Dust Free BIO-FIGHTER Ultra-Flex 1S User manual

®
®
©2021 Dust Free® • All rights reserved. • 212972-00 Rev. 2C 2/21
BIO-FIGHTER
Ultra-Flex 1S and 2S
Ultraviolet Light Systems
STD O3
Model 1S14 #09000 #09003
Model 1S16 #09001 #09004
Model 1S20 #09002 #09005
STD O3
Model 2S14 #09006 #09009
Model 2S16 #09007 #09010
Model 2S20 #09008 #09011
®
GENERAL
This product is designed to help disinfect the inter-
nal 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.
• Compact chassis design.
• Remote-mount lamp configuration.
• 6-ft remote lamp cables.
• Multi-input hvoltage electronic ballast.
INCLUDED INSIDE BOX
• Bio-Fighter® Ultra-Flex UV-C system
• Viewport(s)
• Installation hardware
• Installation & operation manual
• UV warning label for duct
• Registration card
TOOLS REQUIRED FOR INSTALLATION
• Electric drill
• Phillips screw bit or screwdriver
• 1/2" drill bit
• 1" drill bit or holecutter
• Eye protection
BEFORE INSTALLING
• Read all instructions carefully. Failure to do
so could damage the equipment or cause
harm to yourself or others.
• Acknowledge all warnings.
• Only qualified technicians should perform
the installation.
Installation & Operation Manual

BIO-FIGHTER® ULTRA-FLEX INSTALLATION & OPERATION MANUAL
2
Dimensions
Chassis: 9.25"L x 4"W x 2 "H
Lamp Housing: 3.6"L x 3"W x 1.25"H
Lamp Bracket: 3.25"L x 3"W x 4"H
Weight:
Approx. 4 lbs.
Electrical:
120V-240V, 50/60Hz, 1PH. 3 amp-250V fuse.
6 ft. power cord.
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.
UV-C Light May Degrade Plastic and Rubber.
Shield exposed plastic drain pans, wire insula-
tion, flex duct, or other plastic/rubber compo-
nents from UV-C light.
REMOTE LAMP MOUNTING LOCATION
Select a mounting location with enough clear-
ance for the lamp to be installed and replaced
easily. Allow a 1" clearance between duct sur-
face and lamp tip.
A 120V or 240V electrical supply is required.
CAUTION
Special Installation Notes
• Do not install in closet return grille applications.
• Do not install in outdoor 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).
250V/3 Amp Fuse Only
ON
OFF
9.25"
2"
4"
Remote Lamp Housing
3.6"
1.25"
3"
ETL LISTED
CONFORMS TO
UL STD 1598
CERTIFIED TO
CSA STD C22.2 NO. 250.0
2002554
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® ULTRA-FLEX INSTALLATION & OPERATION MANUAL
3
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. 1 Use included mounting screws to install device at desired
location.
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.
MOUNTING THE BASE (Fig.1)
Remove the cover and place the base at the
desired location. Use the included mounting
screws to install the base to the surface.
Replace the cover after the base is mounted.
FUSE
REMOTE LAMP BASE MOUNTING (Fig.2)
Remove the remote lamp housing from the
remote lamp base by removing the knurled
nuts. Then install the remote lamp base to the
surface with the included mounting screws.
Using the remote lamp base as a template,
drill a 1" hole for the lamp.
Fig. 2 Lamp is secured with a sliding bracket tightened with two
knurled nuts.
INSTALLING THE LAMP (Fig.3 )
To maximize the efficiency and life of the UVC
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.
Slide the bracket over the retaining lip of the
lamp and tighten the two knurled nuts until the
lamp is securely fastened. The lamp seals
against the base of the unit using a rubber
grommet which prevents air leaks. Repeat for
each lamp of the installation.
Fig. 3 Lamp is secured with a sliding bracket tightened with two
knurled nuts.
Clean lamp(s) prior to installation.
Failure to remove dirt and fingerprints from
the lamp(s) could shorten their lifespan.
NOTICE
Sharp Edge Hazard.
Be careful of sharp edges on device and
HVAC equipment while installing the device.
Personal injury may result.
CAUTION

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® ULTRA-FLEX INSTALLATION & OPERATION MANUAL
4
Fig. 4 Reinstall lamp housing.
INSTALLING THE LAMP HOUSING(s) (Fig.4 )
After lamp has been installed, reinstall the
remote lamp housing using the knurled nuts.
The remote lamp housing must be in place
prior to attaching the electrical harness.
Fig. 5 Attach lamp harness to lamp. The plastic boot slips over
the lamp and seals the connection from moisture.
Fig. 6 Install lamp bracket inside air handler
Fig. 7 Attach lamp to bracket.
CONNECTING THE HARNESS (Fig.5)
Attach the connector to the lamp. Hold back the
protective boot to expose the harness connector.
The harness connector is asymmetrical and can
only be attached one way. If the harness does
not attach easily, rotate 90 degrees and try again.
After the harness connector is attached, slide the
protective boot over the lamp/connector. The pro-
tective boot fits snugly over the lamp and seals
the connection from moisture, dust, etc.
OPTIONAL INTERNAL LAMP MOUNTING
Use the optional lamp bracket(s) to install the
entire lamp assembly inside the AHU.
Install the lamp bracket(s) at the desired loca-
tion with two self-drilling screws. (Fig. 6)
Insert lamp base into bracket, slide lamp
retaining washer over lamp and fasten using
two knurled nuts. Use knurled nuts from
remote lamp housing.(Fig. 7)
Connect harness to lamp. Refer to "Connecting
The Harness" on this page for details.

BIO-FIGHTER® ULTRA-FLEX INSTALLATION & OPERATION MANUAL
5
CONNECT POWER AND CHECK OPERATION
Connect the device to 120V-240V power.
(Fig.8)
The device power switch must be turned on
and device checked for operation using the
viewport(s). The lamp(s) should be radiating a
bright blue light.
OPERATION
Under normal conditions the Bio-Fighter®
Ultra-Flex should be operated continuously to
extend the life of the lamp(s), and to increase
the effectiveness in disinfecting the location
selected. A convenient power switch is located
on the device, and should be turned off before
any maintenance on the device or HVAC sys-
tem is performed.
INSTALLING THE AHU VIEWPORT(s)
The Ultra-Flex comes with UV-C safe viewports
that must be installed separately. To install the
viewport, select a location near the lamp
installation and drill a 1/2" hole in the duct.
Then press the viewport into the hole.
Connect green wire
to ground.
Power Cord
Connect black and
white wires to
120V-240V power.
Fig. 8 Power cord connection.
FUSE REPLACEMENT
1. Turn off power to the equipment.
2. Unscrew the knob marked "Fuse" and
remove fuse.
3. Install new fuse and screw knob back in
place. Only use a 250V/3 amp fuse.
4. Turn on power to the equipment.
TROUBLESHOOTING
Maintenance and troubleshooting should be
performed by a qualified technician.
Device fails to operate.
1. Check that device is connected to proper
power.
2. Check that fuse is in good working order.
Replace the fuse if necessary.
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.
6. Check that lamp is properly connected to
lamp receptacle.
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® ULTRA-FLEX INSTALLATION & OPERATION MANUAL
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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
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 power to the equipment. Allow
lamp to cool 10 minutes before touching.
4. Disconnect the lamp harness.
5. Remove the remote lamp housing. (Not
required for internal lamp mount option.)
6. Unscrew the two knurled nuts of the lamp
retaining bracket and slide the bracket
away from the lamp retaining lip. For inter-
nal lamp mount option, remove the two
knurled nuts and lamp retaining washer.
7. 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.
8. Slide the retaining bracket back in place
and tighten knurled nuts. For internal lamp
mount option, secure the lamp with the
lamp retaining washer and fasten with
knurled nuts.
9. Reattach the remote lamp housing. The
remote lamp housing must be in place
prior to attaching the lamp harness. (Not
required for internal lamp mount option.)
10. Reconnect lamp harness.
11. Reconnect power.
12. Verify operation using viewport.
Burn Hazard.
During replacement, allow lamps to cool 10 minutes
before removing them. Personal injury may result.
WARNING
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
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
PROPER CLEAN-UP TECHNIQUE IN CASE OF
LAMP BREAKAGE
GWear protective gloves, eyewear and mask.
GSweep 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.
GDo not use a vacuum cleaner. Do not
incinerate.
Replacement Parts Part No.
UVC Lamp - 14" 06413
UVC Lamp - 16" 06417
UVC Lamp - 20" 06421
UVC-O3 Lamp - 14" 06415
UVC-03 Lamp - 16" 06419
UVC-O3 Lamp - 20" 06423
Ballast - Multi-Voltage 06426
Power Cord - Whip-Type 06303
On/Off Switch 06617
Slide Bracket Springs (2) 210-0005-001
Slide Bracket 210929-00
Knurled Nuts (2) 210226-00
Fuseholder 212225-00
Fuse 750-0108-001
For information on the dealer in your area call: 1-972-635-9564.
Visit us at http://www.dustfree.com

BIO-FIGHTER® ULTRA-FLEX INSTALLATION & OPERATION MANUAL
7
LIMITED LIFETIME WARRANTY
Dust Free LP 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 which
carrys a five (5) 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 LP'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 param-
eters defined herein. Dust Free LP reserves the right to replace or repair the defective part or component.
DUST FREE LP 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 LP
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 LP 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
1-972-635-9565