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Operating Manual Freeze Dryer

ALPHA 1-4 LD-2 / 2-4 LD-2

, Version 0203, Page 24

3

Control System LD-2

A particular advantage of the user friendly LD control system (Lyo-display) is that all
functions are explained on the control panel.

-

LC display showing the most important process data (temperature of ice
condenser, vacuum)

-

Conversion of temperature and vacuum in accordance with the vapour pressure
curve above ice

-

RS-232 communications interface (PC) is available as an option.

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Summary of Contents for 101041

Page 1: ......

Page 2: ...Gefriertrocknungsanlagen OPERATING MANUAL Freeze Dryer ALPHA 1 4 LD 2 Best Nr 101041 101141 101241 ALPHA 2 4 LD 2 Best Nr 101042 101142 101242 M A R T I N C H R I S T Gefriertrocknungsanlagen GmbH...

Page 3: ...g Manual ALPHA 1 4 LD 2 and ALPHA 2 4 LD 2 Order Number Serial Number In case of inquiries or repair please state the above numbers For service please contact MARTIN CHRIST Gefriertrocknungsanlagen Gm...

Page 4: ...ecial advantage is the user friendly control system LD Lyo display the functions of which are explained on the control panel LC display showing the most important process data temperature of ice conde...

Page 5: ...bited freeze drying processes 11 2 Installation and Commissioning of the Unit 2 1 Site of installation 13 2 2 Mains electricity 13 2 3 Fuses on site 13 2 4 Checking the Earth connection 2 5 Defrosting...

Page 6: ...d of drying and venting 34 4 5 Defrosting 34 5 Description of the Freeze Drying Processes 5 1 Freezing separately and drying on shelves 35 5 2 Drying with sealing device 35 5 3 Freezing separately and...

Page 7: ...nser temperature 44 8 Appendix Declaration of conformity for ALPHA 1 4 LD 2 2 4 LD 2 Explanation to the panels ALPHA 1 4 LD 2 4 LD Explanation to the panels ALPHA 1 4 LD 2 2 4 LD 2 Operating manual of...

Page 8: ...ophilisation is also the most gentle process for preserving the biological properties of sensitive tissue and tissue components Through freeze drying the product mainly of biological origin such as ti...

Page 9: ...urface areas 360 Max shelf surface area when drying in injection vials according to DIN with sealing under vacuum or nitrogen atmosphere Only outside with 4x shelf surface areas 250 Drying in round bo...

Page 10: ...onnection DN 25 KF ISO 28403 DIN 2861 Condensate drain hose nozzle DN 10 with 0 5 m silicon hose D 8 x s 2mm Scope of supply includes 1 tube high vacuum grease 1 litre vacuum pump oil if pump is suppl...

Page 11: ...the vacuum pump if necessary check with our service department Special caution is necessary when using azides because a dangerous explosive develops in combination with copper or non ferrous metals It...

Page 12: ...Freeze Drying Processes 1 Operation of freeze dryer when not installed correctly 2 Operation without panels 3 Operation by non authorised personnel 4 Operation with shelves not installed properly 5 Op...

Page 13: ...ining liquids near the freeze dryer 10 Products which could react to the supply of high energy during the freeze drying process must not be dried 11 Do not freeze dry explosive or highly inflammable s...

Page 14: ...ators or heat sources and direct insolation must be avoided In the event of insufficient air circulation or a too high ambient temperature pressure and temperature in the refrigerating system will inc...

Page 15: ...t which is produced must be removed A hose is connected to the exhaust flange of the vacuum pump RZ 2 or RC 5 and a hose is connected to the exhaust flange of the vacuum pump DUO 005 or DUO 010 The ho...

Page 16: ...LD 2 ALPHA 2 4 LD 2 according to the process flow diagram above Centering rings and clamping flanges with wing nuts are used as connecting elements small flange connections according to ISO 28403 res...

Page 17: ...g Clamping flange Vacuum release valve separate accessory Lay out assembly of vacuum connections Place centering ring on one side of small flange connection e g vacuum hose Connect second flange the c...

Page 18: ...e g drying chamber shelves and connections for round bottom flasks are added accordingly Example Accessory for drying on 5 unheated shelves as well as individually sealable rubber valves for round bot...

Page 19: ...300 with 12 connections Rubber valve Ampoule manifold Drying vessel e g ampoule Product dish Ground in stopper Drying vessel e g injection vial Drying vessel e g round bottom flasks Additional chamber...

Page 20: ...LD 2 2 4 LD 2 Version 0203 Page 19 ALPHA 1 4 LD 2 ALPHA 2 4 LD 2 Lid 300 Rubber valve Drying chamber e g round bottom flaks Drying vessel e g injection vial Drying vessel e g wide neck filter Manifold...

Page 21: ...PHA 2 4 LD 2 Drying vessel e g round bottom flasks Drying chamber 457 Rubber valve Ampoule manifold Drying vessel e g injection vial Connection flange 5 shelves 360 unheated Drying vessel e g Ampoule...

Page 22: ...nd control elements Mains switch Controler LD 2 Condensate drain valve Name plate Vacuum connection Ice condenser Connection for vacuum measuring sensor TPR 265 Interface connection Option seperate ac...

Page 23: ...to lift the acrylic chamber or lid anymore 2 8 Error messages A possible error is showed in form of ER XX Error in the lower part of the LC Display XX is marking the error code In case of a fault the...

Page 24: ...the fuse of the freeze dryer Mains connection cord fuse insert cord respectively the fuse of the building and exchange if necessary Refrigeration system does not work No vacuum 1 Position of the cent...

Page 25: ...iendly LD control system Lyo display is that all functions are explained on the control panel LC display showing the most important process data temperature of ice condenser vacuum Conversion of tempe...

Page 26: ...ssory is necessary for measuring the vacuum The upper pressure range not important for freeze drying is displayed in rough steps only A corresponds to atmosphere If the unit is not equipped with a vac...

Page 27: ...sor is inserted into the socket on the back of the unit The measuring sensor is supplied with a T piece with small flange connections With this T piece the sensor is connected to the connection at the...

Page 28: ...um This part of the drying process is referred to as final drying desorption Construction of the freeze dryer The components of a freeze dryer are Drying chamber and heating accessories a heatable and...

Page 29: ...0 47 0 055 67 0 0047 8 3 010 28 0 470 48 0 050 68 0 0035 9 2 840 29 0 420 49 0 045 69 0 0030 10 2 560 30 0 370 50 0 040 70 0 0026 11 2 380 31 0 340 51 0 035 71 0 0023 12 2 170 32 0 310 52 0 030 72 0 0...

Page 30: ...cessary if the product is pre frozen or stored in e g a deep freeze In this case especially when freeze drying small quantities it is advisable to pre cool the shelves in order to avoid partial thawin...

Page 31: ...onsequently the product continues to cool down The maximum rate of sublimation is reached at the start of the drying process Depending on the rate of sublimation the ice condenser temperature and thus...

Page 32: ...llast valve a final pressure which corresponds to the water vapour partial pressure that can be reached The residual moisture of the dried product depends mainly on the temperature of the dried produc...

Page 33: ...ng takes place as close as possible to the eutectic point The drying time depends heavily on the drying vacuum The nearer the vacuum is to the eutectic point in accordance with the vapour pressure cur...

Page 34: ...h is ice free porous and dried and has a corresponding temperature gradient between the wall of the vessel and the product The poor heat conductivity of the already dried product can lead to an increa...

Page 35: ...d of Drying and Venting A rough indication of the end of drying is the vacuum and the ice condenser temperature The ice condenser is no longer loaded and reaches the final temperature of approx 50 C t...

Page 36: ...re moved against each other by a pressure plate using a spindle The height of the pressure plate must be adjusted according to the height of the bottles The screw for height adjustment is removed The...

Page 37: ...e vacuum pump is switched on it is necessary to check that all valves are closed CAUTION The frozen samples cannot be connected to the valves until a pressure of less than 1 030 mbar is reached Liquid...

Page 38: ...evacuation process is avoided With this procedure one ampoule after the other is connected Sealing of the ampoule is carried out in the same way The hose of the ampoule to be sealed is clamped and th...

Page 39: ...In general an oil change is necessary after approx 500 to 1000 operating hours The oil change should always be carried out with warm pump 6 2 Exhaust Filter If the unit is equipped with an exhaust fil...

Page 40: ...tinuously Otherwise the operating point of the measuring sensor can change e g 800 mbar is indicated instead of A atmosphere For adjustment of the sensor two values must be set A Atmosphere HV High va...

Page 41: ...tions or solvents or agents with abrasive particles Remove product residues from the chamber using a cloth It is recommended that the lid to the freeze dryer is left open when the freeze dryer is not...

Page 42: ...aulty operation of the freeze dryer Therefore take care that no product or other residues will get into the pipe to the condensate drain valve 6 7 4 Disinfection of Chamber and Accessories All usual d...

Page 43: ...ns plug the left side panel of the unit is unscrewed and then the hose inside the unit is detached from the defrosting water valve the pipe connection is sealed with a rubber stopper and the unit evac...

Page 44: ...directly connected to the vacuum flange of the vacuum pump If the warm vacuum pump reaches a final pressure of at least 0 011 mbar the vacuum pump and the measuring system can be presumed to be in wor...

Page 45: ...is released and the refrigerator is switched off Once the permissible operating conditions are reached again after a few minutes the refrigerator is automatically switched on again via the motor prot...

Page 46: ...Heat exchanger 014 Capillary tube 019 Schrader valve suction side of compressor 020 Schraderventil 023 Overpressure switch compressor 2 024 Compressor 2 033 Capillary tube ice condensor 038 Schrader...

Page 47: ...gloves only General characteristics of the substances Corrosive Explosive Biologically hazardous Radioactive Toxic Which combination of substances may lead to the development of hazardous materials N...

Page 48: ...Please understand that we cannot carry out any work before we have the declarations We recommend that you make several copies of this page IMPORTANT This form must be glued onto the outside of the pa...

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