Dust Free BIO-FIGHTER 4Xtreme User manual

©2021 Dust Free® • All rights reserved. • 212731-00 Rev. 3A 2/21
BIO-FIGHTER
4Xtreme 21", 33", 45"
Ultraviolet Light Systems
P/N
4Xtreme 21" #06159
4Xtreme 33" #06160
4Xtreme 45" #06168
®
GENERAL
This product is designed to help disinfect the
internal surfaces of heating, ventilation, and air
conditioning systems where the light shines.
Bacteria and viruses that are in the air stream that
pass through the system can also be reduced. The
result is an improved level of indoor air quality for
occupants and improved system hygiene.
The Bio-Fighter® emits ultraviolet(UV-C) radiation
at a frequency of 254 nanometers, which has been
proven effective in damaging the DNA of
microorganisms such as viruses, bacteria,
yeast and molds. This process either destroys
the microorganism or neutralizes its ability to
reproduce.
FEATURES
•Reduces or prevents mold growth on HVAC coils,
allowing them to operate at peak efficiency where
the light shines. Also significantly reduces
bacteria, viruses, fungi, and yeasts on surfaces
exposed to the UV-C energy.
• NEMA 4X weatherproof enclosure.
• High output, long life UV-C lamps.
• Multi-voltage electronic ballast.
• Low maintenance and reduced costs.
INCLUDED INSIDE BOX
• Bio-Fighter® 4Xtreme ultraviolet light system
(UV-C lamp shipped separately.)
• Installation & operation manual
• UV-C warning label for duct
TOOLS REQUIRED FOR INSTALLATION
• Electric drill
• Phillips screw bit or screwdriver
• 1.125"-1.25" uni-bit or holecutter
• 3/32" drill bit
• Weatherproof conduit & conduit connector
• Weatherproof sealant
• Cotton cloth and rubbing alcohol
• Eye protection
BEFORE INSTALLING
• Read all instructions carefully. Failure to do
so could damage the equipment or cause
harm to yourself or others.
• Read all warnings and cautions.
• Only qualified technicians should perform
the installation.
Installation & Operation Manual
PO Box 519
Royse City, TX 75189
PH: 1-972-635-9564
Http://www.dustfree.com

BIO-FIGHTER® 4XTREME INSTALLATION & OPERATION MANUAL
2
Base Dimensions
All Models - 11.563"L x 8"W x 4.25"H
Weight:
All Models - 8.2 lbs.
Electrical:
120V-240V, 50/60 Hz. 3 amp-250V fuse.
Listings:
U.S. Patent Nos. 5,334,347, 5,817,276, 6,245,293, 6,267,924,
6,280,686, 6,313,470, 6,627,000, 6,539,727, 6,932,494, 6,550,257.
Specifications subject to change without notice.
4Xtreme 21 - 20"
4Xtreme 33 - 32"
4Xtreme 45 - 44"
4.25"
8"
11.56"
SPECIFICATIONS
EPA Device Manufacturer Establishment No. 73316-TX-1
The product and technologies described are not medical devices, and are
not intended to diagnose, treat, cure, or prevent any disease or illness.

BIO-FIGHTER® 4XTREME INSTALLATION & OPERATION MANUAL
3
SIZING & PLACEMENT
Use a lamp length that covers the largest area
of the coil while maintaining a minimum clear-
ance of 1" from coil. and duct. Lamp should
not touch or be closer than 1" to any surface
along the length of the lamp. For coil disinfec-
tion applications, install the device no closer
than 1" from coil.
INSTALLATION GUIDELINES
This device installs on the air handling system.
Installation location must be at least 12" wide
and deep enough to allow a minimum of 1"
clearance at the tip of the lamp when installed.
Allow sufficient clearance in front of the device
to remove the lamp.
120V or 240V power must be available at the
installation location. Hard-wire device to electri-
cal service in accordance with NEC.
SPECIAL UV-C INSTALLATION NOTES
• Do not install in closet return grille applications.
• Do not expose wiring or plastic parts to UV-C light.
• Do not install where UV-C light can be seen
after installation.
• Do not install beneath a humidifier.
•If the UV device is installed on the inlet side
(return air side) of a coil, make sure that the
HVAC system is configured such that the
blower is located between the return air filter
and the inlet side (return air side) of the coil,
such as would be found in a traditional up-
flow, or horizontal furnace with the coil
placed after the heat exchanger.
• If the UV device is installed near an air filter,
check with filter manufacturer for UV-C
resistance properties.
• If the desired UV installation location is
intended to irradiate an air filter, to neutralize
the microbiological matter on the air filter
surface, such as would be found in the
return air drop of a basement application or
in the return plenum of a horizontal system
in an attic; take precautions as described in
note above, and make sure the UV fixture is
placed on the return side of the filter. DO
NOT INSTALL THE UV FIXTURE ON EITHER
SIDE OF THE FILTER IN HALL / CLOSET
RETURN AIR APPLICATIONS. (See ATTEN-
TION! Warning sheet #212945-00).
IMPORTANT:
The 4Xtreme 45" should not be in installed in
applications where air flow velocity exceeds
3,000 FPM. Lamp breakage may occur.
For optimum coil and drain pan disinfec-
tion efficiency, the following placement
guidelines are recommended.
Each foot of lamp length irradiates:
1 sq. ft. of coil area when installed 1"-2" from coil.
2 sq. ft. of coil area when installed 3"-6" from coil.
3 sq. ft. of coil area when installed 7"-12" from coil.
TROUBLESHOOTING
Maintenance and troubleshooting should be
performed by a qualified technician.
Device fails to operate.
1. Check proper power is being supplied to
the device, and that the switch lights when
unit is turned on.
2. Check that the lamp connector is securely
attached to the lamp.
3. Check that ballast is receiving correct
power. Replace ballast if necessary.
4. Check continuity of lamp filaments.
(Replace lamp if necessary.)
5. Check that wires are properly connected
to lamp and ballast.
Professional Installation Only.
Only a qualified technician should install and main-
tain UV-C lighting or service equipment in which it
is installed. Improper installation could cause
human injury or equipment damage. Always dis-
connect electrical power prior to any HVAC mainte-
nance. THIS INCLUDES FILTER MAINTENANCE.
CAUTION

BIO-FIGHTER® 4XTREME INSTALLATION & OPERATION MANUAL
4
UV-C Light May Degrade Plastic and Rubber.
Shield exposed plastic drain pans, wire insu-
lation, flex duct, or other plastic/rubber com-
ponents from UV-C light.
DEVICE ORIENTATION
The NEMA 4X enclosure of the device allows it
to be installed outdoors, either horizontally or
vertically, and remain weatherproof.
For applications where the device is mounted
horizontally, the tilt-lamp configuration is rec-
ommended. The device comes pre-configured
for tilt-lamp operation. This configuration pro-
vides greater UV-C exposure into the drain
pan condensate. (See Fig. 1)
For vertical applications the device may be
installed in its tilt-lamp or straight-lamp config-
uration. (See Fig. 2)
CAUTION UV-C Light Hazard.
UV-C light can cause temporary or perma-
nent loss of vision, and sunburn. To prevent
exposure, do not install device in any appli-
cations that allows UV-C light to be visible
after installation.
WARNING
Fig. 2 For vertical installations use either the straight-lamp or tilt-
lamp configuration. Note: Removal of lower slide clip is
required for straight-lamp configuration.
Fig. 1 For horizontal installations use the tilt-lamp configuration
for greater UV-C exposure into the drain pan.
ENCLOSURE MOUNTING (Fig.3 )
Tape the provided mounting template at the
desired installation location. Use this template
to mark locations for the lamp hole and
mounting screw pilot holes. Remove the tem-
plate after use.
Use a 1.125" - 1.25" drill bit or holecutter to
make the lamp hole. Use a 3/32" drill bit to
make the pilot holes for the mounting screws.
Once the holes are drilled apply a sealer suit-
able for outdoor use around the mounting
holes. Check to make sure the surface is flat
to provide a good seal for the gasket and
position the enclosure so that all holes align.
Use #10 x 5/8" or longer sheet metal screws
and washers to mount the device to the air
handling system.
Fig. 3 Mount the device using #10 x 5/8" or longer sheet metal
screws and washers. Be sure to use weatherproof sealant around
the mounting holes if installing outdoors.

TILT-LAMP INSTALLATION (Fig.6 )
To maximize the efficiency and life of the UV-C
lamp, clean each lamp prior to installation.
Use isopropyl alcohol and cotton cloth to wipe
dust and fingerprints from the lamp.
Gently insert the lamp into the lamp hole.
While holding the lower slide bracket under
the retaining lip of the lamp, push the upper
slide bracket over the retaining lip of the lamp
and tighten the two knurled nuts until the lamp
is securely fastened.
Fig. 6 Hold lower slide bracket in place under lamp retaining lip
while pushing upper slide bracket over lamp retaining lip. Secure
with two knurled nuts.
Mercury Hazard. Do Not Break.
Each UV-C lamp contains a small amount of
Mercury. May cause redness or irritation. Use
proper disposal techniques in case of breakage.
WARNING
UV-C Light Hazard.
UV-C light can cause temporary or permanent
loss of vision, and sunburn. Take precautions
to protect eyes and skin from direct exposure.
WARNING
BIO-FIGHTER® 4XTREME INSTALLATION & OPERATION MANUAL
5
IMPORTANT:
The device must be installed in compliance
with all national and local electrical and
mechanical codes. Failure to do so will void
Dust Free® warranty.
CONDUIT INSTALLATION (Fig.4 )
Remove the two cover retaining screws and
swing open the cover to access ballast and
wiring. Install an appropriate weatherproof
conduit on the side of the enclosure. Drill
points are marked on two sides of the enclo-
sure where it is safe for conduit installation.
Connect the electrical service, through the
conduit, to the ballast wires. Connect the black
and white wires to power and the green wire to
ground. Refer to Fig. 5 for wiring diagram.
Conduit installa-
tion points indi-
cated by dimples
on outside of
enclosure.
Fig. 4 Install weatherproof electrical conduits at either of the loca-
tions marked by dimples on the outside of the enclosure.
Fig. 5 Wiring diagram.
Electrical shock hazard.
Can cause injury or death. Before perform-
ing any service or maintenance disconnect
electrical service to the unit.
WARNING
White Wire
Black Wire
Green Wire
To 120V - 240V
Electrical Service
Ballast
To Ground
Lower slide bracket
Lamp retaining lip
Lower slide bracket
Lamp retaining lip
Important: O-ring
must be between slide
brackets to prevent
damage to ceramic
lamp base.
Upper slide bracket
Upper slide bracket

BIO-FIGHTER® 4XTREME INSTALLATION & OPERATION MANUAL
6
OPERATION
The device operates continuously. It is recom-
mended that the device be interlocked with a
power disconnect to prevent inadvertent UV-C
exposure when access panels are removed.
CONNECTING THE HARNESS (Fig.8 )
After lamp has been installed, attach electrical
harness. The harness connector is asymmetri-
cal and can only be attached one way. If the
harness does not attach easily, rotate 90
degrees and try again.
Fig. 8 Attach electrical harness to lamp.
STRAIGHT-LAMP INSTALLATION (Fig.7 )
To maximize the efficiency and life of the UV-C
lamp, clean each lamp prior to installation.
Use isopropyl alcohol and cotton cloth to wipe
dust and fingerprints from the lamp.
To install the lamp in its straight-lamp con-
figuration the lower slide bracket must be
removed. After the lower slide bracket has
been removed gently insert lamp into lamp hole
and push upper slide bracket over the retaining
lip of the lamp and tighten the two knurled nuts
until the lamp is securely fastened.
Fig. 7 After lower slide clip is removed, slip upper slide bracket
over retaining lip of lamp and tighten two knurled nuts.
FINISH INSTALLATION
Close the cover, reinstall the cover retaining
screws, and turn on the electrical service.
Apply included warning label on nearby main-
tenance access panel.
Note: This device uses a cover safety inter-
lock. The cover must be closed for the device
to operate.
Electrical disconnect required.
Areas where UV fixtures are installed must
have access panel/door disconnect
switches installed. Never view UV-C light
without protective eyewear.
WARNING
Lamp retaining lip
Remove lower slide bracket.
Upper slide bracket

BIO-FIGHTER® 4XTREME INSTALLATION & OPERATION MANUAL
7
LAMP REPLACEMENT(Annually)
The lamp should be replaced annually even if
it appears to be operating normally. UV-C
energy production diminishes over time.
1. Obtain the correct replacement lamp for
your model.
2. Disconnect electrical service
3. Open the cover of the device. Allow lamp
to cool 10 minutes before touching.
4. Disconnect the electrical connector to the
lamp.
5. Unscrew the two knurled nuts of the lamp
retaining bracket and slide the bracket
away from the lamp retaining lip.
6. Carefully remove the UV-C lamp and
replace it with the new lamp. Be sure to
clean the lamp of dust and fingerprints
prior to installation.
7. Slide the retaining bracket back in place
and tighten knurled nuts.
8. Reconnect electrical connector to the lamp.
9. Close the cover.
10. Reconnect electrical service.
PROPER CLEAN-UP TECHNIQUE IN CASE OF
LAMP BREAKAGE
●Wear protective gloves, eyewear and mask.
●Sweep the broken glass and debris into a plastic
bag, seal the bag, and dispose of properly.
Contact your local waste management office for
proper disposal.
●Do not use a vacuum cleaner. Do not
incinerate.
LAMP DISPOSAL
Dispose of your spent UV-C lamps at your
local recycling center. You may also send your
spent lamps in the same container you
received your replacement lamps to:
Dust Free® Lamp Reclamation
1112 Industrial Drive
Royse City, TX 75189
IF THE LAMP DOES NOT ILLUMINATE
• Check that the lamp connector is securely
attached to lamp.
• Check that the fuse is in good working
order. Replace if necessary.
• Check that electrical service is operating.
FUSE REPLACEMENT
1. Disconnect electrical service.
2. Open cover.
3. Remove fuse from fuseholder.
4. Install new fuse. Only use a 250V/3 amp
fuse.
5. Close cover.
6. Reconnect electrical service.
Mercury Hazard. Do Not Break.
Each UV-C lamp contains a small amount of Mercury.
May cause redness or irritation. Use proper disposal
techniques in case of breakage.
WARNING
Replacement Parts Part No.
UV-C Lamp - 21" 06180
UV-C Lamp - 33" 06182
UV-C Lamp - 45" 06184
Ballast - Multi-voltage 06190
Cover Interlock Switch 212108-00
Slide Bracket Springs (2) 210-0005-001
Slide Bracket 212147-00
Knurled Nuts (2) 210226-00
Fuseholder 750-0052-001
Fuse 750-0108-001
For information on the dealer in your area call: 1-972-635-9564.
Visit us at http://www.dustfree.com
Burn Hazard.
During replacement, allow lamps to cool 10 minutes
before removing them. Personal injury may result.
WARNING

BIO-FIGHTER® 4XTREME INSTALLATION & OPERATION MANUAL
8
LIMITED LIFETIME WARRANTY
Dust Free®warrants this Bio-Fighter®UV-C Light to be free from defects in materials and workmanship
under normal use and service, for as long as it is owned by the original purchaser. This warranty does not
cover UV-C lamp(s), which carry a one (1) year warranty from the date of installation, or the ballast(s)
which carry(s) a three (3) year warranty.
This warranty does not cover cosmetic damage, damage due to acts of God, damage as a result of han-
dling or shipment, negligence, misuse, connection to improper voltage, improper maintenance, or abuse.
This warranty is void if defect(s) result from failure to have this unit installed by a qualified, properly
licensed, heating and air conditioning contractor in compliance with all local building and construction
codes.
Dust Free®'s exclusive obligation under this warranty shall be to supply, without charge, a replacement
for any covered component of the Bio-Fighter®UV-C Light which is found to be defective within the
parameters defined herein. Dust Free®reserves the right to replace or repair the defective part or compo-
nent.
DUST FREE®SHALL NOT BE LIABLE FOR ANY LOSS OR DAMAGE OF ANY KIND, INCLUDING ANY
INCIDENTAL OR CONSEQUENTIAL DAMAGES RESULTING, DIRECTLY OR INDIRECTLY, FROM ANY
BREACH OF WARRANTY, EXPRESS OR IMPLIED, OR ANY OTHER FAILURE OF THIS PRODUCT. (Some
states do not allow the exclusion or limitation of incidental or consequential damages, so this limitation
may not apply to you.) THE WARRANTIES SET FORTH HEREIN ARE EXCLUSIVE AND DUST FREE®
EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES, WHETHER WRITTEN OR ORAL, IMPLIED OR
STATUTORY, INCLUDING BUT NOT LIMITED TO ANY WARRANTIES OF MERCHANTABILITY, WORKMAN-
SHIP, OR FITNESS FOR A PARTICULAR USE. If the limited warranty is void due to failure to use a quali-
fied contractor all disclaimers of implied warranties shall be effective upon installation.
How to make a warranty claim or have questions answered:
Should you have a warranty claim or questions about the warranty policy, contact the distributor or dealer
from which you purchased the product. Proof of original purchase and proof of identity that the original
purchasing party is filing the claim is required in order to initiate a warranty claim. Defective parts must be
returned no later than thirty (30) days after the failure to the installing contractor together with the model
number, serial number, and date of installation. All service and removal must be performed by a licensed
HVAC contractor. You must pay shipping charges and all other costs of warranty service. Warranty is only
valid the United States and Canada.
THIS WARRANTY SHALL NOT OBLIGATE THE MANUFACTURER FOR ANY LABOR COSTS AND SHALL
NOT APPLY TO DEFECTS IN WORKMANSHIP OR MATERIALS FURNISHED BY THE INSTALLING CON-
TRACTOR AS CONTRASTED TO DEFECTS IN THE GERMICIDAL LIGHT ITSELF.
NOTE: Do not return any products or parts to the factory without a factory issued Return Authorization
number issued by the Dust Free®customer service department.
In the event you have any questions concerning the use and care of this product or this warranty which
have not been answered to your satisfaction by the distributor or dealer, please call or write the factory.
Dust Free®
PO Box 519
1112 Industrial Drive
Royse City, TX 75189
1-972-635-9564