SP VirTis Wizard 2.0 Operator'S Manual Download

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SP INDUSTRIES, INC.

Controller Operator's Manual

VirTis Wizard 2.0

Lyophilizer Controller

Summary of Contents for VirTis Wizard 2.0

Page 1: ...SP INDUSTRIES INC Controller Operator s Manual VirTis Wizard 2 0 Lyophilizer Controller ...

Page 2: ......

Page 3: ...odifications to or the creation of derivative works from this Controller Operator s Manual by any means and in any form or manner is expressly prohibited except with the prior written permission of SP Industries Inc Permitted copies of this document must retain all proprietary notices contained in the original The information in this document is subject to change without prior notice Always confir...

Page 4: ...n services the refrigeration heat transfer vacuum and electrical systems 9 Always ensure that refrigeration air intake is clear and clean 9 Always ensure vacuum pump exhaust is properly ventilated and or contained 9 Always practice team lifting when moving heavy equipment 9 Always use a maximum one pound regulator if backfilling from an inert gas source 9 Always wear safety glasses when using glas...

Page 5: ...es Replacement or repair of parts pursuant to this warranty shall not in any way extend the original warranty period The Company will not be responsible for any unauthorized repairs replacements or product modifications nor will it be responsible for any product failures resulting from such unauthorized repairs replacements or product modifications negligently or otherwise made by persons other th...

Page 6: ...iv Revision 001 03 09 SP Industries Inc 2009 ...

Page 7: ...tic Mode 7 Creating a Recipe 7 Thermal Treatment Steps 8 Freeze Condenser and Vacuum Phases 9 Drying Cycle Steps 10 Secondary Drying 11 Automatic Operation 12 Optional Features 13 Purge 13 Pressure Rise P Rise 13 Semiauto Isolation Valve 14 Line Printer 14 Calibration 15 Temperature 15 Vacuum 16 Maintenance Settings 17 Clock Adjust 17 Configuration Settings 17 Alarm Settings 18 Factory Settings 19...

Page 8: ...Contents VirTis Wizard 2 0 vi Revision 001 03 09 SP Industries Inc 2009 Appendix B Factory Settings 25 Factory Settings 25 Service Routines 26 PID Control Settings 27 Relay Test 27 ...

Page 9: ...tal display plots the profile of the directed shelf temperature while providing a cycle progress bar graph The display continually scans all configured transducers If an alarm occurs the display indicates the out of tolerance condition To minimize warming during the condenser and vacuum phases the Wizard 2 0 controller can be configured in a special freeze assist mode Once configured the controlle...

Page 10: ...Rugged control panel resistant to dust oils and spills Power outage protection with product recovery routines Full process system alarms for fast diagnostics Optional line printer which is connected via the printer output port Optional computer workstation for data capture and recipe management Door preseal routine which performs a unit vacuum check with safety alarm notification Drying cycle prof...

Page 11: ...ryer as well as navigate through various menus and screens of your Wizard 2 0 controller Button Functions Manual Mode Buttons Freeze activates all components needed to cool the shelves to the Manual Freeze setpoint Condenser activates the condenser refrigeration system and cools the condenser Vacuum activates the vacuum system Use in conjunction with the Vac Ctrl button to control the vacuum press...

Page 12: ...e opens the Recipe Manager which allows you to modify recipe parameters Profile displays the recipe temperature trend line Synoptic returns you to the Synoptic screen System temperature and vacuum control loops are only active when the Synoptic screen is displayed Maintenance displays the Maintenance menu For more information see Chapter 8 Maintenance Settings Alarm displays all possible system al...

Page 13: ...l Setpoint 200 millitorr The vacuum pressure that the system will maintain when Vacuum and Vac Ctrl are selected Note Under heavy vapor loads actual pressure may be higher than the setpoint If this is the case the shelf temperature may need to be lowered Defrost Temperature Setpoint 60 C The maximum temperature that the freeze dryer will reach with the Defrost function enabled Note For units with ...

Page 14: ...f product average temperature whichever is colder 6 Press Vacuum and allow vacuum pressure to reach an acceptable value generally less than 500 mTorr 500 μbar or 50 Pa 7 Press Shelf Ctrl to begin heating to the Manual Heat setpoint Adjust the setpoint as desired to optimize primary drying Note Use the Shelf Ctrl button together with the Condenser button to control the shelf temperature at the setp...

Page 15: ... button to access the main recipe menu 2 Enter a Recipe Number 01 16 using the numeric keypad 3 Select a recipe menu Thermal Treatment Steps Drying Cycle Steps etc using the Up and Down arrow buttons and press Enter to proceed Note Recipe menus are explained in the following sections 4 Once in a recipe menu use the numeric keypad to enter the desired value in each field and the Up and Down arrow k...

Page 16: ...ers of up to 12 Thermal Treatment steps Configurable settings include temperature time and ramp or hold Note These settings must be within the unit s ability Consult your unit specifications or contact SP Service for more information Setting Description Temp C Use the key and the numeric keypad to change the temperature setting in one degree increments up to 99 C Time min Use the numeric keypad to...

Page 17: ...hat the product or shelf must reach before the system will proceed to the next phase Use the key and the numeric keypad to change the temperature setting in one degree increments up to 99 C Additional Freeze Time min 60 minutes Additional freeze time is used to ensure product uniformity The shelf temperature drops as low as possible for the specified period Use the numeric keypad to change the tim...

Page 18: ... the product or shelf temperature for the specified period Use the numeric keypad to change the time in five minute increments up to 1255 minutes per step Ramp or Hold Hold will adjust the product or shelf temperature as rapidly as possible to the setpoint and hold the temperature for the remaining period Ramp will ramp the product or shelf temperature from its current value to the setpoint at a r...

Page 19: ...These settings must be within the unit s reasonable ability Consult your unit specifications or contact SP Service for more information The menu parameters are defined as follows Parameter Description Secondary Setpoint When the product or shelf temperature reaches the Secondary Drying Setpoint the unit will skip the remaining Primary Drying steps and advance to the Post Heat phase Use the key and...

Page 20: ... Start The vacuum system will energize and evacuate the system to a preseal value of approximately 500 Torr 500 mbar or 50 kPa If vacuum does not reach the preseal value within the allotted time an alarm will trigger If this happens stop the process check all valves and gaskets and restart automatic operation 8 Your system will follow the selected recipe until the Secondary Drying phase is complet...

Page 21: ...To determine whether pump oil is adequately clean disable the vacuum pump and drain 100 mL of oil into a clear container Visually inspect the oil for clarity Continue purging if necessary 6 When the purging process is complete close the vacuum pump ballast valve and press the Vacuum button to disable the vacuum pump The Purge option setting will automatically reset to 0 on the Manual Mode Settings...

Page 22: ...e option Line Printer The optional line printer allows you to print recipe and process data directly from the Wizard 2 0 controller without the use of the optional Wizard Workstation If the Line Printer option is purchased your Wizard 2 0 controller will be factory configured for proper output Note The line printer requires a 25 pin to 25 pin RS 232 cable for connectivity When enabled process data...

Page 23: ...alibrator 1 To calibrate the temperature readings 1 Connect the thermocouple calibrator to the shelf probe input and set it to 30 0 C in source mode 2 Allow the system to equilibrate for at least 5 minutes in a draft free area 3 Press the Maintenance button 4 Select the Service Routines menu Option 6 5 Enter the security code 678 and press Enter 6 Record the current Temperature Calibration and Tem...

Page 24: ... such as the Varian Vacuum Reference Gauge Tube For consistency perform all vacuum calibrations in Torr After calibration you can change the vacuum units if desired 1 Allow the system to equalize for at least ten minutes in a draft free area 2 Adjust the Vacuum Probe 1 potentiometer located next to the probe tube connector on the rear of the Wizard 2 0 controller so that the rough vacuum reads 760...

Page 25: ...riven Product Driven 1 Shelf Driven Mode Enter 1 to set the freeze dryer to Shelf Driven Mode When in Automatic Mode the freeze dryer will advance to the next phase depending on the shelf temperature Enter 0 to set the freeze dryer to Product Driven Mode When in Automatic Mode the freeze dryer will advance to the next phase depending on the product temperature mTorr 1 μBar 2 Pa 3 1 Enter 1 to set ...

Page 26: ...Power Outage In the event of a Short Duration Power Outage the freeze dryer returns to the last phase of the freeze drying cycle and triggers the alarm If a power outage exceeds this time limit the freeze dryer goes into Safe Mode refreezing the product and triggering the alarm Note The Power Outage Alarm is active in both Manual and Automatic Modes Freeze Time Limit Hours Typical range 4 6 hours ...

Page 27: ...st For relay test parameters refer to Appendix B Factory Settings Note All control loops are disabled unless you are viewing the Synoptic screen Vacuum Pump Oil Time The Vacuum Pump Oil Time screen is designed to help protect and prolong the life of your vacuum pump This screen displays the time since the last oil change hours minutes The Vacuum Pump Maintenance alarm triggers when the Vacuum Pump...

Page 28: ...Revision 001 03 09 SP Industries Inc 2009 Help Screen The Help screen lists contact information for SP Service This screen also displays your current hardware and software revisions Please have this information ready when contacting SP Service ...

Page 29: ...hase option and continue the product run from the point of alarm The default procedure is to refreeze product whenever an emergency alarm condition causes the system to enter Safe Mode The operator must manually choose to exit Safe Mode See the Maintenance Settings section for more information on alarm features and functionality as well as how to configure alarms to better accommodate your recipes...

Page 30: ... can be a symptom of excessively high shelf temperatures or insufficiently frozen product Test your refrigeration and vacuum systems without product to ensure system integrity Note Periodically test your condenser and vacuum systems in Manual Mode Check Door Seal Alarm The Door Seal Minutes should be at the factory setting or greater typically 5 to 15 minutes Check all gaskets and hoses Ensure tha...

Page 31: ...o clean the vacuum pump oil following an aggressive recipe To use the gas ballast prepare the freeze dryer as you would for a product run and begin a recipe that uses vacuum Open the gas ballast on the vacuum pump by turning the knob on the top of the pump until you can hear the pump get considerably louder Alternatively use the optional Purge function to clean the pump oil Never run the vacuum fo...

Page 32: ...a Freeze phases These phases require all refrigerant to cool the shelves and your product You should be able to cool the shelf temperature between 0 5 C and 1 C per minute depending on your unit Test the refrigeration system periodically by using the Freeze button Refer to the specifications for your unit or contact SP Service at 877 548 4666 Problems with Freezing may be due to refrigeration syst...

Page 33: ...and defrosts the condenser by radiant heat Selecting El means that the condenser is defrosted by a dedicated electric heater but has additional piping Selecting Hg means that the condenser is defrosted by Hot Gas refrigerant circulated within the condenser Refer to your freeze dryer operator s manual for proper setup Vacuum Control 0 Bleed 1 Save Sets the vacuum level control method Bleed allows t...

Page 34: ...r the compressor is enabled If the temperature is lower the compressor is disabled Note The barometric endpoint Pressure Rise P Rise option requires an optional isolation valve and external condenser This function does not apply to all units Refer to the operator s manual for your freeze dryer Service Routines Parameter Description Temperature Span Sets the temperature high point offset based on t...

Page 35: ...displays the four output groups Use this screen for troubleshooting electrical or mechanical problems as well as during a freeze drying run to observe active outputs SSR 1 SSR 2 SSR 3 SSR 4 Vacuum Heater Defrost Alarm Output Vacuum Release Condenser Valve Fluid Pump Stoppering Compressor 1 Compressor 2 Spare Stoppering Freeze Valve Negative Shelf Isolation Valve Spare Pressing the corresponding nu...

Page 36: ...SP Industries 815 State Route 208 Gardiner NY 12525 USA www SPIndustries com 800 431 8232 845 255 5000 ...

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