Bluezone 420 Series Setup guide

Bluezone Products, Inc. 225 Wildwood Avenue Woburn MA 01801
www.BluezoneFresh.com ● [e-mail] ●781-937-0202
Bluezone® Model 420
Air Cleaning System
Installation, Operation and Service
Manual

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IMPORTANT SAFEGUARDS
READ AND SAVE THESE INSTRUCTIONS
Safety
This operation and service manual contains
important instructions and safety information
about the Bluezone Air Purification System.
Observe the following dangers, warnings,
cautions and notices when installing,
operating and servicing the Bluezone Model
420.
Electrical System
Energized electrical circuits present a
potentially life-threatening hazard.
Ensure the unit’s power cord is unplugged
before performing any installation or service
work.
Ensure there are no other electrical power
circuits connected to the Bluezone Model
420.
Do Not Operate unit with a damaged cord or
plug. Discard unit or return to an authorized
service facility for repair.
Follow all lockout/tagout procedures for all
electrical circuits.
System Operation
Do not operate the Bluezone Model 420
while fogging with chlorine bleach or other
disinfectant solutions. Disinfectants can
poison the Bluezone catalyst and reduce its
effectiveness.
•Turn off the Bluezone Units if
disinfectant fogging or cleaning is
underway.
Turn Bluezone units back on after
disinfectants have dissipated. Never hose
down the Bluezone Model 420 or clean with a
water jet. Direct flow of water onto the catalyst
can reduce its effectiveness in eliminating
ozone.
Turn off Bluezone units and cover with plastic
if the room is being hosed with water or
steam.
System Maintenance
The Bluezone Model 420 contains 4 UV-C
light bulbs; the UV light is completely
contained inside the unit during operation.
Unplug or disconnect the unit from power
source prior to any servicing.
The Bluezone Model 420 has multiple safety
systems to ensure that you cannot view the
UV bulbs while they are operating.
Do NOT attempt to override the cover switch
to allow the bulbs to operate when the cover
is off.

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Skin or eye damage may result from directly
viewing the light produced by the lamp in this
apparatus. Always disconnect power before
relamping or servicing. Replace lamps using
Lamp Replacement Kit Model No. 005-
000002, manufactured by Bluezone Products
Inc. or an Authorized Bluezone Partner.
Never look at an illuminated UV-C bulb
without proper eye protection against UV light
frequencies.
The UV-C lamps generate ozone. This ozone
is contained inside the Bluezone Model 420.
When conducting maintenance, power
down the unit and wait 15 minutes before
removing the cover. There will be residual
ozone inside the Bluezone Model 420. Do not
breathe air directly from inside the unit.
Description
The Bluezone® Model 420 is an air
purification device that eliminates airborne
contaminants including microbes (virus, fungi,
mold and bacteria), odors and ethylene.
The Model 420 can be hung or mounted to
the ceiling or wall, or located on a shelf.
The Bluezone Model 420 draws in air
containing viruses, mold, spores or fungus,
and discharges air with a highly reduced
concentration of these impurities.
The unit is completely self-contained. The
facility, equipment, and personnel have no
contact with the process that is cleaning the
air.
The Bluezone unit’s operation is controlled by
a microprocessor-based controller that
ensures safe operation at all times and alerts
the user to any system faults.
Specifications
The specifications of the Bluezone Model 420
are shown in Table 1.
Table 1: Bluezone Model 420
Specifications
Specification Category
Model 420
Size
31” X 14” X 13.5”
79cm X 36 cm X 34 cm
Product Weight
25 lbs./11kg
Shipping Size
36” X 20” X 20”
91cm X 51cm X 51cm
Shipping Weight
28 lbs/13 kg
Operating Environment
50°F –104°F
1C –40C
up to 85% RH
Storage Environment
-4°F –150°F
-20C –65C
up to 85% RH
Input Voltage
120 VAC 1 Phase
Current
3 amps (at 120VAC)
Power
250 Watts max
Electrical Connection
IEC 320-C13 120 VAC power cord
Mounting Options:
Hung from ceiling, placed on
shelf/rack/cart, or mounted to wall
Certifications
cETLus Listed
ARB certified –Ozone Emissions
NSF per request

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Key Components
Figure 1: Bluezone Key Components
2
3
5
4
1
6

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Electrical System
Use the first two numbers in the serial number to identify the wiring in your unit.
First two numbers of serial number
Wiring diagram
45
Figure 3
48
Figure 4
Figure 2: Location of Serial Number

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Wiring diagrams of the Model 420-045 and the 420-048 are shown as Figure 3 and Figure 4
respectively.
Figure 3: Wiring Diagram of Model 420-045 Unit

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Figure 4: Wiring Diagram of Model 420-048 Unit

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Installation
An overview of Mechanical and Electrical
Installation instructions is contained in this
section. Details of steps to hang the Model
420 from the ceiling or mount on a shelf are
contained in Appendix A.
Installation Guidelines
Place the Model 420 in the room so that air
flow from the HVAC system, fans or other
air flow systems does not blow directly into
or pull air through the Model 420 air inlet or
clean air outlet.
Ensure a minimum clearance distance of
10’ (3m) from an air handler outlet to the
Model 420 to avoid excessive air flow
through the unit.
Place the unit so that the control panel and
display are visible and accessible.
If multiple Bluezone Model 420 units are
being installed in a room, the following are
recommended guidelines for the placement
of the Bluezone units:
1. Distribute the units relatively evenly
throughout the space.
2. Generally spreading the locations
across the available space is good
practice.
3. Warning: Hang the units from the
ceiling, mount to the wall or on a
shelf/rack to avoid unintended bumping
of the units.
4. Units hung from the ceiling should be
hung to the level of the lights, but not
below lights to avoid blocking light to
the plants.
5. Warning: If the unit is located in an
area with foot traffic and there is a
concern that it could be bumped by
personnel, it should be labeled with
colored tape to make it more visible
and reduce the risk of collision.
6. Warning: Locate the junction
boxes for the units as close as possible
to the units to avoid the risk of hooking
the cord and pulling it out. If the
distance to the junction box is more
than 2’ (0.6 m), the cord should be tied
to the wall, rack, or ceiling to keep it
protected.

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Mechanical Installation
The Bluezone unit can be hung from the
ceiling or placed on a shelf. A ceiling mount
kit and a shelf mounting kit are available for
purchase.
A drawing of the mounting locations on the
Model 420 is provided in Figure 5.
See Figure 6 for mounting kits.
Sound deadening mufflers can be installed
to reduce noise in occupied space
applications. Installation instructions for the
mufflers are included in Appendix A.
Figure 5: Bluezone Model 420 Mount Dimensions (units in inches)

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Figure 6: Illustration of the Ceiling Mount and Shelf Mount

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Electrical Installation
The Bluezone unit is equipped with a power
entry module.
Model 420-048 must be connected to
120VAC 60Hz input only
Model 420-045 is may be connected to
120V or 230V AC 50/60Hz input.
The unit is cETLus listed at 120 VAC.
The Model 420 is shipped standard with a 6’
(2m) power cord.
Plug the power cord into the power entry
module.
Once the Model 420 is positioned
mechanically in the space, plug the cord
into the nearest un-switched electrical outlet
rated to the voltage on the unit’s
model/serial number plate.
Secure the cord.
Warning
The power cord is attached to the front of
the unit and may be caught and pulled
during activities in the space. Secure the
power cord to the shelving, wall or other
stable surface.
Electrical Requirements
Input Voltage: 120VAC
Input Frequency: 60Hz
Input Current: 3A max @ 120VAC
Input Power: 250W max

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Operation
Figure 7: Control Panel on Bluezone Unit
Once the Model 420 is mounted and wired, it can be turned ‘On’ using the power switch on the
control panel.
Toggle the power switch to the “On” position to energize the unit.
Normal Operation
Once the Bluezone is switched “On”, the Display Screen will indicate “Bluezone M420” on a
green background on the top line.
The bottom line of the display screen will confirm bulb operation, a bulb life counter, the
temperature, humidity and fan speed.
Power Switch
Circuit Breaker
Bulb Counter
Reset Button
Power Entry
Module
(AC Inlet)

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Figure 8: Display Sequence in Time

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Fault Conditions and Fault Codes
If there are issues with the operation of the Model 420, the onboard diagnostics will indicate the
nature of the problem.
Display Screen codes are shown in Error! Reference source not found..
Table 2: Display Screen Status Indicator Fault Codes
Display Color
Display Text
Fault
Operation
Action to Take
Green
Background
Bluezone M420
Unit conditions
scrolling
System operating
properly.
Operates
None
Flashing Green
Background
Bluezone M420
Unit conditions
scrolling
Freezing
temperatures
detected, or
Humidity above
threshold
Unit is off and will
power up when
temperature
increases to >0C or
humidity drops
below 85%
Do not run unit in a
freezing
environment.
Yellow
Background
Contact
Bluezone
Fan not rotating, or
Humidity sensor
failure, or
Bulb counter failure
Unit automatically
powered down.
Check fan for any
visible obstructions.
Contact Bluezone
Products for
service.
Replace Bulbs,
Unit conditions
scrolling
Bulb life >7,200
hours of operation.
Operates until
8,800 hours of
operation.
Check bulb counter
Order new bulbs
Red Background
Contact
Bluezone
Ozone sensor Trip
Unit automatically
powered down until
sensor resets.
Contact Bluezone
Products
Replace Bulbs
Bulb life at 8,800
operation hours.
Unit automatically
powered down until
bulbs replaced and
counter reset.
Replace bulbs and
reset bulb life
counter.

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Diagnostics
If the Display Screen has no light or text
then the Model 420 is not being
powered. Check the following list for
possible causes and solutions:
1. Make sure the cover is on and
the Cover Switch is Activated.
Controls will not energize if the cover is
off or if the cover switch is not engaged.
Make sure the cover switch tab engages
inside the cover switch opening.
See Figure 9 for proper installation of
the cover switch.
2. Check that unit is powered.
a. Power “Off” unit by pressing
the power switch located on
the control panel.
b. Plug unit in.
c. Turn unit “On.”
3. Restart the unit.
a. Power “Off” unit by pressing
the power switch located on
the control panel.
b. Wait 5 seconds.
c. Turn unit “On.”
d. Repeat 3 times
4. Check whether the unit’s circuit
breaker has tripped.
a. Visually check the circuit
breaker located on the
control panel. If a white strip
is visible, then the breaker
needs to be reset.
b. Power “Off” unit using the
power switch located on the
control panel.
c. Reset circuit breaker located
on the control panel by
pushing the visible indicator
back into the circuit breaker.
d. Turn unit “On” using the
power switch located on the
control panel.
Danger
DO NOT activate the cover switch without the cover on. UV light will be emitted.
`

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Figure 9: Bluezone Cover Switch and Cover Switch Hole
Cover switch hole
Cover switch

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New Equipment Warranty
Online warranty registration form must be
completed to validate your New Equipment
Warranty. Please visit
www.BluezoneFresh.com to complete the
online warranty registration.
Bluezone Products, Inc. warrants that new
equipment manufactured in Bluezone’s
facilities are free of defects due to poor
materials or workmanship for a period of 1
year from the date of purchase.
Bluezone Products, Inc. warrants that the
equipment will function properly, to our
specifications and will be repaired, if
necessary, at no charge for a period of 1
year (See our warranty policy for details).
All Bluezone products have been tested by
independent labs and in many facilities,
proving the performance as described in our
literature. Our air purification equipment is a
powerful tool to help purify your
environment yet, we cannot guaranty that
under your operating conditions and
procedures, the results will be the same as
experienced by other users.
If you are not satisfied with the purchase or
the operation of our equipment, it can be
returned if the equipment was un-used and
was returned within 14 days. The customer
will be charged return freight and an
additional 10% of the purchase price as
a restocking fee.
Bulb Disposal
Bulbs contain a small amount of mercury
Bulb handling should be similar to that used for fluorescent or compact fluorescent bulbs.
Bluezone Products, Inc. recommends that you take advantage of available local recycling
options for CFLs. Lists of recycling facilities are available at: www.earth911.org.
Dispose of according to local, state or federal laws.

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Service
BULBS NEED TO BE REPLACED AFTER 8,800 HOURS OF USE. BULB KITS MUST BE
PURCHASED DIRECTLY FROM BLUEZONE PRODUCTS OR AN AUTHORIZED PARTNER
AS THEY ARE PROPRIETARY BULBS.
Bulbs must be replaced at 8,800 hours of
operation. The display screen reads
accumulated bulb hours throughout the
unit’s operation. At 7,200 hours the display
screen will turn yellow and read “Replace
Bulbs.” The bulbs should be ordered and
replaced immediately. At 8,800 hours, the
display screen will turn red and the unit will
automatically be powered OFF until bulbs
are replaced.
After bulbs are replaced, the bulb counter
needs to be reset. To reset the bulb counter
please follow the steps below.
1) Press and hold the red bulb counter
reset button for 5 seconds. The
display screen will read “Hold: reset
counter” during the 5 second hold.
2) After holding for 5 seconds, the
display screen will read “push to
confirm.” Release button and push
to confirm reset.
A bulb replacement kit and instructions can
be ordered from Bluezone Products, Inc.
Please call [phone] or email
[e-mail] for ordering
information.
IMPORTANT: Each bulb kit satisfies
replacement parts for 1 unit. The four bulbs
in each replacement kit cannot be replaced
with bulbs purchased from anywhere, but
Bluezone Products or an Authorized
Partner. Installation of the incorrect bulbs
results in a voided warranty. Purchase of
bulbs from an outside vendor results in a
voided warranty. Bluezone will not operate
correctly with bulbs purchased from outside
vendors.
Service Kit includes:
•(4) U-shaped bulbs
•(2) Nitrile gloves
•Exta cover screws
Additional tools needed:
•N/A

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Instructions for Bulb Replacement:
1) Toggle the power switch located on
the unit’s control panel to OFF.
2) Wait 15 minutes for the ozone to
clear from the Bluezone reaction
zone.
3) WARNING: Before proceeding
to next step, unplug the unit from it’s
power supply.
4) Use the ¼” hex nut driver to unscrew
the 14 screws on the cover, see
Figure 10 below.
5) Slowly, remove the cover and place it
on a flat surface.
6) Use the gloves provided to remove
and replace the bulbs. This will
prevent oil on your hand from
damaging the new bulbs.
7) Unscrew the ¼” screws on Bulb
Support Wires. See Figure 11 below.
8) Carefully remove Bulb Support Wires
and place aside. See Figure 12
below.
9) Unscrew ¼” screws on Bulb Clips.
See Figure 13 below.
10) Remove the old bulbs (Note: pull on
them at the ceramic base, not on the
glass) Put the bulbs to the side for
disposal.
11) Carefully remove Bulb Clips and
place aside. See Figure 14 below.
12) Hold replacement bulbs by the
ceramic end and push the pins into
the slots in the receptacle.
They need to be pushed in
until a “click” is heard and
felt.
13) Put Bulb Clips over new bulbs and
use screws to tighten Bulb Clips in
place.
14) Thread Bulb Support Wires through
bulbs and use screws to tighten Bulb
Support Wires in place.
15) Tighten cover back onto the unit.
16) Dispose of used bulbs, according to
standard practice for florescent bulbs.
IMPORTANT
17)Press and hold the red bulb counter
reset button for 5 seconds. The display
screen will read “Hold: reset counter”
during the 5 second hold. See Figure
12.
18)After holding for 5 seconds, release and
press the bulb counter reset button
again to finalize reset. The display
screen will read “push to confirm” after
the 5 second hold.
Estimated total bulb replacement time:
approximately 30 minutes per unit.

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Figure 10: Unscrew 14 Screws on Bluezone M420 Cover
Figure 11: Remove ¼” Screws Holding Bulb Support Wires
¼” screws to be removed
Bulb Support Wires to be
removed