AAF AstroFan EC FFU User manual

AstroFan™EC FFU
INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
E508161

1
TABLE OF CONTENTS:
Introduction and Precautions .............................................................................................. 02
Important Safety Instructions ............................................................................................... 03
Equipment Overview ............................................................................................................. 04
Transport ......................................................................................................................... 05
Unpacking ....................................................................................................................... 05
Installation............................................................................................................................... 06
Top Side Serviceable Units .............................................................................................. 06
Room Side Replaceable Units ........................................................................................ 07
PermaFrame for Hard/Gypsum Ceiling ........................................................................... 08
Grille Installation and Removal ......................................................................................... 09
Filter Unpacking, Installation, Storage and Operation ....................................................... 10
Unpacking ....................................................................................................................... 10
Installation of Gel Seal Filters ......................................................................................... 10
Storage ...............................................................................................................................11
Operating Conditions.........................................................................................................11
Aerosol Injection and Static Pressure/Upstream Aerosol Ports .................................... 11
Inlet Options ..................................................................................................................... 12
Insulation Options ............................................................................................................. 12
Double Poly Bag Option ................................................................................................... 12
Power and Electrical ......................................................................................................... 13
Wiring Diagram for EBM Blowers and AAF Flanders Control Interface........................... 14
Appendix A – Warranty Information .................................................................................... 15
Appendix B – Manual Revision History............................................................................... 16
Contacting AAF Flanders ...................................................................................... Back Cover

2
INTRODUCTION AND PRECAUTIONS
Intended Use
AAF Flanders AstroFan™EC Fan Filter Units (FFUs) ensure cleanroom-level cleanliness air is
delivered to critical process applications such as Microelectronics, Semiconductor Manufacturing,
Pharmaceutical Manufacturing, Life Sciences, Biosafety, Healthcare, as well as all other applications
where clean supply air is a requirement.
User Responsibility
This document contains the information necessary to properly receive, assemble, install, operate,
and maintain the AAF Flanders AstroFan EC FFU equipment. The purchaser, installer, and operator
of the filter system MUST read and comply with this document in its entirety. Failure to comply with
the requirements of this manual may result in serious injury, potentially death, and void the product
warranty.
These instructions are specific to the AAF Flanders AstroFan EC FFU units and incorporated filters.
All ancillary tasks including, but not limited to, electrical and mechanical work, equipment handling,
and safety procedures must be performed in accordance with industry-accepted practice and all
relevant local, state, and federal government codes, laws, and policies.
Before proceeding with installation, operation, or maintenance, review this Installation, Operation, and
Maintenance Manual in its entirety and all safety procedures with your company’s safety personnel.
Precautions
• Units must be properly transported and handled, as improper transport and/or handling can result
in damage and/or blemishes.
• Deliveries are to be immediately inspected in the presence of the freight carrier to ensure
equipment is delivered in full and damage-free.
• The installation site must be suitable for unit installation.
• The supporting construction must be level, and the structure must have sufficient load strength to
support all equipment supplied.
• Mounting must be carried out by qualified and trained personnel in accordance with all local, state,
and national codes and regulations.

3
IMPORTANT SAFETY INSTRUCTIONS
1. READ AND SAVE THESE INSTRUCTIONS
2. WARNING – To reduce the risk of fire, electrical shock, or injury to persons, observe the
following:
a. Use this unit in the manner intended by the manufacturer. If you have questions, contact
the manufacturer.
b. Before servicing or cleaning unit, switch power off at service panel and lock the service
disconnect means to prevent power from being switched on accidentally. When the
service disconnect mean cannot be locked, securely fasten a prominent warning device,
such as a tag to the service panel.
3. WARNING – To reduce the risk of fire, electrical shock, or injury to persons, observe the
following:
a. The AstroFan AFU fan filter units must be installed with filters that are marked on their
labels to indicate the suitability with this model. Other filters cannot be substituted.
4. CAUTION – Automatically operated device. To reduce the risk of injury, disconnect from
power supply before servicing.
5. CAUTION – For installation by qualified personnel only.
6. WARNING – Risk of electrical shock. Can cause injury or death. Disconnect all remote
electrical power before servicing. If connected to a circuit protected device by fuses,
use time-delay fuses for this appliance.
7. WARNING – To reduce the risk of fire or electric shock, do not use this fan with any
solid state speed control device.
8. WARNING – To reduce the risk of fire, electric shock, or injury to persons, observe the
following:
a. Installation work and electrical wiring must be done by a qualified person(s) in accordance
with all applicable codes and standards, including fire rated construction.
b. Follow the heating equipment manufacturer’s guideline and safety standards such as
those published by the National Fire Protection Association (NFPA), and the American
Society for Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE), and the local
code authorities.
c. When cutting or drilling into wall or ceiling, do not damage electrical wiring or other hidden
utilities.
d. Ducted fans must always be vented to the outdoors.
e. If the unit is to be installed over a tub or shower, it must be marked as appropriate for
the application and be connected to a GFCI (Ground Fault Circuit Interrupter) – protected
branch circuit.

4
EQUIPMENT OVERVIEW
The AstroFan™EC FFU (Fan Filter Unit) utilizes a state of the art Electronically Commutated (EC)
Motor and backward-curved, plastic Blower Wheel assembly to provide the desired airflow through a
HEPA/ULPA filter at an industry-leading efficiency and reduced sound level.
The AstroFan EC FFU is available in Aluminum or Stainless Steel options and as either a Top Side
Serviceable (TSS) or Room Side Replaceable and Serviceable (RSR) configuration, white powder
coat finish also available. For TSS, the AstroFan EC FFU housing sits on top of the HEPA/ULPA filter
frame. For RSR, the housing sits on top of an RSR Filter Adaptor Frame (Extruded Aluminum), and
the RSR Filter is installed from the room side.
AstroFan EC FFUs can be supplied with round duct inlet collars or with a prefilter frame. The latter
is ideal for incorporating AMC (Airborne Molecular Contamination) filters. All units offer universal
mounting via wire or rod suspension for use in a T-Bar grid ceiling, as well as a variety of grille options
and insulation.
AstroFan EC FFUs are available in many configurations, sometimes with custom features. Please
reference order specific data sheets and/or submittal drawings for more information.

5
Transport
Deliveries are to be immediately checked in the presence of the carrier as being intact and complete.
Units must be properly transported. Improper transport can lead to:
• Impeller interference with inlet ring
• Motor shaft deformation
• Bearing damage
Unpacking
• Carefully remove the unit from the shipping carton and inspect for any damage that may have
occurred during transportation. Two workers minimum are required to lift the unit from the
container.
• Remove housing from shipping carton and inspect for concealed damage and any hardware that
may have become loose in transit.
• If RSR configuration is ordered, the RSR Adaptor frame and grill will be shipped in a separate
shipping carton and will need to be inspected for concealed damage and any hardware that may
have become loose in transit.
• The grill for the RSR Adaptor should be set aside. It is good practice to label or mark the grill and
trim components to match with the respective unit to ensure a good fit.
Fig 1: Unit Unpacking
EQUIPMENT OVERVIEW

6
INSTALLATION
CAUTION:
• Mounting may only be carried out by trained personnel in accordance with these instructions
and with regards to regulations in force.
• Safety devices that have been removed for mounting work must be replaced immediately
afterwards, and before electrical connections are made.
• Fans must be installed such that secured fixing is guaranteed at all times during operation.
• Installation site must be suitable for each AstroFan installed.
• Supporting construction must be level, and the structure must have sufficient load strength to
support all fans as needed.
• All electrical connections must be made by qualified trained personnel only in accordance
with all local, state, and national electrical codes and federal regulations.
If connecting flexible duct, connections should be made using stainless steel, worm-gear type
draw bands (supplied by others) for maximum reliability. For square inlet, contractor is responsible
for securing and sealing duct work to factory supplied blank flange. Housing installation must be
accomplished in a professional manner to prevent contaminant infiltration from the interstitial space.
Top Side Serviceable Units
• Install the HEPA/ULPA filter into the
ceiling grid such that the gasketed
channel is pointing upward.
– Extreme caution should be used
when handling glass HEPA/ULPA
filters to minimize any potential for
damage.
• Using the integral handles, carefully lay
the AstroFan™unit onto the filter frame,
ensuring its bottom edge rests in the
gasketed channel of the filter frame.
See Fig. 2.
– It is recommended that two (2)
people work together to ensure
proper handling of units.
• If using a flexible grid (typically
supported with wires or rod), the unit
must be secured to an engineered
support system, suspended with wire
or rod (supplied by others) using the
universal hanging tabs/mounting pads
affixed to the housing. See Fig. 4.
Fig 2: TSS Ceiling Grid Interface
AstroFan
Housing
TSS Filter
Frame
Gasketed
Channel
Filter
Media
Grid / T-Bar
Ceiling
Gasket

7
Room Side Replaceable Units
• Install the RSR Adaptor Frame into
the ceiling grid such that the gasketed
channel is pointing upward.
• Using the integral handles, carefully
lay the AstroFan™unit onto the RSR
Adaptor Frame, ensuring its bottom
edge rests in the gasketed channel of
the filter frame. See Fig. 3.
– It is recommended that two (2)
people work together to ensure
proper handling of units.
• If using a flexible grid (typically
supported with wires or rod), the unit
must be secured to an engineered
support system, suspended with wire
or rod (supplied by others) using the
universal hanging tabs/mounting pads
affixed to the housing. See Fig. 4.
INSTALLATION
AstroFan
Housing
RSR Adaptor
Frame
Gasketed
Channel
RSR
Filter
Filter
Media
Gel
Grid / T-Bar
Ceiling
Gasket
Fig 3: RSR Ceiling Grid Interface
Fig 4: Wire - Hanging Tabs

8
Fig. 6 PermaFrame Mounting
PermaFrame for Hard/Gypsum Ceilings
The PermaFrame provides a support structure and room-side finish trim in one piece. It is supplied
with predrilled mounting holes located on the vertical flanges, which are used to easily level and
anchor the frame to customer-supplied studs above the ceiling structure. Manufactured of 16
gage cold rolled steel or stainless steel and welded on all exposed corners to guarantee a smooth,
cleanable surface. White powder coat paint is supplied as standard finish. The PermaFrame is
ordered separate from the AstroFan units and filters.
Drawing Notes:
Construction - 16–ga. cold rolled steel or 304 stainless steel.
For SS finish use - SS suffix, unit supplied painted white standard
IL - Inside Length
IW - Inside Width
Model
Number
Actual Dimensions (inches) Weight
(lbs)
AstroHood L W IL IW
2 x 2 HCFA 2424 26 26 24 24 4
2 x 4 HCFA 2448 50 26 48 24 5
Dimensional Data - Standard Size AstroHood (1½" T-Bar)
Fig. 5 PermaFrame Dimensions
1½" T-Bar/Grid
INSTALLATION (CONTINUED)

9
INSTALLATION (CONTINUED)
Grille Installation and Removal
The RSR unit is supplied with a standard removable grille made of 40% open area in Painted Steel,
Aluminum, and Stainless Steel. Grille mounting is supplied as standard four (4) corner acorn nut
design for 2x2 & 2x4 units and eight (8) acorn nuts for 3x4 & 4x4 units. The grille is fastened onto
threaded studs using acorn nuts, one in each corner for 2x2 & 2x4 units and two along each side
for 3x4 & 4x4 units (see Fig 7 below). The threaded studs protrude from the RSR Adaptor frame and
through the grille to the room side. Acorn nuts and flat washers are installed on each stud to secure
the grille in place.
To remove grille:
1. Loosen and remove the acorn nuts and flat washers.
2. Carefully remove and lower the grille. To avoid potential injury, it is strongly recommended two
people perform this task.
To replace grille:
1. Align the holes in the grille with the studs.
2. Hold the grille in place and reinstall the flat washers and acorn nuts. To avoid potential injury, it
is strongly recommended two people perform this task.
3. Hand-tighten the acorn nuts. Do not use a wrench or socket, as overtightening may damage
the threaded connection.
RSR
Adaptor
Frame
RSR Filter
Filter Retainer
Gel
Stud
Filter
Media
Acorn Nut Grille
Fig. 7 Roomside Change Frame

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FILTER UNPACKING, INSTALLATION, STORAGE AND OPERATION
Unpacking
• Before removing the filter from the carton, carefully read the removal and handling instructions
printed on the outside of the carton.
• AAF Flanders Cleanroom filters may come packaged in suitcase-style cardboard sleeves. If
so, simply reach into the box and grab the handles pre-punched within the insert.
• If the filter is in a cardboard liner, the filter must be oriented such that the open ends of
the liner are facing outward (i.e. to your left and right rather than upward). Carefully cut the
packing tape that holds the filter in the liner. Always check for torn or deflected liner edges. If
any are found, straighten or flatten such edges prior to liner removal in order to prevent media
damage.
• One person should carefully hold the plastic bag(s) while the other person carefully pulls the
liner, sliding it away from the filter.
• Panel filters will be single- or double-bagged (depending on customer requirements) with
snug-fitting cardboard liners. Ducted filters will be single or double bagged and packed in
reinforced cartons.
• The filter should now be handled with extreme care to avoid contact with the media and/or
face screen.
• While the bag is still present, carry the filter by grabbing the bag. Be careful to keep the filter
away from your body and any objects in your path.
– If the bag is not present, always handle filter from the frame, avoiding contact with the
media and/or face screen.
• Remove the bag carefully. Avoid hand and finger contact with the filter media.
• Additional precautions for gel seal filters:
– Care is taken at the factory to prevent the bag from contacting the gel. Be very careful
when unpacking gel seal filters to remove the bag slowly and carefully.
– If the bag comes in contact with the gel, pull the bag off the gel slowly. Quick removal
of the bag may cause damage to the gel and possible separation of gel from the gel
channel.
Installation of Gel Seal Filters
• Carefully lift the filter into place, inserting it into the housing and taking care to make certain
the knife edge is properly seated into the fluid gel seal. Note: Setting filters properly requires
two (2) people.
• Rotate each of the filter retainers into place, one (1) in each corner, and hand-tighten the
hex nuts.
• Install the grille using the acorn nuts.

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FILTER UNPACKING, INSTALLATION, STORAGE AND OPERATION (CONTINUED)
Storage
• Location: Storage should be indoors (under roof and enclosed) and absolutely protected from
moisture.
• It is strongly recommended that the storage space be climate-controlled.
– Temperature Limits: Maximum temperatures of 250°F (121°C) intermittent, and 100°F
(38°C) steady state. Minimum temperature is 32°F (0°C).
Operating Conditions
• Temperature: The maximum operating temperature is determined by the filter configuration.
– Consult the filter submittal drawing for the specific maximum operating temperature.
• Humidity: 100% relative humidity is acceptable. However, condensation must be avoided to
prevent degradation of performance and potential filter failure.
• Filters should not be operated in caustic or acidic environments.
• Filters should not be operated in excess of twice the rated performance for flow rate or
pressure drop.
Aerosol Injection and Static Pressure/Upstream Aerosol Ports
The AstroFan™EC FFU RSR is supplied with room-side aerosol injection port and aerosol dispersion
system as well as an upstream static pressure/upstream aerosol sample port to facilitate validation
testing. These ports are available standard as 3/8" female NPT fittings, supplied with respective plugs.
These connection points are labeled on the inside surface of the housing and are visible from the
room side.
To remove grille:
1. Loosen and remove the acorn nuts and flat washers.
2. Carefully remove and lower the grille. To avoid potential injury, it is strongly recommended two
people perform this task.
To replace grille:
1. Align the holes in the grille with the studs.
2. Hold the grille in place and reinstall the flat washers and acorn nuts. To avoid potential injury, it
is strongly recommended two people perform this task.
3. Hand-tighten the acorn nuts. Do not use a wrench or socket, as overtightening may damage
the threaded connection.
Fig. 8 Aerosol
Injection System
Fig. 9 3/8" NPT Ports

12
FILTER UNPACKING, INSTALLATION, STORAGE AND OPERATION (CONTINUED)
Inlet Options
The AstroFan™EC FFU is available as standard for plenum supply applications and is also available
with the option for prefiltration, either particulate or AMC, or in a ducted supply configuration. The
prefilter option is designed to accommodate standard 20"x20"x2" pleated prefilters. The ducted
supply option is available as either a 20"x20" square or round duct connection
Insulation Options
Insulation options are available to prevent heat loss, mitigate potential condensation, and/or provide
sound attenuation. Determining the use of these options is the responsibility of the design engineer.
The 2" foil back option is an aluminum foil-backed fiberglass (installed 6.0 R-value) attached to the
outside of the housing using adhesive-mounted insulation anchors and caps.
Double Poly Bag Option
A double poly bag arrangement is available for those clients whose cleanrooms are ultra-sensitive to
potential contamination exposure. The double-bagged FFU housing is removed from the container
outside of the cleanroom. At a staging area, typically in an area of lesser cleanliness than the
cleanroom such as an ante room, the single-bagged FFU housing is removed from the outer bag and
then taken into the cleanroom. Inside the cleanroom, the FFU housing is removed from the second
bag and staged for installation.
Fig. 10 PreFilter/Square Duct Option Fig. 11 Round Duct Option

13
FILTER UNPACKING, INSTALLATION, STORAGE AND OPERATION (CONTINUED)
Power and Electrical
Install wires and make electrical connections to appropriate voltage, matching the nameplate
information on unit. Install wires in accordance with all local, state, and nation electrical codes.
Power into the unit should be connected to the L1, L2, and Ground pins on the power terminal block.
Appropriate gauge wire, cabling, and strain relief should be utilized per governing code. It is highly
recommended that power be supplied to each unit discretely.
Communication with the motor can be established by attaching CAT 5, CAT 5E, or CAT 6 cable to
COMS 1 or 2 from the AstroDrive Control or BMS. Note the ethernet cables are throughput, not
series, and are not directional – you can use either one. Cables can then be attached to subsequent
units, in series, to control more than one FFU; however, this is limited to 1,300 feet as communication
loss will be incurred. Please refer to the AstroDrive controls manual for appropriate communications
wiring configuration.
Fig. 12 Control Box
Fig. 13 Power Wiring

14
WIRING DIAGRAM FOR EBM BLOWERS AND AAF FLANDERS CONTROL INTERFACE

15
APPENDIX A – WARRANTY
AAF INTERNATIONAL
LIMITED WARRANTY
The Seller warrants that it will provide free replacement parts in the event any product manufactured
by the Seller proves defective in material or workmanship for a period of twelve (12) months from
initial startup or eighteen (18) months from date of shipment, whichever expires sooner. Product(s) not
manufactured by the Seller but also sold under this agreement are warranted only to the extent that the
manufacturer warranted them to the Seller or directly to Buyer.
The Seller’s liability to Buyer shall not exceed the lesser of the cost of correcting defects in the
product(s) sold or the original purchase price of the product(s), and the Seller shall in no event be
liable to Buyer or third parties for any delays. The Seller’s warranty does not apply to any product(s) or
goods which: (1) have been opened, dissembled, repaired, or altered by anyone other than the Seller
or its authorized service representative; or (2) which have been subjected to misuse, misapplication,
negligence, accidents, damage, abuse, improper storage, or abnormal use or service; or (3) have been
operated or installed in a manner contrary to Seller’s printed instructions; or (4) have been installed in
an incorrect or improper application; or (5) have become corroded or subjected to abrasion. The Seller
is not obligated to pay any costs or expenses in connection with the removal and re-installation of such
product(s) or goods, including but not limited to labor, service costs, and shipping charges. The same
obligations and conditions shall extend to replacement parts furnished by the Seller hereunder. This
parts warranty and any optional extended warranties are granted only to the original user. Seller’s duty
to perform under this or any warranty may be delayed, at Seller’s sole option, until Seller has been paid
in full for all products or goods purchased by Buyer. No such delay shall extend the warranty period.
To obtain assistance under this limited warranty please contact the selling agency. To obtain information
or to gain factory assistance, contact AAF International Warranty Claims Department, 9920 Corporate
Campus Drive, Suite 2200, P.O. Box 35690, Louisville, Kentucky 40223-5000; Telephone (502) 637-
0011, FAX [phone].
THIS WARRANTY CONSTITUTES BUYER’S SOLE REMEDY. IT IS GIVEN IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED. THERE IS NO IMPLIED WARRANTY OF MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE. NOTWITHSTANDING ANY OTHER TERMS OF ANY
AGREEMENTBETWEEN THE SELLER AND BUYER,IN NO EVENT AND UNDER NOCIRCUMSTANCES
SHALL SELLER BE LIABLE FOR INCIDENTAL, INDIRECT, SPECIAL, OR CONSEQUENTIAL
DAMAGES, WHETHER THE THEORY BE BREACH OF THIS OR ANY OTHER WARRANTY, BREACH
OF CONTRACT, NEGLIGENCE, OR STRICT LIABILITY.
No person (including any agent, salesman, dealer, or distributor) has the authority to expand the Seller’s
obligation beyond the terms of this express warranty, or to state that the performance of the product(s)
is other than published by the Seller.

16
APPENDIX B – MANUAL REVISION HISTORY
Revision
Version
Revision
Date Description of Change Approval

AAF International Plant Locations
AAF, the world’s largest manufacturer of air
filtration solutions, operates production,
warehousing and distribution facilities in 22
countries across four continents. With its
global headquarters in Louisville, Kentucky,
AAF is committed to protecting people,
processes and systems through the
development and manufacturing of the
highest quality air filters, filtration equipment,
and associated housing and hardware
available today.
Contact your local AAF Flanders representative
for a compete list of AAF Flanders Air Filtration
Product Solutiobns.
Americas
Louisville, KY
Atlanta, GA
Ardmore, OK
Bartow, FL
Columbia, MO
Fayetteville, AR
Hudson, NY
Momence, IL
Smithfield, NC
Tijuana, Mexico
Votorantim, Brazil
Washington, NC
Europe
Cramlington, UK
Gasny, France
Vitoria, Spain
Ecoparc, France
Trencin, Slovakia
Vadstena, Sweden
Vantas, Finland
Asia & Middle East
Riyadh, Saudi Arabia
Shah Alam, Malaysia
Suzhou, China
Shenzhen, China
Miaoli, Taiwan
Bangalore, India
Noida, India
Yuki, Japan (Nippon Muki)
For Technical or Application Questions:
Phone: [phone]
Email: productsupport@aafintl.com
9920 Corporate Campus Drive, Suite 2200, Louisville, KY 40223-5690
888.223.2003 Fax [phone] | aafintl.com
AAF Flanders has a policy of continuous product
research and improvement. We reserve the right
to change design and specifications without notice.
ISO Certified Firm
©2020 AAF International and its affiliated companies.
AFP-3-103 12/20