IS-20929

Instruction Sheet

UV LIGHTS INSTALLATION IN AC COMPARTMENT
First Release

09-30-2020
H SERIES FROM E-2662 ; X SERIES FROM F-5760

MATERIAL
Kit #IS20929 includes the following parts:
Part No.

Description

Qty

7771178

UVC LIGHT KIT

1

N91098

UV RESISTANT CABLE TIE 8" LG, BLUE

20

IS-20929

INSTRUCTION SHEET

1

FI-20929

INSTRUCTION SHEET

1

Available replacement parts:
Part No.

Description

TBD

UVC Tube 25W

830155

Ballast T8 32W

TBD

Wiring Harness UV1-A

TBD

Wiring Harness UV1-B

TBD

Wiring Harness UV2-A

TBD

Wiring Harness UV2-B

TBD

UVC tube central support

TBD

Main wiring Harness

563332

Relay 24V

NOTE
Material can be obtained through regular channels.

CAUTION
HIGH INTENSITY ULTRAVIOLET LIGHT.
WHEN THIS KIT INSTALLATION IS COMPLETED, AVOID EYE & SKIN EXPOSURE. TURN OFF
UV-C LIGHTING BEFORE ACCESSING THE COMPARTMENT.

Writer: mg

IS-20929
Page 2 / 11

PROCEDURE

DANGER
Park vehicle safely, apply parking brake, stop engine. Prior to working on the vehicle, set the ignition
switch to the OFF position and trip the main circuit breakers equipped with a trip button. On Commuter
type vehicles, set the battery master switch (master cut-out) to the OFF position.
Lock out & Tag out (LOTO) must be performed during set-up, maintenance or repair activities. Refer to
your local procedure for detailed information regarding the control of hazardous energy.

1. Open the main AC compartment door and
remove the plastic cover protecting the I/OEB module (located between the two main
ducts).

2. Disconnect the I/O-EB module. Also
disconnect all harness connections and cable
ties that prevent the removal of the upper
cover (on which is mounted the I/O-EB
module).

3. Remove the top and bottom cover to access
the AC motor and evaporator coil.

Writer: mg

IS-20929
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4. Two 7/8in holes must be drilled behind the
evaporator housing ducts (one on each side)
to allow passage for the tubes power cables.
−

The left side hole must be drilled 3.75in from
the top of the housing and 3.25in from the
cover opening.

−

The right side hole must be drilled 2.25in
from the top of the housing and 2.5in from
the cover opening.

NOTE
For this procedure, a knockout punch was
used to perforate both holes in the housing.

If knockout punches are unavailable, the holes
can be drilled using a large step drill or a
corresponding diameter hole saw.

5. Secure the UV1-B harness gray tube
connector to the top support opening (gray
connector is labeled FLUO-L2).
6. Secure the UV2-A harness gray tube
connector to the lower support opening (gray
connector is labeled FLUO-R3).

Writer: mg

IS-20929
Page 4 / 11

7. Position the support at the top of the housing
and maintain in place using locking C-clamp.
−

Keep the support centered in the opening as
much as possible.

−

The support tabs must sit flat against the top
45deg part of the housing.

8. From the inside (using an angled drill), drill
the two mounting holes in the housing (use
the holes in the support tabs as a guide). Use
a short 1/4 or 7/32 in (6mm) drill bit.

9. Secure the support using the supplied
screws, washers & nuts.

Writer: mg

IS-20929
Page 5 / 11

10. Remove the (plastic gray) tube hold-down
nuts from all harnesses (UV1-A, UV1-B, UV2A & UV2-B). Slide the hold-down nuts over
the two tubes.

11. Insert a UV tube in the bottom UV2-A/FLUOR3 connector (and tighten the hold down nut).
−

Have the other end of the tube contact the
inside wall panel of the housing.

−

Keep the tube leveled as much as possible
(horizontal & vertical).

12. Using a sharpie, insert your hand and mark
the tube position (perimeter of the tube).

13. Repeat operation 11 & 12 for the other side
(top) UV1-B/FLUO-L2 connector.

Writer: mg

IS-20929
Page 6 / 11

14. From the inside, drill a small pilot hole in the
middle of the marks (both sides).

15. Before drilling the final (larger) holes, validate
from the outside of the housing that the pilot
holes are drilled at the correct positions.

−

Both pilot holes should be located
approximately 1.75in from the edge of the
housing (horizontal position).

−

Top tube pilot hole should be located
approximately 5.5 in from the top of the
housing and the lower pilot hole 8.75 in from
the top (vertical positions).

NOTE
The pilot hole positions given above are
approximate, some variations are acceptable.
If the holes position are way off, re-adjust
accordingly and drill new holes in correct
positions.

Writer: mg

IS-20929
Page 7 / 11

16. Once the pilot holes correct positions are
confirmed, enlarge the holes (both sides) to
1.375in using a knockout punch or other
suitable tool.

NOTE
For this procedure, a knockout punch was
used to enlarge the holes in the housing.

If knockout punches are unavailable, the holes
can be drilled using a large step drill or a
corresponding diameter hole saw.

17. Pass the UV1-B & UV2-A harness through
the top openings and secure their black
fittings with the conduit locknuts.

18. Insert a fluo tube in each center connector
(FLUO L2 & FLUO R3).

Writer: mg

IS-20929
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19. Insert the gray FLUO L1 (top/left) & FLUO R4
(bottom/right) connectors through the side
holes of the housing to connect the fluo
tubes.

20. Secure the gray FLUO L1 (top/left) & FLUO
R4 (bottom/right) connectors to the sides of
the housing using the conduit locknuts.

21. Hand tighten the four inner tube nuts to
finalize the tubes installation in the evaporator
housing.

Writer: mg

IS-20929
Page 9 / 11

22. Replace all the cable ties attached to the fan
motor power cable (+ POS) by the supplied
N91098 UV resistant cable ties.

23. Reinstall the housing top cover with the I/OEB module (hand tight the screws).
24. Reconnect
the
module,
relays
and
surrounding harnesses. Also secure the
harnesses with new N91098 UV resistant
cable ties.

25. Locate the R12 relay at the lower right corner
of the cover (just below the I/O-EB module).

−

Connect the CB3 fused wire (10 amps) of the
ballast box to the CB3 connection of the R12
relay (left wire).

Writer: mg

IS-20929
Page 10 / 11

−

Disconnect the R12 relay AMP type
connector (sealed) and connect the two R12
connectors of the ballast box. One end goes
to the relay the other end to the disconnected
harness.

−

Connect the ballast box ground connection to
the ground stud of the fan motor (GND).

26. Connect the four tubes connectors to the UV
tubes ballast box. Connectors are numbered
and must fit with the numbers on the box
connectors.

27. Fit the fully connected ballast box to the black
plastic cover that goes over the I/O-EB
module.
−

Secure the plastic cover (and ballast box) over
the module.

−

Secure the harnesses coming out of the
ballast box as required using UV resistant
cable ties.

−

Do not reinstall the lower cover of the housing
or tighten the upper cover screws yet.

Writer: mg

IS-20929
Page 11 / 11

28. Set the main switch & circuit breakers to the
ON position and activate the AC system.

CAUTION
DO NOT LOOK DIRECTLY AT THE UV LIGHT
−

Make sure that both UV tubes are working
properly.

−

Also make sure that both tubes are off when
the vehicle AC is not running.

29. After the correct operation is confirmed, the
lower cover can be put back in place and the
upper cover screws tightened.

30. Install the supplied warning sticker to the
lower cover to finish the installation.

PARTS / WASTE DISPOSAL
Discard waste according to applicable environmental regulations (Municipal/State[Prov.]/ Federal)

Writer: mg