Doosan BL400 Manual

This manual contains
important safety information
and must be made available to
personnel who operate and
maintain this machine.
46702181_en_B_01/19
BALLOON LIGHT
BL400, BL600
OPERATION & MAINTENANCE MANUAL
Original Instruction

3 BL400, BL600 LED Operation & Maintenance Manual
ACKNOWLEDGEMENTS
You have just acquired a balloon. Thank you for choosing
DOOSAN. We hope this product gives you total
satisfaction.
Please feel free to send your remarks to our Customer
Service department.
LET THERE BE LIGHT
The BALLOON LIGHT is specifically designed for night
work: rescue, safety, work-site operations, etc.
EXTREMELY IMPORTANT SAFETY
INSTRUCTIONS
Ensure that the operator reads and understands the
decals and consults the manuals before maintenance or
operation.
WARNING
REDUCE THE RISK OF FIRE, ELECTRIC SHOCK,
EXPOSURE TO EXCESSIVE UV RADIATION, OR
INJURY:
1. LIGHTED LEDs ARE EXTREMELY HOT. Turn off,
unplug, and allow the unit to cool before touching
LEDs.
2. ALWAYS disconnect your equipment before
servicing.
3. Do not touch the lamp cage until it has completely
cooled.
4. Do not look directly at lighted lamps.
5. Do not operate the Balloon Light unit near flammable
materials.
6. Use only with LED light engine 46769985 (BL400 -
6000°K) or 46700835 (BL600 - 6000°K).
7. Use a soft cloth or glove when handling lamps. Oil
from skin may damage the lamp during operation.
8. Do not operate the Balloon Light with damaged
electronics or if parts are missing.
9. Do not operate the Balloon Light with a damaged
envelope or without an envelope.
10. All service must be performed by DOOSAN qualified
personnel only. See Warranty Info for details.
11. Always use this lighting equipment at heights of at
least 5ft (1,5m).
12. Do not operate your stand-mounted Balloon Light on
an uneven surface or a gradient of more than 8
degrees.
13. Do not use the Envelope if the wind speed exceeds
50mph (80km/h).
14. Use only recommended stands with an ability to
support a 20lb (9kg) Balloon Light unit, and endure
wind speeds of 50mph (80km/h) at a height of 16,5ft
(5m).
WARNING
When using outdoors, basic safety precautions
should always be followed to reduce the risk of fire,
electric shock, and personal injury, including the
following:
1. Use only NEMA 5-15 “Edison” plug extension cords
connected to the correct electrical source outlets.
2. Always use Ground Fault Circuit Interrupter (GFCI)
protection when operating your Balloon Light in areas
near water, and during inclement weather.
KEEP THESE INSTRUCTIONS WITH YOUR PRODUCT

BL400, BL600 LED Operation & Maintenance Manual 4
MINIMUM DISTANCES NEAR HIGH-VOLTAGE LINES
KEEP THESE INSTRUCTIONS WITH YOUR PRODUCT
PRECAUTIONARY PRINCIPLES TO
RESPECT TO MAINTAIN YOUR PRODUCT
WARRANTY
1. Use the included glove when handling lamps to
prevent potential damage caused by the transfer of
oils and dirt to glass.
2. Always disconnect the power before performing a
service.
3. Do not operate your Balloon Light without its
envelope, or with a damaged envelope.
4. Protect the envelope by operating away from walls,
projectiles, electric wires, trees, animals, etc.
5. DO NOT LEAVE A DEFLATED ENVELOPE
UNCOVERED WHEN NOT IN USE.
6. Always use the included protective cover when
storing your Balloon Light. Failure to do so may result
in loss of warranty coverage.
7. Store your Balloon Light in a dry, ventilated area away
from heat sources and chemical products.
8. Be sure that envelope is completely dry before
installing the protective cover.
9. Do not use chemical solvents to clean the envelope.
Use mild soap and water as necessary.
10. Do not modify the electrical components or unit
structure.
11. Do not operate your Balloon Light if the cable is
damaged, twisted, or tangled.
12. Care must be taken to always operate the product
with a filter as clean as possible and not clogged. The
change in color or in appearance of the filter indicates
that it requires cleaning. A poor air intake results in
the overheating of the product that may cause a life
term reduction of certain components or their
destruction.
13. Care must be taken when handling the product stored
in its original packaging (incorporating its
reinforcements). Be careful not to drop the product
under its own weight when loading or unloading. A
damaged or eviscerated container will not protect the
product correctly anymore and must be replaced.
FAILURE TO COMPLY WITH ONE OR MORE OF
THESE RECOMMENDATIONS WILL LEAD TO LOSS
OF THE PRODUCT WARRANTY.

5 BL400, BL600 LED Operation & Maintenance Manual
RECOMMENDED GENERATOR CAPACITY
FOR DOOSAN UNITS
14. NOTE: When using generator power, ALWAYS start
your generator BEFORE plugging in your DOOSAN
unit.
15. Generator set: minimum recommended capacity:
Single phase 100-240V 50-60Hz – 1kVA.
16. WARNING: Be sure to avoid phase imbalance when
several devices are connected to the same generator.
BUILT-IN SAFETY SYSTEMS
Your Balloon Light is equipped with special safety
mechanisms that are designed to protect you and the unit
in the event of equipment failure or in certain unsafe
operating conditions:
• The BL600 is equipped with a safety pressure switch
that turns off the light if internal envelope air pressure
falls below safe operating levels.
• If a light starts blinking due to excessive heat, check
and clean the filter, be sure the fan is running and that
fresh air can come in. Make sure the envelope is
always under surveillance.

BL400, BL600 LED Operation & Maintenance Manual 6
BALLOON DESCRIPTION
Remark: The stand is optional.
1 Nut
2a BL400 Internal Structure (cage + base + support stem)
2b BL600 Internal Structure (cage + base + support stem)
3 Envelope
4 Power Supply Cord
5 Zipper
6a BL400 LED light engine (6000°K)
6b BL600 LED light engine (6000°K)
7 South Pole Plate
8 Stand (recommended accessory purchased separately)
9 Repair Kit (2 pieces)
10 Protective Storage Cover
11 Storage Tube
12 User Manual

7 BL400, BL600 LED Operation & Maintenance Manual
ENVELOPE INSTALLATION INSTRUCTIONS
Unpack your new envelope.
• Unfold the envelope on a smooth, clean surface.
• Open the zipper.
When REPLACING an old envelope, FIRST remove
original envelope.
• Unplug the balloon unit and open the envelope zipper.
Figure 1
• Unscrew the nut on the top of the envelope. (Fig. 1)
Set the nut safely aside.
• Pass the cage through the envelope zipper opening.
Figure 2
• Unscrew the 12 screws which secure the strap. (Fig.
2)
Figure 3
• Set the strap with its screws mounted aside. (Fig. 3)
Figure 4
• Unplug the ground wire from the cage. (Fig. 4 black
arrow)
• Unscrew the six nuts on the South Pole Plate inside
the envelope. (Fig. 4 white arrows)
• Carefully remove the cage from the assembly.
• Detach the old envelope from the assembly by sliding
up along the equipment.
• Put the envelope back in place.
Figure 5
• Take care of the gasket: DO NOT lose it. (Fig. 5)
• Position the zip in front of the ground wire.
• Slide the cage inside the envelope through the zipper
opening.
Figure 6
• Reattach the ground wire to the ground pin on the
cage. (Fig. 6 black arrow)
• Screw the six South Pole Plate nuts onto the cage.
(Fig. 6 white arrows)

BL400, BL600 LED Operation & Maintenance Manual 8
• Engage the « 3rd screw » and « 4th screw » of the
strap inside the holes of the heatsink located on the
right of the inside harness cable.
• Tighten these two screws for two turns only.
In order not to damage the screws, use a 4mm
Allen key.
• Move the strap to the right and outside the vertical
grid wire.
• Engage the « 5th screw » and the « 6th screw » of the
strap inside the holes of the heatsink.
• Tighten these two screws for two turns only.
• Proceed around the unit in the same way with the
other screws located on the strap.
• Stop before the two last holes of the strap that do not
have screws.

9 BL400, BL600 LED Operation & Maintenance Manual
• Position the two end screws through the vacant holes
at the other end of the strap and tighten these two
screws for two turns only.
• Then, screw these two screws fully through both sets
of strap holes only, by using a hexagonal screwdriver
4x50mm bit on a cordless screwdriver.
• Place the two screws inside the holes of the heatsink
without screwing them.
• Tighten these two screws for two turns only.
In order not to damage the screws, use a 4mm
Allen key.
Model of cordless screwdriver to use: type BOSCH GSR
10.8-2-LI with hexagonal screwdriver 4x50mm bit.

BL400, BL600 LED Operation & Maintenance Manual 10
• Tighten the 12 screws using the cordless screwdriver
set to « torque 15 » (= about 4 Nm).
If you do not have this type of screwdriver, adjust the
torque setting of the available tool to 4 Nm.
Too high a torque setting may result in a twisted
strap.
Too low a torque setting may result in the strap being
too loose.
Figure 7
• Loosely replace the nut on the top of the envelope. Do
not tighten until after the envelope is fully inflated.
(Fig. 7)
• Close the zipper.
• Inflate the envelope.
• Tighten the nut on the top of the envelope. (Fig. 7)

11 BL400, BL600 LED Operation & Maintenance Manual
LED LIGHT ENGINE REPLACEMENT INSTRUCTIONS
• Unplug the balloon unit and open the envelope zipper.
Figure 1
• Unscrew the nut on the top of the envelope. (Fig. 1)
Set the nut safely aside.
• Pass the cage through the envelope zipper opening.
Figure 2
• Unscrew the 12 screws which secure the strap. (Fig.
2)
Figure 3
• Set the strap with its screws mounted aside. (Fig. 3)
Figure 4
• Unplug the ground wire from the cage. (Fig. 4 black
arrow)
• Unscrew the six nuts on the South Pole Plate inside
the envelope. (Fig. 4 white arrows)
• Carefully remove the cage from the assembly.
Figure 5
• Unscrew the six screws on the transparent cover.
(Fig. 5)
Figure 6
• Slide the transparent cover to the top. (Fig. 6)

BL400, BL600 LED Operation & Maintenance Manual 12
Figure 7
• Replace the LED light engine 10-85-058 (6000°K)
with a new one. (Fig. 7)
Figure 8
• Replace the transparent cover and screw the six
screws on the transparent cover. (Fig. 8)
• Slide the cage inside the envelope through the zipper
opening.
Figure 9
• Reattach the ground wire to the ground pin on the
cage. (Fig. 9 black arrow)
• Screw the six South Pole Plate nuts onto the cage.
(Fig. 9 white arrows)
• Engage the « 3rd screw » and « 4th screw » of the
strap inside the holes of the heatsink located on the
right of the inside harness cable.
• Tighten these two screws for two turns only.
In order not to damage the screw, use a 4mm
Allen key.
• Move the strap to the right and outside the vertical
grid wire.

13 BL400, BL600 LED Operation & Maintenance Manual
• Engage the « 5th screw » and the « 6th screw » of the
strap inside the holes of the heatsink.
• Tighten these two screws for two turns only.
• Proceed around the unit in the same way with the
other screws located on the strap.
• Stop before the two last holes of the strap that do not
have screws.

BL400, BL600 LED Operation & Maintenance Manual 14
• Position the two end screws through the vacant holes
at the other end of the strap and tighten these two
screws for two turns only.
• Then, screw these two screws fully through both sets
of strap holes only, by using a hexagonal screwdriver
4x50mm bit on a cordless screwdriver.
• Place the two screws inside the holes of the heatsink
without screwing them.
• Tighten these two screws for two turns only.
In order not to damage the screws, use a 4mm
Allen key.
Model of cordless screwdriver to use: type BOSCH GSR
10.8-2-LI with hexagonal screwdriver 4x50mm bit.

15 BL400, BL600 LED Operation & Maintenance Manual
• Tighten the 12 screws using the cordless screwdriver
set to « torque 15 » (= about 4 Nm).
If you do not have this type of screwdriver, adjust the
torque setting of the available tool to 4 Nm.
Too high a torque setting may result in a twisted
strap.
Too low a torque setting may result in the strap being
too loose.
Figure 10
• Loosely replace the nut on the top of the envelope. Do
not tighten until after the envelope is fully inflated.
(Fig. 10)
• Close the zipper.
• Inflate the envelope.
• Tighten the nut on the top of the envelope. (Fig. 10)

BL400, BL600 LED Operation & Maintenance Manual 16
IN THE EVENT OF BROKEN LAMP(S)
If a lamp breaks or cracks inside the envelope,
disconnect the electrical power supply and disassemble
the envelope. (see Envelope Installation Instructions) Be
sure to remove all fragments of glass, using a vacuum
cleaner to thoroughly clean the electronics and envelope.
Use extreme caution when handling glass fragments to
avoid injury.
INSTALLING YOUR BALLOON LIGHT ON A
STAND
CAUTION
Always use DOOSAN approved stands designed to
work with your DOOSAN unit.
Always securely tighten all T-Handles to avoid injury.
Stands are designed for vertical mounting of
DOOSAN units ONLY.
USING THE OPTIONAL DOOSAN P500TA (FIG. 1)
STAND.
• Unfold the stand.
• Lock the base in place.
On the P500TA, slide the stand legs out from the
folded position until the support bars are exactly
horizontal.
• When using your stands in windy conditions, use the
following weighting recommendations to keep your
stand stable.
• On the P500TA (Fig. 1), weights must be placed on
each support at 20 in (50 cm) from the centre of the
stand.
Follow this correlation table.
• Indicative for a flat floor and a steady wind, only the
guy ropes ensure the mechanical strength of the feet
in a strong or gusty wind.
• Guy ropes are recommended if installing on an
inclined floor.
• Do not operate your stand-mounted Balloon Light on
an uneven surface or a gradient of more than 8
degrees.
Figure 1
WIND SPEED RECOMMENDATION
0 to 31 mph
(0 to 50 km/h)
79 lbs (3x26.5 lbs)
36 kg (3x12 kg)
31 to 43 mph
(50 to 70 km/h)
159 lbs (6x26.5 lbs)
72 kg (6x12 kg)
OR guy ropes
43 to 62 mph
(70 to 100 km/h)
159 lbs (6x26.5 lbs)
72 kg (6x12 kg)
AND guy ropes

17 BL400, BL600 LED Operation & Maintenance Manual
MAINTENANCE
LAMP
A damaged envelope must immediately be repaired or
replaced.
Regularly clean the envelope with mild soap and water.
Citrus-based cleaners can be used, although be sure to
test a small area before cleaning the entire envelope.
ENVELOPE
WARNING
It is important to replace lamps showing signs of
wear and tear (cracked lamp, small fragments of
glass inside the lamp, or whitened lamp glass).
Failure to do so could cause lamp failure, or possibly
explosion, resulting in bodily injury and/or damage
to the DOOSAN unit.
To replace a lamp, please refer to “Assembly (Lamp
replacement)”
Patching A Hole
• Be sure to thoroughly clean the area to be patched.
• Cut a square out of the included self-adhesive fabric
sheet just large enough to cover the damaged part of
the envelope.
• Remove the protective film from the adhesive side of
the patch material.
• Carefully place the patch onto the damaged part of
the envelope, firmly applying pressure to the areas of
contact around the patch edge.
CLEANING THE AIR FILTER
Remove sponge-type air filter, located under the south
pole plate, by sliding along the support stand.
Wash it or replace it.
Replace the clean air filter in the same way.
WARRANTY
The envelope of the balloon is guaranteed for 6 months
from the date of purchase against any manufacturing
defects and under normal conditions of use.
The rest, except for “consumables”, such as bulbs, etc.,
is guaranteed for 2 years from the date of purchase
against any manufacturing defects and under normal
conditions of use.
In any case of a manufacturing defect or incorrect
operation, please return the balloon to your DOOSAN
distributor.
DOOSAN cannot be held responsible for improper
handling by the user. Any operation on the envelope or
electric equipment that is not specified in this manual, or
any use of unapproved tools, components or bulbs is not
covered by this warranty and remains the sole
responsibility of the user.

BL400, BL600 LED Operation & Maintenance Manual 18
TECHNICAL DATA TABLE
Not contractual information - given as an indication only and subject to change without notice.
TECHNICAL DATA BALLOON LIGHT
LED 4X100W
BALLOON LIGHT
LED 6X100W
Power supply 100-240V
50-60Hz
100-240V
50-60Hz
Luminous flux 50000 Lm 60000 Lm
Module number 4 6
Power by bulb 100 W 100 W
Bulb type LED LED
Bulb socket DOOSAN bulb socket DOOSAN bulb socket
Restrike type - -
Restrike time < 2 seconds < 2 seconds
Power supplied by exterior ballast No No
Colour temperature 6000 °K 6000 °K
Average bulb life > 50000 h > 50000 h
Protection type Fuse
Pressure switch
Breaker
Fuse
Anti-vibration system No Yes
Envelope diameter 90 cm 90 cm
Envelope shape Tubular Tubular
Weight 7 kg 8.3 kg
Max. ambient temperature 45 °C 45 °C
Power 410 W 610 W
Power generating unit 1 kVA 1 kVA
Bulb number 4 6

19 BL400, BL600 LED Operation & Maintenance Manual
PARTS SECTION

BL400, BL600 LED Operation & Maintenance Manual 20
FRAME AND ENVELOPE