

consists of two essentially parallel systems. One is for white

smoke and the other is for black smoke. Generally both are subject

to the same problems. Therefore, we will discuss them simultaneously.

The components of the fuel delivery system are:

1. Fuel reservoir (usually a 5 or 6 gallon tank).

2. Fuel interconnect lines to "pick up" the fuei Zromthe reservoir and transport it to the consolecontaining the ?umps.

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3.

4 .

5 .

6.

7 .

Fuel pumps (one for each fuel) which operate on12 volts DC current and are the heart of the fueldelivery system.

A 12 volt DC current supply which converts the120 volt AC current to the 12 volt DC required bythe pumps.

Fuel interconnect lines to transport *-he fuel fromthe pumps in the console and "deliver" it to the"convenience" connections on the rear of thegenerator trailer.

Trailer mounted delivery lines are copper tubingwhich transport the fuel from the convenienceconnections at the rear of the trailer to the com-bustion chamber for black smoke and the vaporizerfor white smoke.

The combustion cbander and the vaporizer each containtheir respective final section. These are metaldelivery tubes several inches long. They are select-ively sized, shaped and placed for their specificapplication. They deliver the fuel to the exactplace for combustion and vaporization.

A major problem with any one of the fuel delivery system

components can have the effect of disabling the entire system.

Therefore, we will pose one problem and trace through the system

to try and correct it. Each major component will be discussed in

turn and appropriate corrective procedures given.

Problem: NO FUEL TO COMBUSTION CBAMBER OR VAPORIZER

1. Verify that main power and fuel pump switches are on.

2. Verify that the appropriate fuel pump is running -listen for sound or feel for vibration. If pumpis running, proceed to step 3. If pump is notrunning, proceed to step 11.

3. Check fuel resemoirs for an adequate suoply and insurethat pick-up line is submerged far enough for goodpick up.

4. Check for disconnected, broken or crimped supply lines.

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5 .

6 .

7 .

8 .

9.

Check for loose connections or leaks. See if fuelcan be observed flowing through flexible lines.IF BUBBLES ARE VISIBLE PROCEED TO STEP 15.

Make sure that fuel reservoir container has its ventopen to allow air to replace the fuel removed.

If the problem has not been found by this time, turnoff the fuel pump. Very carefully disconnect theline in question at the rear of the trailer. Turnon pump briefly and check for fuel flow. If fuelflows smoothly at this point, proceed to step 8. Iffuel does not flow, proceed to step 9. IF FUELFLOW IS ERRATIC PROCEED TO STEP 16.

Reconnect fuel line at the rear of the trailer.Exercising extreme caution - especially if equipmentis hot - disconnect fuel line at last couplingbefore it enters the combustion chamber or vaporizer.Check for fuel flow. If fuel flows at this point,the problem is most likely carbonized fuel in thefinal section of the delivery line. Carefullyremove the appropriate section and clean it out orreplace it. if fuel does not flow at this pointbut does flow at step 7, proceed to step 10.

1f fuel cannot be pumped through the delivery linewhen disconnected at the rear of the trailer, theproblem is before that point. Work backwards onestep at a time to locate the problem. After checkingthe fuel lines to ensure thei= integrity and pzopezconnections, check the pump to see if it is pumpingfuel. See step 12.

10. The fuel delivery lines between the combustion chamberand the reaz of the trailer and between the vaporizerand the rear of the trailer are copper tubing. Onrare occasions these will get crimped or c:ushed andprevent fuel flow. If so, replacement of the entizesection is the best procedure from a safety standpoint.However, one may replace only the crushed portion ifdesired. The appropriate swagelock or other sealingfittings should be used.

11. If the fuel pump is not running and the switches areon, check the console for a blown fuse. If the fuseis good, check the electric supply (12 volts DC) atthe rear of the console with a VO?l meter. If tseelectric supply for the pumps is adequate and the

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pump is properly connected but still will not run,an internal short in the motor is indicated. Repairor replace the pump. If the electric supply isturned on but does not supply electricity seestep 14. For emergency only see step 13.

12. If the fuel pump is running but not pumping fuel, aruptured diaphragm is indicated. A repair kit forthe fuel pump can be obtained and this part rebuilt.For emergency only, see step 13.

13. If a fuel pump goes down in the field and replacementor repair is not feasible, the one remaining fuel pumpcan be used for both the white smoke and black smokesys terns . This will necessitate disconnecting thefuel lines for one system and connecting the linesfor the other system alternating as needed.

14. On rare occasions the 12 volt DC electric supply whichprovides electricity to the fuel pumps may fail. If so,replacement is usually the best procedure. In anemergency, an auto battery or other similar 12 volt DCsupply can be substituted for short periods of time.

15. (a)

(5)

(c)

16. (a)

(b)

(cl

Bubbles in fuel lines may occur when the generatcris first set UD due to fuel draining out of theinterconnect lines. Operate the generator at about30% opacity for either black or white smoke fcr aperiod of time adequate to clear the lines.

If the bubbles are very small and Fersist fcr morethan a few minutes they may be forming at a looseconnection by aspiration or at the fuel pump bycavitation. Tighten all fuel line connections.Vary the flow through the pump by opening and clcsingthe fuel valve.

If the small bubbles appear to be developing at 5sfuel pump, are almost constant and cannot be elirL.nateby tightening and adjustment a problem. with the fuelpump diaphragm is indicated. This can be correctedby use of a fuel pump repair kit.

If the fuel flow fluctuates without adjusting thecontrol valve, check to see if the pump speed varies.If the speed varies, check the electrical supply andthe fuel supply in the reservoir.

Check the control valve on the console for trash inthe valve. Carefully take the valve apart andclean with cotton tipped cleaners. Be careful toavoid damage to the valve. The valves should bechecked periodically.

If pump speed is fairly constant and valves areclean and fuel flow is erratic, a Troblem with the

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fuel pump diaphragm is indicated. Purchase arepair kit and service the ~pump.

SLACK SMOKE SYSTEM

This discussion assumes that the induced draft fan is

working properly and that there are no problems with fuel supply.

Corrective measures for these item have been discussed in their

respective sections.

Problems

Fire goes out in combustionchamber at low opacities.

Possible Cause & Remedv

1.

2.

3.

4.

Unable to stabilize smoke. 1.

NOTE: Smoke will not be stablewith erratic fuelsuPPlY* See procedures 2.for this problem underFuel Delivery System.

3.

Check propane ignition torchto verify that it is burning.

Check fuel pan to verify itsintegrity - is it severely bent,warped or burned out?

Check for a small piece of brickor small amount of rubble infuel pan to act as a wick.

Check air directional vanes oncombustion chamber grill to ensurethey are adjusted for proper airflow.

Check air directional vanes oncombustion chamber grill to ensureadjusaent for proper air flow.

Check damper in mixing chamberbetween combustion chamber andinduced draft fan. It should beadjusted so there is not too muchair passing through the combustionchamber - approximately at a450 angle.

Check position of trailer to ensurethat a stiff breeze is not blowingdirectly into the combustionchamber grill or the open end cfthe mixing chamber.

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Problems (continued) Possible Cause 6 Remedy (continued)

4. Check the fuel reservoir forwater or other contaminants.Impurities result in erraticburning rates.

5. Check the inside of the combustionchamber for severe heat distortion.If this is the cause an extensiverebuilding or replacement of thecombustion chamber is indicated.

WHITE SMOKE SYSTEM

This discussion assumes that the induced draft fan is

working properly and that there are no problems with fuel supply.

Corrective measures for these items have been discussed in their

respective sections.

Problems Possible Cause & Remedy

Vaporizer floods. 1. Check the vapor delivery pipefor adequate heat where it exitsthe vaporizer. This is mosteasiIy done by applying a fewdrops of water from a laboratorysqueeze bottle. The water droosshould vaporize immediately -and not boil on the surface ofthe pipe.

2. Check warm-up time. The vaporizerrequires several minutes to XeiChproper temperature. It willrequire slightly longer in coldweather.

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Problems (continued) Possible Cause & Remedv (continued)

Unable to adjust propanetorch flame properly.

3.

4.

5 .

6 .

1.

2 .

3.

4.

Check adjustment of flame frompropane torch to ensure it isadequate for heating the vaporizerbut not so high as to causecombustion in the far end of thevaporizer. A "mushrooming" or"drumming" flame is too high.

Check the distance between thetip of the propane nozzle andthe air intake port of thevaporizer. Correct spacing isrequired (approximately one-halfinch) for proper performance.

Check alignment of torch withintake port.

Check for adeauate air flow throughthe vapor delivery pipe insidethe mixing chamber. A build-upof soot or other particulate matterwill reduce the air flow throughthe vaporizer. If clogged, removethe vapor delivery pipe and cleanit out with a device to remove -,heresidue such as a 12 guage shotgunbore brush.

Check all connections fortightness.

Check supply of propane fuel.

Make certain main valve onpropane cylinder is openedsufficiently.

Check the adjustment valve byfeeling of it. If it isextremely cold, it may be"freezing up" due to theexpanding gas. Heat it upcarefully - a small portablepropane torch may be used ifextreme caution is exercised.

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Problems (continued)

Insufficient draft through~vaporizer.

Possible Cause & Remedv (continued)

5.

6.

7 .

1.

2 .

3 .

4 .

If the main valve on top of thepropane tank is opened too fastafter a period of storage, theinternal safety mechanism mayclose and prevent the flow ofpropane. A c~lick may be heardif this occurs. Reclose thevalve and open it again very slowly

Check the distance between thetip of the torch and theheat/air intake port on thevaporizer. This distance shouldbe approximately one-half inch.

Check alignment of torch withintake port.

Check position of damper inmixing chamber. It can be adjustedto pull more air through thevaporizer by closing off the airflow in the mixing chamber somewhat

Check the delivery pipe from thevaporizer for build up of sootand other particulate matter.This will reduce the air passagethrough the vaporizer. If clogged,remove the vapor delivery pipeand clean it out.

Check the vaporizer chamber itselffor any type of physical obstruc-tion.

Check operation of the main blowerfor adequate air flow. Some oldermodel smoke generators equippedwith a l/2 hp motor and paddlewheel type blower blades do not-develop, in some cases, sufficientair flow to accommodate a propaneoperated white smoke vaporizer.

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problems (continued)

Flame up in vaporizer.

Possible Cause 6 Remedv (continued)

1.

2.

3.

4 .

5 .

6.

Check to verify that proper fuel(fuel oit not toluene) is beingdelivered to vaporizer.

Check fuel reservoir for contamin-ants.

Check the fuel delivery linefitting on the final sectionat the top of the vaporizer forproper fit and tightness ofconnection. A loose connec'ior- Aallowing fuel to drip outside ofvaporization chamber can causea flame up.

Check propane torch for properflame adjustment and alignmentwith intake port of vaporizer.

Check for draft throughvaporizer - see if smoke froma cigarette or a match is drawninto vaporizer when held nearintake port.

If above four items are correct,it may be necessary to obtainfresh fuel oil from a differen=source to ccrrect the problem.

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