Author：DanielDate：2023-9-25
The cleanliness levels of clean rooms are divided into static levels such as level 10, level 100, level 1000, level 10000, level 100000, and level 300000. The majority of industries using Class 100 clean rooms are LED electronics and pharmaceuticals. This article focuses on introducing the design scheme of using FFU fan filtration units in GMP Class 100 clean rooms.
FFU Construction Technology for Class 100 Clean Room
The maintenance structure of clean room rooms is generally made of metal wall panels. After completion, the layout cannot be changed arbitrarily. However, due to the continuous updates of production processes, the original cleanliness layout of clean room factory rooms cannot meet the needs of new processes, resulting in frequent changes in the clean room factory due to product upgrades, wasting a lot of financial and material resources.
If the number of FFU purification units is increased or decreased, the cleanliness layout of the room can be partially adjusted to meet process changes. Moreover, the FFU purification unit comes with power, air vents, and lighting fixtures, which can save a lot of investment. This is almost impossible to achieve the same effect for a purification system that typically provides centralized air supply.
Design Scheme for Using FFU Fan Filter Unit in a Class 100 Clean Room
1. The suspended ceiling of the Class 100 area is covered with FFU fan purification units.
2. Clean air enters the static pressure box through the elevated floor or vertical air duct at the lower part of the side wall in the level 100 area, and then enters the room through the FFU fan purification unit to achieve circulation.
3. The upper FFU fan purification unit in the Class 100 area provides vertical air supply, and the leakage between the FFU fan purification unit and the hanger in the Class 100 area flows indoors to the static pressure box, which has little impact on the cleanliness of the Class 100 area.
4. The FFU fan purification unit is lightweight and adopts a cover in installation method, making installation, filter replacement, and maintenance more convenient.
5. Shorten the construction cycle. The FFU fan filtration unit system has significant energy saving, thus solving the shortcomings of centralized air supply caused by the large air conditioning room and the increased operating cost of the air conditioning unit. The structural characteristics of FFU independence can be adjusted at any time to compensate for the lack of mobility in the clean room, thus solving the problem of unsuitable adjustment of production processes.
6. The use of FFU circulation system in clean rooms not only saves operating space, has high cleanliness and safety, low operating costs, but also has high operational flexibility. It can be upgraded and adjusted at any time without affecting production, which can well meet the needs of clean rooms. Therefore, the use of FFU circulation system has gradually become the most important clean design solution in semiconductor or other manufacturing industries.
Installation conditions for high-efficiency filters
1. Before installing the high-efficiency filter, the clean room must be thoroughly cleaned and wiped. If there is dust accumulation inside the purified air conditioning system, it should be cleaned and wiped again to meet the cleaning requirements. If a high-efficiency filter is installed in the technical interlayer or ceiling, the technical interlayer or ceiling should also be thoroughly cleaned and wiped.
2. When installing, the clean room must be already sealed, the FFU must be installed and started to operate, and the purification air conditioning must be put into trial operation for more than 12 hours of continuous operation. After cleaning and wiping the clean room again, install the high-efficiency filter immediately.
3. Keep the clean room clean and dust-free. All keels have been installed and leveled.
4. Installation personnel must be equipped with clean clothes and gloves to prevent human contamination of the box and filter.
5. To ensure the long-term effective operation of high-efficiency filters, the installation environment should not be in oil fumes, dusty, or humid air. The filter should avoid contact with water or other corrosive liquids as much as possible to avoid affecting its effectiveness.
6. It is recommended to have 6 installation personnel per group.
Precautions for unloading and handling
1. The FFU and high-efficiency filter have undergone multiple protective packaging before leaving the factory. Please use a forklift to unload the entire pallet. When placing goods, it is necessary to prevent them from tipping and avoid severe vibrations and collisions.
2. After unloading the equipment, it should be stored indoors in a dry and ventilated place for temporary storage. If it can only be stored outdoors, it should be covered with tarpaulin to avoid rain and water ingress.
3. Due to the use of ultra-fine glass fiber filter paper in high-efficiency filters, the filter material is prone to breakage and damage, resulting in particle leakage. Therefore, during the process of unpacking and handling, it is not allowed to dump or crush the filter to prevent severe vibration and collision.
4. When removing the high-efficiency filter, it is prohibited to use a knife or sharp object to cut the packaging bag to avoid scratching the filter paper.
5. Each high-efficiency filter should be handled by two people together. The operator must wear gloves and handle it gently. Both hands should hold the filter frame, and it is prohibited to hold the filter protective net. It is prohibited to touch the filter paper with sharp objects, and it is prohibited to twist the filter.
6. Filters cannot be placed in layers, they should be arranged horizontally and orderly, and placed neatly against the wall in the installation area waiting for installation.
Installation precautions for FFU high-efficiency filter
1. Before installing an efficient filter, the appearance of the filter must be inspected, including whether the filter paper, sealing gasket, and frame are damaged, whether the size and technical performance meet the design requirements. Filter screens with severe damage to the appearance or filter paper should be prohibited from installation, photographed, and reported to the manufacturer for treatment.
2. When installing, only hold the filter frame and handle it gently. To prevent severe vibration and collision, it is strictly prohibited for installation personnel to touch the filter paper inside the filter with their fingers or other tools.
3. When installing the filter, pay attention to the direction, so that the arrow on the filter frame marks outward, that is, the arrow on the outer frame should be consistent with the airflow direction.
4. During the installation process, it is not allowed to step on the filter protection net, and it is prohibited to discard debris on the surface of the filter. Do not step on the filter protection net.
5. Other installation precautions: Gloves must be worn and fingers must be cut on the box. The FFU installation should be aligned with the filter, and the edge of the FFU box should not be pressed on top of the filter, and it is prohibited to cover items on the FFU; Do not step on the FFU intake coil.
6、 Installation process of FFU filter in Class 100 clean room
1. Carefully remove the high-efficiency filter from the shipping packaging and check for any component damage during transportation. Remove the plastic packaging bag and place the FFU and high-efficiency filter in a clean room.
4. When installing power and network cables, brute force should not be exerted, and the power and network cables should be fixed to prevent them from being kicked off during construction; When routing strong and weak current lines, it is necessary to avoid parallel routing as much as possible. If the parallel routing is too long, the spacing should be more than 600mm to reduce interference; It is prohibited to have the network cable too long and bundle it with the power cable for wiring.
5. Pay attention to protecting the FFU and filter during the construction on the interlayer, keep the surface of the box clean, and prevent water from entering the FFU to avoid damaging the fan. When connecting the FFU power cord, power should be cut off and attention should be paid to preventing electric shock caused by leakage; After connecting all FFUs to the power cord, a short circuit test must be conducted. Only after passing the test can the power switch be turned on; When replacing the filter, the power must be turned off before proceeding with the replacement operation.
