The Genevac R4 Evaporation System User Manual

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The Genevac R4 Evaporation System User Manual | Manualzz

E v

T a h p e o

G r r a e t t i i n o o e n v a

S c y

R s t t

4 e m

U s e r r M a n u

Issue 1-5 – October 2008 a l l

Genevac R4 Evaporating System

Contents

1 Introduction ..................................................3

1.1

Safety .............................................................4

2 System description ......................................5

3 Scope of delivery and installation...............6

3.1

Checking the delivery .....................................6

3.2

Arranging commissioning ...............................6

3.3

Training ..........................................................6

3.4

Positioning the evaporator..............................6

3.5

Fitting a remote condenser.............................7

3.6

Fitting a vacuum pump ...................................7

4 Safety ............................................................8

4.1

Safe loading of rotor .......................................8

4.2 Maintenance……………………………………..9 operation.................................................10

4.4

Sample traceability .......................................10

4.5

Limitations of use..........................................10

5 Getting started ............................................ 11

5.1

How to switch on the pump .......................... 11

5.2

How to switch on the evaporator .................. 11

5.3

Using the keypad.......................................... 11

5.4

Condenser defrost........................................16

5.5

Dri-Pure........................................................16

6 Technical data.............................................17

7 EC Declaration of Conformity....................18

8 Safety ..........................................................18

9 Location and mounting consideration......18

10 Useful information......................................19

These instructions are subject to change without notice.

No part of these instructions may be reproduced in any form or be processed, duplicated or distributed by electronic or optical means without the written permission of Genevac Limited.

All rights reserved. © Genevac Limited

These operating instructions should be read before you use the

Genevac R4 Evaporating System.

Keep them near the system for easy reference.

Your attention is drawn in particular to Section 4 Safety.

Issue 1-5 – October 2008 Page 2 of 18

Genevac R4 Evaporating System

1 Introduction

The Genevac R4 range of evaporation systems are state-of-the art and represent a significant step forward in evaporation technology for the R&D laboratory.

Drawing on extensive experience in the drug discovery field, the R4 systems are designed to provide very high performance coupled with ease of use.

As you will discover, the system is simple to set up, easy to operate and very flexible.

The status of the system is displayed and controlled on a single keypad, display module indicating the run time, the vacuum, rotor temperature and chamber temperature on digital displays.

Simple to use up-down controls enable the run time, rotor and chamber temperatures to be set in an instant and single push buttons set the other functions.

This manual will guide you through the start up requirements, set up needs and operation of the system to facilitate the most efficient procedure to protect your product’s integrity and to ensure optimum performance at all times.

Issue 1-5 – October 2008 Page 3 of 18

Genevac R4 Evaporating System

Issue 1-5 – October 2008

1.1 Safety

The following safety symbols are used throughout this manual.

The definitions and scope of each symbol is as described below.

WARNING

THIS SYMBOL WILL INDICATE HAZARDS THAT

CAN LEAD TO SERIOUS MATERIAL DAMAGE OR

POTENTIAL SERIOUS INJURY.

Caution

This symbol will give information about hazards that can be harmful to your health or lead to material damage.

Note

This symbol will give information about technical requirements which if not followed, can lead to malfunctions, inefficiency and reduced productivity.

Genevac and the ATEX Directive:

Please note that it remains the responsibility of the user to consider any solvents being evaporated within the context of the ATEX directive. The presence of solvents on the list above indicates only that they will not damage the system. If further information is required, please contact your Sales

Representative or visit http://www.genevac.com/

Genevac Evaporators and Combustible Solvents

Please note it remains the responsibility of the user to consider safety when evaporating any combustible solvents and ensure the system is placed in a well ventilated environment. Genevac's position regarding evaporation of such solvents, particularly with respect to the European ATEX directive, is available on our website or from your local sales representative.

IMPORTANT

THIS SYSTEM MUST BE

EARTHED – SEE PAGE 18

Page 4 of 18

Genevac R4 Evaporating System

System

Status

Run Time, Vacuum and Temperature Displays

The basic R4 Evaporation System is comprised of an evaporation chamber and rotor.

The diagram below shows the R4, combined with the in-built cryopump-condenser unit.

Vacuum is provided by the unique, corrosion proof

Genevac CVP vacuum vapour pump (although other types of vacuum pumps can be used).

The control of chamber, bucket and sample temperature, vacuum ramping rate, chamber pressure, rotor speed and run time are all handled by an onboard microprocessor.

The display-keypad enables the user to change the parameters quickly and easily and displays the status of the system in an uncomplicated and easily assimilated manner.

Start/Stop

Controls

Run Time

Modes

Aquaspeed and other functional controls

The R4 incorporates the RotoGuard infrared temperature detection system, which monitors and controls the maximum temperature of the sample rotor.

Each R4 is fitted with an Autobalance unit. Inside which, there is a number of loose balls that can move freely in a raceway. When an imbalance occurs, the balls will automatically strive to find the positions that neutralize the imbalance. The balls place themselves to act as counterweights.

The system also incorporates the Aquaspeed control system to increase the evaporation rates with water and aqueous solvent mixtures.

When selected, Aquaspeed controls the system pressure to prevent water from freezing and thus increases evaporation rate.

Lid

CoolHeat lamps

Solid rotor

Vacuum port

Condenser inlet

Keypad / display

Lid release switch

Chamber

Condenser

Rotor assembly

Condenser and chamber drains

ON / OFF switch

Issue 1-5 – October 2008 Page 5 of 18

Genevac R4 Evaporating System

Issue 1-5 – October 2008

3 Scope of delivery and installation

You will have purchased your system with or without the option of commissioning by Genevac personnel and possibly, without the option of a Genevac vacuum pump and integral condenser.

Reference will be made in the following notes to the installation procedures required to cover these options.

On delivery, it is advisable to unpack your system at the point of receipt, to ease the movement of the component parts to the point of use.

3.1 Checking the delivery

Check the contents of the delivery as soon as possible against the delivery note and notify

Genevac Ltd immediately of any missing or damaged parts. (Refer to section 10 for contact details).

If your system is to be delivered separately, Genevac

Ltd will contact you prior to the delivery, to agree a date to commission your system.

3.3 Training

Commissioning will normally include training in the basic operation of the System. Further in house training is recommended to fully exploit the flexibility of the system.

THE R4 EVAPORATOR MUST NOT BE

OPERATED BY PERSONNEL WHO LACK THE

TRAINING OR PROFESSIONAL EXPERIENCE TO

COMPREHEND THE HAZARDS THAT CAN ARISE

WHEN USING THE SYSTEM.

Personnel without such training require thorough instruction. These operating instructions should form the basis of this instruction.

3.4 Positioning

POSITION THE EVAPORATOR AT LEAST 300 MM

AWAY FROM THE EDGE OF A BENCH AND THE

SAME DISTANCE CLEAR OF BREAKABLE

OBJECTS OR AREAS WHERE ENTRAPMENT

COULD OCCUR.

Page 6 of 18

Genevac R4 Evaporating System

Chamber Condenser Pump

REFER TO PARAGRAPH 9 “LOCATION AND

MOUNTING CONSIDERATIONS FOR

EVAPORATORS FITTED WITH AUTOBALANCE”.

GENEVAC SHOULD BE CONSULTED FOR

ADVISE ON ANY OTHER POSITIONAL

REQUIREMENTS.

3.5 Fitting a remote condenser (Optional)

The connecting relationship of the chamber, condenser and vacuum pump is as shown.

The connection for your remote condenser is located at the rear of the evaporator.

Connect your condenser to the evaporator chamber using a suitable Kline flange fitting.

It is recommended that a heated inlet tube is used to connect the chamber to the evaporator, to prevent solvent from condensing in the tube.

Please consult Genevac Sales for details of the range of heated inlet tubes available.

3.6 Fitting a vacuum pump

If your evaporator has an integral condenser, the connection for your vacuum pump is located at the rear of the evaporator.

Connect your vacuum pump to the evaporator using a suitable connecting pipe and Kline flange fitting.

If a Genevac pump has been supplied with your evaporator, the connecting pipe, fittings and power control lead will also be included.

Connect the power and control lead between the pump and the socket on the rear of the chamber.

If a Genevac pump has been supplied, it must have an adequate supply of cooling air and the hot outlet must have at least 300 mm of space beyond the hot air grille in the pump base.

It should not be placed in a cupboard without special precautions to ensure adequate cooling.

Consult Genevac Service for advice in such cases.

Issue 1-5 – October 2008 Page 7 of 18

Genevac R4 Evaporating System

Issue 1-5 – October 2008

4 Safety

BEFORE OPERATING THE SYSTEM, IT IS

IMPORTANT THAT THE FOLLOWING NOTES ARE

READ TO ENSURE THAT THE IMPLICATIONS TO

THE SAFETY OF PERSONNEL OPERATING THE

SYSTEM AND FOR THE PROTECTION OF

SAMPLE INTEGRITY ARE UNDERSTOOD.

Samples in the chamber are subjected to accelerations of up to 500G.

The following precautions should therefore always be observed.

4.1 Safe loading of rotor

Your system will operate with up to 350g of imbalance, BUT it is still important to load the solid rotor in systematic manner to ensure that this level is not exceeded.

Always try to load the rotor in a symmetrical and balanced manner.

If an odd number of full sample holders are to be loaded, then an empty sample holder is to be loaded to offset the imbalance condition, examples are shown opposite of acceptable loading configurations.

Rotate the rotor by hand after loading and check that all tube holders are correctly located before starting a run and before re-starting an interrupted run.

Do not load tubes into sample holders other than those types that have been approved by Genevac

Ltd.

Do not use sample holders that have not been supplied with system without consulting Genevac

Service.

Genevac Ltd will accept no responsibility for any loss or damage incurred by improperly or excessively loaded rotors.

Page 8 of 18

Genevac R4 Evaporating System

4.2 Maintenance

Regular inspection and maintenance of the sample holders should be performed at least monthly. The following inspection routine is mandatory following any tube breakage or solvent spillage. Never use wet holders or rotors in an evaporator.

Inspection:

Visually inspect holders each month. Debris should be cleaned off, especially any in the sample holder wells as this may lead to glassware breakage. The number one cause of repeat glassware breakage is glass fragments from a previously broken tube.

Sometimes the sample sticks the glass fragments to the inside of a holder well, and can be difficult to remove. Residual solvent / sample - should be cleaned off.

Superficial surface damage (e.g. scratches) will not affect the performance of a sample holder. If there is structural damage (a bend of deformation) of any part of a rotor or holder - do not use - contact

Genevac for evaluation.

Cleaning:

Loose dirt or debris can be removed using a brush and / or airline. Adhered dirt / debris or sample / solvent residue should be cleaned off using methanol or acetone, soak sample holders if required. Holders should then be washed in clean water and fully dried before use.

Issue 1-5 – October 2008 Page 9 of 18

Genevac R4 Evaporating System

4.3 Lid operation

The lid is secured by an electromechanical catch that is activated automatically to lock the lid.

Press the button on the front panel of the evaporator to release the catch.

Note that you will be unable to open the lid whilst the rotor is rotating.

Lift the lid past 45 degrees to ensure that it remains in the open position.

Note that when the lid is near its closed position, it is designed to close under its own weight.

4.4 Sample traceability

Each solid rotor has a label that indicates the cassette location.

Whilst this will aid loading, it is recommended that a separate log is kept of sample position when dissimilar products are loaded.

Alternatively, use a suitable label to identify the samples.

Note that labels can affect performance.

4.5 Limitations of use

Your R4 evaporating system is unsuitable for use under the following circumstances:

• With strong mineral acids such as HCl and HBr at any concentrations.

EVAPORATING DIETHYL ETHER AND

SIMILAR LOW AUTO-IGNITION SOLVENTS

WITHOUT A GENEVAC INERT GAS PURGE

SYSTEM FITTED TO THE EVAPORATOR AND

PUMP.

• For use as a pressure vessel.

Issue 1-5 – October 2008 Page 10 of 18

Genevac R4 Evaporating System

Issue 1-5 – October 2008

The following notes describe the basic start up, set up and run instructions for your R4 evaporating system.

If a Genevac vacuum pump is fitted, the chamber is powered from the pump and so it is only necessary to connect the pump to a suitable mains power supply.

5.1 How to switch on the pump

Connect the pump to the mains and switch on the mains.

Switch the pump mains switch on as shown.

The pump will not be ready for use until the green ready light on the front panel is illuminated (Approx 7 minutes) – but power is available to the evaporator.

5.2 How to switch on the evaporator

Switch the mains switch on as shown.

ALL LEDs will light to check operation.

The READY light will be illuminated in red, to indicate that there is power to the evaporator.

Press START to power up the evaporator.

The vacuum pump and the condenser will start after a short delay.

The READY light will remain red until the pump and condenser have reached their operating temperature.

Amber indicates that the pump has reached its operating temperature but that the condenser has not yet reached its operating temperature.

The system is ready for use when the READY light is illuminated green.

On power up, the RUN TIME, VACUUM, ROTOR

TEMP and CHAMBER TEMP will be illuminated.

5.3 Using the keypad

The R4 keyboard controls and displays have been designed for ease and simplicity in use.

Page 11 of 18

Genevac R4 Evaporating System

Using and setting the timer

Using the TIMED mode

Using the NON-STOP mode

Using the 2 STAGE mode

During a run the RUN TIME can display either the elapsed time, E or the remaining time, R.

Press the up and down keys simultaneously, to toggle between the elapsed and remaining times.

The timer has three different modes that are accessed by pressing the MODE key.

The selected mode will be illuminated.

The TIMED mode is used when a predetermined run duration is required with CoolHeat.

The duration can be modified at any time prior to or during a run.

To set the run duration in TIMED mode use the up and down keys to input the desired run time.

Coarse setting is achieved by holding down either key.

Fine setting is achieved by pressing either key once.

A maximum time of 99 hours 59 minutes and a minimum time of 1 minute can be set. Elapsed or remaining time can be displayed in this mode.

The NON-STOP mode will run continually with the

CoolHeat facility enabled, until the STOP key is pressed.

This mode is particularly useful if the evaporation time for a particular solvent or solvent mixture is not known. Only elapsed time is displayed in this mode.

The 2 STAGE mode is used when the CoolHeat facility is required for a predetermined period.

After this period has elapsed, the CoolHeat facility will be disabled and the system will continue to run at full vacuum until the STOP key is pressed. Elapsed or remaining time can be displayed during the first stage of this mode, but only elapsed time during the second stage.

Issue 1-5 – October 2008 Page 12 of 18

Genevac R4 Evaporating System

The VACUUM Display

Using the AQUASPEED function

Using the Rotor temperature control

This mode is particularly useful for lengthy evaporation times, when it may be necessary to run the system overnight.

Since the CoolHeat facility will be disabled after the predetermined period, sample temperature may reach the temperature to which the chamber has been set.

The vacuum display indicates the absolute pressure of the system in millibar (mbar).

As the vacuum pump evacuates the system, the value will continually change, until the full vacuum capability of the pump is reached.

The key below the vacuum display enables the

AQUASPEED function.

AQUASPEED has been developed to significantly improve system performance when evaporating water or water mixtures. It limits the system pressure to 8 mbar,

Press the AQUASPEED key to select this facility, the lamp will illuminate.

This function can also be used simultaneously with the optional DRI-PURE facility.

The maximum rotor temperature is monitored and controlled by the RotoGuard infrared temperature detection system.

The setting of this control determines the temperature at which the CoolHeat lamps are disabled.

For instance, if the temperature is set at 30°C, the

CoolHeat lamps will be turned off when RotoGuard senses a temperature of 30°C.

Note that from power up, this control defaults to the previous settings.

Issue 1-5 – October 2008 Page 13 of 18

Genevac R4 Evaporating System

Using the Chamber temperature control

To change the setting, press both keys simultaneously and the SET prompt will flash.

Use the up and down keys to set the required rotor temperature.

Hold the key down for coarse setting or press once for fine setting.

The value will be accepted and the display will revert to ACTUAL after a short period.

Press either key to display the set temperature at any time.

The display will automatically revert to the actual setting after a short period.

The temperature setting can be changed during a run using the same procedure.

This control displays and controls the temperature of the chamber.

If this is set above ambient, prior to a run, the run will not start until the chamber temperature has preheated to the set value.

Preheating will be indicated by the point between hours and minutes on the RUN TIME display flashing.

To change the setting, press both keys simultaneously and the SET prompt will flash.

Use the up and down keys to set the desired chamber temperature.

Hold the key down for coarse setting or press once for fine setting.

The value will be accepted and the display will revert to ACTUAL after a short period.

Press either key to display the set temperature at any time.

The temperature setting can be changed during a run using the same procedure.

Issue 1-5 – October 2008 Page 14 of 18

Genevac R4 Evaporating System

The STATUS indicators

The status of the system is indicated by the row of lamps on the far left of the display.

When switched ON, the SYSTEM READY lamp will be red and all other lamps will be off.

On pressing the START key, the displays will be illuminated and the SYSTEM READY lamp will remain red until the pump and condenser are ready.

Note that from cold, the Genevac vacuum pump will take approximately 10 minutes to reach operating temperature.

When the run commences (after preheat if required), the ROTOR SPINNING lamp will be illuminated green.

Note that the lid will not open whilst the rotor is rotating.

If an excessive out of balance is detected by the system, the red IMBALANCE lamp will be illuminated, flash and the run terminated.

In such cases, press the STOP button after the rotor stops, this shuts down the evaporator.

Correct the source of the imbalance.

The CoolHeat indicator lamp will be illuminated when the lamps are on.

Issue 1-5 – October 2008 Page 15 of 18

Genevac R4 Evaporating System

Using Condenser

Using the DRI-PURE feature

Issue 1-5 – October 2008

5.4 Condenser defrost

The R4 is fitted with an Automatic Drain Valve, ensure that the chamber drain is connected to a suitable container.

Manual Defrost:

Press the DEFROST button (to initiate the defrost cycle). The lamp will illuminate green. On completion of defrost cycle the lamp will turn red.

DEFROST and DRAIN can be terminated at any time by pressing the DEFROST button.

During Manual Defrost the rotor should not be spinning or heated.

Automatic Defrost

When the AUTO DEFROST button is pressed, the

R4 is capable of continuous unattended operation.

Once the condenser is full the following will occur:

If the current run is a TIMED run and within 30 minutes of the end, then the run will end as normal:

The rotor will stop, lid lock release will be activated and the condenser will enter the DEFROST and

DRAIN cycle.

If the run is a NON STOP or TWO STAGE run or the run has more than 30 minutes remaining, then the automatic DEFROST and DRAIN cycle will commence.

When the DEFROST and DRAIN cycle has completed, the run will continue.

5.5 Dri-Pure

DRI-PURE combines a high rotational speed with a gradual reduction of vacuum over a predetermined period, at the end of which the full vacuum capability of the vacuum pump comes into effect.

This feature is particularly useful in preventing bumping, (the violent boiling of solvents), resulting in solvents and compounds being expelled, which is a source of cross contamination of samples.

Bumping can also cause products to be deposited on the glass lenses of the CoolHeat lamps, which eventually results in breakages.

To select this feature press the DRI-PURE key, the lamp will illuminate.

Note that during the DRI-PURE cycle, which is approximately 40 minutes, the CoolHeat function will be disabled.

Page 16 of 18

Genevac R4 Evaporating System

Controls

Temperature control range

Temperature Accuracy

Temperature control resolution

Temperature control

Temperature control range

Chamber temperature range

End of run

Mechanical data

Max rotor speed

Max rotor speed

Ambient to 60°C

+/- 2.5°C

1°C

Infrared pyrometer

0°C to + 60°C

Ambient to 45°C

Run timer/continuous

Max Force

Drive system

Operation imbalance

Max load (swing rotor)

IR lamps number

1300 standard

1800 Dri-Pure

300-500G

Direct

350g

8 x 1.0 kg @ 500G

2

Weight 120

Vacuum system

Pressure display/resolution

Pressure control (Aquaspeed)

0 -1200 mbar/1.0 mbar

8 mbar

Dri-Pure Yes

System ultimate vacuum 0.5 mbar (CVP 100 pump)

Auto vacuum vent valve

Vacuum chamber

Inert gas purge

Condenser data

Condenser temperature

Vacuum condenser capacity

Condenser level detector

Yes

Cast aluminium with corrosion proof coating

External option

-40°C

2.0 litres

Yes

Stainless steel

Automatic Stainless steel and PTFE

Condenser chamber

Condenser drain valve

Dimensions

W x D x H (lid closed)

H (lid open)

Chamber diameter

535 x 640 x 578 mm

950 mm

458 mm

Electrical

Power supply 230V, 50Hz, single phase, 9A

208V, 60 Hz, single phase, 9A

Issue 1-5 – October 2008 Page 17 of 18

Genevac R4 Evaporating System

7 EC Declaration of Conformity 8 Safety

We Genevac Limited

Declare that this product:

Series II Evaporating System

Complies with the relevant Essential Health and

Safety Requirements of the European Machinery

Directive (89/392/EEC as amended by 91/368 EEC and 93/44/EEC). The EMC Directive 89/336/EEC and the Low voltage Directive 73/23/EEC.

Conformity is demonstrated by compliance with the following specifications:-

EN 292 parts 1 & 2:1991, Safety of Machinery -

Basic concepts, general principles for design

EN 60204-1:1998, Safety of machinery– Electrical equipment of machines-Pt 1 General Requirements

EN 249: 1992, Safety of machinery– Safety distances to prevent danger zones being reached by upper limbs.

EN 1088: 1996, Safety of machinery. Interlocking devices associated with guards. Principles of design and selection.

EN 1050: 1997, Safety of machinery. Principles of risk assessment.

BS EN 50082: 1998, Electromagnetic compatibility-

Generic immunity standard.

BS EN 61010-2-020: 1995, Safety requirements for electrical equipment for measurement, control and laboratory use. Particular requirements for laboratory centrifuges.

WARNING!

THIS SYSTEM MUST BE EARTHED

THIS EVAPORATOR IS A SAFETY CLASS 1

PRODUCT ACCORDING TO IEC

CLASSIFICATION. IT MUST NEVER BE USED

WITH ANY INTERRUPTION TO THE SAFETY

EARTH CONDUCTOR. IT IS AN INSTALLATION

CATEGORY II PRODUCT AND IS INTENDED TO

OPERATE FROM A NORMAL SINGLE-PHASE

SUPPLY.

THIS EVAPORATOR HAS BEEN DESIGNED TO

BE USED IN A POLLUTION DEGREE 1

ENVIRONMENT (NO POLLUTION, OR ONLY DRY

NON-CONDUCTIVE POLLUTION).

ANY MAINTENANCE OR REPAIR OF THIS

PRODUCT SHALL BE CARRIED OUT BY

GENEVAC PERSONNEL (OR APPROVED

REPRESENTATIVES OF GENEVAC) USING ONLY

APPROVED SPARE PARTS

9 LOCATION AND MOUNTING CONSIDERATIONS FOR EVAPORATORS FITTED WITH

AUTOBALANCE

The performance of Genevac’s autobalance can be affected by the resonant characteristics of the bench or trolley on which the evaporator is mounted. Therefore, it is important that evaporators fitted with autobalance are mounted either on a heavy stiff laboratory bench or on a Genevac Series II evaporator trolley. In addition, it is a requirement that evaporators fitted with autobalance are bolted to the bench or trolley. The five mounting feet on all systems are provided with a M10 female thread for this purpose.

Issue 1-5 – October 2008 Page 18 of 18

Genevac R4 Evaporating System

Genevac Limited

The Sovereign Centre

Farthing Road

Ipswich

IP1 5AP

United Kingdom

Sales and Service Hotlines

Service Hotline: +44 (0) 1473 243000

Sales Hotline: +44 (0) 1473 240000

Fax: +44 (0) 1473 461176

Email: [email protected]

Web site: http://www.genevac.com

Genevac Inc

SP Industries

815 State Route 208

Gardiner

NY 12525

United States of America

Sales and Service Hotline

(1) 914 687 5303

Fax (1) 914 267 2212

Email: [email protected]

If you need to contact Genevac for assistance, use either the telephone or fax Hotlines given.

It will always help Genevac Service if you have the serial numbers at hand for the components of your system

If you need to contact Genevac Sales for information on Service Contracts or products, use the telephone or fax Hotlines given.

Alternatively, Email or visit our web site.

Issue 1-5 – October 2008 Page 19 of 18

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