Monmouth Scientific Cleanroom Kit 4M Installation Manual Download Page 8

Page: 8 / 72

Issue 03 – June 2018

Complete Parts List

r o

raw

Lengt

Qty

12M

Lower Wall Bar

970mm

7 10 9 12 11 15 13 17

30100-PA-970

Mid Wall Bar

970mm

7 10 9 12 11 15 13 17

30100-2PA-970

Top Wall Bar with side filler strip

970mm

8 10 10 12 12 14 14 16

3050-PA-FS-970

Top Wall Bar (for internal walls)

970mm

3050-PA-970

Plastic Reducer Strip

1045mm 26 36 34 44 42 56 50 64

PP-02371-1045

Plastic Reducer Strip

735mm

PP-02371-735

Plastic Reducer Strip

205mm

PP-02371-205

Corner Post with foot

2350mm 3

3030C-FT-2350

Summary of Contents for Cleanroom Kit 4M

Page 1: ...Issue 03 June 2018 1 Cleanroom Kits ...

Page 2: ...Issue 03 June 2018 2 Installation Guide ...

Page 3: ...Issue 03 June 2018 3 ...

Page 4: ...embly 27 4M 2m x 2m room 27 4Mplus 2m x 2m room with 1m x 2m atrium 28 6M 3m x 2m room 29 6Mplus 3m x 2m room with 1m x 2m atrium 30 9M 3m x 3m room 31 9Mplus 3m x 3m room with 1m x 3m atrium 32 12M 4m x 3m room 33 12Mplus 4m x 3m room with 1m x 3m atrium 34 Using CAM1000 in 9M 9M 12M 12M 35 Top Door Runner Assembly 36 Hanging the door s 37 Bottom Door Runner Assembly 38 Soft Close Door Adjustment...

Page 5: ...ramework without panels 57 4M 2m x 2m room 4Mplus 2m x 2m room with 1m x 2m atrium 57 6M 3m x 2m room 58 6Mplus 3m x 2m room with 1m x 2m atrium 59 9M 3m x 3m room 60 9Mplus 3m x 3m room with 1m x 3m atrium 61 12M 4m x 3m room 62 12Mplus 4m x 3m room with 1m x 3m atrium 63 Complete Cleanroom Layouts 64 4M 2m x 2m room 4Mplus 2m x 2m room with 1m x 2m atrium 64 6M 3m x 2m room 65 6Mplus 3m x 2m roo...

Page 6: ... process do not attempt to build the room on your own Significant injury can occur when lifting or moving heavy parts Construction time of the room will vary depending upon expertise and room size Please do not rush and ensure you understand the process at each stage If in doubt ask Start with a clear area and make sure you have enough space to install the cleanroom including enough height Make su...

Page 7: ...ut this task Monmouth Scientific Limited does not accept responsibility for any injury or damage howsoever caused Any electrical work necessary should be carried out by a qualified electrician If at any time you are not comfortable with any aspect of the installation then STOP and seek professional assistance Monmouth Scientific can provide free of charge support on the telephone by calling 44 127...

Page 8: ... 13 17 30100 2PA 970 Top Wall Bar with side filler strip 970mm 8 10 10 12 12 14 14 16 3050 PA FS 970 Top Wall Bar for internal walls 970mm 0 2 0 2 0 3 0 3 3050 PA 970 Plastic Reducer Strip 1045mm 26 36 34 44 42 56 50 64 PP 02371 1045 Plastic Reducer Strip 735mm 2 4 2 4 2 4 2 4 PP 02371 735 Plastic Reducer Strip 205mm 4 8 4 8 4 8 4 8 PP 02371 205 Corner Post with foot 2350mm 3 3 3 3 3 3 3 3 3030C F...

Page 9: ...ot two additional 25mm slots 2350mm 0 0 0 0 0 1 0 1 3030D 2S FT 2350 Double faced post with foot and door runner additional 25mm slot 2350mm 1 1 1 1 1 1 1 1 3030D S FT 2350 Double faced post with foot and door runner two additional 25mm slots 2350mm 0 1 0 1 0 1 0 1 3030D 2S FT 2350 Single Faced Post with foot 2350mm 0 2 0 2 0 2 0 2 3030S FT 2350 Outer Door Post with foot 2350mm 1 1 1 1 1 1 1 1 306...

Page 10: ... 0 2 2 3 3 3050 FS 2970 30100 3030 Standard Ceiling Beam 0 Connectors 970mm 2 2 2 2 2 2 4 4 3050 FS 970 0 Standard Ceiling Beam 90 Connectors 970mm 0 1 0 1 0 2 0 2 3050 FS 970 90 Standard Ceiling Beam with alternate connectors 1no 0 1no 90 Connector 970mm 1 1 2 2 4 4 4 4 3050 FS 970 0 90 Ceiling Support Rail 919 5mm 8 12 12 16 16 22 22 28 MW 04473 919 5 Ceiling Support Rail 969 5mm 4 8 8 12 16 22 ...

Page 11: ...iling Support Rail 469 5mm 0 0 4 4 0 0 0 0 MW 04473 622 only with CAM2250 in ISO7 6M or 6M Ceiling Support Rail 1072 mm 0 0 0 0 4 4 4 4 MW 04473 419 5 only with CAM1000 in ISO8 9M 9M 12M or 12M Door Header slotted 970mm 1 2 1 2 1 2 1 2 30100 PA 970SL Door Rail Support slotted 970mm 1 2 1 2 1 2 1 2 30100 2PA 970SL Door 1995mm x 1000mm 1 2 1 2 1 2 1 2 Door Door Runner 1960mm 1 2 1 2 1 2 1 2 ...

Page 12: ...adjacent to door 731mm x 980mm 1 2 1 2 1 2 1 2 Part Clear Window Panel 980mm x 203mm 2 4 2 4 2 4 2 4 Standard White Ceiling Panel 960mm x 960mm 2 4 4 6 8 11 11 14 If ISO 8 CAM1000 selected then 2no less will be provided and substituted with 2no If 2no CAM2250 are selected then 1no less will be provided Standard White Ceiling Panel with LED light and associated transformers and leads 960mm x 960mm ...

Page 13: ...0 0 2 2 2 2 only with CAM1000 in ISO8 9M 9M 12M or 12M Socket Head Button Screw M5x12mm 12 24 12 24 12 24 12 24 For use with door brackets Channel T Nut M5 12 24 12 24 12 24 12 24 For use with door brackets 5mm washer 12 24 12 24 12 24 12 24 For use with door brackets Spare 0 Union 5 5 5 5 5 5 5 5 Spare 90 Union 5 5 5 5 5 5 5 5 End Caps 30mm x100mm 0 0 0 0 4 4 4 4 30100EC Union Cover Stickers Shee...

Page 14: ...0 0 0 0 0 0 CAM1000 Control Panel ISO8 1 1 1 1 1 1 1 1 ISO7 1 1 0 0 0 0 0 0 CAM2250 Clean Air Module with support brackets 4 and power leads ISO8 0 0 0 0 0 0 0 0 K CAM2250 Optionally 2no ISO7 0 0 1 1 1 1 1 1 CAM2250 Control Panel ISO8 0 0 0 0 0 0 0 0 ISO7 0 0 1 1 1 1 1 1 4mm Allen Key Colours vary 4mm 2 2 2 2 2 2 2 2 3mm Allen Key Colours vary 3mm 1 1 1 1 1 1 1 1 White Rubber Mallet 1 1 1 1 1 1 1 ...

Page 15: ... one at 0 and one at 90 A third double union to join mitres is used on the doors but the doors are pre assembled for your convenience Union Parts Each primary union consists of 4 parts m8 grub screw 11 8mm Ø barrel Spring 10mm Ø draw bar When assembled the point of the grub screw must locate into the indent in the draw bar so the correct orientation of the drawbar is essential 0 Union 90 Union ...

Page 16: ...ightened which pushes the point of the grub screw into the dimple on the draw bar and pulls the head of the drawbar toward the end of the Aluminium profile This traps the adjoining profile into position Small teeth in the underside of the head of the bar aid this process by gripping into the adjoin profile m8 grub screw 11 8mm Ø barrel Spring 10mm Ø draw bar ...

Page 17: ...describe how to fit a union into the Monmouth profile 1 Take the aluminium profile with a 12mmØ hole 2 Fit the barrel into the 12mmØ hole with the barrel cross hole parallel to the hole in the aluminium profile 3 Place the spring over the draw bar and insert them both into the aluminium and push through the barrel 4 Push the draw bar in against the spring and ensure dimple on the side of the draw ...

Page 18: ... the barrel you can release the barrel and it will stay assembled 7 You should only tighten the grub screw so that at least 3mm of draw bar is visible behind the head of the fixing 8 It is quite possible to over tighten making attachment to the next piece of aluminium impossible In this case relax the grub screw until at least 3mm of draw bar is visible ...

Page 19: ...uminium into place down the connector 2 Slide to the desired position Be careful to keep both pieces square as you may mark the aluminium 3 4 This second method is ideal when both ends of a piece need to locate into uprights Line up the head with the slot at 90 from the required position and push in so the head can rotate freely in the slot ...

Page 20: ...p both pieces square as you may mark the aluminium If the piece will not easily rotate relax the grub screw slightly 6 Hold the two pieces in the desired position 7 And tighten the grub screw to draw the two pieces together Please ensure that the two sides are flush when being drawn together for the best joint 8 ...

Page 21: ...rew if necessary 2 Horizontal slots will be fitted with the sloped reducer strip however vertical surfaces will need a plastic 8mm to 6mm reducer strip 3 Tuck the plastic reducer just behind the aluminium reducer for the best finish 4 Tap the plastic reducer strip in carefully along its entire length using a soft non marking mallet You can push in with fingers however this can be tough ...

Page 22: ...nserting the panel This will stop any movement in the panel once fitted however it will be more difficult to take apart should you wish to relocate the room If you choose to do this and silicone squirts out from the sides of the panel and becomes visible then you are using too much ONLY A SMALL AMOUNT IS REQUIRED 7 Position the sheet into the slots as necessary The sheet will slide in the slots ho...

Page 23: ...er it is solid or clear 1 Tilt the ceiling support before offering to the slot 2 Move the leading edge of the ceiling support toward the slot ensuring the two pieces are parallel 3 Tuck the leading edge of the ceiling support into the slot 4 Tip the support downwards 5 And allow to drop into position 6 ...

Page 24: ...Issue 03 June 2018 24 Standard Wall Panel ...

Page 25: ...Issue 03 June 2018 25 Door Panels ...

Page 26: ...Issue 03 June 2018 26 Door Door is supplied fully assembled however for reference exploded view below ...

Page 27: ...Issue 03 June 2018 27 Ceiling Assembly 4M 2m x 2m room ...

Page 28: ...Issue 03 June 2018 28 4Mplus 2m x 2m room with 1m x 2m atrium ...

Page 29: ...Issue 03 June 2018 29 6M 3m x 2m room ...

Page 30: ...Issue 03 June 2018 30 6Mplus 3m x 2m room with 1m x 2m atrium ...

Page 31: ...Issue 03 June 2018 31 9M 3m x 3m room If using the CAM1000 and not the CAM2250 please see the additional parts included on page 34 ...

Page 32: ...Issue 03 June 2018 32 9Mplus 3m x 3m room with 1m x 3m atrium If using the CAM1000 and not the CAM2250 please see the additional parts included on page 34 ...

Page 33: ...Issue 03 June 2018 33 12M 4m x 3m room If using the CAM1000 and not the CAM2250 please see the additional parts included on page 34 ...

Page 34: ...Issue 03 June 2018 34 12Mplus 4m x 3m room with 1m x 3m atrium If using the CAM1000 and not the CAM2250 please see the additional parts included on page 34 ...

Page 35: ...Issue 03 June 2018 35 Using CAM1000 in 9M 9M 12M 12M ...

Page 36: ...Issue 03 June 2018 36 Top Door Runner Assembly ...

Page 37: ...e to tighten it will stay in position and clamp the bracket Once in position tighten the brackets to the rail with a 10mm spanner Hanging the door s When the rail is sited hang the door from the M8 bolts fitted into the door carriage runners inside the rail using the two metal brackets fitted to the top of the door and tighten using a 13mm spanner When the door is hung move slowly to the maximum d...

Page 38: ...ng that the runner locates in the bottom groove of the door You should ensure the weight of the door is NOT resting on the runner Once the door runner is adjusted tighten the three retaining screws Operate the door several times and re adjust the height of the bracket as necessary The bottom of the door should not rub on the white bracket at all ...

Page 39: ...Issue 03 June 2018 39 Soft Close Door Adjustment 1 Fixtures on top of door are fitted with M5 Channel T Nuts M5 Screws 2 3 4 ...

Page 40: ...Issue 03 June 2018 40 5 ...

Page 41: ...ly competent in all tasks associated with assembly All personnel must be suitably trained in the use of any equipment used during the installation of this Cleanroom Kit It is the customer s responsibility to ensure the safety of all colleagues and personnel carrying out this task Monmouth Scientific Limited do not accept responsibility for any injury or damage howsoever caused Any electrical work ...

Page 42: ... ensure and maximise stability in the structure from the start Do not forget to add the vertical 8mm to 6mm plastic reducer strips either side of a panel It is advisable to add these as you go and not to fit in advance 3 It is important that the slots at the top of the double faced profiles used in the mid wall sections and the slots on the top bars are facing inwards This will allow the ceiling b...

Page 43: ...ll upright poles Use a spirit level throughout to ensure the room is level and straight Ensure the room is square at all times If it is not erected square minor adjustments can be made during the construction however you must take care not to stress any joints 5 Build to the first corner and add the first return panel Add the ceiling cross members and using the internal vertical slots highlighted ...

Page 44: ... this point to allow the internal walls to connect 8 Build the full internal wall Plus models only ensuring the door is in the right position Please remember to install the sliding door header rails and in the appropriate positions above the door opening and immediately adjacent to the sliding door panel Please ensure the additional slots on these pieces are on the side that the door is to be hung...

Page 45: ...iles are used and the 919 5mm bar is to be substituted with or See drawings for layout Note No tile bars are not fitted in a CAM location The outer structure is now complete Ensure all unions have been fully tightened 10 Add the CAM unit s to the structure in the appropriate place along with the control panel see section Installing Clean Air Modules CAM THIS UNIT IS HEAVY ENSURE ALL SAFETY PROCEDU...

Page 46: ...d door s to the room and fit the door rail cover s After calibration set up of the CAM units the room is then complete Prior to use as a cleanroom all surfaces must be cleaned in accordance with the requirements of your application The room may now be validated if required prior to any usage For UK based installations Monmouth Scientific will be happy to quote for validation if not already selecte...

Page 47: ...t is a two person minimum process Suitable access equipment should be used and your own risk assessment should be undertaken when installing CAM modules All personnel must be suitably trained in the use of any access or lifting equipment It is the customer s responsibility to ensure the safety of all colleagues and personnel carrying out this task Monmouth Scientific Limited do not accept responsi...

Page 48: ...nect two or more together then up to 4 units can be daisy chained from the IEC socket mounted on the side of the unit If not used to power a second CAM1000 then this socket can be used to power the lights in the room This way they are all turned on and off by a single switch Power Link Socket Link Fuse Holder 3A T Power Inlet Socket Main Inlet Fuse Power Switch IMPORTANT The loading on the whole s...

Page 49: ...afety first The CAM1000 needs to be lifted to ceiling height and we strongly recommend the use of suitable lifting equipment Before fitting ensure the hole is a suitable size The hole should measure 970mm x 665mm The side rails are already fitted to the CAM1000 as per the picture above The CAM unit must be handled very carefully If it is dragged on or hit by the aluminium frame damage may be cause...

Page 50: ...e HEPA filter The air volume required to achieve N air changes per hour can be calculated by the following formula Air volume required m hour Room Volume m X N The air volume through the module can be calculated by the following formula CAM1000 Air Volume m hour 0 37 filter area in m X measured HEPA velocity m sec x 3600 secs hr Based on the filter size used in this module 610mm x 610mm the follow...

Page 51: ...ce pre filter with the correct type see page 5 5 Replace the screws securing the pre filter retaining frame 6 Reconnect the mains supply and switch on 7 Check the airflow and adjust if necessary as detailed in the setup section Changing the HEPA filter 1 Turn the system off and disconnect from mains 2 Remove the screws securing the filter retaining frame 3 Remove the filter frame cover filter if f...

Page 52: ...e control panel below by means of an RG45 control cable 5m cable provided If you have two modules then the first links to the control panel and the second links to the first Subsequent modules can be added later should requirements change maximum of 8 units permissible Each module is fitted with an electronic airflow monitor which provides a visual warning on the control panel should the airflow d...

Page 53: ...s to be lifted to ceiling height and we strongly recommend the use of suitable lifting equipment Fit the four side rails to the CAM2250 as per the picture above You will notice that two rails are positioned higher than the others this facilitates all round support when fitting over the 100mm high reinforced ceiling members below The CAM unit must be handled very carefully If it is dragged or hit b...

Page 54: ...Issue 03 June 2018 54 System Set up CAM Module Connections Control Panel Control cable 230v 13A ac supply 230v 13A ac supply 230v 13A ac supply Control cable ...

Page 55: ...ollowing formula Air volume required m hour Room Volume m X N The air volume of each CAM can be calculated by the following formula Air Volume m hour 3000 X measured HEPA velocity m sec The following table gives an indication of air volume m hour against HEPA velocity HEPA Velocity m sec Air Volume m hour 0 30 900 0 35 1050 0 40 1200 0 45 1350 0 50 1500 0 55 1650 0 60 1800 0 65 1950 0 70 2100 0 75...

Page 56: ...alarm should sound and the warning light should come on 6 Reset the fan speed to the original set point and repeat the procedure with all other modules if fitted Maintenance Changing the pre filters If the airflow monitoring system indicates a low airflow this normally indicates that the Pre Filter s require changing 8 Turn the system off 9 Remove the thumb screws securing each of the pre filter r...

Page 57: ...Issue 03 June 2018 57 Colour Coded Aluminium Framework without panels 4M 2m x 2m room 4Mplus 2m x 2m room with 1m x 2m atrium ...

Page 58: ...Issue 03 June 2018 58 6M 3m x 2m room ...

Page 59: ...Issue 03 June 2018 59 6Mplus 3m x 2m room with 1m x 2m atrium ...

Page 60: ...Issue 03 June 2018 60 9M 3m x 3m room ...

Page 61: ...Issue 03 June 2018 61 9Mplus 3m x 3m room with 1m x 3m atrium ...

Page 62: ...Issue 03 June 2018 62 12M 4m x 3m room ...

Page 63: ...Issue 03 June 2018 63 12Mplus 4m x 3m room with 1m x 3m atrium ...

Page 64: ...Issue 03 June 2018 64 Complete Cleanroom Layouts 4M 2m x 2m room 4Mplus 2m x 2m room with 1m x 2m atrium ...

Page 65: ...Issue 03 June 2018 65 6M 3m x 2m room ...

Page 66: ...Issue 03 June 2018 66 6Mplus 3m x 2m room with 1m x 2m atrium ...

Page 67: ...Issue 03 June 2018 67 9M 3m x 3m room ...

Page 68: ...Issue 03 June 2018 68 9Mplus 3m x 3m room with 1m x 3m atrium ...

Page 69: ...Issue 03 June 2018 69 12M 4m x 3m room ...

Page 70: ...Issue 03 June 2018 70 12Mplus 4m x 3m room with 1m x 3m atrium ...

Page 71: ...rchase Therefore should you have any questions or require any support on the assembly or operation of your new cleanroom please contact Monmouth Scientific by any of the methods below Telephone UK 01278 458090 International 44 1278 458090 Office Hours 8 45am to 5 00pm Email info monmouthscientific co uk Alternatively please contact your sales agent ...

Page 72: ...Issue 03 June 2018 72 Monmouth Scientific Limited Units 5 6 Kilnside East Quay Bridgwater Somerset TA6 4DB info monmouthscientific co uk www monmouthscientific co uk 44 0 1278 458090 ...

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