BSG CCX-QWK-18-01 Series Coilcare CCX Kit Instruction Manual

BSG CCX-QWK-18-01 Series Coilcare CCX Kit

Thank you for purchasing the BSG COILCARE System kit, a highly effective ultraviolet (UV) irradiation disinfection system for commercial HVAC applications. The UV light inactivates microorganisms and breaks down organic residue, preventing growth and keeping HVAC systems clean and operating efficiently. This can lead to significant savings in maintenance and energy costs while improving indoor air quality. When properly sized, the UV radiation can also provide air stream disinfection. The water-resistant power supply is easy to mount and withstand the humid environments of HVAC enclosures.

Product Information

COILCARE Kits The COILCARE Kits come in various lamp lengths and single or dual variants, including 18, 24, 33, 45, and 61 lamp lengths. The model numbers and details for each kit are listed below:

The COILCARE Kits are designed to be used by certified technicians only. Installation by anyone other than licensed HVAC or electrical contractors voids the warranty, and BSG assumes zero liability.

The COILCARE Kits come with various parts, including a UV lamp, lamp connector, power supply (ballast), cabling, UV warning label, sight glass, mounting screws, door interlock switch, contact plates, lamp clip pack, light switch, conduit, stand-off support bracket, magnets x 2, and L brackets. Optional accessories include a UV lamp shield, additional door interlock, 10ft extension cable, and radiometer. The standard lamp life for replacement lamps is 18,000 hours or 2 years. Contact BSG for replacement lamps.

Product Usage Instructions

COILCARE Kits Before servicing the COILCARE Kits, turn off the unit or disconnect it and protect your eyes from UV light.

To install the COILCARE Kits:

1. Mount the power supply to the air handler unit (AHU) using 4 sheet metal screws. Note that the power supply is not weatherproof and should not be mounted outdoors without adequate protection.
2. Route the lamp cabling and use zip ties to secure the cables to the frame. When possible, route the cabling where it will be shadowed from lamps to reduce total UV exposure.
3. Use junction boxes, cable glands, grommets, etc. to pass cabling from interior to exterior surfaces as needed. The lamp connector diameter is 0.75 [19mm], the lamp cable diameter is [6mm], and the status cable diameter is [4mm].
4. Connect the power cable to 120-77 VAC single-phase electrical power according to all state and local electrical and building codes. If power surges occur often, it is suggested that you use an external power suppressor.
5. Install an interlock switch (part number CCX-KT-DS) to prevent accidental exposure to UV light if the panel/door is opened. If multiple power supplies are used on one AHU, the switch should be wired to interrupt electrical to all power supplies.

Contact your BSG commercial UV specialist for more information or if you have any questions about installing or using the COILCARE Kits.

COILCARE CCX Kits

BSG offers free UVCalcTM analysis to assist with system configuration and selection. Contact your BSG commercial UV specialist for more information.

WARNING: PROTECT EYES FROM UV LIGHT TURN OFF THE UNIT OR DISCONNECT BEFORE SERVICING.

IMPORTANT

• Qualified technicians should install this product
• Install in accordance with relevant building codes
• Read instructions carefully including safety warn

Warning: BSG COILCARE CCXsystems must be installed by certified technicians only. Installation of this product by anyone other than licensed HVAC or electrical contractors voids warranty, and BSG assumes zero liability.

CCX KIT Parts

• A UV Lamp
• B Lamp Connector
• C Power Supply (Ballast) and 6ft (1.8m) cabling
• D UV Warning Label
• E Sight Glass
• F Black Nylon Zip Ties
• G Mounting Screws
• H Door Interlock Switch
• I Contact Plates
• J Lamp Clip Pack
• K Light Switch
• L Conduit
• M Stand-off support bracket
• N Magnets x 2
• O L Brackets

Call BSG for Optional Accessories

1. UV Lamp shield
2. Additional door interlock, CP-03-0065 Door Interlock – Minimum of one required per AHU door with exposure to UVC
3. 10ft extension cable – PT-CCX-0002 10′ Extension Cable
4. Radiometer – PT-CCX-0018 Radiometer

_ NOTE: _Call BSG for replacement lamps. Standard lamp life: 18,000 (2-Years)

WARNING

• STRONG MAGNETIC FIELD
• PLEASE USE with CAUTION

INSTALLATION INSTRUCTIONS

Power Supply

The power supply is IP 54 water resistant and is suitable for mounting to the interior or exterior of the air handler. The power supply is not weather proof and should not be mounted outdoors without adequate protection.

NOTE: POWER SUPPLY IS NOT FIELD SERVICEABLE. DO NOT OPEN POWER SUPPLY ENCLOSURE OR INGRESS PROTECTION WILL BE COMPROMISED.

1. Fasten power supply to AHU with 4x sheet metal screws. Lamp cables are 10ft [3m] long; optional extensions are also 10ft
2. Route lamp cabling; use zip ties to secure cables to frame. When possible, cabling should be routed where it will be shadowed from lamps to reduce total UV exposure.
3. Use junction boxes, cable glands, grommets, etc to pass cabling from interior to exterior surfaces as needed.
   • Lamp Connector diameter: 0.75” [19mm]
   • Lamp Cable diameter: [6mm]
   • Status cable diameter: [4mm]

Electrical: Power

IMPORTANT:  Connect in accordance with all state and local electrical and building codes. If power surges occur often, it is suggested that you use an external power suppressor.

Connect the power cable to 120-77 VAC single phase electrical power. Alternatively, two legs of a 3 phase source may be used if the total voltage difference is within the above rating. Conductor colors may vary according to the diagram above depending on intended region for sale.

Electrical: Interlock Switch

An interlock switch (BioZone Part Number: CCX-KT-DS) is required to prevent accidental exposure to UV light if the panel/door is opened. If multiple power supplies are used on one AHU, the switch should be wired to interrupt electrical to all power supplies.

IMPORTANT:  Switch is rated to 10A, 300VAC. If lamp quantity exceeds 6 (120VAC) or 12 (277VAC), then multiple switches or a higher rated switch must be used.

1. Adjust Switch Head
   • Remove the switch cover and the head’s combo-head screw (do not loosen Torx screws)
   • Lift slightly on the switch head and rotate to any of the 4 positions as needed.
   • Re-install the combo head screw
2. Install Lever Arm
   • Attach stainless steel roller arm to switch head and set to desired length so the switch will be engaged when the access door/panel is closed.
   • Mount Switch
   • The switch has dual-role M5 threaded or M4 (4.2mm / 0.17in) through holes.
   • Attach switch to AHU structure where the lever arm can engage the door or panel.
3. Wiring
   • Switch cable gland accepts cable diameters: 4.0 – 6.5mm [0.16 – 0.26in]
   • Route Line power to the NO contacts (#3 & #4) to disconnect power when the switch is opened
   • Reinstall cover & tighten cable gland
   • Use multimeter to confirm that circuit closes when switch is activated and opens when switch is released.

Electrical: Lamp Status

Dry contact relay provides status of each individual lamp. For 1-lamp power supplies, the secondary lamp status circuit remains unused.

• Lamp 1: white & black wires
• Lamp 2: red & green wires

If circuit is closed, the lamp is on. If the circuit is open, lamp is not on – this may indicate failed lamp, disconnected power, etc.

• Maximum load through the solid state relay: 60V, 0.5A

Example

• A single status circuit is desired for an AHU with 5 UV lamps. The individual lamp status circuits can be wired in series as shown.

Install the UV Lamps

1. Attach the lamp connector cable(s) to the UV lamps by aligning electrical pins and pushing them firmly together.
2. Press UV lamps into the lamp clips inside shield (Shield is available as an optional accessory). Clips should only be attached to 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.

NOTE

• When handling lamps makes sure that you are wearing gloves or only touch the ceramic ends.
• Do not touch the lamp glass with bare hands as skin oils can degrade lamp performance.
• The use of gloves is recommended when handling UV lamps.
• Wipe UV lamp with isopropyl alcohol as needed to clean glass.

Install Sight Glass

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. Drill a 1/2” hole and press the sight glass into the hole until it snaps in place.

(if not using included installation kit components)

EMT / Conduit

• Lightweight and economical solution commonly used in HVAC systems that require 1-4 lamps. Vertical support tube adds strength and prevents sagging on installations with 2+ lamps per tubing length.

Channel Strut

• For HVAC systems that require large numbers of lamps and a stronger frame. Vertical support struts can add strength to the framing and prevent sagging on installations with multiple lamps per strut length.
• Framework should be securely fixed to air handler surfaces with L-brackets and/or conduit clamps, and self-drilling sheet metal screws.

Magnetic Mounting

In situations where small coil surfaces require CCX systems comprising single UV lamps, the use of magnets fitted 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.

Note: Magnetic Mounting Measure the distance between the L-brackets and cut tubing 1” less than the distance between the L-brackets.

• Extend the tubing between the L-brackets and fasten at each end.
• Use 6″ standoff magnet to fix the lamp from the ceiling of the air handler.

WARNING

• STRONG MAGNETIC FIELD
• PLEASE USE WITH Caution

Additional Equipment Needed

Components

• Metallic lamp framework at installer’s discretion Examples: channel strut, EMT or IMC conduit Electrical junction boxes, cable glands, etc as needed

Tools required

• 1/32″ socket or wrench for lamp clip attachment
• Drill
• 1/2″ hole saw for viewport installation
• 1/4″ socket for power supply mounting screws

Lamp Framework

• Lamp clips should be attached to the framework so clip centers are spaced I .5″ [38mm] less than the lamp length.
• Lamp should be equally distributed on the framework

Example AHU

• Dimensions (H xwx D): 12″ x 30″ x 18″ [300 x 750 x 450mm]
• Specified UV Lamps: 2x 24″ [610mm] UV lamps.

1. Install framework at midpoint of depth: 18″ / 2 = 9″ [450mm / 2 = 225mm]
2. Framework post spacing: 24″ – 1.5″ = 22 5
   • [61 Omm – 38mm = 572mm]
3. Divide the height by lamp quantity: 12″/2 = 6″ [300mm /2 = 150mm] section height.
4. Place UV lamps at the midpoint of each section: 3″ and 9″ [75mm and 225mm]

_ NOTE: _Recommended lamp placement and coordinates are provided as part of a BSG UVCalc analysis report.

Mount options

TWO MOUNT OPTIONS FOR CUSTOMERS:

• MAGNETIC ATTACHMENT
• SCREW ATTACHMENT

Fixings and brackets

T5 LAMP CLIP

UV Warning Label

Affix the UV Warning Label to the door or access panel used to service the unit. Record the installation information on the UV Warning Label. The UV Warning Label contains fields convenient to record installation and service information.

OPERATION AND MAINTENANCE

Powering Up the System

WARNING

• PROTECT EYES FROM UV LIGHT TURN OFF UNIT OR DISCONNECT BEFORE SERVICING.

Caution

• UV light 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. Use the sight glass to confirm that the UV lamp is operating.

Maintenance

• 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.

COIL SIZING INSTRUCTIONS

CCX mounting instructions – UV Lamp Configuration

BSG offers free UVCalc™ analysis to assist with system configuration and selection. Contact your BSG commercial UV specialist for more information.

1. Measure the coil dimensions that requiring UV treatment
2. Choose the required coil sizing guide to ensure that optimum number of lamps are selected
3. If you have a larger coil, multiple lamps will be required, standard kits available with 1-2 lamps with lengths of 18-60″
4. BSG will be able to provide consultancy advice for accurate sizing and system confiruration of lamps
   • UV Lamp Positioning Diagrams – to illustrate number of lamps per coil

• Lamp Horizontal
• Lamp Vertical
• Lamp Horizontal
• Lamp Horizontal
• Lamp Vertical
• Lamp Horizontal
• Lamp Stacked

Coil and lamp sizing guide

(in)| 24| 32| 40| 48| 56| 62| 72| 82| 98| 108| 120| 144| (in)
---|---|---|---|---|---|---|---|---|---|---|---|---|---
144| 3×48| 3×48| 3×36| 3×36| 3×48| 3×48| 3×64| 3×64| 4×48| 4×64| 4×64| 6×48| 144
120| 3×18| 3×24| 3×36| 3×36| 3×48| 3×48| 2×64| 3×64| 4×48| 4×48| 6×36| 4×64| 120
108| 2×48| 2×48| 2×36| 3×36| 2×48| 3×48| 2×64| 3×64| 4×48| 4×48| 4×48| 4×64| 108
98| 2×48| 2×48| 2×36| 2×48| 2×48| 3×48| 2×64| 3×64| 4×48| 4×48| 4×48| 4×48| 98
82| 2×36| 2×24| 2×36| 2×36| 2×48| 2×48| 2×64| 2×64| 3×64| 3×64| 3×64| 3×64| 82
72| 1×64| 1×64| 2×36| 2×36| 2×48| 2×48| 2×64| 2×64| 2×64| 2×64| 2×64| 3×64| 72
62| 2×18| 2×24| 2×36| 2×36| 2×48| 2×48| 2×48| 2×48| 3×48| 3×48| 3×48| 3×48| 62
56| 1×48| 1×48| 2×24| 2×36| 2×48| 2×48| 2×48| 2×48| 2×48| 2×48| 3×48| 3×48| 56
48| 2×18| 2×18| 2×24| 2×36| 2×36| 2×36| 2×36| 2×36| 2×36| 3×36| 3×36| 3×36| 48
40| 1×36| 1×36| 1×36| 2×24| 2×24| 2×36| 2×36| 2×36| 2×36| 2×36| 3×36| 3×36| 40
32| 1×18| 2×18| 1×36| 2×18| 1×48| 2×24| 1×64| 2×24| 2×48| 2×48| 3×24| 3×48| 32
24| 1×18| 1×18| 1×36| 2×18| 1×48| 2×18| 1×64| 2×36| 2×48| 2×48| 3×18| 3×48| 24

Lamp Replacement

• BSG HIGH OUTPUT (HO) lamps are rated for 16000 hours (~2 years) of germicidal effectiveness on CCX systems.
• The lamps will continue to illuminate with a blue glow after they have exceeded their rated lifespan, however, their germ-killing effectiveness diminishes with time, so they must be replaced on schedule for the system to function properly.

Contact your local dealer for replacement lamps

Power Requirements Chart

Important

• Use only authentic BSG replacement lamps.
• Use of replacement lamps from other manufacturers will immediately void the system warranty and affect the performance of the system.

WARRANTY

• Lamps: 16,000 hours
• Ballasts: 5 years (when lamps are replaced on schedule)
• All other components: 12 months from installation, or 18 months from dispatch, whichever is soonest

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 accordance with manufacturer’s instructions.

How Long Does The Coverage Last?

1. CCX UV lamps are warranted for germicidal output for 16,000 hours of run-time (approximately two-years) from the date of installation.
2. CCX system ballasts are warranted for 5 years; a ballast warranty is applicable only when lamps have been replaced on schedule.
3. All other CCX components are warranted for 12 months from installation or 18 months from dispatch, whichever occurs first. This warranty is not transferable.

What Will BSG do?

• BSG 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.

What Does This Warranty Not Cover?

• THIS PRODUCT IS INTENDED TO BE PURCHASED AND INSTALLED BY LICENSED HVAC OR ELECTRICAL CONTRACTORS.

This warranty does not

• Cover products or parts purchased from any source other than licensed HVAC or electrical contractors.
• Cover parts installed by unlicensed HVAC or electrical contractors.
• 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, modification or adjustments. BSG, Inc. shall have no responsibility for charges incurred by the customer for installation or removal of warranted items.
• Cover parts or equipment used with the BSG system that are not manufactured by BSG.
• This warranty shall be void if UV lamps from manufacturer’s other than BSG. are used with this equipment. 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 profit, 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 here of.

How Do You Get Service?

If something is wrong with your product, call your installing contractor to receive a Return Merchandise Authorization (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. There is no charge for 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.

How Does State Law Apply?

• This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

Glossary of Terms

ASHRAE

The American Society of Heating, Refrigerating and Air-Conditioning Engineers. It focuses on building systems, energy efficiency, indoor air quality, refrigeration and sustainability technologies. ASH RAE publishes guidelines for treatment of air and surfaces with UV lamp systems.

Irradiance (UV)

The power per unit area received as electromagnetic radiation from a UV source at a wavelength or wavelength range. For evaporator coil surface disinfection, ASH RAE recommends a minimum of 50-100 μW/cm2 on the coil surface at 254nm.

Cooling Effects

Lamp UV output is critically dependent on mercury vapor pressure, which is dependent on temperature. Below 80°F [27°C] UV output can decrease by as much as 50%. Cooling effects are factored into CoilCare® system design.

Reflectance

Ultraviolet light can reflect off of surfaces, depending on the specific material. CCX reflectors can re-direct and focus up to 75% more irradiance onto the coil surface than the same system without reflectors.

Ultraviolet

Ultraviolet (UV) light is electromagnetic radiation with a wavelength 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 and can also be produced by specialized lights. 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 inactivate microorganisms by destroying nucleic acids and disrupting their DNA, leaving them unable to perform vital cellular functions. UVGI is used in a variety of applications, such as food, air, and water purification.

CONTACTS

• 9651 Satellite Boulevard, Ste 300 Orlando FL 32837 USA
• Tel: +1.407.876.2000
• Fax: +1.407.876.7630
• technical@bsg-uv.com
• www.bsg-uv.com

© 2023 BSG

© 2023 BSG (BIOZONE SCIENTIFIC GROUP)

References

• British plc - Emergent technology consultancy.
• BSG-UV - UV Disinfection for Air and Water

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