Question:
What do the 'Continuous Output' statement and the fluid consumption numbers in the product specs of smoke/haze machines actually mean?
Answer:
Example numbers taken from the ZR45 User Manual/Specification sheet:
Continuous effect output
Fluid consumption (max.) ............................................................ 210 ml per minute
Maximum operating time, maximum output, 5L of fluid ........................ 1.18 hours
Problem:
The numbers for fluid consumption do not seem to add up...
210ml per minute means it will get through the 5L of fluid (the included bottle) in approx. 24 minutes….but we state 1.18 hours…??
Summarised Answer:
The maximum consumption is the rate measured for the initial 100% output trigger...
For the first 10-20 seconds of true 100% output the device will consume more fluid than over the next 20 seconds (as the pump will start to reduce output) and then the pump will reduce
further etc...
So if performing short bursts (for example 100% for 3 seconds...0% for 3 seconds) the device will use a lot more fluid in 1 minute than performing a constant trigger for 1 minute.
The maximum operating time for 5L is how long it will take to empty the included 5L bottle if you trigger the machine at 100% constant output (not in bursts).
A more detailed explanation can be found below
Detailed Answer:
How the machine works:
All of the ZR range (and our other products) will operate continuously...but...not at true 100% output constantly.
All ranges (designed since 1998) use Pump Ramping Technology.
This is a software/hardware control system that allows one to change the speed of the fluid pump(s) depending on the actual current operating temperature of the heater.
As fluid flows through the heater to create the smoke it rapidly cools the heater.
The heater thermocouple (temperature sensor) reports the live temperature of the heater back to the main PCB and when it drops below a specified lower threshold, the PCB will supply
power to the heater to try to maintain/recover as much temperature as possible.
It will try to keep the heater within the correct operating temperature range so that the fluid will 'burn' correctly and produce 'safe' smoke output.
On older machines (such as the Martin Magnum 2000 unit)...pump control was not available…If the temperature drops beyond the lower threshold (usually about 10 seconds of output) then
the software/hardware will need to physically stop the output to prevent 'wet' smoke output (where the temperature is not enough to correctly convert the fluid to smoke).
Once the heater has recovered enough temperature to be within the safe temperature range again. The software/hardware will then allow the pump to operate again and resume smoke output.
This will result in an on/off output…not continuous.
From 1998 onwards (JEM ZR22 model) we had the ability to add better software/hardware control of the heaters and pumps.
Pump Ramping Technology allows for altered output of the fluid pump in relation to the heater temperature so that the temperature drop is less rapid at its lower temperature range.
The power being applied to the heater and the reduced smoke output allow the heater to get to a stage of equalized temperature gain/loss.
This means that the output does not have to be stopped as the heater will now stay within its safe operating temperature range (but at a lower output level) creating 'safe' smoke.
If triggering the machine at 100% output there will be approx. 10-15 seconds of true 100% output. During this time the temperature in the heater will drop rapidly.
Once below a pre-defined temperature threshold we will then slow the pump speed until an equal state of heat gain/loss is reached.
Despite triggering at 100%...the real smoke output may be as low as 40%...but still outputting...it will not stop.
After 30 seconds or so...you may see the output rise slightly (to 50% for example) as the temperature gain is greater than the temperature loss...
It will maintain smoke output at this lower output level as long as sufficient fluid is available
If output is paused long enough to regain optimal temperature (approx. 30s) the next time the machine is triggered at 100% output it will provide full output and the cycle will repeat.
If you just do short bursts of 100% output then the heater will recover enough temperature between triggers to allow each burst to still be true 100% output.
If you trigger the machine at a lower output level (for example 40%) then the 'pump ramping' will not have as much effect on the output as the drop in temperature will not be as extreme...so
you will get a much smoother constant output level...it will stay around 40% output as long as you can keep feeding fluid into it....
So this is true constant output...but the level of output is varied depending on the demand of the heater...
We do not have to stop to reheat...but the output level will drop to allow heat recovery/stabilisation.
So...onto the fluid consumption...
The maximum consumption is the rate measured for the initial 100% output trigger...
For the first 10-20 seconds of true 100% output you will consume more fluid than over the next 20 seconds (as the pump will start to reduce output) and then the pump will reduce further
etc...
So if you were doing short bursts (for example 100% for 3 seconds...0% for 3 seconds)...you will use a lot more fluid in 1 minute then you would if you did a constant trigger for 1 minute.
The maximum operating time for 5L is how long it will take to empty the included 5L bottle if you trigger the machine at 100% constant output (not in bursts).
You will initially use a large amount (for 10-20 seconds) but as the output drops and stabilises at a lower output level (due to pump ramping)...the consumption will go down and you will get
a longer run time.
No smoke machine (any brand) can claim to operate at true 100% output constantly (unless 100% output is actually a very low output value compared to the heater wattage of that unit).
It will either run at 100% with no change in output...then stop the output after about 10-15 seconds to reheat (like our old Martin Magnum 2000 unit)...or it will slow the output down to allow constant (but lower) output (like all of our products since 1998).
