BioSafe® Ceiling Grid Structure and Ceiling-Mount Components
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All BioSafe® Cleanrooms feature a modular ceiling grid structure that accommodates HEPA fan/filter units (FFUs) and fluorescent lights to meet diverse cleanliness and lighting requirements. Power Distribution Modules allow easy connection of ceiling modules to 115 or 230VAC power. Ionizing Modules neutralize static charges for additional contamination control. |
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| BioSafe® ceiling plenum with grid structure during installation |
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BioSafe® ceiling plenum with insulating foam panels on top ceiling |
Double-Wall Ceiling Plenum
A double-wall ceiling structure, standard on most BioSafe® Cleanrooms, allows cooled make-up air to be recirculated into a plenum chamber, which feeds the fan/filter units (FFUs) positioned on the lower ceiling, directly above the controlled environment. This design eliminates the need for individual make-up air ducts to be installed for each FFU and simplifies air balancing since all FFUs draw from a common air source.
In this design, return air is pulled from the cleanroom panels into return ducts installed along the ceiling. In applications requiring containment of potential biohazards, high-volume air handlers can be installed in the ceiling plenum to draw enough air out of the cleanroom to create a negative air pressure (see BioSafe® Cleanroom HVAC and Air Control for more information on air handling and balancing).
The double-ceiling plenum is fabricated of interlocking powder-coated steel joists, creating a rigid T-bar structure that requires no suspension cables or other external supports. Although not intended to be a walkable surface, the ceiling provides ample strength to support spans of up to 24 feet (7315 mm), even when loaded to capacity with FFUs.
The ceiling plenum typically operates under negative air pressure with respect to controlled cleanrooms below it. This ensures that particles inside the plenum are not pulled through cracks or other breaches into the cleanroom. Blank ceiling panels, made of 3/8” (9.5 mm)-thick polypropylene, are heavy enough to maintain a seal despite the negative pressure inside the ceiling plenum, which tends to lift lighter-weight panels.
All ceiling modules, which also include FFUs and lights as well as blank panels, rest in the T-bar grid supports along the openings created by the grid structure. Typically, these bays are 24” x 48” (610 mm x 1219 mm), although some cleanroom designs require 24” x 36” (610 mm x 914 mm) or 24” x 24” (610 mm x 610 mm) bays. Closed-cell neoprene gasketing installed along the perimeter of the T-grid creates seals these drop-in modules to prevent particle influx from the ceiling plenum |
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| HEPA Fan/Filter Unit (FFU): 24” x 48” (610 mm x 1219 mm) model shown, 24” x 36” and 24” x 24” (610 mm x 914 and 610 mm x 610 mm) models also available |
Fan/Filter Units (FFUs)
Fan/Filter Units provide the vertical flow of filtered air that creates a clean environment.
Each FFU consists of a 3-speed motorized impeller fan, which provides an average of 650 CFM, cubic feet per minute, (1105 m³/hr) of air moving at a speed of between 80 and 90 feet per minute (.41 and .46 m/s), on medium speed. Before it exits the FFU, this air passes through a High Efficiency Particular Air (HEPA) filter that removes 99.99% of all particles ≥0.3 microns in diameter. Airflow baffles inside the FFU ensure uniform air speed across the filter face, and sound-deadening foam reduces noise and vibration. Each FFU generates less than 50 dBA measured 30” (762 mm) from the filter face at high speed.
Related Pages:
| HEPA FFUs |
Cat. # |
23.625” x 47.625” x 12.5”H (600 mm x 1210 mm x 318 mm),
for use in 24” x 48” (610 mm x 1219 mm) ceiling bays |
6601-24H |
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Fluorescent light for 24” x 48” (610 mm x 1219 mm) grid space
(No. 3800-80) |
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“Teardrop” fluorescent light installed between 24” x 48” (610 mm x 1219 mm) grid space occupied by FFUs (No. 6704-15) |
Fluorescent Lights
Terra offers several ceiling lights to ensure ample cleanroom illumination and accommodate all cleanliness requirements.
| 2’ x 4’ (610 mm x 1219 mm) Light Module |
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Cat. # 6704-15 |
| This painted steel housing includes four T8 fluorescent tubes, providing 4,560 foot candles. Each module occupies a standard 2-foot by 4-foot (610 mm x 1219 mm) bay in the ceiling grid. |
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| Teardrop Light |
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Cat. # 3800-80 |
| Ideal for cleaner-than-Class 100 (ISO 5) rooms in near-100% FFU coverage leaves no room for standard lights, these modules attach to the T-grid supports between ceiling bays. Their aerodynamic design ensures minimal interference of laminar airflow. Dimensions: 48”L x 2”D x 6”H (1219 mm x 51 mm x 152 mm). Intensity: 1,260 foot candles of illumination. |
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| Flow-Through Light Module |
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Cat. # 6704-77 |
| Low-profile fluorescent-tube module stacks beneath a 2’ x 4’ (610 mm x 1219 mm) FFU. Adds 4.75” (121 mm) to the ceiling height. Intensity: 3,150 foot candles. Must be ordered together with FFU. |
Recommended lighting configurations.
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| Power Distribution Module covers removed (ceiling mount on left, panel mount on right) |
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| Electrical panel, installed in service corridor, gives easy access to serviceable electrical components (all UL-listed breakers, transformers, relays, switches) and provides a single power connection for the entire cleanroom |
Power Distribution Modules (PDMs)
Thee modules dramatically simplify connection of ceiling FFUs and lights and allow operation from a single Control Panel. Each accommodates up to 5 FFUs and 5 lights and includes a step-down transformer for low-voltage control and operation of status indicator circuits (Control Panel below). Includes relays and circuit breakers for overload protection of all connected devices, AC contactors, and NEC-compliant quick-connect fitting for lights and FFUs. Includes installation on specified Terra cleanroom.
For Multiple Power Connection Points
Each module must be wired to a dedicated 24A fused 120 or 240VAC circuit.
View Configuration
| Cat. # |
$/Each |
| 6600-29 |
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| 6600-29-220 |
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For Single Power Connection Point
Includes NEC compliant electrical panel mounted to the side of the cleanroom that provides easy access to serviceable components, including circuit breakers. Electrical panel allows multiple Power Distribution Modules and all other cleanroom electrical equipment to be hard-wired to a single dedicated power source, reducing reliance on an electrical contractor to complete cleanroom installation.
View Configuration
| Cat. # |
$/Each |
| 6600-28 |
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| 6600-28-220 |
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| EnergySaver™ FFU Control simplifies air balancing and reduces energy costs |
EnergySaver Filter/Fan Unit Control
This programmable unit lets you adjust FFU operation levels, either individually or on a room-by-room “cluster” basis. This remote operation lets you balance air pressure and cleanliness levels in multiple-room configurations to meet specified cleanliness levels, simplifying final testing and certification of your facility.
A “Not in Use” setting maintains desired cleanliness levels at a lower fan speed when rooms are not occupied, saving energy expenses and cutting heat generation. Passcodes ensure security.
Complete specifications and ordering information.
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| Ionizing bars enhance static and contamination control by eliminating surface charges that attract particles |
Ionizing Bars
Ionizing bars use intrinsically safe low-voltage (24V) circuits to generate balanced streams of positive and negative ions, which neutralize static charges. Each bar is mounted beneath an FFU, so that the vertical airflow distributes ions throughout the cleanroom.
By neutralizing charges, ionizing bars protect static-sensitive parts against electro-static discharge (ESD), which can degrade or destroy sensitive electronics. They also eliminate charges surfaces that can attract and hold particles, resulting in a cleaner work environment.
Complete specifications and ordering information.
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| Control panel includes switches for lights and FFUs, along with a Magnehelic® Differential Pressure Gauge to monitor room air pressure (shown above with additional switch for optional UV lights) |
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Operation Status Indicators, included as part of control panel system, glow to indicate FFUs are operational, flash when FFUs are turned off |
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| Control Panel with Operation Status Indication (OSI) |
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Cat. # 6600-26 |
| Mounted outside each cleanroom, this panel allows convenient operation of FFUs, lights, ionizing modules, and other environmental monitoring equipment selected for your BioSafe®facility. Fabricated of 304/316 stainless or powder-coated steel to match your cleanroom, it includes a Magnehelic® Gauge (-.25 – 0 – .25”WC) that displays room differential air pressure.
This system also includes top corner indication lights that display cleanroom operation status: lights glow when FFUs are in operation and flash to indicate they are off.
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Related BioSafe® Pages
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