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LS40/60 Freeze Dryer
Instruction Manual
Severn Science Limited
4 Short Way
Thornbury
Bristol
BS35 3UL
Info@severnscience.co.uk
Tel: 01454 414723
Fax: 01454 281680
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CONTENTS
1.0
INTRODUCTION
1.1
Scope
1.2
General safety
1.3
General description
1.3.1
Freeze Drying – Basic Principles
1.3.2
The Condenser Unit
1.3.3
The Drying Chamber
1.3.4
Control System
2.0
TECHNICAL DATA
3.0
INSTALLATION
3.1
Unpack and inspect
3.2
Equipment Placement
3.3
Preparation of Vacuum Pump
3.3.1
Check Pump Oil Level
3.3.2
Vacuum Pump Settings
3.3.3
Pump Exhaust Connection
3.4
Preparation of Refrigeration System
3.5
Electrical Installation
4.0
OPERATION
4.1
Power Up
4.2
Security Control
4.3
Switch On Condenser
4.4
Switch On Shelf Refrigeration
4.5
Loading the Product
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4.6
Running a Freeze Drying Cycle
4.6.1
Run a program Now
4.6.2
Run a program from a Point
4.6.3
Scheduling a Program
4.6.4
End of Program Sequence (EPS)
4.7
Program Monitoring
4.7.1
Monitor Facility
4.7.2
Pre-Plot Facility
4.7.3
Trends
4.8
Holding a Program
4.9
Aborting a Program
4.10
Stoppering
4.11
Removing Product
4.12
Condenser Defrost
5.0
CREATING / EDITING A PROGRAM
5.1
Save / Save As
5.2
Inserting a Segment
5.3
Deleting a segment
5.4
Amending the End-of-Program Sequence
6.0
DATA LOGGING
6.1
Changing Logging Configuration
6.2
Logging Monitor
7.0
MANUAL OPERATION
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8.0
ALARMS
8.1
Alarm Acknowledgment
8.2
Alarm History
8.3
8.4
Alarm Note
Alarm History Archive
9.0
MAINTENANCE
9.1
Maintenance Plan
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
Vacuum pump Oil level
Oil Mist Filter Element
Oil Drain Kit
Change Vacuum Pump Oil
Vacuum Pump Service
Door Seals
Drying Chamber Silicone Fluid
Refrigeration Heat Exchangers
Appendix 1
Appendix 2
Manufacturers Literature
List of Drawings
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Declaration of Conformity
Manufacturer’s Name:
Severn Science Ltd
Manufacturer’s Address:
5 Short Way
Thornbury, Bristol
BS35 3UL England
Model / Serial No:
Date of Issue:
Severn Science Limited hereby declares that the above
product conforms with the essential protection requirements
of:
Low Voltage Directive 73/23/EEC amended by 93/68/EEC.
EMC Directive 89/336/EEC as amended by 92/31/EEC.
Machinery Directive 89/392/EEC
by application of the following standards:
Safety:
Safety:
Emissions:
Immunity:
BS EN61010, 1993
BS EN 292-1, -2 : 1991
BS EN 50081-2: 1994
BS EN 50082-2 : 1995
Signed on behalf of Severn Science Limited
Dr A.D Hilton (Technical Director)
Severn Science Limited
5 Short Way,
Thornbury, Bristol, BS35 3UL
Tel: 01454 414723 Fax: 01454 281680
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1.0 INTRODUCTION
1.1 SCOPE
This manual provides installation and operation instructions for the LYOSCIENCE LS40
and LS60 freeze dryers. The manual and all accompanying documentation must be
read before operating the equipment.
Important safety information is highlighted as WARNING and CAUTION instructions;
you must obey these instructions. The use of WARNINGS and CAUTIONS are defined
in the general safety section.
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GENERAL SAFETY
WARNING: Warnings are given where failure to observe the instruction could result
in injury or death to persons.
CAUTION: Cautions are given where failure to observe the instruction could
damage to the equipment, associated equipment or process. Refer to the
accompanying manufacturers’ instruction manuals for the technical data on
individual components.
See Appendix 1 for list of Instruction Manuals.
WARNING: Sodium Azide Explosion Hazard
Sodium Azide, which is sometimes used in the freeze-drying process, is a toxic and
(when dry) highly explosive material. In the process of pumping product containing
this chemical, a reaction can occur in the presence of heavy metals (copper, lead,
zinc and cadmium). The resulting reaction is the formation of heavy metal azides
that are highly unstable, and which present a very severe explosion hazard.
Standard LS40 and LS60 freeze dryers are not suitable for use with Sodium
Azide. Please contact Severn Science if you wish to use Sodium Azide; the
equipment can be modified by the manufacturer for safe operation with Sodium
Azide if required.
1.3 GENERAL DESCRIPTION
1.3.1 FREEZE DRYING - BASIC PRINCIPLES
Freeze drying is a method used to dehydrate heat sensitive materials via a process involving the
sublimation of any water content (in the form of ice) under vacuum conditions. The process can
be subdivided into three (3) stages; freezing, primary drying, where the bulk of the water content
is removed by sublimation, and secondary drying where residual bound water is removed at
higher temperatures. The LS range of freeze dryers is capable of automatically performing all
these functions in a controlled and reproducible manner.
The equipment consists of a large vacuum drying chamber mounted directly above a
refrigerated condenser with integral vacuum pump. The drying chamber contains up to five
refrigerated shelves that can be moved up and down via an electrically operated ram for
stoppering processes. Both condenser and drying chambers are fitted with their own
refrigeration systems, specified for either high temperature (denoted model LS40) or low
temperature (model LS60) use. The temperature of the product shelves used in the LS40
can be controlled between +60oC and –40oC whereas shelf temperatures can be varied
between +60oC and –60oC for the LS60 version. Both systems have a compact footprint
allowing the equipment to be moved through standard sized doorways. Commissioning is
simple and straightforward, requiring no external services other than mains power. All
components are housed inside a free-standing cabinet with detachable inspection panels at
the front, rear and sides for easy maintenance.
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1.3.2 THE CONDENSER UNIT
The condenser unit consist of a cylindrical chamber (290 X 620 mm) with an inlet port
situated near the front of the chamber and a 25 mm outlet port positioned at the rear
of the chamber. The chamber walls are cooled directly by an integral CFC free
refrigeration system mounted in the base of the unit. During freeze drying, water
vapour that is extracted from the product, is condensed onto the chamber walls,
resulting in the formation of an ice ‘plug’. The chamber has a total ice capacity of
~15Kg between defrost cycles. The minimum temperature of the chamber wall under
vacuum conditions with no load applied is –45oC and –80oC for the LS40 and LS60
models respectively.
The condenser inlet is connected to the drying chamber via an electrically actuated
high vacuum butterfly valve. The chamber outlet is connected to the inlet of an RV12
vacuum pump. A transparent perspex door at the front of the condenser allows the
operator to inspect the ice plug and provides convenient access for cleaning
purposes.
The chamber is automatically defrosted when the condenser refrigeration system is
turned off. Defrosting is assisted using a band heater that is wound round the external
surface of the chamber. The ice can be removed as a solid plug after defrosting the
chamber for ~ 1 hr. Any ice that has melted can be removed via a solenoid operated
drain valve in the bottom of the chamber or removed by the operator during general
maintenance.
A two stage oil-sealed rotary vacuum pump (RV12) mounted on the base of the unit is
used to evacuate both condenser and drying chambers. The pump outlet is fitted with
a mist filter to prevent oil mist escaping to the atmosphere. The exhaust of the filter is
piped to a stub connection at the rear of the freeze dryer, which in turn should be
connected to the user’s exhaust extraction system.
Oil collected in the mist filter is continuously returned into the gas ballast port of the
pump.
The condenser temperature and pressure is monitored with a PT100 and a pirani
gauge respectively; data can be continuously displayed on the touch screen if
required.
1.3.3 THE DRYING CHAMBER
The drying chamber is mounted directly above the condenser unit (refer to figure 1).
The chamber is fitted with up to five temperature controlled product shelves, a
refrigeration / heater plant with heat transfer fluid circuit and a shelf stoppering
mechanism. A transparent perspex door at the front of the chamber allows the
operator to inspect the product during the freeze drying process and provides access
for loading and unloading.
Each shelf contains an internal network of channels through which the heat transfer
fluid can flow freely and continuously. Heat is extracted or introduced into the fluid via
the refrigeration / heater plant and is then distributed to each shelf in parallel through
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a common manifold and liquid re circulating pump. Sensors in the fluid circuit provide
feedback for closed loop temperature control. Temperature control is achieved by
modulating the flow of heated and cooled fluid with the use of solenoid operated
isolation valves in the fluid circuit.
The shelves are mechanically linked to an electrically actuated ram with variable
torque drive. The ram moves the shelves up and down allowing automatic stoppering
of vials under vacuum and other controlled atmospheres. Operation of the ram is
interlocked with safety switches on the front perspex door ensuring that the actuating
mechanism is disabled when the door is opened.
WARNING: The interlock switches should never be removed or tampered with.
1.3.4 CONTROL SYSTEM
The freeze dryer is controlled by an on-board microprocessor with touch screen
display (see figure 1). Freeze drying cycles (process recipes) can be programmed
directly using the touch screen (refer to section 5). The general layout of the controller
is shown in figure 2. All freeze drying segments (e.g., primary and secondary drying,
end point determination, backfill and stoppering) can be fully automated if required
with an almost limitless number of temperature / pressure profiles with defined ramp
rates, dwell points and times. Programs can be saved and retrieved for use at a later
date, if required. The operator can access all status and control functions from the
display screens and system data can be reviewed in real time or downloaded onto
1.44Mb floppy disks via the integral disk drive.
The control system is password protected for various levels of access.
An emergency stop button is situated on the front control panel, for disabling the
stoppering drive in cases of emergency.
2.0 TECHNICAL DATA
Table 1: Technical Specification
FUNCTION
Minimum condenser temperature (@ 25oC
ambient)
Minimum shelf temperature (@ 25oC
ambient)
Shelf cool down times (fitted with 3 product
shelves). Temperatures measured on shelves.
Maximum shelf temperature
Temperature uniformity (between shelves)
Temperature uniformity (across each shelf)
Temperature control
Condenser capacity
Defrost time (for ice plug removal)
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MODEL
LS40
LS60
LS40
LS60
LS40 (to -35oC)
LS40 (to –40oC)
LS60 (to –55oC)
LS60 (to –60oC)
LS40/60
LS40/60
LS40/60
LS40/60
LS40/60
LS40/60
PERFORMANCE
-45oC
-80oC
-40oC
-60oC
100 minutes
220 minutes
130 minutes
160 minutes
60oC
+ 0.6oC
+ 0.3oC
+ 0.2oC
15 kg
1 hour
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Vacuum Pump
1. Type
2. Nominal Pumping speed
3. Pump down time (to 0.5 mbar)
Vacuum Pump Oil
Heat Transfer Fluid
Electrical
a) Supply
b) Power rating
(ambient temperature 20oC)
Dimensions (w x h x d)
Weight
Shelf area
a) Maximum (5 shelves)
b) Standard (3 shelves)
Refrigerants
Maximum ambient operating temperature
(measured at inlet to heat exchangers)
LS40/60
LS40/60
LS40/60
LS40/60
LS40
LS60
LS40/60
LS40/60
LS40/60
LS40
LS60
LS40/60
Edwards RV12
12 m3/hr
Approx 10 minutes
Ultragrade 19
Silicone M90.055.03
230V, 50Hz, 1 ph, or
110V, 60 Hz, 1 ph.
5.1 kW
6.9kW
700 x 1906 x 950 mm
600 Kg
0.85 m2
0.51 m2
R404A
R404A / R508B
30oC
3. 0 INSTALLATION
3.1 UNPACK AND INSPECT
Remove all packing material and protective covers from vacuum outlet port.
CAUTION: Remove all packing material before operating system.
If the equipment is damaged, notify your supplier and the carrier in writing within three
days.
3.2 EQUIPMENT PLACEMENT
Locate the freeze dryer in the required position, ensuring that the floor is adequate to
support the equipment and that due consideration is given to:
a) Air flow for ventilation
b) Access to framework panels.
c) Adequate space for maintenance.
CAUTION: The ventilation holes in the framework panels must not be blocked or
impeded in any way. If they are, overheating and damage may result.
CAUTION: Heat generated by the refrigeration compressors is significant. If the
equipment is situated in a confined space it may be necessary to provide some
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additional air flow / air conditioning to ensure that the temperature at the inlet to the
refrigeration heat exchangers is kept below 30oC. Please consult with Severn Science
for further details.
After placement, remove all panels to carry out initial inspection (see sections 3.3 and
3.4). The panels are fitted with lockable latches. To remove panels, unlock the latch
using the key provided, press the top end of the latch lever closest to the key hole and
lift bottom end of lever away from panel.
3.3 PREPARATION OF VACUUM PUMP
The vacuum pump is located on the base of the condenser unit. Both dryer and
condenser chambers are dispatched from the factory under vacuum. To check
vacuum integrity ensure that the two front perspex doors can not be easily opened.
Only use moderate force. If either chamber is not under vacuum when supplied,
contact Severn Science immediately.
3.3.1 CHECK PUMP OIL LEVEL
Check the sight glass located on the vacuum pump body (refer to manufacturer’s
literature). The oil level must be between the MAX and MIN level indicators.
3.3.2 VACUUM PUMP SETTINGS
The vacuum pump is configured at the factory with the following settings (see to
manufacturers’ literature).
•
Gas ballast 1 (or 0 for some applications)
•
High vacuum mode
Check that these setting have not been changed.
3.3.3 PUMP EXHAUST CONNECTION
The vacuum pump exhaust is internally ducted to a stub pipe located on the rear
panel of the condenser unit. Exhaust gases must be ducted away for suitable
disposal.
WARNING: Exhaust gases must be ducted away from the surrounding atmosphere if
any pumped vapours present a possible health hazard .
WARNING: Do not obstruct any vacuum pump exhaust port (refer to manufacturer’s
manual before operation).
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3.4 PREPARATION OF REFRIGERATION SYSTEM
The refrigeration plant in both condenser and drying units should be examined before
use. First check that the refrigeration gas lines are not contaminated with moisture by
examining the colour coded indicators (only applicable for LS40 models). If the
indicators are yellow, do not use the equipment and contact Severn Science
immediately.
The cooling circuit in the drying unit uses a heat transfer fluid (silicone oil). Check the
chamber insulation for signs of oil leaks and confirm that the oil reservoir is
approximately half full. The oil level in the reservoir can be checked again when the
panels are refitted by comparison with the MIN / MAX levels on the panel viewing
port. If the oil level is low, do not use the equipment and contact Severn Science
immediately.
3.5 ELECTRICAL INSTALLATION
Ensure that all framework panels are refitted before connecting to any services.
WARNING: Failure to refit all panels prior to connecting to mains power may result in
injury or death to the operator.
The freeze dryer is supplied with one (1) 32 amp plug. Connect this to suitable a
socket.
CAUTION: The unit is factory configured for 230V single phase supply. Check that
your voltage supply is compatible. The equipment will be damaged if it is connected to
the wrong voltage supply.
4.0 OPERATION
4.1 POWER UP
Press the illuminated green “power” button located at the top left hand side of the front
panel of the drying unit. Allow approximately 35 seconds for the control system to run
its “power up” cycle. The Severn Science screen will appear on the display. Check
that the emergency stop is in the unlocked position and press the blue reset button if it
is illuminated to reactivate the stoppering mechanism ready for later use.
4.2 SECURITY CONTROL
The control system is password protected to ensure controlled access to freeze dryer
functions and data. There are 3 user levels of entry :-
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Locked level: This is the default level from power up and hence no password is
required. At this level, the user can monitor the current status of the freeze dryer
through a limited number of screens, but does not have the ability to make any
parameter changes. The locked level is accessed by pressing the HOME button.
Operator Level: At the operator level, the user can start up and close down the
refrigeration systems, load and run pre-configured programs and view the alarm
history.
Supervisor Level: At the supervisor level the user has the same access
compared with that of the operator level but can also create new programs, set up
the end of program sequence, customise the data logging facility and acknowledge
alarms.
To log on at the operator or supervisor levels, a user id and password are required.
To log on at the operator or supervisor levels first press the ACCESS button. The
Security Access screen will appear displaying the current security level and separate
fields for inputting the user identity and password. When either the identity or
password fields are pressed a keypad will appear. The user inserts the relevant code
and presses the green RETURN key (note: all codes are case sensitive). When both
codes have been inputted the Security Access screen will again appear. To complete
the access procedure the user presses the LOG ON button. The controller will
automatically recognise the security codes and will allow the operator to enter at the
relevant security level.
Screens and text are colour coded depending on the security level of the operator, as
indicated in table 2.
Table 2. Screen and Text Colour Coding
Type
Fields
Screen buttons
Appearance
Blue figures/white background
Blue figures / yellow background
Greyed out wording
Black wording
Access
NO
YES
NO
YES
Users can be designated during commissioning by the Severn Science engineer or at
any time after installation by following the procedure below:
a) Log on as per the above procedure taking the id and password information
from Table 3 (according to the level of access required).
b) To personalise the password, select the PASSWD button (on the Security
Access screen). Press the password field and type in the new password (case
sensitive).
c) Press the enter and OK buttons
d) Re enter the password in the field provided and press OK
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The new user can then log on using the new password at the designated security
level.
Note: The id is not user adjustable.
Table 3. Additional id and Password codes
id
OP1
OP2
OP3
OP4
OP5
SUP1
SUP2
SUP3
SUP4
SUP5
Password
OP1
OP2
OP3
OP4
OP5
SUP1
SUP2
SUP3
SUP4
SUP5
Access Level
Operator
Operator
Operator
Operator
Operator
Supervisor
Supervisor
Supervisor
Supervisor
Supervisor
4.3 SWITCH ON CONDENSER
Security level : Operator or supervisor
Press the menu key on the printed keypad located below the screen (see figure 2)
and select the HOME button. The Home screen will appear. Follow the instructions
below to start the condenser.
a) press the field showing condenser defrost on the left hand side of the screen
(CONDENSER CHAMBER). From the options press ‘CONDENSER RUNNING’.
b) Press the green RETURN button.
The vacuum pump will temporarily switch on to seal the door and the condenser will
then begin its cool down cycle. When a temperature of –60oC is reached, the vacuum
pump will automatically switch on and both the refrigeration and vacuum pump will run
continuously. The condenser is ready to use when it reaches a temperature relevant
for the freeze drying process.
WARNING: Do not touch any part of the Condenser during the cooling process. The
cold surfaces will cause tissue damage.
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4.4 SWITCH ON SHELF REFRIGERATION
Security level : Operator or supervisor
Cooling of the shelves in the drying chamber is provided by a separate refrigeration
system. To turn the shelf refrigeration system on, follow the instructions below:
a) From the Home screen press the field showing Refrigeration off on the right
hand side of the screen (DRYING CHAMBER). From the options press
‘REFRIGERATION ON’.
b) Press the green RETURN button.
The temperature of the shelves will now be controlled at the temperature shown in the
set point field on the right hand side of the Home screen.
Note: The shelf temperature can be adjusted by inputting the appropriate value in the
set point field. When the set point field is pressed a keypad will appear (see figure
2(d) ). Insert the required value and press the green RETURN button.
WARNING: Do not touch the shelves during the cooling process. The cold surfaces
will cause tissue damage.
4.5 LOADING THE PRODUCT
Security level : Operator or supervisor
The freeze dryer can be used for both vial and bulk dying. The number of shelves
mounted in the drying chamber (ranging from 1 to 5) is factory set according to the
user requirement. Inter shelf measurements and vial capacities for different shelf
configurations are given in Table 4. The door to the dying chamber can be opened
using the quarter turn handle.
Note: Do not use excessive force to open the chamber door. If the drying chamber is
under vacuum (for instance when the freeze dryer is first delivered) it will not be
possible to open the chamber door.
Note: To open the chamber door if the chamber is under vacuum, first vent the
chamber, as follows (operator and supervisor access only):
a) From the Home screen, press the field showing vent closed on the right hand
half of the display (DRYING CHAMBER). From the options press ‘VENT OPEN’.
b) Press the green RETURN button.
Note: The system is interlocked so that the vent valve can not be opened unless the
vacuum valve between the drying and condenser chambers is also closed. If it is
necessary to close the vacuum valve, refer to section 7, Manual Operation.
After loading the product into the chamber, any pre loaded freeze drying programs
can be run (see section 4.6 below), or new programs can be edited or created
(section 5.0).
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Table 4: Vial Capacity and Inter-shelf Distances
Vial Diameter (mm)
13.5
22.0
25.0
30.0
30.5
36.5
43.0
Vial Capacity
4 shelf
5 Shelf
3744
4680
1408
1765
1064
1330
768
960
720
900
3 shelf
2808
1056
798
576
540
351
264
Per Shelf
936
353
266
192
180
117
88
Number of Shelves
Maximum working
height (mm)
Minimum working
height (mm)
2
137
87
3
95
38
4
66
24
5
49
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4.6 RUNNING A FREEZE DRYING CYCLE
Security level : Operator or supervisor
From a control viewpoint, a complete freeze drying cycle is typically split into two
distinct phases; an initial program phase which controls the temperature and pressure
profiles required during freezing and drying, followed by an optional end-of-program
sequence (EPS) where the user can customise how the cycle is finished after initial
drying is complete (e.g., stoppering, backfill etc.). This section describes how to run a
program and how to select the required EPS (4.6.4).
There are three ways to run a program.
a) Run a program now
b) Run a program from a point
c) Schedule a program to run from a time
4.6.1 RUN A PROGRAM NOW
To run a program, first load the required program from the list of stored recipes.
a) Press the MENU printed key (see figure 2(a) )
b) Press the PROGRAMMER button. The Programmer Menu screen will be
displayed.
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c) Press the PROGRAMS button. The Load/Save Program screen will be
displayed.
d) Press the file name field . A list of program names will appear in the Options
Menu (see figure 2 (c) ). From the list, press the name of the program to be
loaded.
Note: When the equipment is first delivered there will only be one program
template called Prog 1. Once loaded this can be edited as required (see section
5).
e) Press the green RETURN key. The display returns to the Load /Save Program
screen and the file name field now displays the name of the program that has
been selected.
f) Press the LOAD button. At this stage, the Programmer menu appears and the
program name and status is displayed in the program panel.
g) Press the RUN button. The program panel changes to green indicating that the
program is now running. The time when the program is due for completion is
also displayed together with a number that indicates the number of segments
that have been completed (see figure 2). At the same time the EPS screen
automatically appears, giving the operator the opportunity to review the End of
Program Sequence.
The freeze dryer will automatically run each segment of the selected program until it is
complete. On completion, the program panel will either display ‘complete’ or ‘idle’
depending on the end-of-program sequence (see section 4.6.4) .
Note : If the program panel does not change to green after pressing RUN, go to the
Status screen to check for possible causes (see figure 3).
4.6.2 RUN A PROGRAM FROM A POINT
Select this function if you wish to run a program from a point other than the start point
of the selected program.
a) Press the MENU printed key
b) Press the PROGRAMMER button. The Programmer menu will be displayed.
c) Press the PROGRAMS button. The Load/Save Program screen will be
displayed.
d) Press the file name field . A list of program names will appear in the Options
Menu (see figure 2(c) ). From the list, press the name of the program to be
loaded.
e) Press the green RETURN key. The display returns to the Load /Save screen
and the file name field now displays the name of the program that has been
selected.
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f) Press the LOAD button. At this stage, the Programmer menu screen will
appear. The program name and status will be displayed in the program panel in
the top left hand corner of the screen.
g) Press the RUN FROM button. A screen headed with the name of the program
is loaded. The total running time for the program selected is displayed. Press
the Run From field (default setting is 00:00:00) and input the time on the
numeric keypad (in hours:minutes:seconds) after the start of the program when
the program should run from. Press the green RETURN key when inputting is
complete. Details of the segment which will be running when the program
starts will then be shown in the lower half of the display.
h) To run the program, press the RUN button. The Programmer menu will appear
and the colour of the program panel changes to green (indicating that the
program is running). The time when the program is due for completion is also
displayed together with a number that indicates the number of segments that
have been completed. At the same time the EPS screen is automatically
displayed, giving the operator the opportunity to review the End of Program
Sequence.
Note : If the program panel does not change to green after pressing RUN, go to
the Status screen to check for possible causes (see figure 3).
4.6.3 SCHEDULING A PROGRAM
Scheduling a program allows the operator to set a time at which a program will start
and run automatically.
a) Press the MENU printed key
b) Press the PROGRAMMER button. The Programmer menu will be displayed.
c) Press the SCHEDULE button. The Schedule Program screen will be displayed.
d) Press the File Name field. A list of program names will appear in the Options
Menu (see figure 2(c) ). From the list, press the name of the program to be
loaded.
e) Press the green RETURN key. The display returns to the Schedule Program
screen and the file name field now displays the name of the program that has
been selected.
f) Press the Start Date field. Input the required start date on the numeric key pad
(day:month:year). Press the green RETURN button.
g) Press the Start Time field. Input the required start time on the numeric key pad
(hours:minutes:seconds). Press the green RETURN button.
h) To change the number of iterations (number of complete cycle to be performed
sequentially), press the Iterations field. Input the required number and press
the green RETURN button. Note: The default number of iterations is 1.
Entering a value “0” will run the program continuously.
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i) Press the ACCEPT button. The program will automatically start at the date and
time shown in green at the top of the screen.
4.6.4 END OF PROGRAM SEQUENCE (EPS)
The EPS function allows the user to select a method to complete the cycle after the
initial freeze drying program is complete. EPS functions include automatic end point
determination (EPD), secondary drying, backfill and stoppering. The functions are
optional and can be activated manually if required. The EPS screen is accessed from
the Home screen by pressing the EPS button.
a) Automatic end point determination (EPD): This is an automatic pressure rise
test that gives an indication of the state of dryness of the product at the end of
the drying program. During EPD, the vacuum valve is first closed. The rate of
pressure rise in the drying chamber is then monitored and automatically
compared with a pre programmed user adjustable set point. If the rate exceeds
the target value, the vacuum valve is re opened and drying continues at the last
programmed temperature set point. Drying continues for a period of time
determined by the user when initially setting up the EPD after which the
pressure rise test is then repeated. The sequence (drying / test / drying) is
repeated until the pressure rise test is within the target value or if the test is
manually aborted.
Automatic end point determination can be selected or deselected from the EPS
screen, by toggling between YES and NO on the field provided. Instructions to
set the pass /fail limit and drying time are described in section 5.
b) Secondary Drying: Secondary drying is typically used to remove bound water from
the product after primary drying is complete. A secondary drying profile can be
included in the initial program. However, if secondary drying is required after
automatic end point determination (see above), then this part of the cycle must be
programmed using the EPS facility.
Secondary drying can be selected or deselected from the EPS screen, by toggling
between YES and NO on the field provided. Instructions to set the drying temperature
and time are described in section 5.
c) Automatic Backfill: This facility is used to inject controlled atmospheres into the
equipment before stoppering and venting.
Automatic backfill can be selected or deselected from the EPS screen, by toggling
between YES and NO on the field provided. Instructions to set the backfill pressure
are described in section 5.
d) Automatic Stoppering: Automatic stoppering is used to stopper vials after the freeze
drying cycle is complete.
Automatic stoppering can be selected or deselected from the EPS screen, by toggling
between YES and NO on the field provided.
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CAUTION: When using the stoppering facility (automatic or manual), the stoppering
jacks provided must be used. Instructions to set up the stoppering jacks are described
in figure 4. Failure to do so may result in damage to the vial samples.
4.7 PROGRAM MONITORING
The program monitoring function allows the operator to review program status in real
time. This can be viewed as a list or graphically using the monitor and Pre-Plot
facilities.
4.7.1 MONITOR FACILITY
Security Level : Operator or Supervisor
To view the current program status, follow procedure below.
a) Press the MENU printed key
b) Press the PROGRAMMER button. The Programmer screen will appear.
c) Press the MONITOR button. The Current Program screen will display
information about the program as it is running. Information provided under the
‘Program’ heading includes:
Name :
(Program name)
Status :
(e.g., RUN, HOLD, etc)
Duration :
(total program length)
Completion :
(Time to complete program)
Iteration :
(Current program cycle /total number of cycles)
Information provided under the ‘Segment’ heading includes
Name :
(Segment name).
Time remaining :
(Time to complete current segment).
4.7.2 PRE-PLOT FACILITY
Security level: Operator or Supervisor
To view a summary of the program status in graphical form, follow the procedure
below:
a) Press the MENU printed key.
b) Press the PROGRAMMER button. The Programmer screen will appear.
c) Press the PRE-PLOT button. A graph will appear on the screen, headed with the
title of the program in use. Process parameters are logged on the ‘Y’ axis as a
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function of time (‘X’ axis). Actual and set point data is colour coded as per the legends
displayed on the right hand side of the screen.
To review historical data and to zoom in on different parts of the graph, press the
OPTIONS printed key (see figure 2(a) ) followed by the VIEW button. Pan and Zoom
controls then appear on the major axes (see figure 5). A cursor (dotted vertical line)
will also appear on the right hand side of the screen. This can be dragged to any point
on the graph. Actual data, corresponding to the point where the cursor intercepts the
graph, is displayed in the legends.
4.7.3 TRENDS
The ‘Trends’ facility gives the user the ability to review all product and chamber
information in graphical form. To view all trends follow the procedure below:
a) Press the menu printed key.
b) Press the USER SCREENS button. The User Screens menu will appear.
c) Press the TRENDS button.
d) Select the button according to the data that must be reviewed (Chamber
Trends, Product Trends, Condenser Trends).
4.8 HOLDING A PROGRAM
The Hold facility is used to freeze the program if amendments to the program are
needed after it has been initiated.
To Hold a program follow the sequence below:
a) Press the green program panel in the top left hand corner of the screen (see
figure 2(b) ). The Programmer screen will appear.
b) Press the HOLD button. The program panel will change to yellow and will read
‘HELD’. The program finish time will be adjusted automatically according to the
time the program is held. Amendments to the program can then be made as
per section 5.0.
To restart a program:
a) Press the yellow program panel in the top left hand corner of the screen. The
Programmer screen will appear.
b) Press the RUN button. The program panel will change to green and read
‘RUN’.
4.9 ABORTING A PROGRAM
Security level : Operator or Supervisor.
To abort a program:
a) Press the green program panel in the top left hand corner of the screen (see
figure 2(b) ). The Programmer screen will appear.
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Press the ABORT button. The program will abort and the program panel will change
to white and read ‘IDLE’. The program can then be run again from the start or a new
program loaded (see section 4.6).
4.10 STOPPERING
Stoppering can be pre programmed via the EPS facility (see section 4.6.4).
Alternatively, shelves can be moved up and down by pressing the arrowed buttons
located on the control panel and holding until the required shelf position is achieved.
Note:
Safety interlocks ensure that the shelves can only be operated when the front acrylic
door to the drying chamber is closed.
CAUTION: Stoppering jacks must be fitted and positioned before attempting to
stopper vials either manually or as part of a program. Ensure that the overall height of
the stoppering jack is identical to the combined height of the product vial with a
stopper fitted (in sealed position). For further instruction, refer to figure 4. Failure to fit
the jacks may result in damage to the vials during the stoppering process.
Note: Activation of the emergency stop button mounted on the front panel will stop
any movement of the shelves.
Note: Manual stoppering is not possible when a freeze drying cycle is in progress.
Note: To reactivate the stoppering system after the emergency stop button has been
depressed, twist and release the stop button and press the blue ‘reset’ button.
WARNING: Activation of the emergency stop button does not isolate the electrical
supply to the equipment.
4.11 REMOVING PRODUCT
Check that the freeze drying cycle is complete before attempting to remove the
product (the Cycle Status on the Home screen will read ‘Finished’). If the chamber is
left under vacuum at the end of the cycle, product can be removed by first ensuring
that the vacuum valve is closed and then manually venting the chamber. To vent the
chamber follow the instructions below:
a) From the Home screen, press the field showing vent closed on the right hand
side of the display (DRYING CHAMBER). From the options, press ‘VENT OPEN’.
b) Press the green RETURN button.
If the chamber is automatically vented to atmospheric pressure at the end of the cycle,
no further action is required before removing the product.
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4.12 CONDENSER DEFROST
Security level : Operator or Supervisor
To turn the condenser off, press the field labelled ‘CONDENSER RUNNING’ from the
Home screen. Select ‘CONDENSER DEFROST’ from the Options Menu followed by
the green RETURN button.
Note:
a) When CONDENSER DEFROST is selected the air admittance valve will open,
the vacuum pump and refrigeration system will switch off and the defrost heater
will activate. When a temperature of 25oC is reached, the defrost heater will
automatically switch off.
The ice inside the condenser chamber can be removed as a solid plug after partial
defrost. Residual water can removed via the solenoid drain valve (manually operated
from either the Manual or Home screens) situated under the front of the Condenser
chamber behind the Drain Access Panel (see figure 1).
CAUTION: Do not attempt to open the condenser door for about an hour after defrost
has been selected. This may cause damage to the condenser door ‘O’ ring.
5.0 CREATING / EDITING A PROGRAM
Security level : Supervisor only
A new program is created by editing an existing program and by saving the modified
program under a new name. When creating a new program for the first time, use the
program called “Prog 1” which has been installed into the Controller memory prior to
shipping. To load Prog 1, follow the instructions below:
a) Press the MENU printed key (see figure 2)
b) Press the PROGRAMMER button. The Programmer Menu screen will be
displayed.
c) Press the PROGRAMS button. The Load/Save Program screen will be
displayed.
d) Press the file name field . A list of program names will appear in the Options
Menu. From the list, press the name of the program to be edited.
e) Press the green RETURN key. The display returns to the Load /Save screen
and the file name field now displays the name of the program that has been
selected.
f) Press the LOAD button. At this stage, the selected program can either be run
or modified. To edit the program, press the EDIT button. Details of the program
will appears in the form of a table ( referred to as the Editor Screen). Each
column of the table represents a segment of the freeze drying process and
each row describes the freeze drying conditions. Individual cells (denoted SP
cells) define the temperature or pressure set points for any particular segment.
The top row of cells (referred to as ‘segment headings’) define the segment
name (e.g., freezing, primary drying etc) and duration (hours:minutes:seconds).
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To configure the segment headings follow the instructions below:
a) Press the segment heading that must be modified. A box displaying data about
the segment will appear. To change the segment name press the segment
field. Use the keyboard to input the required name (see figure 2(e) ). Press the
green RETURN key. The Editor screen reappears, showing the new segment
name.
b) To change the segment duration press the Duration field and use the
keyboard (figure 2(d) ) to input the required time (hours: minutes : seconds).
Press the green RETURN key. The Editor screen reappears, showing the new
segment name and duration.
Repeat for any segment heading as necessary.
Note : Changing the duration will not be permitted if the “Ramp @ ” function has been
selected previously anywhere in that segment.
Note: Any value entered on the keypad must be within the capability range of the
freeze dryer. If an invalid number is entered, the display value will turn red and a new
number must be entered.
To configure the segment SP cells follow the instructions below:
a) Press the SP cell that must be modified. A box displaying data about the cell
will appear. Press the Type field. A list of optional functions will be displayed.
The choice of functions available include Dwell, Step, Ramp and Ramp@.
These function are described in more detail in Table 5.
Note: The first column of SP cells can only be specified as a Step.
b) Select the function that is required and press the green RETURN key.
c) Depending on the function selected, rate and temperature set point values can
then be modified by pressing the appropriate field and entering the value on the
numeric keypad (refer to Table 5). Press the DONE button to update the
program table (the set point data and SP code is displayed in each cell) .
Table 5: Function Descriptions and Coding
Function
Name
Dwell
Step
Ramp
Ramp@
Function
Description
Temperature set point is held for
duration of segment
Temperature ramps to temperature
set point as fast as possible
Temperature ramps to temperature
set point at a constant rate over
the duration of the segment
Temperature ramps to temperature
set point at specified ramp rate
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code
D
Set point
fields
None
S
Temperature
R
Temperature
R@
Rate (/hr)
Temperature
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5.1 SAVE / SAVE AS
To save the updated program under the same file name after editing is complete, or to
save the program as a new file name, follow the procedure below. To insert or delete
segments prior to saving, see sections 5.2 and 5.3 respectively.
a) From the Editor screen, press the OPTIONS button on the printed keypad (see
figure 2(a) ).
b) To save the edited program under the same file name press the SAVE button.
c) To save the edited program under a new file name, press the SAVE AS button.
The Save As screen will appear.
d) Press the File Name field and enter the new file name on the keypad.
e) Press the green RETURN key and the OK buttons to confirm.
5.2 INSERTING A SEGMENT
To add a new segment to the freeze drying program, follow the procedure below:
a) From the Editor screen, press the segment heading that will proceed the new
segment you wish to insert. A box displaying data about the segment will
appear.
b) Press the INS SEG key. The New Segment screen will appear.
c) Press the Segment field and use the keyboard to type in the segment name.
d) Press the green RETURN button. Press the OK button on the New Segment
screen. A column will then appear in the program table, representing the new
segment.
e) Configure the new segment as per section 5.0.
To save the updated program under the same file name after inserting a segment, or
to save the program as a new file name, refer to section 5.1.
5.3 DELETING A SEGMENT
To remove a segment from the freeze drying program, following the procedure below:
a) From the program editor screen, press the segment header to be deleted.
Details of the segment will appear.
b) Press the DEL SEG button. The Confirm Delete screen will appear. Press OK,
to confirm delete command.
To save the updated program under the same file name after deleting a segment, or
to save the program as a new file name, refer to section 5.1.
Note: The first segment of a program can not be deleted.
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5.4 AMENDING THE END-OF–PROGRAM SEQUENCE (EPS)
To amend the set points in the end-of-program sequence, first select the EPS screen.
a) Automatic EPD. To amend the pressure rise limit, press the field labelled ‘mbarl/s’.
Enter the required rate (in scientific notation) on the numeric keypad and press the
green RETURN button. To amend the drying time programmed for EPD, press the
field labelled ‘hrs’. Enter the required value on the numeric keypad and press the
green RETURN button. The amended values will be displayed on the EPS screen.
Note: There is no standard setting for the pressure rise rate. An appropriate value
should be determined by the user by experiment.
b) Secondary Drying: To amend the temperature set point for secondary drying, press
the field labelled ‘oC’. Enter the required temperature on the numeric keypad and
press the green RETURN button. To amend the duration for secondary drying, press
the field labelled ‘hrs’. Enter the required duration in hours on the numeric keypad and
press the green RETURN button. The amended values will be displayed on the EPS
screen.
c) Automatic Backfill: To amend the backfill pressure, press the field labelled ‘mbar’.
Enter the required pressure (in scientific notation, absolute pressure) on the numeric
keypad and press the green RETURN button. The amended values will be displayed
on the EPS screen.
Note: Any value entered on the keypad must be within the capability range of the
freeze dryer. If an invalid number is entered, the display value will turn red and a new
number must be entered.
6.0 DATA LOGGING
To log process data, a standard 3.5’’ disc must first be inserted into the disc drive
located behind the hinged flap directly below the touch panel (refer to figure 2(a) ).
The equipment is factory configured to automatically record all process parameters
(including chamber and condenser vacuum, condenser and product shelf
temperatures, isolation valve and alarm status) after a program cycle is started. Data
logging is automatically stopped when the program cycle is complete. Data is logged
to disc as an ASCII file (.ASC), which can be imported into most spreadsheet
applications for further interrogation after logging is complete.
Note:
1. Always use a new formatted floppy disk for logging
2. Do not use the same disk for recording other types of data.
3. Do not use the same disk for more than one month.
4. Never remove a floppy disk while logging is in progress.
CAUTION: Removing the disc while the data is logging (on line) may cause damage
to the equipment.
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6.1 CHANGING LOGGING CONFIGURATION
Several data logging functions (e.g., archive interval, file type/name) are factory set.
However, the logging configuration can be changed if necessary, as follows:
a) Press the MENU printed key.
b) Press the LOGGING button. The Logging Menu will appear.
c) Press the SETUP button. The Logging Setup screen will be displayed, giving a
summary of the logging configuration. The default setting for the field labelled
‘logging’ will display on event, meaning that logging will start and finish
automatically as described above. No other settings can be changed until this
field is set to off from the drop down menu.
Once the logging is set to off, the other settings can be altered by pressing the
appropriate field and either selecting an option from the Options Menu or inputting the
required value on the keypad. In both cases, press the green RETURN button to
accept any selection. Ensure that the SAVE button is pressed to confirm any
alterations.
6.2 LOGGING MONITOR
The logging monitor facility can be used to view the current logging status, including
media size, free space and free running time. This screen can be accessed as
follows:
a) Press the MENU printed key.
b) Press the LOGGING button. The Logging Menu will appear.
c) Press the MONITOR button. Logging can also be interrupted from this screen by
pressing the OFFLINE button. The disc can then be safely removed.
CAUTION: Removing the disc while the data is logging (on line) may cause damage
to the equipment.
7.0 MANUAL OPERATION
CAUTION: Ensure the user is fully trained before manually operating the freeze dryer.
Manual operation can bypass process interlock, which may cause damage to the
equipment.
Security level : Supervisor
Most equipment components can be manually operated if required. For manual
operation follow the instructions below:
a) Press the menu printed key and select the USER SCREENS button. The User
Screens menu will appear.
b) Select the MANUAL button. The Manual Operation screen will display a list of
components that can be controlled manually in both condenser and drying
chambers.
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From this screen, pressure and temperature set points and the positions of system
valves can be changed by pressing the appropriate field and either selecting an option
from the menu or inputting the required value on the keypad. In both cases, press the
green RETURN button to accept any selection.
Note: Some of the above functions can also be manually controlled from the Home
screen (see section 4).
Note:
Some components have safety interlock to avoid damage to the vacuum system or
injury to personnel.
Note: A set point value can only be inputted that is within the capability range of the
freeze dryer. If an invalid number or value is entered, the display value will turn red
and a new number must be entered.
8.0 ALARMS
The freeze dryer is fitted with a number of alarms that can be used for fault diagnosis
and to warn the operator of any faults that may have occurred during a program cycle.
If an alarm is activated the alarm panel will flash red and display the code
corresponding to the last alarm that was triggered. A number is also given showing
the total number of alarms that are active as a ratio of the number of alarms that are
still to be acknowledged (e.g., a number of 3/2 means there are 3 active alarms, two
of which have been acknowledged).
If an alarm is activated the freeze dryer automatically aborts the current program,
closes the vacuum valve and drives the shelf temperature to –20oC. A volt free
contact is also given for remote indication of the alarm condition (mounted on the
framework at the rear of the drying chamber) . Connection details are shown on
drawings 7705 and 7788 for the LS60 and LS40 respectively (see Appendix 2). The
relay will remain energised until all alarms are acknowledged (see section 8.1).
Note: The alarm marked * in Table 6 is display only.
Note: All alarms will automatically clear when the fault is removed. However, all
alarms are logged on the Alarm History screen and have to be acknowledged (see
below).
A summary of alarm codes and descriptions is given in the Table 6 below.
Table 6. Alarm Codes and Descriptions
CODE
DESCRIPTION
CAUSE
TRIP-VACPUMP
Failure of Vacuum pump
CB2 tripped
TRIP-FRIDGE
Failure
system
CB3 or CB7 tripped
TRIP-FLUID
Failure of fluid pump
CB6 tripped
TRIP-HP 3
Overpressure on drying chamber
refrigeration
HP3 pressure switch tripped*
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CODE
DESCRIPTION
CAUSE
FAIL-DRY APG
Failure of drying chamber pirani
gauge
APGX1 calibration out of limits/
filament failure
FAIL-COND APG
Failure of condenser chamber
pirani gauge
APGX2 calibration out of limits /
filament failure.
FAIL-HI PRESS
Evacuation
time
in
chamber out of limits
Vacuum pump or vacuum valve
failure, system leak.
FAILCONDTEMP
Condenser temperature high
Condenser refrigeration fail. High
load.
FAIL-DRYTEMP
Shelf temperature out of limits
Drying chamber refrigeration / heater
fail. Temperature control valve fail.
Program requirements outside of
instruments capability.
RTDFAIL-FLUID
Failure
sensor
temperature
RTD1 failure / calibration out of limits
RTDFAIL-COND
Failure of condenser temperature
sensor
RTD2 failure / calibration out of limits
of
fluid
drying
8.1 ALARM ACKNOWLEDGEMENT
Security level: Supervisor only
To acknowledge an alarm, follow the instructions below:
a) Press the alarm panel. The Alarms menu will be displayed.
b) Press the ACK button to acknowledge individual alarms or the ACK ALL button
to acknowledge all alarms. If ACK ALL is selected, a separate screen will
appear asking the operator to confirm the acknowledgement.
8.2 ALARM HISTORY
Security level: Operator or Supervisor
The Alarm History screen displays a list of alarm conditions and events, showing
when they occurred, and if appropriate, when they were cleared.
8.3 ALARM NOTE
Security level: Operator or Supervisor
The Note facility allows an operator-defined text message to be added to the alarm
history as follow:
a) From the Alarms menu press the NOTE button. The Add Note window will
appear.
b) Press the field labelled ‘Your note’
c) Enter the note on the key pad (maximum 16 characters) and press the Green
RETURN button to confirm.
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The note is then added to the alarm history, where it is displayed along with its time of
entry.
8.4 ALARM HISTORY ARCHIVE
Security level: Operator or Supervisor
The Archive facility permits the current alarm history to be saved in ASCII format to
floppy disc. To use the Archive facility, follow the instructions below:
Note: In order to avoid the possibility of loss of logging data it is strongly
recommended that archiving is performed with normal logging turned off (see section
6.1).
a) From the Alarms menu, press the ARCHIVE button. The Alarm Archive window
will be displayed.
b) The field labelled File Name shows the default of YYMMDDHH.ALH, which the
instrument supplies automatically. To change this name, press the field and
enter the required name on the keyboard. The file extension is always .ALH
(not editable).
c) Press the OK button when the correct name has been entered.
If required the field labelled ‘Date Format’ can be edited in a similar fashion.
9.0 MAINTENANCE
WARNING: Isolate the freeze dryer from the electrical supply before you start maintenance
work, so that it cannot be operated accidentally.
WARNING: Dispose of oil and components safely.
CAUTION: Take care to protect sealing faces from damage.
9.1 MAINTENANCE PLAN
The plan below details the minimum maintenance operations necessary to maintain the
freeze dryer in normal use. Instructions for each operation are given in the sections shown.
The required frequency of maintenance will depend on how often the freeze dryer is used
and type of product. If necessary, adjust the maintenance plan accordingly to your
experience.
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Table 7: Maintenance Plan
OPERATION
Check the vacuum pump
oil level
Change the oil mist filter
element
Inspect the oil drain kit
Change the vacuum
pump oil
Service the vacuum
pump
Check condition of door
seals
FREQUENCY
Weekly
REFER TO SECTION
9.2
6 Monthly
9.3
Monthly
6 monthly
9.4
9.5
Yearly
9.6
Weekly
9.7
Monitor the drying
Weekly
chamber silicon fluid level
Check cleanliness of both Monthly
refrigeration systems
heat exchangers
9.8
9.9
9.2 VACUUM PUMP OIL LEVEL
Check that the pump oil level is between the MIN and MAX markers on the bezel of the sight
glass. The oil must be clean and transparent. Refer to manufacturers literature for more
information.
9.3 OIL MIST FILTER ELEMENT
Change the element as described in the instruction manual for the oil mist filter supplied.
9.4 OIL DRAIN KIT
Inspect the oil drain kit as described in the instruction manual.
9.5 CHANGE VACUUM PUMP OIL
Remove the right hand side panel from the condenser unit.
Use the procedure described in the instruction manual to drain the oil from the pump.
9.6 VACUUM PUMP SERVICE
The vacuum pump must be removed from the freeze dryer in order to carry out a full service.
To remove the pump first remove the right hand side panel from the condenser unit. Open
the drain access panel and remove the two screws retaining the pump tray to the support
framework. Carefully disconnect the vacuum pipe, mist filter and oil return kit and lift the
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pump out of the framework. Inspect and clean the vacuum pump inlet filter, gas ballast
control, oil sight glass and motor fan cover, as described in the pump instruction manual.
When refitting, ensure that all fittings are correctly reconnected to the vacuum pump.
9.7 DOOR SEALS
Routinely inspect the door seals fitted to the drying and condenser chamber.
CAUTION: Do not attempt to open the condenser door if the condenser temperature is below
0oC (this may damage the seal).
9.8 DRYING CHAMBER SILICONE FLUID
Check the silicone fluid reservoir sight glass. This is located on the left hand side panel of the
drying chamber. Ensure that the level is between the MIN and MAX markers.
Note: The levels should only be taken when the freeze dryer is switched off and the fluid is at
ambient temperature.
9.9 REFRIGERATION HEAT EXCHANGERS
Regularly check the two heat exchangers fitted at the rear of the freeze dryer. Ensure that
they are free from the ingress of dust and other foreign objects.
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Figure 1. Freeze Dryer layout
SILICONE OIL RESERVOIR
TOUCH SCREEN
CONTROLLER
DRYING CHAMBER
REFRIGERATED SHELVES
CONDENSER CHAMBER
WITH INTEGRAL
VACUUM PUMP
DRAIN ACCESS
PANEL
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Figure 2(a). Controller Layout
0/0
TEST PROG
IDLE
????
HOME
12:52:29
TEMP. -80.0 C
19/05/01
TEMP. -60.0 C
PRESS. 1.0E-02 mbar PRESS. 7.0E-01mbar
CONDENSER RUNNING
REFRIGERATION ON
DRAIN OPEN
VENT OPEN
STATUS
Printed
keypad
EPS
Options key
SETPOINT
-60 C
CYCLE STATUS
FINISHED
Floppy disk
drive
(1.44Mb disk
required)
Menu key
Flip-front
protective
cover
Figure 2(b). Screen Layout
Screen name shown in
italics in manual text
Program panel
0/0
TEST PROG
IDLE
????
HOME
12:52:29
TEMP. -80.0 C
Alarm panel
19/05/01
TEMP. -60.0 C
PRESS. 1.0E-02 mbar PRESS. 7.0E-01mbar
CONDENSER RUNNING
REFRIGERATION ON
DRAIN OPEN
VENT OPEN
STATUS
SETPOINT
-60 C
CYCLE STATUS
FINISHED
EPS
Selectable
fields shown in
bold in manual
text
Screen buttons shown in
UPPERCASE in manual text
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Figure 2(c). Drop down menu (option list)
Selecting certain fields will reveal a drop down menu with an options list.
0/0
TEST PROG
Options menu
IDLE
????
CONDENSER
12:52:29 RUNNING
HOME
CONDENSER RUNNING
TEMP. -80.0 C
Select option
Press to accept
option
CONDENSER DEFROST
19/05/01
TEMP. -60.0 C
PRESS. 1.0E-02 mbar PRESS. 7.0E-01mbar
CONDENSER RUNNING
REFRIGERATION ON
DRAIN OPEN
VENT OPEN
STATUS
SETPOINT
-60 C
CYCLE STATUS
FINISHED
EPS
Figure 2(d). Numeric keypad.
Selecting certain fields will reveal a keypad for entering numeric values.
0/0
TEST PROG
IDLE
????
HOME
12:52:29
00:00:00:00
Value entered
7 8 9
PRESS.
4 1.0E-02
5 6mbar
CONDENSER RUNNING
1 2 3
DRAIN OPEN
0 +-
TEMP. -80.0 C
STATUS
EPS
19/05/01
TEMP. -60.0 C
PRESS. 7.0E-01mbar
REFRIGERATION ON
VENT OPEN
SETPOINT
-60 C
CYCLE STATUS
FINISHED
Press to reject
Press to accept
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Figure 2(e). Keyboard
Selecting certain fields reveals a keyboard for text entry
0/0
TEST PROG
IDLE
????
HOME
12:52:29
PASSWORD
19/05/01
Q W E R T Y TEMP
U . I-60.0
O PC
D Fmbar
J K7.0E-01mbar
L ;
A S1.0E-02
G HPRESS.
PRESS.
CONDENSER RUNNING
Z X C V B REFRIGERATION
N M , ON
TEMP. -80.0 C
Toggle between
upper/lower case
DRAIN OPEN
VENT OPEN
STATUS
SETPOINT
-60 C
CYCLE STATUS
FINISHED
Toggles
between letters
or numbers
Publication reference 1HZ204-1
EPS
Press to
clear text
Press to
accept text
Arrows move the cursor
position
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Figure 3. Status screen
The status screen provides a summery of the present condition of the freeze dryer functions.
Note: Any conditions highlighted in RED will prevent an automatic program cycle from
running.
0/0
TEST PROG
IDLE
????
12:52:29
STATUS
DOOR CLOSED
REFRIGERATION OFF
PUMP OFF
VENT VALVE OPEN
DRAIN VALVE OPEN
Publication reference 1HZ204-1
19/05/01
DOOR OPEN
REFRIGERATION OFF
SHELVES HOME
FINISHED
VAC VALVE CLOSED
VENT CLOSED
BACKFILL CLOSED
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Figure 4. Stoppering Jacks
Height
adjustable shaft
19mm jack
base
Lock nut
49mm jack
base
Vial height
32mm – 42mm
42mm – 52mm
52mm – 62mm
62mm – 72mm
62mm – 82mm
70mm – 90mm
Jack base required
19mm
19mm
19mm
49mm
49mm
49mm
Cap screw shaft length required
20mm
30mm
40mm
20mm
30mm
40mm
Mechanical stoppering jacks must be used when stoppering glass vials. A minimum of three
jacks must be used on each shelf (one at each front corner and one equidistant between the
rear corners). Ensure that each jack is correctly adjusted, so that it’s height equals the height
of the vial with a stopper fully inserted.
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Figure 5. The pre-plot facility
0/0
TEST PROG
IDLE
????
PROG 1
12:52:29
Condenser
temperature
trend
Shelf
temperature
trend
19/05/01
CONDENSER
TEMP 7.5 deg C
TEMP. -80.0 C
TEMP. -60.0 C
SHELF
PRESS. 1.0E-02 mbar PRESS. 7.0E-01mbar
TEMP
0.5 deg C
CONDENSER RUNNING
REFRIGERATION ON
DRAIN OPEN
VENT OPEN
STATUS
SETPOINT
-60 C
CYCLE STATUS
03:56
Slide button to view
program history
Publication reference 1HZ204-1
EPS
00:00
Slide
button to
magnify
scale
03:56
03:56
Drag dotted line across screen to read
off values where dotted line intercepts
the trend line
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Appendix 1: Manufacturers Literature
a) T800/T2900 Visual Supervisor (Eurotherm Controls)
b) 2500 PID controller (Eurotherm Controls)
c) 605 series drive unit (Eurotherm Controls)
d) Cascade refrigeration system (Ernest West & Beynons)
e) RV12 rotary pump (BOC Edwards)
f) EMF adjustable gas ballast oil drain kit (BOC Edwards)
g) EMF10 Oil mist filter (BOC Edwards)
h) Active pirani gauge (BOC Edwards)
i) Screw jack assembly (Precision Actuation Systems)
j) Induction motor (ABB motors)
k) Pressure transducer (Thermospeed)
l) Thermostat (Ranco)
m) Safety interlock switch (Schmersal)
n) Safety interlock actuator (Schmersal)
o) Series 102 connector (RS Components)
p) Fluid circulator pump (Grundfoss)
q) Safety relay (Pilz)
r) ML50.100 power supply unit (PULS)
s) MKS type 1249A valve driver (MKS Instruments)
t) MKS type 248A/B/C control valve (MKS Instruments)
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Appendix 2: List of Drawings
Electrical circuit diagram, 7705 rev A
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