gUIDE Specification for

ORTHO-ISLAND^Ū CR (CEILING RETURN) Laminar flow surgery system

Section 158XX

DIFFUSERS/REGISTERS/GRILLES/AIR CONTROL DEVICES 
 
 

NOTE TO ENGINEERS:  READ & FOLLOW INSTRUCTIONS IN ALL RED CAPS. 
 
 

PART 1 - GENERAL 
 

1. SUMMARY

1. Furnish and install ORTHO-ISLAND^Ū Model CR vertical laminar airflow surgery system in the operating room within the ceiling and walls, as located on drawings.  Supply air from a central air-handling unit (AHU) shall be mixed with the recirculated return air.  The airflow pattern shall be of uniform flow from the ceiling-mounted diffuser plenums, downward through the surgical work and outward, under the air containment panels and then up to the ceiling-mounted return air grilles on the outside of the air containment shield.  A true constant pressure/constant velocity, unidirectional laminar flow pattern is created in the work area through utilization of laminar flow supply diffuser plenums and fixed air containment panels at the perimeter of the work area.  The containment panels decrease the induction of impure air into the clean zone.

2. Return air shall be ducted back to the system’s supply fans and filtered diffusers from ceiling-mounted air intakes as located on the drawings.  The return air shall be mixed with system supply air (makeup air) and then recirculated by the system’s supply fans.

3. Locate system’s Electrical control panel within operating room.

4. Material and Work by Others:

1. Any demolition work required must be completed prior to arrival of factory’s installation supervisor.

2. Any installation of center surgical light and associated structural support shall be by the General Contractor.  Structural supports and Electrical conduit for the surgical light and medical gas piping must not interfere with the space requirements of the Special High-Capacity Perforated Panel HEPA Diffuser Plenums, Blower Cabinets and Ductwork, as defined by the system’s submittal drawings.
3. The General Contractor’s sheet metal subcontractor shall be responsible for the following:
   1. Installation of the Special High-Capacity Perforated Panel HEPA Diffuser Plenums, HEPA Filters (while under direct supervision by manufacturer’s personnel), Air Containment Panels, Blower Cabinets and Ductwork, Blank-Off Panels and Support & Suspension System.
   2. Furnish and install ductwork required for supply and exhaust of make-up air outside the surgical area as defined outside the perimeter of blower cabinets.
   3. Furnish any concrete anchors and additional structural support and hardware other than as recommended by system’s shop drawings and noted as “furnished by manufacturer”.
   4. Removal of construction debris and cleaning of room to such state for owner’s final cleaning before testing and certification of system.
4. General Contractor’s electrical subcontractor shall be responsible for the following:
   1. Furnish and connect the main power service to the system’s main control cabinet.
   2. Install wall-mounted main control cabinet for system.
   3. Wire and connect the blower motors to the system’s main control panel.
   4. Install, wire and connect the air pressure sensors furnished by system manufacturer to the main control cabinet from location within supply air plenums where shown on drawings.
   5. Furnish, install, connect and control any lay-in style fluorescent light fixtures surrounding the diffusers.
   6. Install, connect and control any optional teardrop light fixtures furnished as part of the system as located by submittal drawings.
5. After the construction cleaning is complete, the owner shall be responsible for final sterilization of the rooms prior to the factory testing, balancing and certification phase of the project.  The hospital’s normal sterilization procedure shall be followed in order to prepare the room for this phase.

      E. All exposed surfaces, including border trim, to have finish specified. 
 

F. Verify exact locations of diffusers, registers, and grilles with architectural reflected ceiling plan where shown.  Coordinate frame types with room finish schedule. 
 

1.2 SUBMITTALS 
 

1. Make all submittals in accordance with Division 0 and 1 conditions.

2. Product Data: Manufacturer’s published literature on actual components to be installed within the system.

3. Shop Drawings:  Show system’s architectural reflected ceiling plan, mechanical duct layout and locations of air supply diffusers and return air inlets, elevation views, structural support details, electrical coordination drawing, and trade installation and coordination notes.

4. Operation and Maintenance Manuals:  Include operating instructions, replacement parts list, control panel wiring diagrams, manufacturer’s warranty, initial particle count test results and Certificate of Compliance to ISO Standard 14644.

1.3 WARRANTY 
 

A. Provide manufacturer’s warranty on all parts covering defects in materials and workmanship for one (1) year from date of certification and testing of installed system. 
 
 

PART 2 - PRODUCTS 
 

1. MANUFACTURERS

1. Acceptable Manufacturer: Precision Air Products Co., Hopkins, MN.  (800) 404-0931,  Fax: (952) 854-4543.

2. Substitutions:  Not permitted.

2. SPECIAL ORTHOPAEDIC O.R. VENTILATION SYSTEM

1. Furnish and install Special Orthopedic Operating Room Ventilation System where indicated on drawings.  This system shall supply air to a network of laminar airflow diffusers with integral ductwork that house terminal room-side replaceable HEPA filters.  The system shall include special high-capacity laminar flow supply diffuser plenums, HEPA filters, air containment panels, blower cabinets and motors, integral ductwork, return grilles, controls, special teardrop style lighting (optional), blank-off panels and support/suspension grid as described herein under System Components.

2.3 SYSTEM COMPONENTS 
 

1. SPecial HIGH-capacity perforated panel HEPA diffuser plenums

1. The diffuser shall utilize an equalization chamber and HEPA filter to deliver filtered air to the space with zero aspiration at the face of the perforated plate with velocities in the plane of the perforated plate to vary no more than 10%. The frame assembly shall be constructed of .063" extruded aluminum with mitered back-welded corners and .040" aluminum top plate. This assembly shall provide a rigid filter retainer frame with a "knife edge" which is pressed tight into the filter's liquid gel channel to ensure an airtight seal.  Assembly shall allow HEPA filter installation and service from room side of diffuser.

2. ENGINEER TO CHOOSE FACEPLATE STYLE BY SELECTING ONE OF THE FOLLOWING (DELETE OTHER CHOICE & RED TEXT):

For standard framed style faceplate:

Perforated distribution plate shall be of 0.050" aluminum with 23% open area.   Plate shall be retained to the module frame through the use of quarter-turn fasteners. Manufacturer shall provide safety retainers of vinyl-coated stainless steel cables on two opposite sides in order to prevent accidental dropping of faceplate.  Distribution plate shall be installed in extruded aluminum mounting frame with mitered back-welded corners.

For optional wrap-around style faceplate:

Perforated distribution plate shall be of 0.050" aluminum with 23% open area and shall extend over and wrap around plate frame on all four sides to assure continuous perforated surface appearance between ceiling tee frames.  Plate shall be retained to the module frame through the use of quarter-turn fasteners.  Manufacturer shall provide safety retainers of vinyl-coated stainless steel cables on two opposite sides in order to prevent accidental dropping of faceplate.

3. Diffuser plenums shall be lined on the interior surface with 1” thick polyester urethane sound attenuating material with a flame-bonded Tuftane coating on all exposed surfaces. 
 

2. HEPA FILTERS

1. A terminal HEPA filter shall be mounted within each laminar flow diffuser. Each HEPA filter shall be accessible and removable from the room side of the filter cabinet.  The "knife edge" of the filter cabinet’s retainer frame and the filter's liquid gel shall form an airtight seal.

2. The HEPA filters shall have an ASHRAE Minimum Efficiency Reporting Value (MERV) number of not less than 18 (or MERV-18 filters) in accordance with ASHRAE Std. 52.2, an efficiency of 99.99% versus particulate size of 0.3-microns.
3. The HEPA filters shall be laminar flow grade panel filters consisting of micro glass fiber media pleated to 70mm pack thickness.  The pressure drop across the filter shall not exceed 0.38" w.g. at a filter face velocity of 100 ft./min.  All materials used shall be in accordance with UL586 and UL900 classification.  Filters shall be individually tested for overall efficiency and scan tested for pinhole leakage.
4. The extruded aluminum filter frame shall be 3.55” deep and shall be furnished with a liquid gel seal within filter's channel-type frame. 
5. HEPA filters shall be installed into diffusers by General Contractor’s sheet metal subcontractor while under direct supervision by factory personnel after the ducts are cleaned and the room has been thoroughly cleaned and sterilized.  HEPA filters shall remain in sealed packages until they are installed within in the diffusers by means of stainless steel filter clips, nuts, and bolts.

3. AIR CONTAINMENT PANELS

1. Each system to include ceiling-mounted clear air containment panels.  Clear panels shall be framed with an extruded aluminum, mounted to 3” wide Tee around the entire perimeter of the surgical area.  Panels shall be supported and suspended from above and hang to a height of ___” (ENGINEER TO SPECIFY DIMENSION - 84” SUGGESTED) above the finished floor, surrounding the clean zone.  Panels to be constructed of 3/16” thick optically clear polycarbonate with GE LEXAN MR-10 mar-resistant coating framed with an anodized aluminum extrusion to provide structural rigidity.  Polycarbonate material to meet the following criteria: 
 

4. Blower Cabinets and Ductwork

1. Each system shall include four (4) blower cabinets, to supply air to the special diffusers as indicated on plans.  Blower cabinet shall house one (1) blower each. 

2. Each blower shall be provided with a dedicated direct-drive 3/4 HP, 1075 rpm, high-efficiency fan motor.  At full speed, each fan shall be rated to provide between 1500-1800 CFM while working against 1” w.g. static pressure.

3. The discharge velocity at the lower edge of the air containment shield at high speed shall be 80 ft./min. +/-10 ft./min. 

4. Each blower cabinet shall be suspended from the ceiling slab above by not less than four (4) ž” dia. threaded rods fastened to metal framing provided.
5. Access to blower cabinets shall be by means of removable blank-off panels provided by manufacturer and located directly below each cabinet as shown on drawings.
6. All blower cabinets and diffuser plenums shall be lined on the interior with 1” thick polyester urethane sound attenuating material with flame-bonded Tuftane coating on all exposed surfaces and when tested in compliance with ASTM Standard E-84-87, shall have a flame spread rating not to exceed 25 and a smoke developed rating not to exceed 50.
7. Finish of blower cabinets shall identically match the finish of the special diffusers.

5. Electrical Controls

1. Each system shall be provided with one (1) U.L. Label main electrical control cabinet with full color touch screen operator interface panel (OIP) surface-mounted on the control cabinet access door.  A separate control box shall be provided to house an uninterruptible power supply (UPS). The electrical control cabinet shall house all control components necessary for 2-speed operation of the system, the overload protection devices, and the main system power disconnect.  The control cabinet shall be wall-mounted within the operating room by the electrical subcontractor at a location determined by the owner.  Location of UPS control box to be determined by owner. 

2. Each system shall be provided with four (4) high efficiency, ū horsepower, 3-phase, 208/480 volt, direct-drive fan motors.  The number of fan motors provided shall be based on the design criteria of the room.  The owner shall provide one (1) ENGINEER TO SELECT VOLTAGE FROM ONE OF THE FOLLOWING AND DELETE OTHER TEXT:

1. 30 Amp, 4-wire, 3-phase, 208 Volt
2. 15 Amp, 4-wire, 3-phase, 480 Volt

      power feeder from the emergency power system for each control cabinet. 

3. The control cabinet shall be 36” x 36” x 6” and fabricated from 14-gauge aluminum with a white powder-coat finish. The cabinet shall have 1” wide perimeter flange for flush mounting.  The access door shall be hinged and grounded and shall be held closed by two quarter-turn fasteners.  All controls components located within the panel shall be mounted on a 14-gauge aluminum back plate.  The back plate shall have the same white powder-coat finish as the cabinet and shall be grounded. 
4. Speed control of each of the fans shall be provided by individual variable frequency drives (VFD’s) in conjunction with a single programmable logic controller (PLC).  The VFD’s shall be used to set the speed for each fan motor in each mode during startup.  Each VFD shall be provided with a supply line filter to prevent any reflected signal noise from interfering with the building’s power systems.  All conduit containing power wires from the VFD’s to the motors shall be metallic and grounded to prevent the propagation of radio frequency interference (RFI).
5. The PLC shall be factory programmed to switch the system between the high and low speed modes, to monitor the status of the fan motors, VFD’s and plenum air pressure sensors, and to relay all operational signal information between the OIP and the other control components.  All operational commands and system mode changes input at the OIP shall be processed by the PLC to run the fan motors at the appropriate speed. Faults and alarms generated by the VFD’s or the pressure or temperature sensors shall be processed by the PLC to send the appropriate code to the OIP both notifying the user of the problem and aiding in troubleshooting.  The PLC will also continuously monitor the system status and HEPA filter loading and send this information to the OIP to be displayed.  An alarm relay is provided for fault communication with the building energy management system.
6. Overload protection of the VFD’s, line filters, and the motors shall be provided by fusing at the main power disconnect and at each of the lines feeding the individual VFD’s.  Fusing in the power feeds of each component shall provide protection of the step down transformer, the PLC, and the control side of the VFD’s.  All components shall have positive grounding.

      F. Lighting 
 

1. Lay-in style fluorescent light fixtures (nom. 2’x 4’ and/or 2’ x 2’ size) surrounding the diffusers shall be furnished, installed, and controlled by General Contractor’s electrical subcontractor.

 
FOR OPTIONAL TEARDROP PROFILE LIGHT FIXTURES INCLUDE PARAGRAPHS 2. & 3. BELOW:

2. System shall include teardrop profile, single lamp lighting fixtures designed for cleanroom use between diffusers where shown on drawings. Fixtures shall be 24", 36", or 48" in length and 2" in width at the base.  Fixture housing lamp holder brackets and channel cover shall be constructed of code gage steel.  All metal parts shall be chemically treated with a rust resistant phosphatized solution and finish coating on reflective surfaces shall be white acrylic enamel electro-statically applied.  The light diffuser shall be milk white acrylic linear prism.  All electrical components shall be U.L. Listed. Fixture voltage shall be 120 Volt/Single Phase/60 Hz.  Each fixture shall be provided with a 40-Watt lamp with a rapid start, high power factor ballast and radio frequency interference (RFI) suppressor. Mounting shall be to the bottom of 3" wide T-bar included in system’s suspension and support system.
3. Installation, wiring, and control of the teardrop fixtures to shall be by General Contractor’s electrical subcontractor.  Control responsibility to be determined by owner.

7. BLANK-OFF PANELS

1. System shall include perforated blank-off panels identical in appearance to the panel diffusers for the following areas where columns may penetrate the ceiling or where interstitial access is required:

2. surgical light column(s)
3. medical gas column(s)
4. other ceiling-mounted equipment column(s)
5. access to blower cabinets

2. Blank-off panels shall have solid plate installed behind perforated plate, providing a seal between the room and interstitial space. 

3. The installing contractor shall cut all fill-in panel(s) for the surgical light, medical gas, and/or other equipment column(s) as required after this equipment located.

---------------------------------------------------------------------------------------------------------------------------------------BLANK-OFF PANEL OPTION:

To specify SOLID BLANK-OFF PANELS, replace SECTION 2.3 PARA G. with the following:

1. System shall include solid face blank-off panels where indicated on the drawings and where columns may penetrate the ceiling or where interstitial access is required:

1. surgical light column(s)
2. medical gas column(s)
3. other ceiling-mounted equipment column(s)
4. access to blower cabinets

2. Panel to have solid plate installed within extruded aluminum perimeter frame with mitered corners providing a seal between the room and interstitial space. 

3. The installing contractor shall cut all fill-in panel(s) for the surgical light, medical gas, and/or other equipment column(s) as required after this equipment located.

--------------------------------------------------------------------------------------------------------------------------------------- 
 

8. support and Suspension System

1. The entire laminar flow system shall be suspended from the structure above.  Support and suspension system shall include integral extruded aluminum tee and angle assembly to support air distribution modules, lighting fixtures, fill-in panels, and ceiling-mounted return air grilles.  The minimum wall thickness of the aluminum tee shall be 0.125 inches with a minimum weight of 0.43 lbs./ft.  The completed assembly shall be capable of supporting a load of 10 lb./sq. ft. The frame system to be either pre-cut and pre-assembled at the factory and marked for ease of reassembly in the field by the installing contractor or heliarc-welded at all intersection points at the factory into subassemblies not larger than 6’x18’ which butt to adjacent subsections for field assembly with "U" clips.  All members shall be pre-punched on 6” centers for attachment for support hanger wires or ž” threaded rod to be attached on 2’-0” centers in two directions to strut support members.

2. Panel manufacturer shall furnish 1/8" thick closed cell polyethylene PSA-backed gasket tape to be field-installed onto the frame assembly.

3. Finish of the exposed ceiling level support and suspension system shall identically match the finish of the special perforated diffusers and blank-off panels.

4. Each blower cabinet shall be suspended from the slab above by not less than four (4) ž” threaded rods attached on corners. 

5. The system manufacturer shall furnish all P-1000 Unistrut members, ž” threaded rods, rod couplers, spring nuts & washers as necessary for structural support of the system as shown on system’s submittals. 

6. Installing contractor shall furnish concrete anchors.  
 

9. RETURN AIR GRILLES WITH PREFILTERS

1. Manufacturer shall furnish ceiling-mounted return grilles where shown on drawings.

2. Manufacturer shall furnish two (2) sets of prefilters sized to fit return grilles with an ASHRAE Minimum Efficiency Reporting Value (MERV) number of 8 (or MERV-8 filters) in accordance with ASHRAE Std. 52.2.   
 

10. Finishes and Coatings

1. The complete tee and angle frame assembly, fan cabinets, return air grilles, diffusers and fill-in panels shall be finished in white baked enamel.

2. The finish on the aluminum trim around the entire perimeter of the air containment shield shall be 215-R1 clear anodized. 

3. System to be provided with certification of all coatings and materials that have been furnished and installed. 

PART 3 – EXECUTION 
 

1. Installation

A. Installation shall be by General Contractor’s sheet metal subcontractor at location shown on drawings.  The General Contractor’s sheet metal subcontractor shall be responsible for the following: 
 

1. Installation of the Special High-Capacity Perforated Panel HEPA Diffuser Plenums, HEPA Filters (while under direct supervision by manufacturer’s personnel), Air Containment Panels, Blower Cabinets and Ductwork, Blank-Off Panels and Support & Suspension System.
2. Furnish and install ductwork required for supply and exhaust of make-up air outside the surgical area as defined outside the perimeter of blower cabinets.
3. Furnish concrete anchors and any additional structural support and hardware other than as recommended by system’s shop drawings and noted as “furnished by manufacturer”.

4. Removal of construction debris and cleaning of room to such state for owner’s final cleaning before testing and certification of system. 
 

B. The General Contractor’s electrical subcontractor shall be responsible for the following: 
 

1. Furnish and connect the main power service to the system’s main control cabinet.
2. Install wall-mounted main control cabinet for system.
3. Wire and connect the blower motors to the system’s main control panel.
4. Install, wire and connect the air pressure sensors furnished by system manufacturer to the main control cabinet from location within supply air plenums where shown on drawings.
5. Furnish, install, connect and control any lay-in style fluorescent light fixtures surrounding the diffusers.
6. Install, connect and control any optional teardrop light fixtures furnished as part of the system as located by submittal drawings.

3. The system manufacturer shall supervise the installation of the system on an intermittent basis and provide start-up of the system.  Factory-approved local representative shall be available for coordination meetings.

2.  PREPARATION FOR BALANCING, TESTING & CERTIFICATION

A. The General Contractor’s sheet metal subcontractor shall be responsible for removal of construction debris and initial cleaning of the room. 
 

B. After the construction cleaning is complete, the owner shall be responsible for final sterilization of the rooms prior to the factory testing, balancing and certification phase of the project.  The hospital’s normal sterilization procedure shall be followed in order to prepare the room for this phase. 
 

3.3 BALANCING 
 

1. The manufacturer shall, after the unit has been installed, balance the system to obtain uniform airflow over the discharge face of the laminar flow diffusers in accordance with manufacturer’s recommended balancing procedures.

3. TESTING AND CERTIFICATION

A. Upon completion of installation and sterilization of all rooms by owner, system manufacturer will supervise the installation of the filters and test, balance and certify the systems.  The complete, balanced installation, while in the "High/Operating" Mode shall be certified by the manufacturer to be in compliance with Class 5 cleanroom standards as defined in Part 1 "Classification of Air Cleanliness" of ISO Standard 14644 titled "Cleanrooms and Associated Controlled Environments" (supercedes Federal Standard 209E titled "Airborne Particulate Cleanliness Classes in Cleanrooms and Clean Zones" where this same system shall meet Class 100 cleanroom conditions as defined as an area that must have less than 100 particles of 0.5 micron or larger size per cubic ft. of air). 
 

B. At time of factory testing and certification, system manufacturer’s personnel will perform one (1) In-Service Training Session for the hospital’s operating staff and maintenance personnel.  Manufacturer shall discuss overall system operation, answer questions regarding hospital’s protocol in relation to system operation, discuss filter replacement procedures, system troubleshooting and routine service, maintenance, and parts replacement procedures.