BioZone Scientific International CoilCare Series Parts list manual

COILCARE©X
© 2017 BioZone Scientic International, Inc.
81200012B
Installation Instructions and Operating Manual
CoilCare Series

IMPORTANT!
•
Qualified technicians should install this product
•Install in accordance with relevant building codes
•Read instructions carefully including safety warnings
WARNING
PROTECT EYES FROM UV LIGHT
TURN OFF UNIT OR DISCONNECT
BEFORE SERVICING
CCX Parts
Thank you for purchasing BioZone Scientic’s CoilCare® ultraviolet light germicidal irradiation
disinfection system for commercial HVAC applications. CoilCare can keep HVAC evaporator
coils clear of contamination and biolm, allowing signicant savings in maintenance and energy
costs, while improving indoor air quality. CoilCare works by irradiating coil surfaces in germicidal
ultraviolet light. The UV light inactivates microorganisms and breaks down organic residue,
preventing growth and keeping coils clean and operating eciently. The system is equipped with
a UV lamp and a reector to direct and focus UV light on the coil surface. The water-resistant
power supply is easy to mount and can withstand the humid environments of HVAC enclosures.
The quantity and positioning of UV lamp modules is determined by several factors, including the
coil dimensions and other HVAC system design specications. Your BioZone Scientic commercial
UV specialist can help congure the best system for your application.
2
BioZone CoilCare systems must be installed by certied technicians only.
Installation of this product by anyone other than licensed HVAC or electrical
contractors voids warranty, and BioZone assumes zero liability.
A UV Lamp
B Lamp Connector
C Power Supply
D UV Warning Label
E Sight Glass
F Black Nylon Zip Ties
G Mounting Screws
Optional Parts
G UV Reector
J Lamp Cable Extension 10ft
K Door Interlock Switch
L Contact Plates
M Control Box, Congurable
N Lamp Clip Pack
O Light Switch

CoilCare Conguration Guidelines
• Maximum germicidal eectiveness is within an 18in [457mm] radius from lamp
center axis
• The optimal distance between lamp(s) and the irradiated surface is 12in [305mm]
• The distance between stacked lamps should not exceed 35in [889mm]
• The distance between end to end lamps should not exceed 12in [305mm]
• The distance of lamp ends to the edge of irradiated surface should not exceed 6in
[152mm]
• Minimal germicidal eectiveness expected at/beyond 48in [1219mm] radius from
lamp center axis
• When coil depth is more than 12in [305mm], treating both sides of the coil may be
indicated
12” [ 305 mm] max. space between lamps
6” [152 mm] max. space to end of coils
Overlap lamps where necessary
SYSTEM CONFIGURATION GUIDELINES
3
Determine the dimensions of the evaporator
coils or area to be treated.
1.
Use the guidelines below to select the
proper conguration and number of lamps
needed to treat the required dimensions.
2.
BioZone Scientic oers free
of charge UVCalc™ to assist
with system conguration and
selection. Contact your BioZone
commercial UV specialist for
more information.

• Air Velocity: 400-500 fpm [2-2.5m/s] maximum
• Air Temperature: 40°F – 110°F maximum [4°C – 43°C]
• Lamp Distance from Coil: 6in – 48in [152mm – 1219mm]
• Electrical Wiring: compliant with local and national code, UL/ETL standards
• Safety Measures: alarms and disconnects, warning signage, employee training
• Lamp Disposal: in accordance with local and national regulations (see lamprecycle.org
for more information)
• Insulation Guidelines for Safety: the use of UV resistant materials such as aluminum
reectors, shielding, jacketing, and tape, may be indicated to protect non-UV-compatible
materials in the treatment area. Contact BioZone Scientic if specic questions arise
concerning material compatibility.
4
Recommendations for Eective CoilCare Installations
EMT/Conduit
In most situations, when the system is mounted to surfaces perpendicular to the
surface to be irradiated, L-brackets are attached to the wall or support with self-
tapping screws.
Measure the distance between the L-brackets and cut tubing 1” less than the distance
between L-brackets. Extend the tubing between the L-brackets and fasten at each
end.
1.
Install Framing
INSTALLATION INSTRUCTIONS
First, determine the ideal mounting location within the HVAC system, and then
congure the CoilCare system accordingly. CoilCare can be mounted to the air handler
wall or similar support several ways depending on the size, orientation, and distance
between the mounting surfaces and surfaces to be irradiated.
Contact your BioZone commercial UV specialist with any questions or concerns prior
to installation.

Magnetic Mounting
In situations where small coil surfaces require CoilCare® systems comprising single
UV lamps, the use of magnets tted on L-brackets combined with EMT/conduit may be
indicated. The system is mounted to
surfaces perpendicular to the surface
to be irradiated, and L-brackets are
attached to the wall or support with
provided 30lb magnets for a quick
and easy installation.
Measure the distance between the
L-brackets and cut tubing 1” less
than distance between L-brackets.
Extend the tubing between the L-brackets and fasten at each end.
1.
INSTALLATION INSTRUCTIONS
5
2.
Optional vertical support adds strength to the tube framing and prevents sagging on
installations with two or more lamps per tubing length.
Measure the distance from oor to ceiling and cut tubing 7/8” less than oor to ceiling
height. Use pipe coupling to extend the vertical support between the oor and ceiling
for a snug t.
Channel Strut
In situations where larger coil surfaces require CoilCare systems comprising several UV
lamps, the use of channel strut may be indicated. The system is mounted to surfaces
perpendicular to the surface to
be irradiated, and L-brackets are
attached to the wall or support with
self-tapping screws.
Measure the distance between the
L-brackets and cut channel strut
½” less than distance between
L-brackets. Extend the channel
strut between the L-brackets and
fasten at each end.
Optional vertical support adds strength to the strut framing and prevents sagging on
installations with two or more lamps per strut length.
Measure the distance from oor to ceiling and cut channel strut ½” less than oor to
ceiling height. Attach L-brackets at desired mounting points on oor and ceiling with
self-tapping screws. Extend the vertical support strut between the oor and ceiling
and fasten to L-brackets for a snug t.
1.
2.

IMPORTANT! Connect in accordance with all state and local electrical and
building codes. Proper voltage is automatically selected by the unit between
120–277 VAC Single Phase 50/60hz.
IMPORTANT! If power surges occur often, it is suggested that you use an
external power suppressor.
Mount Power Supply
P
H
Turn o main electrical supply before making electrical connections.
Refer to the Electrical Diagram for proper connection of the power supply to the main power.
INSTALLATION INSTRUCTIONS
6
Mount the power supply in a location (interior or exterior of the HVAC system) that is
convenient for access to the electrical supply and for connection to the UV lamps.
The power supply is weather resistant and is suitable for mounting to the interior or exterior
of the air handler. Note that the power supply is not waterproof and should not be mounted
outdoors without protection from a secondary enclosure.
1.
Install the UV Lamps
Place UV lamps into the lamp clips. Be sure to
clamp only on the ceramic lamp bases at each
end. Use black nylon zip-ties to secure lamp
cables to supports as needed.
DO NOT clamp onto
the lamp glass.
Do not touch the glass portions of UV lamps with bare hands. The use of gloves is
recommended when handling UV lamps. Wipe UV lamp with isopropyl alcohol as needed to
clean glass.
1.

LAMP
CONNECTOR
UV LAMP
PUSH FIRMLY
TOGETHER
Mount Power Supply (continued)
Use the supplied self-tapping sheet metal screws
to mount the power supply in place through the
mounting holes on the sides of the base.
It is recommended to use junction boxes, our
optional 3/4” or 1” cable strain relief, or other sealing
methods in order to pass the power cord and lamp
cables between the interior of the air handler and
exterior for connections, as needed.
INSTALLATION INSTRUCTIONS
7
1.
Connect Lamps and Cables
Arrange cables as needed for installation. If necessary
use the Optional 3/4” or 1” cable strain relief to pass
cables through cabinets, air system walls, etc.
Optional 10’ cable extensions are available for longer
runs.
When UV lamps, power supplies, and cables are
in place, join the UV lamp and lamp connectors by
aligning the electrical pins and corresponding slots
on the lamp connectors and pushing them rmly
together. Note that lamp connector may need to be
rotated to matchup with the lamp pins.
2.
2.

1. Ax the UV Warning Label, shown here, to
the door or access panel used to service the
unit.
Safety Components
Install Sight Glass
Install an Optional Light Switch
1. To help prevent accidental exposure to UV light, Biozone can provide an optional
on/o switch, to be installed by a licensed contractor on the circuit between the
main power supply and the CoilCare power supply. Electrical wire for the switch
not provided.
Contact BioZone for additional information.
2. Record the installation information on
the UV Warning Label. The UV Warning
Label contains elds convenient to record
installation and service information. It is
recommended to record installation and
service details on the UV Warning Label as
those functions are performed.
INSTALLATION INSTRUCTIONS
8
Install a UV Warning Label
Caution: UV light that can cause serious eye burns and temporary
blindness. Ensure all access panels have been replaced and doors
closed before activating the system.
1. The sight glass allows safe viewing of the UV
light system when in operation to verify system
operational status. Find a suitable location such as
a door or access panel to the HVAC system for the
sight glass.
2. Drill a 1/2” hole and press the base of the sight
glass through it.

1.
Install an Interlock Switch
Per ASHRAE, the use of Optional Door Interlock Switch(es) is
highly recommended to prevent accidental exposure to UV Light.
The door interlock switch is installed in the electrical circuit between
the main supply and the CoilCare power supply.
Interlock switches are mounted on the access panels and doors so
the CoilCare system is de-energized and the UV lights turn o when
the panel/door is opened.
See the Door Interlock Switch Kit for specic wiring instructions and diagram for the
door interlock switch (BioZone Part Number CCX-KT-DS).
Maintenance
WARNING
PROTECT EYES FROM UV LIGHT
TURN OFF UNIT OR DISCONNECT
BEFORE SERVICING
OPERATION AND MAINTENANCE
9
As needed, periodically wipe the UV lamps with a clean cloth or alcohol swab to remove any
accumulated dust or dirt. This process should be performed at least every six months or during
routine maintenance intervals.
Lamp fouling could occur if lamps are installed under chilled water lines. Wipe clean or install an
optional shield.
Use of replacement lamps from other manufacturers will cause system failure and will
immediately void the system warranty.
Before Powering Up the System
Caution: UV light that can cause serious eye burns and
temporary blindness. Ensure all access panels have
been replaced and doors closed before activating the
system.
Turn on the electrical supply and switch on the UV
light power supply. Use the sight glass to conrm that
the UV lamp is operating.

Troubleshooting
Lamp Replacement
10
Issue Solution
UV lamp(s) not lighting 1. Check all electrical connections.
2. Check that power is applied to power supply.
3. Check that the unit is turned ON.
4. Ensure the lamp cables are properly connected.
5. Install new UV lamp(s).
6. Consult BioZone.
UV lamp(s) ickering 1. UV lamp(s) have reached end of eective service life. Install
new lamp(s) of same type.
2. If unit is new, lamp connectors at both ends to ensure proper
connection.
3. If new lamps still icker, consult BioZone.
UV lamps have burned
out prematurely
1. Consult factory.
Power supply will not
light UV lamp(s) even
after new lamps are
installed
1. Consult factory.
2. If power surges occur, an external power suppressor may be
needed.
BioZone Scientic lamps are rated for up
to two years of germicidal eectiveness
on CoilCare systems. The lamps will
continue to illuminate with a blue glow
after they have exceeded their rated
lifespan, however their germ-killing
eectiveness diminishes with time, so
they must be replaced on schedule for
the system to function properly.
Contact your local dealer for replacement
lamps.
Part Number Part Details
CCX-10-H64000-1 1554mm lamp High Output, 1 Year
CCX-10-H48000-1 1148mm lamp High Output, 1 Year
CCX-10-H36000-1 842mm lamp High Output, 1 Year
CCX-10-H24000-1 610mm lamp High Output, 1 Year
CCX-10-H64000-2 1554mm lamp High Output, 2 Year
CCX-10-H48000-2 1148mm lamp High Output, 2 Year
CCX-10-H36000-2 842mm lamp High Output, 2 Year
CCX-10-H24000-2 610mm lamp High Output, 2 Year
CCX-10-64000-1 1554mm lamp, 1 Year
CCX-10-48000-1 1148mm lamp, 1 Year
CCX-10-36000-1 842mm lamp, 1 Year
CCX-10-24000-1 610mm lamp, 1 Year
CCX-10-64000-2 1554mm lamp, 2 Year
CCX-10-48000-2 1148mm lamp, 2 Year
CCX-10-36000-2 842mm lamp, 2 Year
CCX-10-24000-2 610mm lamp, 2 Year
Important! Use only authentic BioZone
replacement lamps. Use of replacement
lamps from other manufacturers will
immediately void the system warranty
and aect performance of the system.

This warranty supersedes and replaces any warranty statements orally made by the Sales Person, Distributor or Dealer or contained in the written
instructions or other Brochures or informational documents in relation to this product. This warranty gives you special legal rights, and you may
also have other rights which vary from State to State.
What Does This Warranty Cover? This lifetime limited manufacturer warranty covers any defects or malfunctions in material and workmanship
under the normal use and service when operated and maintained in strict accordance with manufacturer’s instructions for the Lifetime of the
equipment.
How Long Does The Coverage Last? 1) BioZone Scientic CoilCare® Power Supply: For as long as you own the real property where the product is
installed. 2) The Ultraviolet Lamp is warranted for germicidal output for two-years from the date of installation. This warranty is not transferable.
What Will BioZone Scientic International, Inc. do? BioZone Scientic will replace any defective or malfunctioning part at no charge. You must
pay any labor charges and shipping charges of defective product to our warranty department. You are also responsible for any shipping charges
to return the warranty
What Does This Warranty Not Cover? THIS PRODUCT IS NOT INTENDED TO BE PURCHASED AND INSTALLED BY UNLICENSED HVAC OR ELECTRI-
CAL CONTRACTORS. This warranty does not cover products or parts purchased from any source other than licensed HVAC or electrical contractors.
This warranty does not cover parts installed by unlicensed HVAC or electrical contractors. This warranty does not cover parts damaged as a result
of misuse, abuse, or any use other than its intended use, accident, acts of God, neglect, or from improper operation, maintenance, installation,
modication or adjustments. BioZone Scientic International, Inc. shall have no responsibility for charges incurred by the customer for installation
or removal of warranted items.
This warranty does not cover parts or equipment used with the BioZone system that are not manufactured by BioZone Scientic International,
Inc. **This warranty shall be void if UV lamps from manufacturer’s other than BioZone Scientic International, Inc. are used with this equip-
ment. Consequential and incidental damages are not recoverable under this warranty. Manufacturer assumes no liability for any harm, which
may occur as a result of the use of the equipment herein and shall not be liable for consequential or any other damages whether or not caused
by manufacturer’s negligence or resulting from any express or implied warranty or breach thereof. Consequential damages for the purpose of
this warranty shall include, but not be limited to, loss of use, income or prot, or loss of or damages to property or injury or death to persons or
animals occasioned by or arising out of operation, use, the operation, installation, repair or replacement of the equipment or otherwise. Some
states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.
There are no Warranties which extend beyond the description of the face hereof.
How Do You Get Service? In order to be eligible for service under this warranty you MUST return the warranty registration card or register online
at www.biozonescientic.com. If something is wrong with your product, call your installing contractor to receive a Return Merchandise Authoriza-
tion (RMA) and instructions for returning the product to a licensed distributor in your area or the manufacturer.
Once the product is returned, we will inspect your product and contact you within 10 business days of our receipt of the product to give the results
of our inspection. If we determine that the product is covered under this warranty, we will ship to you at no additional cost a replacement part.
Replacement parts may be refurbished. If we determine that the product is not covered under this warranty, or that this warranty is void, the
product will be returned to you COD. There is no charge for inspection.
How Does State Law Apply? This warranty gives you specic legal rights, and you may also have other rights which vary from state to state.
11
WARRANTY
Lifetime Warranty
The manufacturer’s lifetime warranty covers parts replacement for the CCX system as long as
the BioZone (OEM) 1-year Lamps are replaced annually and/or the BioZone 2-year Lamps are
replaced every 2 years.
Standard Warranty
The manufacturer’s standard warranty covers replacement parts for a period of one (1) year from
the date of installation as noted below.

7616 Southland Blvd., Suite 114, Orlando FL 32809 USA
Tel.: [phone] ● Fax: [phone]
ccx@biozonescientic.com ● www.biozonescientic.com
© 2017 BioZone Scientic International
81200012B
Glossary of Terms
ASHRAE The American Society of Heating, Refrigerating and Air-Condi-
tioning Engineers. It focuses on building systems, energy e-
ciency, indoor air quality, refrigeration and sustainability technol-
ogies. ASHRAE publishes guidelines for Ultraviolet lamp systems
for treatment of both air and surfaces.
Irradiance (UV) The power per unit area received from a UV source in the form
of electromagnetic radiation at a wavelength or in a wavelength
range. For evaporator coil surface disinfection, ASHRAE recom-
mends a minimum of 50-100 μW/cm2 as measured on the coil
surface at 254nm.
Cooling Eects Lamp UV output is critically dependent on mercury vapor pres-
sure, which in turn is dependent on temperature. Below 80°F
[27°C] UV output can decrease by as much as 50%. Cooling
eects are noted and are factored into CoilCare® system design.
Reectance Ultraviolet light can be reected o of surfaces, the degree of
which depends on the specic material. CoilCare®’s reectors
can re-direct and focus up to 1.75 times more irradiance onto
the coil surface than the same system without reectors.
Ultraviolet Ultraviolet (UV) light is an electromagnetic radiation with a wave-
length from 400 nm to 10 nm, shorter than that of visible light
but longer than X-rays. UV radiation constitutes about 10% of
the total light output of the Sun. UV light can also be produced
by specialized lights, and UV systems have been used for over a
century to disinfect water, surfaces, and air.
UVGI Ultraviolet germicidal irradiation (UVGI) is a disinfection method
that uses short-wavelength ultraviolet (UV-C) light to kill or inac-
tivate microorganisms by destroying nucleic acids and disrupting
their DNA, leaving them unable to perform vital cellular func-
tions. UVGI is used in a variety of applications, such as food, air,
and water purication.