User`s Manual

User`s Manual
User’s Manual
FreeZone® Triad™ Freeze Dry System
Models
7400030
7400040
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Labconco Corporation
8811 Prospect Avenue
Kansas City, MO 64132-2696
800-821-5525, 816-333-8811
FAX 816-363-0130
E-MAIL [email protected]
HOME PAGE www.labconco.com
Please read the User’s Manual before operating the equipment.
Copyright © 2005, 2007 Labconco Corporation. All rights reserved.
The information contained in this manual and the accompanying products are copyrighted and
Labconco Corporation reserves all rights. Labconco Corporation reserves the right to make
periodic design changes without obligation to notify any person or entity of such change.
Warranty
Labconco provides a warranty on all parts and factory workmanship. The warranty includes areas of
defective material and workmanship, provided such defect results from normal and proper use of the
equipment.
The warranty for all Labconco products will expire one year from date of installation or two years from
date of shipment from Labconco, whichever is sooner, except the following;
•
Purifier® Delta® Series Biological Safety Cabinets and PuriCare® Lab Animal Research
Stations carry a three-year warranty from date of installation or four years from date of
shipment from Labconco, whichever is sooner.
•
SteamScrubber® & FlaskScrubber® Glassware Washers carry a two-year warranty from date
of installation or three years from date of shipment from Labconco, whichever is sooner.
•
Blood Drawing Chairs carry a ten year warranty.
•
Carts carry a lifetime warranty.
•
Glassware is not warranted from breakage when dropped or mishandled.
This limited warranty covers parts and labor, but not transportation and insurance charges. In the event
of a warranty claim, contact Labconco Corporation or the dealer who sold you the product. If the cause
is determined to be a manufacturing fault, the dealer or Labconco Corporation will repair or replace all
defective parts to restore the unit to operation. Under no circumstances shall Labconco Corporation be
liable for indirect, consequential, or special damages of any kind. This statement may be altered by a
specific published amendment. No individual has authorization to alter the provisions of this warranty
policy or its amendments. Lamps and filters are not covered by this warranty. Damage due to corrosion
or accidental breakage is not covered.
Returned or Damaged Goods
Do not return goods without the prior authorization from Labconco. Unauthorized returns will not
be accepted. If your cabinet was damaged in transit, you must file a claim directly with the freight
carrier. Labconco Corporation and its dealers are not responsible for shipping damages.
The United States Interstate Commerce Commission rules require that claims be filed with the
delivery carrier within fifteen (15) days of delivery.
Limitation of Liability
The disposal and/or emission of substances used in connection with this equipment may be
governed by various federal, state, or local regulations. All users of this equipment are required to
become familiar with any regulations that apply in the user’s area concerning the dumping of
waste materials in or upon water, land, or air and to comply with such regulations. Labconco
Corporation is held harmless with respect to user’s compliance with such regulations.
Contacting Labconco Corporation
If you have questions that are not addressed in this manual, or if you need technical assistance,
contact Labconco’s Customer Service Department or Labconco’s Product Service Department at
1-800-821-5525 or 1-816-333-8811, between the hours of 7:00 a.m. and 6:00 p.m., Central
Standard Time.
Part #7373300, Rev. B
ECO E077
TABLE OF CONTENTS
CHAPTER 1: INTRODUCTION
Freeze Dry Process
Freeze Dry Rates
Freeze Dry Capacity
Samples Containing Volatile Substances
1
1
2
3
3
CHAPTER 2: PREREQUISITES
Electrical Requirements
Location Requirements
Vacuum Pump Requirements
5
5
5
6
CHAPTER 3: GETTING STARTED
Unpacking Your Triad Freeze Dry
Triad Freeze Dry Components
Setting Up Your Triad Freeze Dry System
Component Orientation and Hose Connection
Venting the Vacuum Pump
Electrical Connection
Chemical Resistance of Freeze Dryer Components
Solvent Safety Precautions
7
7
8
8
8
9
9
9
10
CHAPTER 4: OPERATING INSTRUCTION
Triad Freeze Dry Controls
Operation Checklist
Vacuum Pump Ballast Setting
Operating the Triad Freeze Dry System
Set-Up
Setting the Operating Vacuum Level
Manual Control Operation
Automatic Control Operation
Programming
Starting the Freeze Dry Cycle
Changing the Program Parameters in the Middle of a Run
Stopping the Freeze Dry Cycle
Monitoring the system Operation
Sample Freezing
Shelf Loading
12
13
14
14
15
15
17
18
19
20
21
22
22
23
23
23
Freeze Drying inside the Chamber
Manual Mode with Pre Frozen Samples
Manual Mode with Unfrozen Samples
Auto Mode with Pre Frozen Samples
Auto Mode with Unfrozen Samples
Stoppering Vials
Vacuum Break/Backfilling
Freeze Drying using Manifold Valves
Defrosting
Alarms
System Temperature Variations
Collector Temperature Variations
Vacuum
Vacuum Pump Service
Shelf Temperature Set Point
Power Failure
Platen Tilt
23
23
24
24
24
25
25
26
27
28
28
28
28
28
28
28
29
CHAPTER 5: MAINTAINING YOUR FREEZE DRY SYSTEM
30
CHAPTER 6: USING THE RS232 RECEPTACLE
Computer Connection for Computer Interface
32
32
CHAPTER 7: TROUBLESHOOTING
Vacuum System
Vacuum Pump
Gaskets, Tubing, Connections, Sample Valves
Diagnostic Mode
Refrigeration Module Operation
Filling the Fluid System
Heat Transfer Fluid Precautions
Heat Transfer Fluid First Aid Procedures
35
35
35
36
37
39
39
41
41
CHAPTER 8: MODIFYING YOUR FREEZE DRY
SYSTEM DISPLAY
Modifying the Display
42
42
APPENDIX A: FREEZE DRY SYSTEM COMPONENTS
44
APPENDIX B: FREEZE DRY SYSTEM DIMENSIONS
46
APPENDIX C: FREEZE DRY SYSTEM SPECIFICATIONS
Electrical Specifications
Environmental Conditions
Performance Specifications
47
47
47
48
APPENDIX D: FREEZE DRY SYSTEM ACCESSORIES
49
DECLARATION OF CONFORMITY
55
Chapter 1:
Introduction
Congratulations on your purchase of a Labconco FreeZone® Triad™ Freeze
Dry System, which is designed for laboratory lyophilization procedures. The
refrigerant used in the refrigeration system is CFC-free so it will not
endanger the environment. The unit is easy to install and maintain. Proper
care and maintenance of this product will result in many years of dependable
service.
Freeze Dry Process
Freeze drying is an important process in sample preparation and for the
preservation and storage of biologicals, pharmaceuticals and foods. Of the
various methods of dehydration, freeze drying (lyophilization) is especially
suited for substances that are heat sensitive. Other than food processing (e.g.,
coffee, whole dinners), freeze drying has been extensively used in the
development of pharmaceuticals (e.g., antibiotics) and preservation of
biologicals (e.g., proteins, plasma, viruses and cell lines). The nondestructive
nature of this process has been demonstrated by the retention of viability in
freeze dried viruses and microorganisms.
Freeze drying is a process whereby water or other solvent is removed from
frozen material by converting the frozen water directly into vapor without the
intermediate formation of liquid water. The basis for this sublimation
process involves the absorption of heat by the frozen sample in order to
vaporize the ice; the use of a vacuum pump to enhance the removal of water
vapor from the surface of the sample; the transfer of water vapor to a
collector; and the removal of heat by the collector in order to condense the
water vapor. In essence, the freeze dry process is a balance between the heat
absorbed by the sample to vaporize the ice and the heat removed from the
collector to convert the water vapor into ice.
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1
Chapter 1: Introduction
Freeze Dry Rates
The efficiency of the freeze drying process is dependent upon the surface
area and the thickness of the sample, the collector temperature and vacuum
obtained, the eutectic point and solute concentration of the sample. It is
important to remember these factors when trying to obtain efficient
utilization of your freeze dry system. A listing of selected materials and their
approximate drying times are shown in Table 1 for your reference.
Table 1
Safe Temperature and Drying Times for Selected Materials
Material 10mm
Thick
Milk
Urea
Blood Plasma
Serum
Vaccinia
Influenza Vaccine
Human Tissue
Vegetable Tissue
Safe
Temperature °C
-5
-7
-10 to -25
-25
-30 to -40
-30
-30 to -40
-50
Collector
Temperature °C
-40
-40
-40
-40
-50
-50
-50
-80
Hours
(Approx.)
10
10
16
18
22
24
48
60
*Total sample quantities are contingent on various Triad Freeze Dry System capacities.
Up to the point of overloading the system, the greater the surface area of the
sample, and the faster the rate of freeze drying. By contrast, for a given
surface area, the thicker the sample the slower the rate of freeze drying. This
is based on the fact that the heat of sublimation is usually absorbed on one
side of the frozen sample and must travel through the frozen layer to vaporize
water at the other surface. In addition, as the sample is freeze dried, the
water vapor must travel through the layer of dried material. The thicker the
sample, the greater the chance that the dried layer may collapse which would
cause an additional decrease in the rate of freeze drying.
The surface area and thickness of the sample can usually be ignored when
each sample contains only a few milliliters. However, for larger volumes, the
samples should be shell frozen to maximize the surface area and minimize
the thickness of the sample. The volume of the freeze dry container should
be two to three times the volume of the sample.
In order for lyophilization to occur, ice must be removed from the frozen
sample via sublimation. The collector and the vacuum pump accomplish this.
The collector, which should be at least 15 to 20°C colder than the eutectic
temperature (melting temperature) of the sample, traps vapor as ice. Since
the vapor pressure at the collector is lower than that of the sample, the flow
of water vapor is from the sample to the collector.
Since this vapor diffusion process occurs very slowly under normal
atmospheric conditions, a good vacuum is essential to maintain an efficient
rate. In many applications, the maintenance of a vacuum of 0.133 mBar or
less is recommended.
2
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Chapter 1: Introduction
The rate of freeze drying is directly proportional to the vapor pressure and the
vapor pressure is dependent upon both eutectic temperature and solute
concentration of the sample. For example, a solution of sodium chloride and
water would freeze dry at a slower rate than pure water. The eutectic
temperature of a sodium chloride solution is about –21°C and at this
temperature the vapor pressure is about 1/16 that of water at 0°C. Although
the eutectic temperature is not dependent upon the concentration of sodium
chloride, the vapor pressure of the water would decrease as the concentration
of sodium chloride increased. This is due to the fact that as the solute
concentration increases, less of the surface area of the frozen sample is
occupied by water. In general, most solutions or biological samples will have
a eutectic temperature of –10° to –25°C. However, if the sample contains a
simple sugar such as glucose or if the sample is animal or plant tissue, the
eutectic temperature may be as low as –30° to –50°C.
Freeze Dry Capacity
The volume of a sample that can be freeze dried at one time is related to
factors discussed previously and the size and design of the freeze dry system.
With any given instrument, the capacity is based on the surface area of the
sample, the eutectic temperature and concentration of the sample and the rate
and amount of heat transferred to the frozen sample. Of these factors, the
eutectic temperature is the most important factor in determining the amount
of sample that can be freeze dried at one time, particularly when flasks are
used. This is because as the eutectic temperature decreases, the vapor
pressure decreases but the rate of heat absorption by the sample does not
change. This tends to promote melting of the sample, which leads to a
marked increase in vapor pressure and ultimately overloads the collector and
vacuum pump. Samples that have eutectic temperatures of –20°C or lower
should be placed on the freeze dry system one flask at a time so that the
vacuum in the system may recover before adding another sample to the
system. If the vacuum does not recover, the capacity of the freeze dry system
has been exceeded and the sample should be removed.
If there is a problem with a particular type of sample melting when placed on
the freeze dry system, dilution of the sample with more water or providing
some insulation around the flask to decrease the rate of heat absorption by the
sample may help.
Samples Containing Volatile Substances
In certain cases the solvent in a sample to be freeze dried may contain
volatile components such as acetonitrile, methanol, acetic acid, formic acid or
pyridine.
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Chapter 1: Introduction
In addition to these substances having an effect on the eutectic temperature,
they may increase the vapor pressure at the surface of the sample. Also,
compared to water, they will require the absorption of less heat for
sublimation to occur. Hence, samples that contain volatile substances will
have a greater tendency to melt, particularly when placed in flasks or exposed
to room temperature. If a sample containing a volatile substance tends to
melt when placed on a freeze dry system, dilution of the sample with more
water will help keep the sample frozen. For example, a 0.2M solution of
acetic acid is much easier to freeze dry than a 0.5M solution.
4
Product Service 816-333-8811 or 1-800-522-7658
Chapter 2:
Prerequisites
Before you install your Triad Freeze Dry System, you must be certain that the
area is level and of solid construction. An electrical source must be located
near the installation site.
Carefully read this chapter to learn:
• Electrical supply requirements.
•
Location requirements.
•
Vacuum pump requirements.
Refer to Appendix C: Freeze Dry System Specifications for complete
electrical and environmental conditions, specifications and requirements.
Electrical Requirements
The Triad Freeze Dry System requires a dedicated electrical outlet. This
outlet requires a 20 Amp circuit breaker or fuse for all models. The power
cord on 230V models is equipped with a NEMA 6-20P plug. If this does not
match with the available receptacle, remove this plug and replace it with an
approved plug of the suitable style.
Location Requirements
The Triad Freeze Dry System should be located in an area that provides an
unobstructed flow of air around the cabinet. This air cools the refrigeration
system. The refrigeration system draws air in through the left side and
exhausts it through the right side. A minimum of 3" must be allowed
between the rear and both sides of the Triad Freeze Dry System and adjacent
wall surfaces. Restriction of airflow during operation could adversely affect
performance. The Triad Freeze Dry System must be placed on a work surface
or table that will support over 400 lbs.
Refer to Appendix B: Freeze Dry System Dimensions for drawings.
Product Service 816-333-8811 or 1-800-522-7658
5
Chapter 2: Prerequisites
Vacuum Pump Requirements
The user must provide a vacuum pump. A vacuum pump with a
displacement of 144 liters per minute and 0.0002 mBar ultimate pressure is
adequate for most samples. The inlet fitting on the vacuum pump must be
suitable for 3/4" ID vacuum hose, which is provided with the FreeZone®
Triad Freeze Dry System. It is recommended that the vacuum pump is
equipped with an exhaust filter to minimize oil mist exhausting from the
vacuum pump.
The operating vacuum level may be set on the freeze dry system. The higher
the pressure is set, the more likely it is that oil mist will be exhausted.
Vacuum pumps should be equipped with a reverse IEC plug. This will allow
the vacuum pump to be plugged into the receptacle on the back panel of the
Freeze Dry System. Refer to Appendix D: Triad Freeze Dry System
Accessories for vacuum pumps available from Labconco.
6
Product Service 816-333-8811 or 1-800-522-7658
Chapter 3:
Getting Started
Now that the site for your Triad Freeze Dry System is properly prepared, you
are ready to unpack, inspect, install and test your freeze dry system.
Read this chapter to learn how to:
•
•
•
Unpack and move your freeze dry system.
Set up your freeze dry system.
Safely use solvents with your freeze dry system.
Unpacking Your Triad Freeze Dry System
Carefully unpack your freeze dry system and inspect it for damage that may
have occurred in transit. If your freeze dry system is damaged, notify the
delivery carrier immediately and retain the entire shipment intact for
inspection by the carrier.
The Triad Freeze Dry System weighs over 400 lbs. (181 Kg). The
carton allows for lifting with a mechanical lift truck or hand
truck. If you must lift the freeze dry system manually, use at least
four (4) persons and follow safe lifting guidelines.
If your freeze dry system was damaged in transit, you must file a
claim directly with the freight carrier. The United States
Interstate Commerce Commission rules require that claims be
filed with the delivery carrier within fifteen (15) days of delivery.
Labconco Corporation and its dealers are not responsible for
shipping damage.
Do not return goods without the prior authorization of Labconco,
unauthorized returns will not be accepted.
Do not discard the carton or packing material for your freeze dry
system until you have checked all of the components, installed and
tested the system.
Product Service 816-333-8811 or 1-800-522-7658
7
Chapter 3: Getting Started
Triad Freeze Dry System Components
Locate the model of freeze dry system you received in the following table.
Verify that the components listed are present and undamaged.
If you did not receive one or more of the components listed, contact
Labconco Corporation immediately for further instructions.
Catalog #
7400030
7400040
Product Description
Triad Freeze Dry System – 230V, 50 Hz
Triad Freeze Dry System – 230V, 60 Hz
Plus the following:
Part #
Qty.
7373300
1342100
7373436
1488800
1291000
1
1
1
2
1
Component Description
User’s Manual
Power Cord – 230V
Tubing
Clamp
Female IEC Plug
Setting Up Your Triad Freeze Dry System
Component Orientation and Hose Connections
A minimum of 3" should be allowed between the back of the freeze dry
system and the adjacent wall surface and between the sides of the Freeze
dryer and the adjacent wall surfaces. Restriction of the airflow through the
cabinet during operation could adversely affect performance.
Position the vacuum pump near the vacuum exhaust port on the rear of the
cabinet. Attach the supplied hose to the exhaust port using the clamp
provided. Attach the other end of the hose to the inlet fitting on the vacuum
pump. Secure with the clamp provided. The hose may be cut to proper length
to allow for gentle bends without kinks.
Connect the power cord from the vacuum pump into the outlet on the back of
the unit. If your vacuum pump power cord does not have a female IEC plug,
replace the cord end with the female IEC plug provided with the unit (Part
number 1291000).
Figure 1
8
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Chapter 3: Getting Started
Venting the Vacuum Pump
If any materials will be placed in the freeze dry system that can liberate
hazardous gases when heated, the vacuum pump exhaust must be vented to a
fume hood or other ventilation device.
Electrical Connection
Connect the power cord into the receptacle on the back of the freeze dry
system and connect the other end into a suitable power receptacle.
The freeze dry system is now installed and must be tested to make certain the
system is free of leaks. Close the door, turn on the freeze dry system
refrigeration and allow the collector temperature to reach –40° or lower, this
could take 20 to 30 minutes. Make sure the Stoppering Control is in the
“RAISED” position and the Vacuum Release control is in the “CLOSED”
position. Start the vacuum pump and monitor the vacuum gauge. The
vacuum on the freeze dry system should reach 0.133 mBar within 30 minutes
and should achieve an ultimate vacuum of 0.040 mBar or lower within 18
hours. If 0.040 mBar cannot be achieved, consult the troubleshooting section
of this manual.
Chemical Resistance of Freeze Dry System
Components
The FreeZone® Triad Freeze Dry System is designed to be chemically
resistant to most compounds that are commonly used in Freeze drying
processes. However, by necessity, the freeze dry system is comprised of a
number of different materials, some of which may be attacked and degraded
by certain chemicals. The degree of degradation is dependent on the
concentration and exposure duration.
Some of the major components of the freeze dry system that are susceptible
to degradation are as follows:
C
D
D
D
C
C
D D
D
C
D
D D
D
C
D
C
C = Moderate degradation; limited use
D = Severe degradation; infrequent use recommended; immediate thorough
cleaning required.
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9
Pyridine
D
D
Cyclohexane
Sodium
Phosphate
Calcium
Chloride
D
Methyl t-Butyl
Ether (BTBE)
D
Dioxane
D
D
Carbon
D
D
Acetonittirle
Silicon Rubber
Stainless Steel
C
D
Solvents
Acetone
Neoprene
C
Buffers
Trifluoroacetic
Acid (TFA)
Material
Acetal (Delrin)
Acrylic
Formic Acid
Component
Valve Stem
Door
Hoses, Gaskets & Valve
Bodies
Flask Top, Drain Hose
Chamber & Fittings
Acetic Acid
20%
Acids
Chapter 3: Getting Started
•
•
Most common compounds used in freeze drying processes, if allowed to
enter the vacuum pump, will degrade the oil and cause damage to the
vacuum pump.
Sugars and proteins typically will have minimal negative effect on any of
the materials of construction.
When using compounds in the freeze dry system that are hostile to the
materials of construction, it is imperative the equipment is thoroughly
cleaned after use.
•
Rubber and plastic components that have been exposed to damaging
compounds should be removed and flushed with water.
•
The oil in the vacuum pump should be checked often. It must be changed
if it is cloudy, shows particles or is discolored. The useful life of vacuum
pump oil can be extended if the vacuum pump is operated for an extended
period of time after a freeze dry run. This allows contaminants to be
purged from the hot oil. This must be done with the inlet to the pump
blocked off to prevent air from free flowing through the pump. This is
accomplished by closing all sample valves on a clean, dry, freeze dry
system and turning on the vacuum pump. If the pump is operated at an
elevated vacuum level (> 10mBar), oil may be expelled from the pump
and damage could occur.
Optional secondary traps are available to help extend the life of the vacuum
pump. These traps are installed between the freeze dry system and the
vacuum pump. Contact Labconco for assistance in determining which trap is
right for your application.
With prudent maintenance the freeze dry system will provide years of
service. Warranty on the affected parts will be voided if maintenance has
been obviously neglected. If you have questions about using specific
compounds in the freeze dry system, contact Labconco Technical Service at
1-800-821-5525 or 816-333-8811 or e-mail: [email protected]
Solvent Safety Precautions
Solvents used in the freeze dry system may be flammable or
hazardous to your health. Use extreme caution and keep
sources of ignition away from the solvents. When using
flammable or hazardous solvents, the vacuum pump must be
vented to a fume hood.
Hazardous materials such as strong acids or bases, radioactive
substances and volatile organics must be handled carefully and
promptly cleaned up if spilled. If a sample is spilled in the
collector chamber it must immediately be cleaned up per MSDS
procedures or damage to the equipment or injury may occur.
10
Product Service 816-333-8811 or 1-800-522-7658
Chapter 3: Getting Started
NOTE: Various Federal, State or local regulations may govern the disposal
of substances used in connection with this equipment. All users of this
equipment are urged to become familiar with any regulations that apply in the
user’s area concerning the dumping of waste materials in or upon water, land
or air and to comply with such regulations.
Product Service 816-333-8811 or 1-800-522-7658
11
Chapter 4:
Operating Instructions
Read this chapter to learn how to:
•
Understand the display.
•
Operate the controls.
•
Connect samples.
Do not use the freeze dry system in a manner not specified by the
manufacturer (refer to Appendix C: Freeze Dry System
Specifications). The electrical protection may be impaired if used
inappropriately.
12
Product Service 816-333-8811 or 1-800-522-7658
Chapter 4: Operating Instructions
Triad Freeze Dry System Controls
The control panel for the Triad Freeze Dry System is shown with a
description about its function.
Figure 2
1. Display: Displays all necessary programming and operational data. Provides
prompts to aid in programming.
2. Display Button: Changes format of display from “monitor” to “auto” to
“manual” to “set up” screen.
3. Display Indicators: Green INDICATOR shows which display “screen” is
shown.
4. Alarm Indicator: Red INDICATOR shows that a system alarm has occurred.
5. Defrost: Used to manually start or stop the defrost operation.
6. Vacuum: Used to manually start or stop the vacuum pump.
7. Decrease Button: Used in programming to decrease a parameter set point.
8. Increase Button: Used in programming to increase a parameter set point.
9. Enter Button: Used in programming to enter a selected set point into
memory.
10. Mode Selector Button: Selects the mode of operation – either manual or
automatic.
11. Mode Indicator: Green INDICATOR shows whether the control is set to
operate either in the automatic or manual mode.
Product Service 816-333-8811 or 1-800-522-7658
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Chapter 4: Operating Instructions
12. Run/Stop Button: Initiates the start or stop of the lyophilization process.
13. Run/Stop Indicator: Green INDICATOR burns steadily while freeze drying
is in progress and turns off when the Run/Stop button terminates a run. The
green INDICATOR flashes if freeze drying is in progress and a power failure
occurs.
14. Stoppering: Controls the stoppering platen up and down movement. The
mechanism will function only while the chamber is under vacuum. The
stoppering action should be closely monitored when operating this control.
15. Vacuum Release: Vents the chamber so the chamber door can be opened.
This control can also vent gas into the chamber when the gas supply is
properly connected to the backfill port.
16. Back Fill: A regulated tank of gas may be connected to the port to allow the
introduction of gas into the chamber after freeze drying. The port accepts 1/8"
tubing.
Ethylene Oxide is not recommended for use in this
freeze dry system for decontamination because of its
hazardous and corrosive properties.
17. Power Switch: Turns all power to Triad Freeze Dry System ON or OFF. (Not
shown). Located on left side of cabinet.
Operation Checklist
The following checklist should be followed prior to each use of your freeze
dry system:
1. Wipe out the interior of the chamber with a soft cloth or paper towel to
remove any moisture or debris.
2. Check the collector tray drain hose to ensure that the hose is free of
moisture and that the drain plug is securely installed.
3. Using a soft, lint-free cloth or paper towel, wipe the door gasket to
remove any dirt and contaminants that could cause a vacuum leak.
Vacuum grease is not required on the door gasket.
4. Check that each sample valve is closed or in the “vent” position. See
Figure 4.
Vacuum Pump Ballast Setting
Most vacuum pumps are equipped with gas ballast mechanism. The freeze
dry process requires high vacuum. Therefore, it is recommended that the gas
ballast be closed during the operation of the Triad Freeze Dry System.
Note: If the gas ballast is left open for extended periods of operation, the oil
can be pumped out the exhaust, causing the pump to fail.
14
Product Service 816-333-8811 or 1-800-522-7658
Chapter 4: Operating Instructions
Operating the Triad Freeze Dry System
Set-Up
Vacuum may be displayed in mBar, Pascal (Pa) or Torr and the temperature
may be displayed as either °F or °C. The refrigeration system and vacuum
pump operating time may be monitored and the operating vacuum level may
be set. To configure your Triad Freeze Dry System, turn the main Power
Switch ON. Press the DISPLAY button until the SET UP indicator is lit.
The display will show:
VACUUM UNITS:
MBar
•
•
Pa
Torr
Press × or Øuntil the desired units are flashing.
Press ENTER.
The display will show:
VACUUM SET POINT:
XXXX
YYY
Where YYY is the units selected above.
•
•
Press × or Øuntil the desired vacuum operating level is displayed.
See “Setting the Operating Vacuum Level” for guidelines.
Press ENTER.
The display will show:
TEMPERATURE UNITS:
^C
•
•
^F
Press × or Øuntil the desired units are flashing.
Press ENTER.
The display will show:
REFRIG TOTAL HOUR: XXXX
SERVICE HOUR: XXXX
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15
Chapter 4: Operating Instructions
•
Press ENTER if you do not want to reset SERVICE HOURS.
•
Press and hold Ø for 5 seconds to reset the Service Hours to 0. This
allows you to keep track of the time the refrigeration system operated
since it was serviced.
The display will show:
REFRIGERATION TOTAL HOURS: XXXX:
RESET SERVICE HOUR: ?
•
X
Press ENTER.
The display will show:
VACUUM TOTAL HOURS: XXXX:
SERVICE HOUR: XXXX
•
Press ENTER if you do not want to reset SERVICE HOURS.
•
Press and hold Ø for 5 seconds reset the Service Hours to 0. This
allows you to keep track of the time the vacuum pump operated since
it was serviced.
The display will show:
VACUUM TOTAL HOURS: XXXX:
RESET SERVICE HOUR: ?
•
X
Press ENTER.
The display will show:
RS-232 TRANSMISSION RATE:
10
16
SECONDS
•
Press × or Øuntil the desired time interval is shown. The time
between data transmission may be set to occur at 10, 30, 60, 300 or
600 seconds intervals.
•
Press ENTER.
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Chapter 4: Operating Instructions
The display will show:
VACUUM UNITS:
MBar
•
Pa
Torr
At any time the DISPLAY button can be pressed to select a different
function.
Setting the Operating Vacuum Level
The vacuum level may be manually set by the user to optimize the freeze dry
process. Normally, the sublimation rate will increase if there is less vacuum
(a higher pressure) in the Triad Freeze Dry System. A good starting place is
to set the vacuum to a level that will hold the sample temperature
approximately 10°C cooler than the eutectic temperature. Adjustments to the
vacuum level must be made for various freeze drying conditions. Factors that
must be considered are whether the sample is freeze dried on heated shelves
or in glassware attached to manifold valves, the volatility of the sample itself,
the size of the sample and the heat energy supplied to the sample. When the
vacuum control is set to operate at less vacuum, the ice holding capacity of
the collector may be decreased.
Some guidelines for setting the Triad Freeze Dry System are shown below.
These show pre-freezing temperature and vacuum levels. The user of the
specific samples that are being freeze dried must determine exact protocols.
Material
Solidification/Eutectic
Temperature
Pre-Freeze
Temperatures
Vacuum Set Point
Bacteria, Virus
-40°C and Colder
-50°C and Colder
0.404 mBar and Lower
Milk
-5 to -13
-15 to -23
1.65 to 0.77
Fungi
-40 and Colder
-50 and Colder
0.04 and Lower
Vegetable Tissue
-25 to –50
-35 to –60
0.22 to 0.01
Human Tissue
-30 to –40
-40 to –50
0.12 to 1.04
Blood Plasma
-10 to –25
-20 to –35
1.03 to 0.22
Vaccine
-30 to –40
-40 to –50
0.12 to 0.04
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Chapter 4: Operating Instructions
Manual Control Operation
The manual operation has three selectable modes: Pre-Freeze, In-Flask and
controlled shelf temperature. The Pre-Freeze setting allows the shelf
temperature to freeze samples below –55°C obtaining “Max Cold”
temperature of approximately –75°C. The In-Flask setting is used to freeze
dry pre-frozen samples when using only the sample valves on the left side of
the unit. There is no shelf temperature control in this mode. When using the
controlled shelf set point temperature setting, the shelf temperature will
maintain the set point selected between –55°C to 50°C. This mode should be
used when freeze drying samples on the shelf. A flask can also be added to
the sample valves in this mode.
(1)
Turn the Power Switch ON. The display will become active.
(2)
Push the DISPLAY button until the MANUAL indicator lights.
This will cause the manual display screen to be shown with the
previously entered set point temperature or operational mode.
SET POINT TEMP –30°C
The temperature units are displayed in the units (°F or °C)
selected in the Set Up.
The temperature may be set to control the shelf anywhere from
+50°C to –55°C in 1°C increments. To pre-freeze samples below
–55°C set temperature to “Pre-Freeze.” To freeze dry samples
using the manifold sample valves change set point temperature to:
“In-flask.”
(3)
If the set point or operating mode needs to be changed, press the
INCREASE or DECREASE button until the desired set point
temperature or mode is displayed.
(4)
Press ENTER. If ENTER is not pressed within 10 seconds, the set
point will revert to the previously entered parameter.
(5)
Press MODE button until the manual indicator lights.
(6)
Press RUN/STOP button. The RUN/STOP indicator will light
and the refrigeration system and/or heater will operate.
(7)
If vacuum is required press VAC Button. Do not run vacuum with
unfrozen samples in chamber.
To change the set point temperature in the middle of a run, repeat
steps 2, 3 and 4. The system will adjust to the new temperature
set point.
To monitor system operation, press DISPLAY until the Monitor
indicator lights. The display will simultaneously show shelf
(SHLF) temperature, collector (COL) temperature and the sample
(SAMP) temperature. If the sample probe is not plugged into its
jack, the SAMP temperature display will show “- - -”. If in the
Pre-freeze mode the (COL) display will show“- - -”. If in the Inflask mode the (SHLF) the display will show“- - -”.
(8)
(9)
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Chapter 4: Operating Instructions
The segment numbers will always show “M” while operating in
the manual mode. Segment numbers are used only in the
automatic mode to identify portions of the programmed cycle.
Temperatures and vacuum are displayed in the units selected
during the set up procedure. Above 5.0 mBar the display will
show “HIGH” vacuum.
SHLF=XXX
COL= XXX
SHLF
SAMP
C
F
COL
SEG
M
VAC
m
P
T
(10)
SAMP=XXX °C
SEG =M
VAC = HIGH m
Shelf temperature
Sample probe (if probe is not installed, the display shows “ -”)
°C
°F
Collector Temperature
Shows what segment is active and ramping or holding.
Manual mode
System vacuum level
mBar
Pascal
Torr
To stop, push RUN/STOP button, which will turn off the
refrigeration system and the heater. To turn off the entire system,
turn the Power Switch OFF.
Automatic Control Operation
The Triad Freeze Dry System is equipped with a microprocessor-based
controller that permits temperature to be programmed using as many as six
different segments. The first segment is Pre-freeze with automatic “Max
Cold” setting and an adjustable time setting of 0, 3 hours to 99.9 hours or
indefinite. The additional five segments consist of a temperature ramp
function and a temperature hold function. There are five programs of six
segments each that can store settings. One of the five may be selected by
pressing the DISPLAY button until the AUTO indicator lights. Press the
UP/DOWN buttons to select the desired program, and then press ENTER.
The display will change to show the parameters for this program. The ramp
allows the temperature of the sample to be increased or decreased at any
desired rate within the capacity of the heating and cooling systems of the
Triad Freeze Dry System.
The Triad Freeze Dry System without samples on shelves is capable of
cooling at a rate of approximately .5°C/minute from 50°C to 0°C,
.25°C/minute from 0°C to –55°C. and can heat at approximately 3°C/minute.
Hold temperatures may be set anywhere from +50°C to –55°C in 1°C
increments. Hold times are set in hours.
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Chapter 4: Operating Instructions
When the desired temperature is achieved, the hold function will maintain
that temperature for the programmed length of time. The microprocessor
control has a built in memory of the last entered program to allow the
identical protocol to be repeated by simply pushing the RUN button. A
typical 3-segment program is shown in Figure 3.
Figure 3
Programming
The Triad Freeze Dry System will store up to five programs numbered 1
through 5. The five programs, once programmed, will be retained in
memory. To program a run, select the program number that you want to use
and enter the parameters as follows.
Turn the Power Switch to the ON position. Press the DISPLAY button until
the AUTO Indicator lights.
NOTE: Values shown in this example are for reference only.
The “P” in the display will flash and the program number that will be run is
shown. To select different programs, press the UP or DOWN button to
change program number (Programs 1 through 5). When the desired program
number is displayed, press ENTER.
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Chapter 4: Operating Instructions
The display will show the parameters that were last entered for this program.
P1
SEG 1
HOLD –34°C
RAMP
00.0°C/MN
TIME 00.0
If any of the parameters are changed, the ENTER button must be pressed for
the new value to be stored. If ENTER is not pressed within 10 seconds after
the last parameter adjustment, the value will return to the previously stored
value. The flashing parameter name shows the parameter that will be
changed. Pressing ENTER only will advance to the next parameter.
After the AUTO RUN cycle is started, segments with a value greater than the
segment running may have their parameters changed. Only the selected
program may be modified. To modify a different program, the system must
be stopped and the desired program selected.
Starting the Freeze Dry Cycle
After the desired cycles have been programmed, push the MODE button to
select AUTO. Push the RUN/STOP button to start the program running. The
RUN/STOP indicator will light. The system display will change and the
display will change to MONITOR mode.
During the pre-freeze segment the status display will be as follows:
P1 SHLF = -70
SAMP= -70°C
COL = --- SEG = PR VAC = hi
P1
SHLF
SAMP
°F or °C
COL
SEG
VAC
Selected Program
Shelf Temperature
Sample Temperature (if probe is not
installed, the display shows ---)
Temperature Units
No temperature displayed
Pre-Freeze Mode R(Ramp) H(Hold)
System Vacuum Level is above 5 mBar
During the ramp cycle of the active segment, the status display will be as
follows:
P1 SHLF = -55
SAMP= -55°C
COL = -85 SEG = 1R VAC = .03M
P1
SHLF
SAMP
°F or °C
COL
SEG
VAC
M
P
T
Product Service 816-333-8811 or 1-800-522-7658
Selected Program
Shelf Temperature
Sample Temperature (if probe is not
installed, the display shows ---)
Temperature Units
Collector Temperature
Shows what segment is active and
Ramping (R)
System vacuum level
MBar
Pascal
Torr
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Chapter 4: Operating Instructions
During the hold cycle of the active segment the display will alternate as
follows:
P1
SHLF
SAMP
P1 SHLF = -55
COL = -85
SAMP= -55°C
SEG = 1H VAC = .030M
COL
SEG
TR
P1 SHLF = -55
COL = -85
SAMP= -55°C
TR = 4.6 VAC = .030M
VAC
M
P
T
Selected Program
Shelf Temperature
Sample Temperature (if probe is not
installed, the display shows ---)
Collector Temperature
Shows what segment is active and holding
(H)
Shows time remaining segment. If time is
10.0 hours or more the time is displayed in
1/10 hours. If time is less than 10.0 hours,
the time is displayed in 1/100 hours. If the
hold time was programmed to be
indefinite, the display will show INDF.
System vacuum level
MBar
Pascal
Torr
Changing the Program Parameters in the Middle
of a Run
(1)
(2)
(3)
(4)
(5)
Press the DISPLAY button to obtain Monitor screen. Note the
current operating segment.
Press the DISPLAY button to obtain Auto screen.
By pressing the up button enter a segment number that follows the
current segment. The current segment cannot be modified while the
system is running. Press ENTER
Modify as required.
Press ENTER.
Stopping the Freeze Dry Cycle
1.
At the end of the last programmed segment, the freeze dry system will
automatically stop. The refrigeration system, the heater and the vacuum
pump will remain on. The display will show Segment “E” (End). To
shut off, press RUN/STOP button.
2.
To stop before the completion of the last programmed segment, press
RUN/STOP. The RUN/STOP indicator will turn off, as will the
refrigeration system, heater and vacuum pump. The display will remain
active but time functions will stop operating.
3.
Pressing the Power Switch will shut off the entire system.
4.
If the power is shut off during the program, when the power is turned
backed on the system will resume operation if the collector temperature
has not risen above –30°C. The unit will then attempt to complete the
programmed cycle from the point at which it was shut off. If the
collector temperature is greater than –30°C the system will not resume
operation. The RUN indicator and ALARM indicator will flash to
indicate power loss during the programmed run.
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Chapter 4: Operating Instructions
Monitoring the System Operation
Press the DISPLAY button to obtain the Monitor Screen. The display will
show the collector temperature, shelf temperature, system vacuum and
sample temperatures. If the sample probe is not connected, the sample
temperature display will show “- - -”. The temperatures and vacuum are
displayed in the units selected in Set Up. Above 5.0 mBar the display will
show “hi” vacuum.
The ice collecting coil temperature and the vacuum level should be
monitored. Higher than desired collector coil temperature or vacuum levels
will inhibit or ruin the freeze dry process.
Sample Freezing
Before the freeze dry process can occur, the products to be dried must be in a
frozen state. This can be accomplished in a freezer separate from the freeze
dry system or on the shelf in the Triad Freeze Dry System. If the samples
will be pre-frozen on the shelf inside the Triad, turn ON the Power Switch
and set the controls to cool the shelf. This is done by setting the temperature
to “pre-freeze” in the manual mode or the pre-freeze segment in the
automatic mode can be programmed to cool the shelves and start the vacuum
after the end of the pre-freeze segment. If desired, place the temperature
probe in a sample vial. Monitor the shelf and sample temperatures by
pressing the DISPLAY button until the monitor indicator lights.
Shelf Loading
The stoppering mechanism is capable of generating a very strong force,
which can damage the shelf or mechanism. Therefore, it is important to
distribute the serum bottles to be stoppered evenly across the entire surface of
the shelf. When stoppering vials, always place a vial on each corner of the
shelf.
Freeze Drying Inside the Chamber
The following procedure should be followed when freeze drying using the
temperature controlled shelf inside the vacuum chamber.
Manual Mode with Pre-Frozen Samples
1. With the display set to manual, select the desired “set point
temperature” between –55°C and 50°C.
2. Select MAN mode.
3. Start the refrigeration system by pressing “RUN/STOP.” Close the
door; turn on the vacuum.
4. When the collector temperature reaches –80°C and the shelf
temperature reaches the desired set point. Turn off the vacuum pump
and release the vacuum. Place the frozen samples on the shelf. Close
the door and turn the vacuum on.
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Chapter 4: Operating Instructions
Note: The system will go from room temperature start up to –55°C in
under 7 hours.
5. Shelf temperatures and vacuum set points can be changed at anytime
during the manual Freeze Dry process.
Manual Mode with Unfrozen Samples
1. With the display set in manual, select “Set Point Temperature” = PreFreeze.
2. Set mode to MAN.
3. Place unfrozen samples on the shelf and close the door. The sample
probe can be placed in the sample.
4. Start the refrigeration system by pressing “RUN/STOP.”
5. Start the vacuum pump by pressing “VAC.” Let the pump run 10
seconds. If the pump is allowed to run too long, sample may be lost.
6. The shelf temperature will cool to approximately –75°C and freeze
the sample.
Note: Starting the system at room temperature will take approximately 6
hours to freeze a 2 liter tray of water.
7. When the sample is frozen change the shelf “Set Point Temperature”
to the desired temperature between –55°C and 50°C.
8. Turn on vacuum.
9. Shelf temperatures and vacuum set points can be changed at anytime
during the manual freeze dry process.
Auto Mode with Pre-Frozen Samples
1. With the display set to Auto, program the desired ramp, temperature
and hold times for each segment of the program. The “PREFREEZE”
segment time should be set to 0. This allows the program to start at
segment 1.
2. Set mode to AUTO.
3. Start the refrigeration system by pressing “RUN/STOP.” Start the
vacuum pump.
4. When the collector temperature reaches –80°C and the shelf
temperature reaches the desired set point of segment 1, turn off the
vacuum pump and release the vacuum. Place the frozen samples on
the shelf. Close the door and turn the vacuum on.
Auto Mode with Unfrozen Samples
1. With the display set to Auto, program the desired ramp, temperature
and hold times for each segment of the program. The “PREFREEZE”
segment time must be set between 3 hours and “INDEF.” This allows
the shelf to cool and pre-freeze the sample. The samples must be
completely frozen during “PRE FREEZE” or samples will be
compromised and damage could occur to the vacuum pump when
turned on in segment 1.
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Chapter 4: Operating Instructions
2. Set mode to AUTO.
3. Place the unfrozen samples on the shelf and close the door.
4. Start the refrigeration system by pressing “RUN/STOP.”
Note: The vacuum pump will run 10 seconds and then turn off
automatically.
Stoppering Vials
The stoppering operation (when desired) is performed after the freeze dry
process is complete and before breaking vacuum. To seal vials, move the
Stoppering control toward the “LOWER” position. This action allows the
diaphragm above the stoppering platen to inflate causing the platen to lower.
The platen will lower until it contacts the vials on the shelf. The rubber
stoppers will be pressed into the vials. Monitor the stoppering process by
looking through the chamber door.
When all of the vials appear to be stoppered, move the Stoppering Control to
the “RAISE” position. This opens the diaphragm to the vacuum pump,
which deflates the diaphragm. Opening the Vacuum Release Control also
deflates the stoppering diaphragm. The Stoppering Control should be left in
the “RAISE” position when not stoppering. The stoppering mechanism is
equipped with anti-tilt switch which will stop the platen from lowering if it
tilts more that 4°: If this happens return the stoppering control valve to
“RAISE” position. This will deflate the diaphragm and allow the platen to
return to the raised position. Determine the cause of the tilt condition before
proceeding.
Vacuum Break/Backfilling
To open the chamber door, the vacuum must be released. To release the
vacuum, move the Vacuum Release Control to the “OPEN” position and shut
off the vacuum pump by pressing the VAC button. The vacuum can also be
released more quickly by opening one of the sample valves.
Air enters the vacuum chamber through the Back Fill Port. When the sound
of air through the Back Fill Port is no longer audible, the chamber door is
ready to open.
To backfill the chamber with a gas, connect a cylinder of the desired gas to
the Back Fill Port. The port will accept 1/8" tubing. The bottle must be
equipped with a regulator set to 15 psi maximum. The gas can be metered
with the Vacuum Release Control and chamber pressure monitored with the
freeze dry system’s vacuum gauge. Allow the vacuum pump to run for a few
minutes while the gas enters to permit the back fill gas to surround the freeze
dried sample. When the vacuum pump is turned off, air will enter the system
through the vacuum break valve located between the vacuum pump and the
collector chamber.
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Chapter 4: Operating Instructions
Freeze Drying Using Manifold Valves
The following procedure should be followed when using the sample valves
for the freeze dry process:
1. Turn on the Triad Freeze Dry System. Select manual mode, change the set
point temp to “IN-FLASK” and turn on the vacuum.
2. Once the collector temperature is less than –80°C and vacuum is less than
0.133 mBar, connect a pre-frozen sample to a sample valve on the left side
of the cabinet using an adapter. Turn the plastic valve knob to the
“VACUUM” position to open the valve. The bevel on the knob should be
positioned toward the sample port to apply vacuum to the sample. (see
Figure 4).
3. Before adding another sample, allow system vacuum to return to the
vacuum set point. Any combination of valves and sample sizes may
be utilized at one time provided that the system vacuum and collector
temperature remain sufficiently low to prevent melting of the frozen
sample.
4.
When all the frost has disappeared from the outer surface of the
sample container and no cold spots can be detected by handling the
container, primary drying is nearly complete. To be certain of low
final moisture content, dry the sample for several hours past this
point.
Figure 4
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Chapter 4: Operating Instructions
5. To remove a container after freeze drying is complete, turn the plastic
knob on the valve to the “VENT” position, which closes the valve and
vents the container. Should backfilling with an inert gas be required,
connect the gas supply line to the vent port on the valve before
turning the plastic knob on the valve to vent position. The sample
container may now be removed. In the vent position the bevel on the
valve knob should point away from the sample port.
6. Ampules may be flame sealed while connected to a valve by using a
sealing torch. Care must be taken not to burn the valve. An
insulation material placed between the valve and the torch is
recommended.
Defrosting
After the freeze dry process is complete the ice that has accumulated on the
collector coil must be removed. The Triad Freeze Dry System is equipped
with a rapid defrost feature.
The following procedure should be followed when defrosting the collector
coil:
1. Press the DEFROST button on the control panel. The defrost
indicator above that button will illuminate. Allow unit to operate in
this condition until all condensate is defrosted from the collector coil.
Turn the system off by pressing RUN/STOP button or it will
automatically shut off after 3 hours.
2. Place the drain hose in a suitable container to collect the
condensation. Remove the drain plug from the drain hose.
3. Replace drain plug and remove drain pan to dispose of the ice and
wipe dry.
4. Press the DEFROST button, the indicator will be off.
5. Wipe any excess liquid from inside of vacuum chamber, replace drain
pan.
Utilization of acid requires immediate cleaning and
neutralization after defrost or physical damage to the
collector chamber and coil will result.
Do not attempt to chip ice from the collector coil as damage
may occur.
Never attempt to start the vacuum pump when there is liquid
in the collector chamber. This could result in damage to the
vacuum pump.
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Chapter 4: Operating Instructions
Alarms
A number of events may occur during a lyophilization procedure that can
adversely effect the operation of the Triad Freeze Dry System. If an event
occurs, the alarm indicator will flash and beep.
The beep will automatically mute itself after one minute. The specific alarm
can be identified by observing the display. The following “out of
specification” conditions will initiate an alarm:
Shelf Temperature Variations
Once the shelf temperature has stabilized for 20 minutes, if the manual set
point temperature or automatic hold temperature varies more than ±2°C as
measured by the shelf temperature sensor, the Alarm Indicator and the word
“SHLF” on the display will flash until the end of the run.
Collector Temperature Variations
If the temperature raises above –40°C and stays there for more than 20
minutes the Alarm Indicator and the word “COL” on the display will flash
until the end of the run.
Vacuum
Once the system vacuum is low and stabilized at a point where it changes less
than 0.020 mBar in 5 minutes, if the vacuum changes more than 0.500 mBar,
the Alarm Indicator and the word “VAC” on the display will flash until the
end of the run.
Vacuum Pump Service
When the vacuum pump service hours reaches 1000 hours. The Alarm
Indicator and the VAC Indicator will flash on for 3 seconds and off for 1
second. When the vacuum is turned off the VAC Indicator will flash 1 second
on and 3 seconds off. Resetting the vacuum pump service hours will cancel
the alarm.
Shelf Temperature Set Point
If during a Ramp mode the system temperature stabilizes without reaching
the set point temperature, the control will enter the next Hold mode. The
Alarm Indicator will flash and the program indicator “Px” on the display will
flash until the end of the run.
Power Failure
If a power failure occurs while a run is in progress, the Alarm Indicator and
RUN/STOP Indicator will flash when the power is restored. Once power is
restored, the process will continue as programmed if the collector
temperature has not risen above –30°C. Pressing Run/Stop cancels the
flashing warning.
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Chapter 4: Operating Instructions
Platen Tilt
If the stoppering platen tilts more than 4° while stoppering, the platen will
stop. The display will read “SHELF UNEVENLY LOADED.”
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29
Chapter 5:
Maintaining Your Freeze Dry
System
Under normal operation, the freeze dry system requires little maintenance.
However, the following maintenance schedule is recommended:
As needed:
1. The user has the responsibility for carrying out appropriate
decontamination if hazardous material is spilled on or inside the
equipment. This may be done by wiping the contaminated surfaces
with a soft cloth dampened with alcohol. Alcohol may craze the
acrylic door. Before using any cleaning or decontamination method
except those recommended by Labconco, users should check with
Labconco to determine that the proposed method will not damage the
equipment.
2. Clean up all spills; remove liquids from the chamber.
3. Clean door and gasket using soft cloth, sponge or chamois and a mild,
non-abrasive soap or detergent.
4. Check oil level of the vacuum pump. It should be between MIN and
MAX. If the oil level is less than an inch (25.4 mm) above MIN, add
oil to proper level.
5. If oil shows cloudiness, particles or discoloration, drain the pump and
replace with fresh oil.
6. The use of acids requires immediate cleaning and neutralization after
a run or physical damage will result.
7. When freeze drying biological substances, it may be necessary to
decontaminate the system. A surface decontaminant should be used
to clean the accessible surfaces.
The use of ethylene oxide is not recommended
because of its hazardous and corrosive nature.
Contact Labconco for additional information.
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Chapter 5: Maintaining Your Freeze Dry System
Monthly:
1. The rubber components on the freeze dry system may eventually
deteriorate and require replacement. The effective life of rubber parts
depends upon both their usage and the surrounding environment. Check
all rubber hoses and gaskets and replace any that show signs of
hardening, permanent set or deterioration.
2. Using a soft cloth, sponge or chamois and a mild, non-abrasive soap or
detergent, clean the acrylic door.
3. Using a soft cloth, sponge, or chamois and a mild, non-abrasive soap or
detergent, clean the exterior surfaces of the cabinet. Liquid spray
cleaners and polishes may be used on the exterior surfaces. Do not use
solvents to remove stains from the exterior surfaces as they may damage
the finish.
Annually:
1. Every 12 months, or more often if the freeze dry system is operated in
a dusty environment, the refrigeration system condenser should be
cleaned. Using a vacuum cleaner with brush attachment, clean the
condenser to ensure proper airflow for peak performance.
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Chapter 6:
Using the RS232 Receptacle
The operation of the Triad Freeze Dry System can be monitored using a
computer connected to the RS232 receptacle located on the rear panel of the
freeze dryer. The computer cannot control the operation of the freeze dry
system.
Computer Connection for Computer Interface
Check your computer to see which type of serial port is provided. Use one of
the two connecting cables listed below:
1. Computers with a 25-pin D-sub male serial connector should use
Connect Cable, Labconco part number 7537801, to connect a
computer to the Labconco Freeze Dry System.
2. Computers with a 9-pin D-sub male serial connector should use
Connect Cable, Labconco part number 7537800, to connect a
computer to the Labconco Freeze Dry System.
The purpose of the RS232 interface is to send data to a data logging computer
to monitor the state and activity of the freeze dry system This data is half
duplex data. The data properties are as follows:
1. Data Rate 2400 Baud
2. 8 bit word length
3. 1 Start bit, 1 Stop bit
4. No parity is transmitted
5. Standard ASCII character set
The time between data transmissions may be varied by the user to occur at
10, 30, 60, 300 or 600 second intervals. Press the display button until the set
up indicator lights. Press the enter button until the RS232 screen appears on
the display.
RS-232 TRANSMISSION RATE
10
32
SECONDS
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Chapter 6: Using the RS232 Receptacle
Press × or Ø until the desired time interval is shown. Press ENTER.
The format of the transmitted message with typical values is as follows:
PROG = 1 SEG = 2R TRM = 17 COL = -85 SHLF = -55 SAMP = -55 VAC = 180
Where:
PROG
1
M
S
SEG
2
R
H
E
P
TRM
COL
-85
SHLF
-55
SAMP
-55
VAC
180
999
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
Program
Program 1 is selected
Manual Mode
Stop
Segment
Segment 2 is operating
Ramping
Hold
End
Prefreeze
Time remaining of current hold segment in hours
Collector
Collector temperature in °C
Shelf
Shelf temperature in °C
Sample Probe
Sample temperature in °C
Vacuum
Vacuum in microbar
Function not active
There are several commercially available software packages, which can read
RS232 data and enter the data into a computer program such as a word
processor (to create a text file) or spreadsheet (to tabulate and plot the data).
Consult your laboratory supply dealer regarding the latest software available.
The following describes how to use an IBM compatible computer with Hyper
Terminal™ software (included with Windows® 95, 98, XP or 2000 operating
systems) to collect the RS232 data from your freeze dry system:
1. Make sure that the freeze dry system is properly connected to the
communication port on the computer.
2. Open Hyper Terminal™ software.
i) Windows® 95 or 98 use:
START/PROGRAMS/ACCESSORIES.
ii) Windows® 2000 or XP use:
START/PROGRAMS/ACCESSORIES/COMMUNICATIONS
The first time Hyper Terminal™ is opened a dialogue box requesting an
area code and phone number will appear. Enter the appropriate numbers
and continue.
Product Service 816-333-8811 or 1-800-522-7658
33
Chapter 6: Using the RS232 Receptacle
3. The “Connection Description” dialogue box will
open. Type in a user defined name and select an
icon for the new connection. Press “OK.”
4. The “Connect To” dialogue box will open. Using
the down arrow selection button, select the
communication port to which the cable has been
connected. Press “OK.”
5. The “Com X Properties” dialogue box will open.
Enter the appropriate data properties and press
“OK.”
6. When the freeze dry system main
power switch is on, the data will be
transmitted and updated at the time
intervals selected by the user.
34
Product Service 816-333-8811 or 1-800-522-7658
Chapter 7:
Troubleshooting
Refer to the following if your freeze dry system fails to operate properly. If
the suggested corrective actions do not solve your problem, contact Labconco
for additional assistance.
Vacuum System
FreeZone® Triad™ Freeze Dry Systems that are clean and dry and without
samples attached should reach a vacuum of 0.133 mBar within 30 minutes
and should achieve an ultimate vacuum of 0.040 mBar within 18 hours when
the refrigeration is operating. If the freeze dry system does not obtain a
satisfactory vacuum, perform the following maintenance tests.
Vacuum Pump
First make sure that the vacuum pump operates. If it fails to operate, check
the electrical connections of the freeze dry system to the power source and
then check the electrical connection of the vacuum pump to the freeze dry
system. If the vacuum pump has a power switch, make sure that it is turned
on. If the vacuum is not adequate when the vacuum pump is operating,
proceed with the following steps:
1. Check the oil and ensure it is clear and clean. If the oil looks cloudy
or has any particulates, replace the pump oil. If the oil is excessively
dirty it may be necessary to flush the pump with clean oil several
times. To flush the pump, run the pump 5 to 10 minutes to allow the
oil to warm up. Drain the oil and refill with clean oil. Repeat as
necessary.
2. Check the oil level in the pump. Ensure it is filled to the correct level.
3. Check vacuum hose connections from the pump to the freeze dry
system and try running the unit.
Product Service 816-333-8811 or 1-800-522-7658
35
Chapter 7: Troubleshooting
If vacuum problems continue, consider obtaining a second vacuum gauge
capable of reading a vacuum of 0.010 mBar. It is often useful in determining
if the vacuum pump is operating properly and the vacuum sensor reading is
accurate.
4. Isolate the pump by disconnecting the vacuum hose from the freeze
dry system. Deadhead the pump by inserting the vacuum sensor from
a secondary vacuum gauge into the end of the vacuum hose and
observe the vacuum reading obtained. Confirm that the pump is
capable of achieving an ultimate vacuum less than 0.010 mBar or
approximately 10 microns. If an inadequate vacuum reading is
obtained, the pump has most likely failed and may need to be replaced
or rebuilt.
Gaskets, Tubing, Connections and Sample
Valves
1. Check all sample valves on the side of the cabinet and ensure all
valves are closed or in the vent position.
2. Check all vacuum tubing for signs of deterioration or cracking.
3. Check all connections and make sure they are secure and leak tight.
4. Check the freeze dry system door gasket for indentations cracks or
tears. Clean gaskets using a soft, lint free cloth or paper towel.
5. The freeze dry system chamber and collector must be dry.
6. When checking the sample valves, pull as much vacuum as possible.
If a vacuum indication is displayed, wiggle or rotate the valves and
watch the gauge for any fluctuation. Fluctuations can show a
potential vacuum leak. If the valve seems to be in good condition,
remove the valve and apply a thin coat of vacuum grease to the stem
and the outside sealing surface of the valve body, and reinstall the
valve. If the valve still seems to be the source of the problem, remove
the valve and stopper the hole with a rubber stopper. Continue
checking the other valves.
36
Product Service 816-333-8811 or 1-800-522-7658
Chapter 7: Troubleshooting
The illustration below shows how the sample valve installs on the
chamber.
Figure 5
Diagnostic Mode
In the event that there is a problem with the Triad Freeze Dry System, a
diagnostic mode is available. This mode can be used to diagnose problems by
isolating individual system components to confirm their operation. With the
unit Power Switch OFF, press the Ø button and turn the Power Switch ON.
The display will show:
DIAGNOSTIC MODE
Press ×.
The display will show:
LEXSOL PUMP ON
The Lexsol pump will turn on or press ×.
The display will show:
LEXSOL AND VAC. PUMP ON
The Lexsol pump, vacuum pump and vacuum valve will turn on or press ×.
The display will show:
REFRIGERATION -- SHELF
Product Service 816-333-8811 or 1-800-522-7658
37
Chapter 7: Troubleshooting
The shelf valve opens and refrigeration system turns on or press ×.
The display will show:
REFRIGERATION -- COLL
The collector valve opens. The (shelf valve closes) refrigeration system
remains on or press ×.
The display will show:
REF + LEX PUMP
The refrigeration system remains on. The Lexsol pump turns on or press ×.
The display will show:
DEFROST
The defrost valve opens or press ×.
The display will show:
VACUUM PUMP
The refrigeration system turns off. The vacuum pump turns on or press ×.
The display will show:
VAC VENT VALVE
The vacuum pump turns off. The vacuum control valve closes or press ×.
The display will show:
SHELF TILT VALVE
The vacuum control valve opens. The shelf tilt valve turns on (open) or press
×.
The display will show:
HEATER ON
The heater turns on for 3 minutes or press ×.
The display will go to monitor screen.
38
Product Service 816-333-8811 or 1-800-522-7658
Chapter 7: Troubleshooting
Refrigeration Module Operation
In the Pre-freeze mode under a no-load condition and an ambient temperature
of 20°C, the freeze dry system refrigeration system can achieve a shelf
temperature of –75°C or lower within 4 hours.
If any repairs are required on the refrigeration module, please call Labconco.
Repairs should only be undertaken by a competent refrigeration technician or
through an authorized Labconco service agency.
Filling the Fluid System
Figure 6
Product Service 816-333-8811 or 1-800-522-7658
39
Chapter 7: Troubleshooting
(1)
Disconnect power cord from supply outlet.
(2)
Make sure the Power Switch is in the OFF position.
(3)
Remove the rear cover to expose the marked back foam insulation.
Cut through the foam along the marked lines and remove center
cutout.
(4)
Remove the insulation and both caps from the fluid circulation valve.
(5)
Attach a flexible tube to the exposed port (service port). The port is
3/8" x 45° male flare.
(6)
Remove the fluid reservoir cap and place the opposite end of the
tubing into the fluid reservoir.
(7)
Fill the reservoir slowly allowing the fluid to drain through the
system. When the system appears full, prepare to start the circulation
pump.
(8)
Open the fluid circulation valve by completely “down-seating” (turn
top valve stem completely clockwise) to direct fluid to by-pass
through tubing to fluid reservoir.
(9)
Connect the unit to the proper power source. Activate the pump by
moving the Power Switch to the ON position, while holding down the
Ø button. To start the diagnostic display, press the × button. The
fluid system will circulate with the fluid going through the add-on
tubing, purging itself of air. Add fluid when needed to keep fluid in
the reservoir. After the fluid stream is established, tilt the entire
freeze dry system up and down. Observe the fluid stream and repeat
the tilt procedure if it is not free of bubbles. Fill reservoir to level
indicated by the label.
(10)
Turn power switch to the OFF position and disconnect power cord
from supply outlet.
(11)
Close “up-seat” fluid circulation valve (turn valve stem completely
counter-clockwise, closing the fluid/tubing by-pass).
(12)
Remove the tubing. Replace the caps on the valve and replace
insulation and covers. Replace the cap on the tank.
(13)
Replace insulation and seal air tight. Replace rear cover.
40
Product Service 816-333-8811 or 1-800-522-7658
Chapter 7: Troubleshooting
Heat Transfer Fluid Precautions
The fluid’s name and manufacturer are:
Name:
Manufacturer:
Lexol 542
Santa Barbara Chemical Co.
927 Indio Muerto
Santa Barbara, CA 93140
805-963-7793
The fluid used for heat transfer in this system is
combustible and hazardous. Leaks and spills should
be attended to immediately or serious injury could
occur.
Handling and Storage Precautions – Dirty Solvent: Store in
accordance with all applicable regulations. Tighten caps and store in
a cool area.
Precautions if Material is Released or Spilled: Spills should be
contained immediately. Spills may be soaked up with absorbent
materials, placed in closed containers, labeled, stored and disposed of
properly. Persons performing this work should wear adequate
personal protective equipment and clothing.
Disposal of Non-Recyclable Solvents: Dispose of in accordance
with all federal, state, and local health and pollution regulations.
Follow same guidelines as when disposing kerosene.
Heat Transfer Fluid First Aid Procedures
Eye Contact: Immediately flush eyes with fresh water for at least 15
minutes. If irritation persists, get medical attention.
Skin Contact: Wash contaminated areas with soap and water.
Remove contaminated clothing and footwear. Wash clothing before
reuse. Discard footwear which cannot be decontaminated. Medical
attention may be required.
Inhalation: Remove patient to fresh air. If breathing stops, give
artificial respiration. Get medical attention immediately, if required.
Ingestion: Get medical attention immediately. Do not induce
vomiting.
Product Service 816-333-8811 or 1-800-522-7658
41
Chapter 8:
Modifying Your Freeze Dry
System Display
Your Triad Freeze Dry System has been carefully calibrated and tested before
shipping, however under certain circumstances it may be necessary to adjust
the calibration of the vacuum display or to reset factory settings. These
adjustments may be necessary if the freeze dry system requires service.
An offset may be added to the vacuum display. Use an accurate traceable
reference to compare the readings.
Vacuum offset may be varied ±0.010 mBar in 0.001 mBar increments.
Modifying the Display
To enter an offset or to restore all factory settings, perform the following
steps:
• Press the DISPLAY button until the SET UP INDICATOR is lit.
• Press and hold DISPLAY button for 10 seconds.
The display will first show the screen used for setting Auto mode
parameters and then will show:
PRODUCTION MENU
MASTER RESET?
If you want to restore all factory settings hold ENTER approximately 5
seconds.
This will reset:
Vacuum units to mBar
Vacuum offset to 0 mBar
Temperature units to °C
Refrigeration service hours to 0
Vacuum total hour to 0
Vacuum service hour to 0
Refrigeration total hours to 0
RS232 transmission rate to 10 seconds
At the completion of Master Reset, the display will return to the monitor
mode.
42
Product Service 816-333-8811 or 1-800-522-7658
Chapter 8: Modifying Your Freeze Dry System Display
If you do not want to restore all factory settings, but want to adjust the
vacuum offset, press DISPLAY briefly and the display will show:
VACUUM OFFSET: 0 mBar
Press × or Ø until the appropriate offset is shown.
Each number represents an offset of 0.001 mBar
Press DISPLAY and the display will show:
COLLECTOR TEMP. OFFSET: 0°C
Press × or Ø until the appropriate offset is shown.
Each number represents an offset of 1°C.
Press DISPLAY and the display will show:
This is the probe mounted in the
shelf. Temperature from this probe
is displayed during Pre Freeze.
SHELF TEMP. OFFSET: 0°C
Press × or Ø until the appropriate offset is shown.
Each number represents an offset of 1°C.
Press DISPLAY and the display will show:
LEXSOL TEMP. OFFSET: 0°C
This is the probe mounted to the Lexsol tube
in the back. Temperature from this probe is
displayed as “SHLF TEMP” during
sequences other than PRE FREEZE.
Press × or Ø until the appropriate offset is
shown. Each number represents an offset of 1°C.
Press DISPLAY and the display will show:
SAMPLE TEMP. OFFSET: 0°C
Press × or Ø until the appropriate offset is shown.
Each number represents an offset of 1°C.
Press DISPLAY and the display will show:
PRODUCTION MENU: MASTER RESET?
Wait approximately 10 seconds and the display will default to show
operational parameters.
Product Service 816-333-8811 or 1-800-522-7658
43
Appendix A:
Freeze Dry System Components
The following pages list components that are available for your freeze dry
system. The parts shown are the most common replacement parts. If other
parts are required, contact Product Service.
Item
Part No.
Qty
1
7591801
7591802
2
2
Compressor 230V – 50 Hz
Compressor 230V – 60 Hz
2
7501902
1
Lexsol Pump 230V
3
7510901
1
Heater 230V
4
7754800
1
Pass thru Board
5
7515300
2
Temperature Sensor – Lexsol Collector
6
7372500
2
Temperature Sensor – Sample/Shelf
7
7765501
1
Diaphragm
8
7424100
1
Door Gasket
9
7766801
1 Gal.
10
7395300
1
Printed Circuit Board Control
11
7448000
1
Printed Circuit Board RS232
12
7425500
1
Door Assembly
44
Description
Heat Transfer Fluid (Not Shown)
Product Service 816-333-8811 or 1-800-522-7658
Appendix A: Freeze Dry System Components
Figure 7
Product Service 816-333-8811 or 1-800-522-7658
45
Appendix B:
Freeze Dry System Dimensions
Figure 8
Serum Bottle Capacity of the Triad Freeze Dry System
Size
2 ml
3 ml
5 ml
10 ml
20 ml
30 ml
50 ml
100 ml
125 ml
46
Labconco No (100 pcs.).
7575010
7575210
7573010
7573210
7573410
7573610
7573810
7574010
7574210
Shelf Capacity
391
441
233
196
121
86
64
42
36
Product Service 816-333-8811 or 1-800-522-7658
Appendix C:
Freeze Dry System Specifications
This Appendix contains technical information about the freeze dry system’s
electrical specifications and environmental operating conditions.
Electrical Specifications
Voltage
Catalog
Number
Description
Nominal
Operating
Range
Frequency
Phase
Amperage
7400030 Triad Freeze Dry System
230
198-254
50
1
12
7400040 Triad Freeze Dry System
230
187-253
60
1
12
Environmental Conditions
•
Indoor use only.
•
Maximum altitude: 6562 feet (2000 meters).
•
Ambient temperature range: 41° to 104°F (5° to 40°C).
•
Maximum relative humidity: 80% for temperatures up to 88°F
(31°C), decreasing linearly to 50% relative humidity at 104°F (40°C).
•
Transient over voltages according to Installation Categories II (Over
voltage Categories per IEC 1010). Temporary voltage spikes on the
AC input line that may be as high as 1500V for 115V models and
2500V for 230V models are allowed.
•
Used in an environment of Pollution degrees 2 (i.e., where normally
only non-conductive atmospheres are present). Occasionally,
however, a temporary conductivity caused by condensation must be
expected, in accordance with IEC 664.
Product Service 816-333-8811 or 1-800-522-7658
47
Appendix C: Freeze Dry System Specifications
Performance Specifications
Collector Minimum Temperature (°C)
-85
Collector Capacity in 24 Hours (Liters)
1.84
Collector Total Capacity (Liters)
2.5
Shelf Minimum Temperature (°C)
-75
Shelf Control Temperature Range (°C)
-55 to +50
Shelf Size (Inches)
12.4 x 14.5 x 5.75 high
Number of Shelves
1
Defrost Method
Hot Gas
Time to Defrost 2.0L (Hr)
1.5
All Temperature Specification @ 20°C Ambient
48
Product Service 816-333-8811 or 1-800-522-7658
Appendix D:
Freeze Dry System Accessories
The following accessories are available for the Triad Freeze Dry System.
PART #
7537800
7537801
7756100
7756200
7516200
7739403
7439200
7769800
DESCRIPTION
Cable
Connect the RS232 output from the Triad Freeze Dry System to an
IBM compatible computer with a 9-pin serial data port.
Cable
Connects the RS232 output from the Triad Freeze Dry System to
an IBM compatible computer with a 25-pin serial data port.
Tray with Slide-Out Bottom
14" wide x 12" deep. Stainless steel tray has separate bottom,
which slides out allowing serum bottles, and ampules direct
contact with the shelf to facilitate the drying process.
Bulk Tray
15" wide x 11-1/2" deep. Stainless steel tray will contain liquids
for bulk drying.
Support Grid
7" wide x 7" deep. Stainless steel tray with removable plastic grid
provides support for stoppering ampules and other small specimen
containers while stoppering under vacuum. Grid holds 144
ampules of 12 mm diameter.
Vacuum Pump
Two stage direct drive pump, 195 liters/minute. 230 VAC,
50/60 Hz, single phase, 4.0 amps. Includes Pump Exhaust
Filter/#1473400.
Vacuum Pump
Two stage direct drive pump, 173 liters/minute. 230 VAC,
50/60 Hz, single phase, 2.9 amps. Includes Pump Exhaust
Filter/#7670400.
Vacuum Pump Corrosion Resistant
Two stage direct drive pump, 173 liters/minute. 230 VAC,
50/60 Hz, single phase, 2.9 amps. Includes Pump Exhaust
Filter/#7670400.
Product Service 816-333-8811 or 1-800-522-7658
49
Appendix D: Freeze Dry System Accessories
PART #
1472200
1473400
1473200
1473300
7670400
1988000
7772700
7772000
7772100
7772500
DESCRIPTION
Pump Inlet Filter
Disposable filter that prevents oil back streaming and protects vacuum
pump from sub micron particles. Fits Vacuum Pump #7739403.
Pump Exhaust Filter
Disposable filter that removes visible oil mist and odor from vacuum
pump exhaust. Fits Vacuum Pump #7739403.
Replacement Element, Oil Mist, Pump Exhaust Filter
Fits Pump Exhaust Filter #1473400.
Replacement Element, Odor, Pump Exhaust Filter, package of 5
Fits Pump Exhaust Filter #1473400 or Vacuum Pump #7739403.
Replacement Filter – Element
Disposable filter that removes oil mist from the vacuum pump
exhaust. Fits Vacuum Pumps #7439200 and #7769800.
Vacuum Pump Oil, 1 Liter
A molecularly distilled hydrocarbon oil with low vapor pressure. For
Vacuum Pump #7739403.
Vacuum Pump Oil 1 Liter
A mineral oil with low vapor pressure. For Vacuum Pumps #7439200
and #7769800.
Soda Acid Trap
Secondary trap that prevents migration of corrosive chemicals into
vacuum pump.
Replacement Media for Soda Acid Trap
Carbon Solvent Trap
Secondary trap that prevents migration of organic solvents into
vacuum pump.
7772600
Replacement Activated Carbon Media for Carbon Solvent Trap
7509600
Sample Valve Kit
Includes neoprene valve body, knob and installation parts.
50
Product Service 816-333-8811 or 1-800-522-7658
Appendix D: Freeze Dry System Accessories
Serum Bottles and Vials
Threaded Vials
Stoppers and threaded vials with Screw
Caps are supplied in packages of 200.
Perfect for long term storage of freeze
dried samples. Labconco Serum
Bottles and Treaded Vials are
specifically designed for lyophilization
applications. Their uniform thin wall
construction ensures even freezing
and drying. Bottles and vials are ideal
containers for use in the FreeZone
Stoppering Tray Dryer. Serum bottles
also connect to valve ports on drying
chambers and manifolds.
Size
Vials with
Screw Caps
Stoppers
5 ml
10 ml
7762300
7762600
7762200
7762200
Serum Bottles
Seal Crimper
Serum Bottles, Stoppers and seals
are supplied in packages of 100.
Secures tear-away Aluminum Seals.
7578000 Seal Crimper for 13 mm corkage.
Shipping weight 3 lbs. (1.4 kg)
7578100 Seal Crimper for 20 mm corkage.
Shipping weight 3 lbs. (1.4 kg)
Size
2 ml
3 ml
5 ml
10 ml
20 ml
30 ml
50 ml
100 ml
125 ml
20 mm
Corkage
7573010
7573210
7573410
7573610
7573810
7574010
7574210
13 mm
Corkage
Split
Stoppers
Aluminum
Seals
Sleeve-Type
Stoppers
7575010
7575210
7576010
7576010
7576210
7576210
7576210
7576210
7576210
7576210
7576210
7577010
7577010
7577110
7577110
7577110
7577110
7577110
7577110
7577110
757710
7577510
7577510
7577510
7577510
7577510
7577510
Product Service 816-333-8811 or 1-800-522-7658
51
Appendix D: Freeze Dry System Accessories
Fast-Freeze® Flasks
Fast-Freeze Flasks are specially designed to be
easier to handle, faster to load and more
convenient to use than other freeze dry
glassware now in your laboratory. Compatible
with all major brands of laboratory freeze dry
equipment, Fast-Freeze Flasks eliminate the risk
of contamination from vacuum grease, reduce
spillage of valuable samples and require no
washers, gaskets or retainers.
How to select Fast-Freeze Flasks for your
Freeze Dry System
Select fast-Freeze Flasks based on your
sample sizes. Flasks should be filled no
more than one-third of their volume so that
maximum surface area is achieved and
efficient lyophilization is assured. A complete
Fast-Freeze Flask includes a rubber top,
glass bottom and a supply of filter paper.
Tops, bottoms and filter paper are available
separately as replacement components.
Adapters are required to attach flasks to
freeze dry valve ports.
Adapters
Add the adapters for connecting the Fast-Freeze
Flasks to the valve ports on your drying
chamber or manifold. Choose borosilicate glass
or stainless steel adapters in ½" and ¾"
diameters
Flask
Size
Complete
Flask
Flask
Bottom
Flask
Top
Flask Top
Adapter
Diameter*
Dimensions/
Flask Bottom
HxD
40 ml
80 ml
120 ml
150 ml
300 ml
600 ml
900 ml
1200 ml
2000 ml
7540000
7540200
7540300
7540400
7540600
7540800
7540900
7541000
7541200
7542000
7542200
7542300
7542400
7542600
7542800
7542900
7543000
7543200
7544000
7544000
7544200
7544200
7544200
7544400
7544400
7544400
7544400
½"
½"
¾"
¾"
¾"
¾"
¾"
¾"
¾"
76mm 34mm
115mm x 34mm
68mm x 59.2mm
85mm x 59.2mm
145mm x 59.2mm
135mm x 90.2mm
190mm x 90.2mm
240mm x 90.2mm
380mm x 90.2mm
*Valves on the freeze dry system, drying chambers and manifolds offered in this catalog fit
adapters of both ½" and ¾" sizes. Size information is provided for selecting adapters for older
Labconco models and other freeze dryers.
52
7544810 Replacement Filter Paper
1000 (10 packages of 100). 1" diameter
(28mm). Pore size 17 micron. Shipping
weight 0.5lb.
Product Service 816-333-8811 or 1-800-522-7658
Appendix D: Freeze Dry System Accessories
Lyph-Lock® Flasks
Lyph-Lock Flasks simplify your
Lyophilization procedures because they
have only three pieces per flask – a high
strength borosilicate glass top and
bottom with a silicone rubber ring seal.
The unique wide-mouth design helps
you load samples easily and lyophilize
efficiently.
How to select Lyph-Lock Flasks for
your Freeze Dry System
Select Lyph-Lock Flasks fast- based on
your sample sizes. Flasks should be
filled no more than one-third of their
volume so that maximum surface area is
achieved and efficient lyophilization is
assured. A complete Lyph-Lock Flask
includes a glass top and bottom and a
rubber ring seal. Tops, bottoms and
seals are available separately as
replacement components. Adapters are
required to attach flasks to freeze dry
valve ports.
25 ml
Complete
Flask
19/38 STj
7550000
Complete
Flask
24/40 STj
7550000
50 ml
7550200
7554200
100 ml
250 ml
7550400
7550600
Flask Size
Adapters
Add the adapters for connecting the Lyph-Lock Flasks to
the valve ports on your drying chamber or manifold.
90° Bend
Adapter
7568000
7568200
7568400
7568600
Description
Connects 19/38 STj Flask Top to ½"
valve*
Connects 19/38 STj Flask Top to
3/4"valve*
Connects 24/40 STj Flask Top to ½"
valve*
Connects 24/40 STj Flask Top to 3/4"
valve*
Dimensions/
Flask Bottom
H x ID
37mm x 34mm
Flask Top
19/38 STj
Flask Top
24/40 STj
Lyph-Lock
Seal
Flask
Bottom
7552000
7556000
7559000
7557000
7552000
7556000
7559000
7557200
67mm x 34mm
7554400
7554600
7552200
7552200
7556200
7556200
7559200
7559200
7557400
7557600
50mm x 59.2mm
110mm x 59.2mm
103mm x 90.2mm
500 ml
7550800
7554800
7552400
7556400
7559400
7557800
750 ml
7550900
7554900
7552400
7556400
7559400
7557900
145mm x 90.2mm
1000 ml
7551000
7555000
7552400
7556400
7559400
7558000
187mm x 90.2mm
*Valves on the freeze dry system, drying chambers and manifolds offered in this catalog fit adapters of
both ½" and ¾" sizes. Size information is provided for selecting adapters for older Labconco models
and other freeze dryers.
Product Service 816-333-8811 or 1-800-522-7658
53
Appendix D: Freeze Dry System Accessories
Ampules
Oxygen/Natural Gas Sealing Torch
7578500 Torch specifically designed for
flame sealing freeze dry ampules. Seals
all types of heat-resistant glass.
Connects to natural gas, butane or
propane and oxygen with ¼" ID hose
connectors. Shipping weight 3 lbs. (1.4
kg).
Labconco Ampules are fabricated of
highest quality borosilicate glass for
strength and durability. They are
available in five different configurations
to provide the ideal ampule for your
specific lyophilization requirements, from
tray drying to flame sealing applications.
Ampule Valve Adapters
7593401 Adapter connects ampules to
valve ports or stainless steel stems. Ten
per package. Shipping weight 0.5 lbs.
Ampules
Ampules are supplied in packages of
100.
Stoppers
Size
Straight
Bulb-Type
1 ml
2 ml
4 ml
5 ml
10 ml
25 ml
50 ml
7572710
7570010
Pre-Scored
Flat Bottom
757010
7570810
Round
Bottom
7572310
757210
7570210
7571010
757110
Stoppering
7572510 Stopper for
Stoppering Ampules 7572310.
100 per package. Shipping
weight 3 lbs. (1.4 kg).
7571610
7571810
7572010
Trident Adapter
7762700 Three Way Adapter permits attachment of three
ampules to a single valve port. Ampules are attached using
Ampule Valve Adapters or 1/8" surgical tubing (not provided).
Cavity in adapter body can be filled with cotton fiber media to
help prevent contamination between samples. Shipping
weight 3 oz. (0.1 kg).
54
Product Service 816-333-8811 or 1-800-522-7658
DECLARATION OF CONFORMITY
Application Council Directive(s):
73/23/EEC, 89/336/EEC, 2002/95/EC (ROHS),
2002/96/EC (WEEE)
Standard(s) to which conformity is declared: EN61010-1, EN55014, EN55104,
EN55022, EN61000-3-2, EN61000-3-3
Manufacturer’s Name:
Labconco Corporation
Manufacturer’s Address:
8811 Prospect Avenue
Kansas City, MO 64132 USA
Importer’s Name:
See Shipping/Customs Documents
Importer’s Address:
See Shipping/Customs Documents for your equipment
Type of Equipment:
Laboratory Equipment – Sample Preparation
Model No.:
Serial No.:
Stoppering Tray Dryer – 230V - #7948030
Triad Freeze Dry/Tray Dryer - 230V - #7400030
Various – See Individual Declaration
Year of Manufacture: 2004 and Subsequent
I, the undersigned, hereby declare that the equipment specified above conforms to the
above Directive(s) and Standard(s).
See individual Declaration of Conformity which
will be signed by the importer for your country.
Place:
_______________________________________
(Signature)
Date:
_______________________________________
(Full Name)
_______________________________________
(Position)
Labconco P/N 3696010, REV E, ECO E077
Product Service 816-333-8811 or 1-800-522-7658
55
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