PLEASE READ THIS MANUAL CAREFULLY BEFORE OPERATION MRC.VER.01-04.10

PLEASE READ THIS MANUAL CAREFULLY BEFORE OPERATION  MRC.VER.01-04.10
INSTRUCTION MANUAL FOR
Freeze Dry Systems
FDL-10N-50 series
PLEASE READ THIS MANUAL CAREFULLY BEFORE OPERATION
3, Hagavish st. Israel 58817 Tel: 972 3 5595252, Fax: 972 3 5594529 [email protected]
MRC.VER.01-04.10
CHAPTER 1
INTRODUCTION
Congratulations on your purchase of our 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 prep procedures 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 microorganisms). 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
materials by converting the frozen water directly into its 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.
About This Manual
This manual is designed to help you learn how to install, use, and maintain your Freeze
Dryer. Instructions for performing routine maintenance and making minor modifications
to your Freeze Dryer are also included.
CHAPTER 2
PREREQUISITES
Before you install your Freeze Dryer, you need to prepare your site for installation.
Carefully examine the location where you intend to install your Freeze Dryer. You must
be certain that the area is level and of solid construction. An electrical source must be
located near the installation site.
Electrical Requirements
The Freeze Dryer requires a dedicated electrical outlet. This outlet requires a 15 Amp
circuit breaker or fuse is required for models rated at 230V (50 Hz). The power cord on
230V models are equipped with a plug on the power cord. It will be necessary to change
a plug to match the available receptacle.
Unpacking Your Freeze Dryer
Carefully unpack your Freeze Dryer and inspect it for damage that may have occurred in
transit. If your Freeze Dryer is damaged, notify the delivery carrier immediately and
retain the entire shipment intact for inspection by the carrier.
Setting Up Your Freeze Dryer
After you verify receipt of the proper components, move your Freeze Dryer to the
location where you want to install it. Then, follow the steps listed below.
Component Orientation
The refrigeration system in the Freeze Dryer draws air in through the bottom of the
cabinet and exhausts air out through the rear sides. A minimum of 2" should be allowed
between the back and sides of the Freeze Dryer and the adjacent wall surface. Restriction
of the airflow through the cabinet during operation could adversely affect performance.
Vacuum Pump Connection
A vacuum pump is required to operate your Freeze Dry System properly. The Freeze
Dryer is equipped with a 25mm ID, heavy wall, vacuum hose for connecting the collector
chamber to the vacuum pump.
Make certain that the oil in the vacuum pump is at the proper level.
Place the vacuum pump near the benchtop Freeze Dryer models, or place the vacuum
pump on the floor.
Connect the vacuum pump power cord to the receptacle on the side of the cabinet labeled
“vacuum pump” , If the vacuum pump has an off/on switch, turn the switch on. The
vacuum pump will be controlled by the Freeze Dryer. Connect the vacuum pump inlet
port to the vacuum tube on the right side of the cabinet with the vacuum hose and clamps
provided. If necessary, cut the hose to proper length to allow for gentle bends without
kinks.
Electrical Connection
Plug the power cord into the receptacle on the rihgt side of the Freeze Dryer and plug the
other end into a suitable power receptacle.
Drying Chamber or Drying Manifold Installation
The drying chamber or drying manifold, purchased separately, may be positioned directly
above the 3-inch hole in the collector chamber lid. When vacuum is applied to the system,
the chamber will be held securely in place.
The installation and setup of your Freeze Dryer is now complete.
CHAPTER 3
USING YOUR FREEZE DRYER
After your Freeze Dryer has been installed, you are ready to begin using your Freeze
Dryer.
Freeze Dryer Controls
The control panel for the Freeze Dryer is shown below with a
description about its function.
The Freeze Dryer is being controlled manually by the operator. Each function must be
started by the operator.
Main Power Switch – Turns the Freeze Dryer on or off. (Not shown, located on the right
side of the cabinet).
1. Temperature LED Display – This display indicates the temperature of the collector.
2. COMP – Manual refrigeration switch ,Used to start or stop the refrigeration
compressor.
3. PUMP – Used to start or stop the vacuum pump, The power is being supplied to the
vacuum pump receptacle on the right side of the Freeze Dryer.
You can start the vacuum pump when the collector temperature reaches –40°C or lower.
4. Vacuum –Vacuum gauge power, This key is used to start or stop vacuum display.
5. CAL. –Calibration, service use only.
6. Vacuum LED Display –Vacuum display, This display indicates the relative system
vacuum level.
Operation Checklist
The following checklist should be followed prior to each use of your Freeze Dryer:
1. Wipe the interior of the collector chamber with a soft cloth or paper towel to remove
any accumulated moisture.
2. Check the collector chamber drain hose to ensure that the hose is free of moisture
and that the drain plug is securely installed. The freeze dryer will not start if moisture is
detected.
3. Using a soft, lint-free cloth or paper towel, wipe the collector chamber lid gasket to
remove any dirt and contaminants that could cause a vacuum leak. Vacuum grease is not
required on the lid gasket to obtain a proper vacuum seal.
4. Remove the accessory drying chamber or manifold from the connection port and
using a soft, lint-free cloth or paper towel, wipe the port gasket and sealing surfaces of
the drying chamber/manifold to remove any dirt and contaminants that could cause a
vacuum leak. Reinstall the drying chamber or manifold on the port. Vacuum grease is not
required on the port gasket to obtain a proper vacuum seal.
5. Check that each sample valve is closed or in the “upwards” position.
Vacuum Pump Ballast Setting
Most vacuum pumps are equipped with a 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 Freeze Dry System. 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.
Operating the Freeze Dryer
To manually run the freeze dry process, Turns the Freeze Dryer on by Main Power
Switch. (Not shown, located on the right side of the cabinet), Temperature LED Display
indicates the actual temperature of the collector.
Press the VACUUM switch, Vacuum LED Display will indicate system vacuum level,
When the vacuum in the system is above 999 Pa, the vacuum display will indicate
“999” ,At 999 Pa and below, the display will show the actual vacuum.
Press the COMP switch, This will start the refrigeration system. The red LED above the
switch will illuminate. When the collector temperature reaches –40°C or lower, the
vacuum pump may be started by pressing the PUMP switch.
Pre-Freezing Samples
Appropriate containers for freeze drying include ampules, serum bottles, and wide mouth
freeze drying flasks. Shell freezing of samples is recommended for wide mouth freeze
drying flasks. Smaller samples in ampules and serum bottles may be frozen in a
freezer or in the center of the collector chamber. The sample container size should always
be at least two to three times the sample size (i.e., 40 ml samples should be prepared in
80 ml containers or larger). The temperature required for pre-freezing is dependent on the
characteristics of the sample. Pre-freezing temperature typically is at least 10° to 20°C
below the eutectic or collapse temperature of the sample.
Adding Sample
The following procedure should be followed when using sample valves in the freeze
dry process:
1. Connect a pre-frozen sample to a sample valve on the drying chamber or manifold
using an adapter. After connecting a pre-frozen sample to a valve, turn the plastic valve
knob to the downwards position to open the valve, which connects the attached sample to
system vacuum. The bevel on the knob should be positioned downwards.
2. Before adding another sample bottle, allow system vacuum to return to 40Pa or
lower. 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.
3. 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, the sample is nearly dry. To
be certain of low final moisture content, dry the sample for several hours past this point.
4. To remove a sample bottle after drying is complete, turn the plastic knob on the valve
to the upwards position, which closes the valve and vents the container. The sample
bottle may now be removed.
5. 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.
Shut Down
At the end of a run or when a sufficient amount of condensate accumulates on the
collector to obstruct the flow of vapor to the collector chamber, the Freeze Dryer should
be defrosted. First, release system vacuum by turning the plastic knob on a valve to the
open position or by pluging the drain hose. Now press the vacuum switch on the control
panel to turn the vacuum pump OFF. Press the Refrigeration Switch next to the
illuminated LED to turn OFF the refrigeration system. Turn OFF the main power switch
on the right hand side of the cabinet.
Defrosting
The following procedure should be followed when defrosting the collector:
1. Install the drain hose plug from the front side of the Freeze Dryer. Place the drain
hose in a suitable container to collect the condensate that will melt off the collector .
2. Remove the collector chamber top and allow ambient room air to melt the ice.
Dispose of the liquid appropriately.
3. Flush the collector chamber with water and wipe chamber dry.
4. If rapid defrost is desired, pour warm water over the collector . Do not allow the
liquid to enter the vacuum port on the upper rear of the chamber.
5. Pulling the drain hose plug out, and put drain hose back into the side of the cabinet.
Dispose of the liquid appropriately.
CHAPTER 4
MAINTAINING YOUR FREEZE
DRYER
Under normal operation, the Freeze Dryer requires little maintenance. The following
maintenance schedule is recommended:
As needed:
1. Clean up all spills; remove liquids from the chamber.
2. Clean lid and gasket using soft cloth, sponge or chamois and a mild, non-abrasive
soap or detergent.
3. Check oil level of the vacuum pump. It should be over the middle line of oil mirror,
If the oil level is lower, add oil to proper level.
4. If oil shows cloudiness, particles or discoloration, drain the pump and replace with
fresh oil.
5. Utilization of acids requires immediate cleaning and neutralization after a run or
physical damage to the collector chamber and collector coil will result.
6. Check the collection chamber for condensed or frozen solvents and dispose of
appropriately. Completely empty the collector chamber before the next run or before
starting the vacuum pump.
7. If chamber or manifold valves leak or stems become difficult to turn, pull the stem
out of the rubber valve body and apply a thin coat of vacuum grease to the stem. Reinsert
the stem into the valve body.
CHAPTER 5
TROUBLESHOOTING
Refer to the following if your Freeze Dryer fails to operate properly. If the suggested
corrective actions do not solve your problem, contact us for additional assistance.
Freeze Dry Systems should reach a vacuum of 999Pa or lower within 10 minutes, and
should achieve an ultimate vacuum of 20Pa or lower within 30 minutes when the
refrigeration is operating. If the Freeze Dryer does not obtain a satisfactory vacuum,
perform the following maintenance tests.
I. Vacuum Pump
First make sure that the vacuum pump operates. If it fails to operate, check the electrical
connections of the Freeze Dryer to the power source and then check the electrical
connection of the vacuum pump to the Freeze Dryer. 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. Sometimes 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 Dryer and try running
the unit.
II. Gaskets, Tubing, Connections, Sample Valves
1. Inspect gasket(s) for cracks or defects. Ensure the gasket is clean. Apply a thin coat
of vacuum grease to the gasket. Keep in mind, too much vacuum grease can actually
cause leaks.
2. Check the drain line and ensure the drain plug is installed and the tube appears to be
in good condition.
3. Check all rubber vacuum tubing for signs of deterioration or cracking.
4. Check all connections and make sure they are secure and leak tight.
5. Check all sample valves on the drying chamber/manifold and ensure all valves are
closed or in the vent position. Check to ensure all fittings are tight and sealed properly
against the chamber. Inspect valves for cracks or cuts.
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