AirStar Light Sirocco User Manual

							 02-07-2012 / 65-63-072 B  1       Models Covered: 2K HA / 4K HA 600 HI-CR 1.2K HMI / 2.5K HMI 1K HI-BT37                 Mode d’emploi Owner’s Manual Instrucciones de uso 10255 General Drive • Unit A6  • ORLANDO, FL 32824 • USA Tel: (407)851-7870 • Fax: (407)851-7831 www.airstar-light.us • e-mail : [email protected]    NAFTA  
						

							 02-07-2012 / 65-63-072 B  2 Welcome To Airstar  Thank you for choosing AIRSTAR. Your new Sirocco unit is hand assembled with pride in USA, and we are committed to your total customer satisfaction.  Your ownership experience is extremely important to us and this user manual is designed to help keep your Sirocco performing at its highest level.  Let There Be Light  Your Sirocco is specifically designed to provide the highest quality light for nighttime workplace safety and productivity.  It is perfect for use in a variety of worksite settings, rescue efforts, and any situation where a well-lit area is required to work.  Models Covered In This Manual  This manual covers the following Sirocco models: - Sirocco 2K (HA 2x1000W), Sirocco 600 (HI CR 4x150W), Sirocco 250 (HI HR 250W), Sirocco 1.2K (HMI 1200W), HMI 2.5K(HMI 2500W), Sirocco 1K (HI-BT37 1000W), Sirocco 4K HA (HA 4x1000W)  EXTREMELY IMPORTANT SAFETY INSTRUCTIONS  WARNING –  REDUCE THE RISK OF FIRE, ELECTRIC SHOCK, EXPOSURE TO EXCESSIVE UV RADIATION, OR INJURY: 1.  LIGHTED LAMPS ARE EXTREMELY HOT.  Turn off, unplug, and allow unit to cool before touching lamp. 2.  ALWAYS disconnect your Sirocco unit from power source prior to servicing. 3.  Do Not touch lamp cage until completely cooled.  4.  Do Not look directly at lighted lamp. 5.  Do Not operate Sirocco unit near flammable materials. 6.  Use a soft cloth or glove when handling lamps. Oil from skin may damage lamp during operation. 7.  Do not operate your Sirocco with damaged electronics or if parts are missing. 8.  Do not operate your Sirocco with a damaged envelope or without an envelope. 9.  All service must be performed by Airstar designated technicians. See Warranty Info for details. 10.  Sirocco units are designed to operate at heights of at least 5ft (1.5m). 11.  Do not operate your stand-mounted Sirocco on an uneven surface or a grade of more than 8 degrees. 12.  Do not use your Sirocco if wind speed exceeds 50mph (80km/h). 13.  Use only recommended stands with an ability to support a 20lb (9kg) Sirocco unit, and endure wind speeds of up to 50mph (80km/h) at a height of 16.5ft (5m).  WARNING –  ALWAYS USE CORRECT LAMPS FOR YOUR SIROCCO TO AVOID DAMAGE OR INJURY: 1.  Sirocco HA 2x1000W : use only with HA 1000W R7S type lamp or smaller 2.  Sirocco HA 4x1000W : use only with HA 1000W R7S type lamp or smaller 3.  Sirocco HI CR 4x150W 230V : use only with HCI-T/P 150W E27 type lamp or equivalent 4.  Sirocco HI CR 4x150W 100-120V : use only with M102/O 150W MEDIUM type lamp or equivalent 5.  Sirocco HMI 1200W : use only with HMI 1200W G38 type lamp 6.  Sirocco HMI 2500W : use only with HMI 2500W G38 type lamp 7.  Sirocco HI-BT37 1000W : use only with HI-BT37 M47 ANSI 1000W type lamp  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. Sirocco 2M HA / HI CR / HI HR: Use only NEMA 5-15 “Edison” plug extension cords connected to the correct voltage electrical source outlets. 2. Always use Ground Fault Circuit Interrupter (GFCI) protection when operating your Sirocco in areas near water, and during inclement weather.   KEEP THESE INSTRUCTIONS WITH YOUR SIROCCO UNIT      
						

							 02-07-2012 / 65-63-072 B  3 Tips To Extend The Life Of Your Sirocco Unit  1.Use the included glove when handling lamps to prevent potential damage caused by transfer of oils and dirt to glass. 2.Always disconnect from power source before performing service. 3.Do not operate your Sirocco 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 DEFLATED ENVELOPE UNCOVERED OR UNATTENDED WHEN NOT IN USE.  6.Always  use  the  included  protective  cover  when  storing  your  Sirocco.  Failure  to  do  so  may  result  in  loss  of  warranty coverage. 7.Store your Sirocco in a dry, well-ventilated area away from heat sources and chemical products. 8.Be sure that envelope is completely dry before installing 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 Sirocco if cable is damaged, twisted, or tangled.    Recommended Generator Capacity For Sirocco Units   NOTE:  When using generator power, ALWAYS start your generator BEFORE plugging in your Sirocco unit.  1.Non-Ballast Sirocco Units – Recommended Capacity : a) Sirocco HA 2x1000W : Single phase 120V 50-60Hz – 3KVA b) Sirocco HA 2x1000W : Single phase 230V 50-60Hz – 3KVA c) Sirocco HA 4x1000W : Single phase 120V 50-60Hz – 5KVA d) Sirocco HA 4x1000W : Single phase 230V 50-60Hz – 5KVA e) Sirocco HI CR 4x150W 100-120V : Single phase 100-120V 50-60Hz – 1KVA f) Sirocco HI CR 4x150W 230V : Single phase 230V 50-60Hz – 1KVA 2.Sirocco Units w/Ballast Regulated Power – Recommended Capacity g) Sirocco HMI 1200W 230V : 2KVA h) Sirocco HMI 2500W 230V : 5KVA i) Sirocco HI-BT37 1000W 120V : 2KVA     WARNING: Be sure to avoid phase imbalance when several devices are connected to the same generator.   Built-In Safety Systems  Your Sirocco is equipped with special safety mechanisms that are designed to protect you and your Sirocco in the unlikely event of equipment failure or in certain unsafe operating conditions:  - The Airstar Sirocco 600 (HI CR 4x150W) is equipped with a safety thermal switch that turns off the lamps if internal operating temperature rises to unsafe levels.  - The Airstar HA, HMI, HI-T, HI-BT37 units are equipped with a safety pressure switch that turns off the lamps if internal envelope air pressure falls below safe operating levels.  - If lamp starts blinking due to excessive heat, check and clean filter, be sure the fan is running and fresh air is circulating through the unit. Be sure the envelope is under consistent observation.     
						

							 02-07-2012 / 65-63-072 B  4 a e d b c 14 Sirocco Parts List                                     1 Nut 2 Internal Structure (Cage + Base + Support Stem) 3 Envelope 4 Power Supply Cable 5 Zipper 6 Lamp(s) (See Lamp Variations – Pictured Above) a HA 1000W R7S lamp b HCI-T/P 150W E27 lamp M102/O 150W MEDIUM lamp c HMI 1200W G38 lamp d HMI 2500W G38 lamp e HI-BT37 1000W E39 ANSI lamp 7 South Pole Plate 8 Stand (Recommended Accessory. Sold separately.) 9 Repair Kit (2 Pieces) 10 Protective Storage Cover 11 Storage Tube 12 User Manual 13 Ballast (Required For Select Models) 14 Cotton Glove (For Lamp Replacement)    6 2* 3* 4 5 7 8 10 11 13 12 9 1 2 3 Sirocco Lamp Variations *see detail at right   
						

							 02-07-2012 / 65-63-072 B  5 Envelope Installation Instructions  · When REPLACING an old envelope, FIRST remove original envelope: · If currently in use, first turn unit off and let cool. · Unplug the Sirocco unit and open the envelope zipper. · Unscrew the nut on the top of the envelope. (Fig. 1) Set top nut in a secure place. · Maneuver top of cage to unzipped opening and pass the cage through until fully exposed. · Unhook the lamp holder springs (Fig. 2 – only select Sirocco models) · Remove lamp(s) from unit.  (See Lamp Replacement Instructions for detailed information on lamp removal.)  · Unplug the ground wire from the cage. (Fig. 3 black arrow) · Unscrew the six(6) nuts on the South Pole Plate at base of cage.  (Fig. 3 white arrows) · Remove zip-ties from cage crossbar and unhook red rubber tabs. (HI CR 4x150W “Sirocco 600” model ONLY) · Carefully remove the cage from assembly. · Detach old envelope from assembly by sliding up along lamp assembly. · Inspect South Pole Plate gasket (Fig. 4) for damage. Replace if damaged and ensure proper alignment. · Slide South Pole opening of new envelope over electronic assembly.                 · Install your NEW envelope: · Unfold the envelope on a smooth, clean surface. · Open the zipper · Position zipper on same side of unit as ground wire. (Fig. 3) · Ensure alignment of envelope holes on South Pole Plate. · Slide the cage inside the envelope through the zipper opening. · Align cage on South Pole baseplate with ground pin on the cage in line with with ground wire on the unit. (Fig. 3) · Reattach ground wire to ground pin on cage. · Screw the six(6) South Pole Plate nuts onto the cage. (Fig. 3) · Reinstall lamp(s).  (See Lamp Replacement Instructions for detailed information on lamp removal.)  · Reconnect lamp holder springs (Fig. 2 – only on select Sirocco models).  Be sure to hook springs OVER the cage crossbars.  · Loosely replace the nut on the top of the envelope.  Do not tighten until after envelope is fully inflated. · Close zipper. · Plug Sirocco unit into appropriate power source.  (CAUTION: When plugging into ballast power, always plug your Sirocco unit into the ballast BEFORE plugging ballast into power source.) · After envelope is fully inflated, tighten top nut. · You are now ready to work.  Disassembly  · Switch off, deflate, and store your Sirocco unit. · Disconnect from power supply and let lamps cool completely. (PACKING HOT LAMPS WILL DAMAGE UNIT.) · Open the envelope zipper to speed up deflation and cooling. · Remove the Sirocco unit from stand or mount. · When lamps are completely cooled, insert Sirocco unit into storage bag and store in included case. (Be sure envelope is dry before storage!)   Fig. 1 Fig. 2  Fig. 3  Fig. 4  
						

							 02-07-2012 / 65-63-072 B  6 Lamp Replacement Instructions  · Sirocco 2K (HA 2x1000W) – (Fig. 1) & Sirocco 4K HA (HA 4x1000W) – (Fig. 2)  · Unplug the Sirocco unit and open the envelope zipper. (Be sure to let unit cool.) · Using a glove, remove old lamps by applying downward pressure and sliding the top of the lamp out of the fixture, then lifting the lamp up and out of the fixture. · Insert new lamps by inserting bottom of lamp into fixture, applying downward pressure, and then sliding top of lamp into the top of the fixture. · Close the zipper.                   · Sirocco 600 (HI CR 4x150W) · Unplug the Sirocco unit and open the envelope zipper. (Be sure to let unit cool.) · Unhook the lamp holder springs and place lamp holder aside. (Fig. 3)                · Using a glove, remove the old lamps and replace with new lamps. (Fig. 4) · Replace top lamp holder and hook springs over the edge and up through lamp support plate. (Fig. 3) · Close the zipper.    Fig. 1 Fig. 2 Fig. 3 Fig. 4  
						

							 02-07-2012 / 65-63-072 B  7 Lamp Replacement Instructions (cont.)  · Sirocco 1.2K (HMI 1200W) · Unplug the Sirocco unit and open the envelope zipper. (Be sure to let unit cool.) · Unhook the lamp holder springs and place lamp holder aside. (Fig. 1)                · Using a glove, remove the old lamp and replace with new lamp. (Fig. 4) · Replace lamp holder and hook springs over the edge and up through lamp support plate. (Fig. 2) · Close the zipper.    · Sirocco 2.5K  (HMI 2500W) · Unplug the Sirocco unit and open the envelope zipper. (Be sure to let unit cool.) · Using a glove, remove the old lamp and replace with new lamp. (Fig. 3) · Close the zipper       Fig. 1 Fig. 2 Fig. 3  
						

							 02-07-2012 / 65-63-072 B  8 Lamp Replacement Instructions (cont.)  · Sirocco 1K (HI-BT37 1000W) · Unplug the Sirocco unit and open the envelope zipper. (Be sure to let unit cool.)  · Unscrew the top-nut at the top of the envelope and set nut safely aside. (Fig. 1) · Lift envelope off of the north pole pin and carefully slide unzipped envelope opening down around cage, toward south pole plate. · Unscrew the nylon thumb wheels at the base of the lamp that secure the included “wrench”. (Fig. 2) · Using the “wrench”, loosen and remove the two nuts on the underside of the top brace and remove the top brace from the cage, allowing you to access the lamp. (Fig. 3)                 · Unhook the lamp holder springs and place lamp holder aside. (Fig. 4) · Using a glove, remove the old lamp and replace with new lamp. (Fig. 5) · Replace top lamp holder and hook springs evenly around cage as shown. (Fig. 4)                 · Reinstall the plate on the top of the cage using the “wrench”. (Fig. 3) · Carefully guide envelope back up around cage and guide the top pin through the top of the envelope. (Fig. 1) · Loosely replace the nut on the top of the envelope.  Do not tighten until after envelope is fully inflated. (Fig. 2) · Close the zipper. · Inflate the envelope. · Using included “key”, tighten the top nut to secure envelope to cage. · Reattach the included “key” with the included plastic thumb wheels. (Fig. 1)   Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5  
						

							 02-07-2012 / 65-63-072 B  9 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 Sirocco On A Stand  NOTE:   · Always use Airstar-approved stands designed to work with your Sirocco unit. · Always securely tighten all T-Handles to avoid injury. · Stands are designed for vertical mounting of Sirocco units ONLY. · ALWAYS use sandbags to weight stands properly.  Airstar sandbags are recommended.  · Using the optional Airstar P500TH (Fig. 1) or  P500TA(Fig. 2) stands. o Unfold the stand. o Lock the base in place. - On the P500TH (Fig. 1), lift the outer cylinder at the base slightly, then hook the oval locking ring over the safety hook. - On the P500TA (Fig. 2), slide the stand legs out from the folded position until the support bars are exactly horizontal.  Be sure to leave  o When using your stands in windy conditions, use the following weighting recommendations to keep your stand stable. - On the P500TH (Fig. 1), weights must be placed on each foot at 24 in (60 cm) from the center of the stand. - On the P500TA (Fig. 2), weights must be placed on each support at 20 in (50 cm) from the center of the stand. - Use the table below to determine proper sandbag weighting.  Wind speed Required Weight Per Leg Total Weight Required 0 – 6 mph (0 - 10 km/h) N/A N/A 6 – 12 mph (10 - 20 km/h) 40 lbs (18 kg) 120 lbs (54kg) 12 - 25 mph (20 - 40 km/h)  66 lbs (30 kg) 140 lbs (90 kg) 25 - 37 mph (40 to 60 km/h) 154 lbs (70 kg) 465 lbs (210 kg) 37 - 50 mph (60 - 80 km/h)  265 lbs (120 kg) 795 lbs (360 kg)                        20 in (50 cm) Load Load Load 24in (60 cm) Load Load Load Fig. 1 Fig. 2  
						

							 02-07-2012 / 65-63-072 B  10 When Operating Ballast Powered Sirocco Units  · Sirocco models that require a ballast: Sirocco 1K, Sirocco 1.2K, Sirocco 2500, and Sirocco 4K.  · ALWAYS PLUG SIROCCO UNIT INTO BALLAST BEFORE CONNECTING TO POWER OUTLET - Connect the Sirocco power cable to the ballast. - Securely lock the power cable connector to ballast socket. - Connect ballast to appropriate power supply. - Reverse procedure when shutting down your Sirocco unit.               Maintenance  · Lamp · 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 Sirocco unit.. · To replace a lamp, please refer to “Assembly (Lamp replacement)”  · Envelope · 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 entire envelope.  · Patching A Hole o Be sure to thoroughly clean the area to be patched. o Cut a square out of the included self-adhesive fabric sheet just large enough to cover the damaged part of the envelope. o Remove the protective film from the adhesive side of the patch material. o 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 · Place clean air filter by the same way.        ON HI-BT37 1000W / HMI 1200W HMI 2500W ON           OFF           HI-T 1000W