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Quick-Start Operating Guide

USP 797 Modular Cleanroom

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Copyright 2015 Terra Universal Inc. All rights reserved. • Revised Dec 2019 • Document No. 1800-90

Terra Universal, Inc. • TerraUniversal.com • 800 S. Raymond Ave. • Fullerton, CA 92831 • TEL: (714) 578-6000 • FAX: (714) 578-6020

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uniform, ¼”-wide bead of silicone along all ceiling panel seams, including cracks where the perimeter frame meets

polypropylene ceiling panels. Typically, caulking is not required along the perimeter of FFUs or lights.

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Summary of Contents for USP 797

Page 1: ... Document No 1800 90 USP 797 Modular Cleanroom Copyright 2015 Terra Universal Inc All rights reserved Rev December 2019 Terra Universal Inc TerraUniversal com 800 S Raymond Ave Fullerton CA 92831 TEL 714 578 6000 FAX 714 578 6020 ...

Page 2: ...allation Site Preparation 8 Required Installation Equipment 8 Component List 9 Component Description 11 Frame Components 14 Assembly Drawings 16 Installing the Support Frame and Control Panel 17 Installing the Power Distribution Module 19 Installing Ceiling Components 21 Fan Filter Unit Hardwiring 24 Installing Wallboard and Air Vents 25 Installing Viewing Window 26 Applying FRP Interior Surfaces ...

Page 3: ...sal s Modular Cleanroom provides an economical alternative to high cost fixed installation cleanrooms while providing the rigidity and durability of a freestanding room Designed to combine economy and versatility this system features ceiling HEPA Fan Filter Units FFUs that direct a continuous flow of HEPA or ULPA filtered air through the enclosure The continuous positive pressure created by this l...

Page 4: ...mounted in a powder coated steel housing with a plenum design that optimizes uniform air velocity across the entire face of the filter A HEPA high efficiency particulate air filter installed inside the housing is rated 99 99 efficient at 0 3 um particles The filtration medium consists of micro porous polyurethane minipleats held in place by strong rigid plastic separators that keep the medium from...

Page 5: ...uminator modules Panels are made of white polypropylene All of these ceiling modules rest against the ceiling grid frame to form a tight seal along the ceiling grid perimeters Walls IMPORTANT SAFETY NOTICE All personnel should wear eye protection and respirators in addition to gloves and appropriate clothing while cutting drilling or sanding FRP panels in accordance with local state safety laws St...

Page 6: ...um frame affords entrance to the enclosure The door is 36 W x 80 H and includes inside and outside handles and a pneumatic self closing damper The door opens inward allowing hands free entry as required by cleanliness protocol Note This room is not sealed airtight Because it is designed to operate under positive pressure small gaps around the doors or in the panel structure will not compromise cle...

Page 7: ...bove each corner these LED indicators glow to show that Fan Filter Units FFUs are turned on and flash if they are turned off They thus provide a convenient visual indication of proper room operation 2 0 Installation Component Inspection Unpack all system components and check for damaged or missing parts refer to component list chart on the next page as well as the sales order to determine correct ...

Page 8: ...esult in the inability to complete the assembly of the room or the insertion of the blowers lights or ceiling For vertical alignment measure with the leveler before assembly Required Installation Equipment not included A Handling cleanroom shipping crates which generally measure over 300 inches long and weigh well over 1 000 pounds requires at least one forklift or pallet jack If crates must be mo...

Page 9: ...Seams Powder coated Steel Trim Strips top horizontal Operation Status Indicators 4 installed in top trim corner pieces U brackets provide mounting support for dry wall installation 25 and 125 plastic spacers for mounting FRP panels Outlet template guide for FRP cut out to accommodate duplex outlet Yellow warning stickers instructing personnel not to stand or walk on cleanroom ceiling Hardware See ...

Page 10: ...r Stopper Sliding Screw SS 20 x 5 8 Phillip Pan Air Conditioning Bolt SS 20 x 1 Slotted Hex Wash Air Conditioning Washer SS Split Lock Air Conditioning Washer SS Flat Air Conditioning Nut SS 20 Cap Cover Control Switch Screw SS 6 32 x Philip Pan Anchor for slotted anchor bracket 2 per door floor anchor bolts not included Screw SS 14 x Hex Washer Pass Through Frame Bolt SS 5 16 x Hex Sliding Door B...

Page 11: ...N PICTURE Ceiling Joists Trim Internal Support Bar SS 12 x Hex Head Sheet Metal Screws Trimming Screw SS 12 x Sheet Metal Phillip Frame Plastic Push In Fastener Top Fascia Trim Connectors Screw SS 8 32 x 5 8 Phillip Pan Top Door Stop Screw SS 10 32 x 1 2 Phillip Pan Top Fascia Trim Connectors Washer SS 8 Flat Top Fascia Trim Connectors Washer SS 8 Split Lock Door Hinge Screw SS 20 x 1 Phillip Flat...

Page 12: ...ll rights reserved Revised Dec 2019 Document No 1800 90 Terra Universal Inc TerraUniversal com 800 S Raymond Ave Fullerton CA 92831 TEL 714 578 6000 FAX 714 578 6020 12 Ceiling Joists Rivet Ceiling Panels Ceiling Panel Clips Drywall Screw Phillips Drywall 6 x 1 5 8 Bugle Head Black Phosphate ...

Page 13: ...All rights reserved Revised Dec 2019 Document No 1800 90 Terra Universal Inc TerraUniversal com 800 S Raymond Ave Fullerton CA 92831 TEL 714 578 6000 FAX 714 578 6020 13 Frame Components Support Bar not used in USP 797 clean rooms Center Post Middle Connector Corner Post Joist Joist Divider ...

Page 14: ... FRP Application to Wallboard 4 Wallboard 8 Access Doors 9 Top Trim Review all of the steps and drawings below before beginning installation IMPORTANT SAFETY NOTICES 1 Terra Universal Cleanrooms are not designed to support more weight than the blower modules and lighting fixtures originally installed In particular the ceiling grid beams are not load bearing and will not support personnel or other ...

Page 15: ...ghts reserved Revised Dec 2019 Document No 1800 90 Terra Universal Inc TerraUniversal com 800 S Raymond Ave Fullerton CA 92831 TEL 714 578 6000 FAX 714 578 6020 15 Assembly Drawings Details about each step are discussed on subsequent pages These drawings can be used as references during assembly ...

Page 16: ...ure Refer to system drawings Before beginning installation of the support frame familiarize yourself with the placement of the frame members and ceiling T joists NOTE it is mandatory that the floor is level to assure the completed room will fit properly and be rectangular Failure to level the floor may result in the inability to complete the assembly of the room or the insertion of the blowers lig...

Page 17: ...location all members are labeled prior to shipping The long T joists span dimension of the cleanroom parallel to the entry door and the short T joists slide in place to complete the 2 x 4 ceiling grid see page 17 Position the joists on top of the frame as shown and loosely fasten the end of each joist in position with two SS 12 x hex screws Do NOT tighten the hex screws until all joists are in pla...

Page 18: ...es for fastening the mounting straps They should be installed so that the control box will be positioned in the correct ceiling grid B Power Distribution Module PDM Assembly Mount Power Distribution Module box to ceiling joists with opposing tapped screw holes using Control Box Mounting Straps To complete the switch circuit attach the yellow cable from the Control Panel extending from the vertical...

Page 19: ...raUniversal com 800 S Raymond Ave Fullerton CA 92831 TEL 714 578 6000 FAX 714 578 6020 19 Installing the Ceiling Grid Use pre drilled holes to fasten the ceiling joists with Terra provided rivets The tabs on the T bars should overlap Use Terra provided ceiling panel clips to secure the ceiling panels in place at the cut outs along the joists Rivets and Tabs Panel Clips ...

Page 20: ...ery 4 along the base frame about 2 from the vertical frame and one into the base of the door frame underneath the control panel The holes should be drilled into the base frame approximately 2 away from the vertical frame posts Avoid drilling through the corner inserts or through the connector pieces drill only through the H frames For the top face of the base frame drill a 5 8 hole to fit the anch...

Page 21: ... to form a tight seal No fasteners are necessary to hold these modules in place B Install the light modules by carefully lowering each into the appropriate opening in the ceiling support frame The light fixture should fit snugly against the ceiling grid frame to form a tight seal No fasteners are necessary to hold it in place C Control Panel Switchbox is installed to the right of the access door T...

Page 22: ...z or 220VAC 50Hz where applicable 40A power source The power connection should be made by a licensed electrical contractor in conformance with local code Turn on the light by flipping the light switch Turn on the FFUs by pressing the green ON switch H To install the remaining ceiling panels remove the protective plastic from each panel and drop it in place The panel below the Power Distribution Mo...

Page 23: ...rsal Inc TerraUniversal com 800 S Raymond Ave Fullerton CA 92831 TEL 714 578 6000 FAX 714 578 6020 23 Duplex Connections Black Wire CB 5 connects to main circuit breaker above White Wire 2100 connects to corresponding terminal above right Green Wire ground connects to ground terminal right Fan Filter Unit FFU Locations Refer to connection instructions below ...

Page 24: ...y this operation which typically does not require an electrician 1 Remove the blue prefilter which rests on top of the fan filter unit Figure 1 2 Unscrew metal top panel of the electrical housing Figure 2 to expose wiring junction Figure 3 3 Install cord grip as shown Figures 4 5 into appropriate opening 4 Thread the AC power cord through the cord grip and connect to wire port as shown Figure 6 St...

Page 25: ...ay between the bottom and top of the panel Note Before installing the wallboard over the window support frame mark it to indicate the window cutout location the distance between the two support bars and the two vertical bars they attach to approx 46 5 8 W x 36 H Note For seismic anchoring drill through the cleanroom frame to anchor it to the floor in accordance with local seismic code 5 Installing...

Page 26: ... sealed see below 6 Installing the Viewing Window The viewing window is sandwiched between two stainless steel retaining frames To install A From inside the room insert the interior stainless steel retaining frame the portion with no pre drilled holes along the window ledge through the wallboard cut out B Place the tempered glass window flush against the frame from outside the room Window Retainin...

Page 27: ...allation Installation Planning and Guidelines Each FRP panel is held in place on a drywall substrate by means of the Cleanroom Recommended FRP Polymer Adhesive which is effective on porous or nonporous surfaces Make sure all drywall applications window outlet and any other drywall penetrations are installed The drywall surface must be free of any material that may deter adhesion including severe a...

Page 28: ...racking For pilot holes a 1 4 diameter router bit or drill bit may be used Use a jig saw to complete the radius cut out Allow 1 8 clearance around all fixtures electric boxes piping etc Applying Adhesive The drywall and FRP surface must be free of any material that may deter adhesion including thick amounts of drywall join compound Patch holes and depression and remove any bumps high spots dust oi...

Page 29: ... one operator is used then each seam will have to processed individually filled and then smoothed by the same operator before moving on to the next seam a new mix tip will likely be needed for each seam in this case With multiple operators one operator can dispense while a second can follow and smooth seams Care will need to be taken to ensure the open time of the material is not exceeded in eithe...

Page 30: ...emove painters tap before the sealant fully cures Any excess adhesive on panels can be cleaned using a solvent dampened rag Preparation of Applicator Remove the plastic nut from the outlet end of the sealant cartridge Remove the metal retaining clip and the plastic plug in the outlet ports of the cartridge and discard Load the cartridge into the dispense gun ensuring that the plungers are lined up...

Page 31: ...e steel uprights Pre drilled holes along the steel uprights indicate proper position Doors open inward so verify that the door closer the ridge along the frame is positioned near the outside edge allowing the door to seat flush with the inside frame B Install the door hinges using self tapping 1 5 8 screws C Door closures mount on the outside of each door D Apply Seam Sealant to all cracks and gap...

Page 32: ...0 degrees inward For each connection use one 8 32 Phillips screw two flat washers one lock washers and one acorn nut Do not tighten Ceiling Panel Caulking To meet USP 797 requirements for a sterile environment seams along the edges of the cleanroom ceiling panels must typically be caulked Terra provides 100 silicone sealant for this purpose Prior to caulking carefully clean all panel to frame seam...

Page 33: ... No 1800 90 Terra Universal Inc TerraUniversal com 800 S Raymond Ave Fullerton CA 92831 TEL 714 578 6000 FAX 714 578 6020 33 uniform wide bead of silicone along all ceiling panel seams including cracks where the perimeter frame meets polypropylene ceiling panels Typically caulking is not required along the perimeter of FFUs or lights ...

Page 34: ...tion has been completed and electrical connections checked turn ON fan filter units by pressing the green ON button When the cleanroom is initially commissioned FFUs should be set in the Medium power setting as specified in the installation procedures above Turn on the light by pushing up on the 2 position switch At initial start up allow the cleanroom to operate for several minutes before enterin...

Page 35: ...s filters continue to retain particles and backpressure grows it will eventually become necessary to replace the filter It is recommended that this adjustment be performed from a ladder or skyjack outside the room Turn OFF FFU power then rotate the speed control dial on the top of each FFU to the desired position see photo below Generally FFUs should operate at the same speed setting If the air pr...

Page 36: ... screen This is never to be used to handle the filter It is only for protection against an accidental touch of the filter Handle filter only by the frame Tools Required Phillips Head Driver Step 1 Disconnect yellow power cable and remove unit from ceiling see next page for recommended procedure Step 2 Remove the 10 screws holding the HEPA ULPA filter to the lid assembly Step 3 Lift the lid assembl...

Page 37: ... Roll the power cord up and place it close to the Fan Filter Unit being removed Since the Fan Filter Unit is hard wired you want the cord rolled up close to the Fan Filter Unit so when you pull it down the wires do not get snagged or catch on other wires 4 Attach double stick tape to all four sides of the polypropylene panel as shown at right 5 Place Polypropylene panel over the filters mesh area ...

Page 38: ...t evaporation and surface residue many varieties available at TerraUniversal com To maximize cleaning uniformity wipe in one direction from top to bottom or left to right Use only slight overlapping strokes and fold the wiper between strokes Do NOT use circular motion which moves but does not remove surface particles and produces non uniform results Begin cleaning from the top of each panel workin...

Page 39: ...ered and paid for separately For Terra s Policy and Procedures for Returning Goods see Terra s Internet site www TerraUniversal com Generally customers can improve the chance of collecting on a freight claim by following these procedures 1 formally requesting that the carrier inspect the shipment immediately upon suspecting damage or shortage to verify condition 2 notifying the carrier upon discov...

Page 40: ...2 X 4 Ceiling Module115VAC 60Hz TUI 3800 80 Replacement Ballast TUI 6704 12 2 X 4 Flow Through Module 115VAC 60Hz TUI 6704 77 2 X 4 Ceiling Module 277 VAC 60Hz TUI 3800 80 277 2 X 4 Flow Through Module 277 VAC 60Hz TUI 6704 77 277 Yellow 12 foot Power Cables For connection of light or fan filter unit to Power Distribution Module electrical box No EL04962 for Fan Filter Units No EL01297 for Fluores...

Page 41: ... Unless otherwise noted all testing is performed with FFUs in the Medium speed setting As filters clog or other operating conditions change FFU speeds can be adjusted upward to High settings in order to increase air change rate internal pressure level and air displacement rate between buffer and anterooms 1 0 Buffer Room Pressure Test Purpose Verifies pressure 0 04 WC Apparatus Magnehelic gauge in...

Page 42: ...atus Mfgr Shortridge Instruments Series 8400 Flow Hood with Airdata Multimeter Model ADM 860C Results Meets Airflow Requirement Average FFU airflow 620 CFM at medium speed Average air change rate 300 4 0 Particle Count Purpose Verifies particle count 352 000 m 3 in buffer area ISO 7 3 520 000 m 3 in ante area ISO 8 0 3 microns Apparatus Terra P N 1510 30 Hand Held Particle Counter Hal Technology M...

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