Laboratory Freeze Dryer CRYODOS
Contents
1. This manual is also included teTEISTAR 4 CAUTIONS BEFORE START UP For a correct start up procedure the following instructions must be followed step by step 4 1 POSITIONING The unit may be placed directly on a table if the surface is perfectly smooth and horizontal The base unit must be firmly settled to prevent vibration 4 2 ELECTRICAL CONNECTION a Connect the electrical cable of the unit to the power supply b Check that the supply voltage is the correct one for the unit The connecting cable is supplied with European plug WARNING A e Before switching the freeze dryer on check that the supply voltage is the same as that mentioned on the specification plate e Whenever there is a power cut or the supply fails for a long period stop the Freeze Dryer e Installation in the place where the Freeze Dryer is connected must comply with curent safety regulations according to each country 4 3 VACUUM PUMP Steps to follow in order to assembly the filter and the gas ballast This operation must be carried out before the start up of the vacuum pump 1 Connect the oil return filter to the vacuum pump by means of the centering ring and the clamp to the DN25 connection 2 Take out the screw and a oil return connection washer Inferior washer teTEISTAR 3 Insert the gas ballast assembly to the screw and thread to the oil return connection Gas ballast assembly Le inferior2. Fig 3 The vacuum level inside the chamber and temperature in the condenser will appear tv TEISTAR Page 15 of 20 At this point the following process automatically begins e The cooling system starts compressor 1 e n the CRYODOS 80 compressor 2 starts 4 minutes after compressor 1 has already started e When the condenser reaches a programmed temperature T the vacuum pump automatically starts 30 in the CRYODOS 50 T2 459C in the CRYODOS 80 REMARK These pump starting Temperature Points are set and cannot be modified by the user Every 3 seconds Fig 3 will be merge with Fig 4 COOL VACUUM TI ME 00 00 00 Fig 4 7 4 STOPPING THE FREEZE DRYER Both models when the freeze drying process ends the equipment is stopped by pressing the ON OFF key Compressor 1 will continue running for 2 minutes to collect the system fluid refrigerant Accidental freeze dryer stopping If there is in the CRYODOS 50 an accidental stop disconnection or power cut the freeze dryer stops and the vacuum in the chamber is maintained Once the current is re established the process continues working at the same conditions before the stop If it happens in the CRYODOS 80 and once the current is re established compressor 2 will run after 4 minutes of the start up 7 5 REMARKS ON EQUI PMENT OPERATI ON Auxiliary screens There are four auxiliary time counters viewing screens for compressor 1 compressor 2 CRYODOS
3. this guarantee will be void if pieces other than the ones supplied by TELSTAR INDUSTRIAL S L are used for the repairing of the equipment NOTE This guarantee is valid for all the equipment unless otherwise stated In order to obtain any information about this guarantee please contact with our Quality Assurance Department tv TEISTAR Page 20 of 20 CE CERTIFICATE DECLARACI N DE CONFORMI DAD DECLARATI ON OF CONFORMI TY Este certificado se emite para el aparato el ctrico This certificate is issued for the electrical apparatus LI OFILI ZADORES DE LABORATORI O E INVESTI GACI N LABORATORY AND RESEARCH FREEZE DRYERS MODELOS MODELS CRYODOS 50 CRYODOS 80 Fabricada y sometida a Certificaci n por TELSTAR INDUSTRIAL S L Manufactured and submitted for Certification by TELSTAR I NDUSTRIAL S L 91 368 EEC y 93 68 EEC Directivas Seguridad en M quinas Machinery Safety Directives Normativa respecto a la cual se declara conformidad Standard s to which conformity is declared EN 292 1 EN 292 2 EN 294 EN 418 EN 349 73 23 EEC Directiva Seguridad El ctrica Electrical Safety Directive Normativa respecto a la cual se declara conformidad Standard s to which conformity is declared EN 61010 1 Requisitos de seguridad de equipos el ctricos de medida control y uso en laboratorio Safety requirements for electrical equipment for measurement control and laboratory use Directiva 89 336 Compatibilidad
4. 80 only vacuum pump and language selection To accede to the auxiliary screens simply press the UP DOPWN keys one after the other being the freeze dryer at rest before pressing the ON OFF key so that SYSTEM READY is shown If there is a delay of more than 5 seconds in pressing the UP DOWN keys on any of these screens the program automatically goes back to the main screen HOUR COUNTER PUMP 00150H Fig 5 HOUR COUNTER COMP E2 00070H Fig 6 tv TEISTAR Page 16 of 20 HOUR COUNTER COMP El 00080 H Fig 7 SELECT LANGUAGE ENGLISH Fig 8 Language change This option allows changing the screen language There are 4 possibilities Spanish English French and German By means of the ENTER key languages will change To fix one press the UP DOWN keys SELECT LANGUAGE English SELECCI N IDIOMA Espa ol SELECTION LANGUE Francais SPRACHWAHL Deutsch 7 6 ALARMS 7 6 1 VACUUM SYSTEM ALARM If when the vacuum pump is running the vacuum level falls below 10 mbar in less then 4 minutes the pump is stopped and the following message appears ALARM lt VACUUM SYSTEM Fig 9 Check all seals Verify that valves and drain are closed tv TEISTAR Page 17 of 20 Once the leak has been found the message will disappear by pressing the ENTER key The vacuum pump will run again If th
5. Electromagn tica Electromagnetic Compatibility Directive Normativa respecto a la cual se declara conformidad Standard s to which conformity is declared EN 50082 1 EN 55022 EN 61000 3 2 El de marcaje CE fue en 1997 The CE marking was affixed in 1997 Por la presente TELSTAR INDUSTRIAL declara que el equipo arriba especificado cumple con las Directivas y Normativas arriba mencionadas siempre y cuando la instalaci n sea acorde a las especificaciones del fabricante TELSTAR INDUSTRIAL hereby declares that the equipment specified above conforms to the above Directives and Standards when installed in accordance with the manufacturers specifications 1 E Eva Perell Quality Assurance Terrassa J uly 2005
6. LCD alphanumeric viewer showing the freeze drying cycle menu During the whole process a screen with the condenser temperature and vacuum value will appear inserting every 3 seconds another that shows the process time teTEISTAR 1 Condenser with 8 cocks 5 Electrical connection 2 LCD alphanumeric viewer 6 Main switch 3 Pressing buttons panel 7 Vacuum pump 4 Draining pipe 2 3 APPLICATION Using the various operative systems that make up the unit and the possibility of connecting several accessories this freeze dryer can be used for freeze drying in flasks vials and bottles or in bulk WARNING A e Under no circumstances may the unit be used with corrosive inflammable or explosive gases e Inthe event of freeze drying product containing corrosive or explosive solvent please contact the Technical Service with a view to taking the specific preventive measurements for the product in question 2 4 REQUIRED SERVICES Power supply 230 V single phase earth 50 Hz 230 V single phase earth 60 Hz Power capacity installed 1 kW for the CRYODOS 50 and 1 5 kW for the CRYODOS 80 Consumption Amps 5 5 A for the CRYODOS 50 and 8 5 A for the CRYODOS 80 Maximum working room temperature 30 te TEISTAR Page 6 of 20 2 5 TECHNICAL FEATURES VACUUM PUMP CRYODOS 50 CRYODOS 80 50 Hz 60 Hz 50 Hz 60 Hz Model VARIAN DS 102 Dimensions Weight 430 x 132 x 2
7. 0 C for a period of between 3 and 4 hours 5 2 FREEZE DRYING When the condenser reaches the programmed temperature and the vacuum pump is running the bottles or flasks with the frozen product are now connected to the condenser cylinder valves Open the valves so that the vacuum is produced in the container and product sublimation starts As soon as all the flasks have been connected and valves opened there should be a vacuum of less than 10 mbar in 4 minutes otherwise the pump will stop appearing the alarm of the vacuum system If this happens check the valve to bottle connections for leaking To continue with the process press the ENTER key When wishing to connect the flask when the freeze drying process has begun proceed as below 1 Connect the new flask and open this valve 2 Wait for a while until a vacuum is recovered in the unit 3 Connect the next flask 4 When all the flasks have been connected let the equipment run until the product has been totally dried out If exterior heating has to be applied to the product while it is dried out to speed up the drying process the heating source should be at the right distance to apply the radiation heat that the product requires Heat from hot air directed directly onto the flasks may also be used At the beginning of the process a layer of ice will form on the outside wall of the flask and this will gradually disappear as drying out continues Total disappearance of product ic
8. 12 22 Suction flow 5 6 Motor velocity 1500 1800 Electric consumption 0 45 0 55 Oil ICE CONDENSER Load capacity Litres e AV 30 Condensing surface Final temperature Ice capacity Condenser unit material REFRIGERATING UNIT 0 136 0 136 kg 4 1 5 kg 24 h 4 4 kg 24 h AISI 316L Nr of compressors Hermetic type Refrigerating power Refrigerant free of CFCs R 404a R 404a R 23 Assembly refrigeration UNIT Electrical connection Power capacity installed unloaded Vacuum at the pump inlet Process vacuum Condenser at 45 CRYODOS 50 4 x 107 By air circulation V ph hz 230 1 50 230 1 60 230 1 50 230 1 60 kw mbar 5 x 10 5 x 10 Condenser at 75 CRYODOS 80 1x10 With room temperature not higher than 212C Dimensions PT100 Temperature probe Weight DIGITAL DIGITAL Kg 60 90 teTEISTAR Page 7 of 20 3 TRANSPORT The freeze dryer is supplied as an individual package and in a suitable way to prevent it from being damaged during transportation With the freeze dryer is supplied the vacuum pump separately crated including technical documentation and 1 litre bottle of oil A tin of silicone oil is also supplied for proper condenser seals maintenance When unpacking the freeze dryer check if the supply includes optional accessories each of which would be separately packed to ensure suitable protection
9. FF ENTER ENTER ENTER COOL ON TEMP 091 0 C PUMP ON VAC 0 010 mBar RESET lt COMP El 00160 H RESET lt COMP 2 00099 H RESET lt PUMP 00150 H tv TEISTAR Page 19 of 20 8 2 GUARANTEE CERTIFICATE TELSTAR INDUSTRIAL S L guarantees the replacement FREE of CHARGE of all the pieces suffering breakdown in the period of ONE YEAR starting in the date of the expedition of the equipment The replacement of the pieces in guarantee can not in any case extend or modify the date of it TELSTAR INDUSTRIAL S L will send in carriage forward and FREE of CHARGE the pieces to be replaced against the reception of the defective pieces The necessary work to be done for its substitution will be paid by the customer If the substitution of the pieces would take place in TELSTAR INDUSTRIAL S L facilities the client will pay the transport of the unit This equipment has undergone satisfactorily all the tests and revisions Therefore any damage caused by transport or wrong installation is excluded of this guarantee This guarantee does not include any of the fungible materials comprised in the equipment such as filters fluids filaments etc The inappropriate use of this equipment provokes the guarantee to be void This involves the exclusion of any liability in concept of indemnity for eventual direct or indirect damages of any nature either material or personal Likewise
10. USER S MANUAL Laboratory Freeze Dryer CRYODOS te TEISTAR Telstar Industrial S L Josep Tapiolas 120 08226 TERRASSA Spain Tel 34 937 36 16 00 CRYODOS rev0105US ES E telstar etelstar com www etelstar com teTEISTAR S INDEX 1 GENERAL DETAILS 3 2 DETAILS OF THE FREEZE DRYER 4 2 1 Aim of this 4 2 2 Description 2 4 2 3 Application 2 LLL LLLA 5 2 4 Required services LLL 5 2 5 Technical features _____________________________________________ 6 3 TRANSPORT 7 4 CAUTIONS BEFORE START UP 0 00 0 8 4 1 Positioning 2 00 0 000 8 4 2 Electrical connection ___________________________________________ 8 4 3 Vacuum Pump 8 4 4 Ice condenser ________________________________________________ 9 4 5 Refrigerating Unit 10 4 6 Lubrication 2 10 4 7 Connection of the vacuum pump discharge 11 1 1 10 4 8 Long storage Periods of 10 5 WORKING PRINCIPLE ______________________________________________ 11 5 1 Freezing 7 0 000 0000000 11 5 2 Freeze drying 22 11 5 3 Air entering drying chamber at end of the process 1 12 6 ACCESSORIES 00000000000 LLLA 13 7 OPERATING INSTRUCTIONS 0 0000000000000 14 7 1 Previous operations before start up 1 1 1 11 111 1 1 14 7 2 Control panel 00000 0000000000000 14 7 3 Instructions for start up ________________________________________ 14 7 4 Stopping the freeze dryer _______________________________________ 15 7 5 Remarks
11. ch gives access to the inside for maintenance of all the components The vacuum pump is delivered separately from the unit Cryodos components e One two stage vacuum pump provided with Gas Ballast It holds inside a closing valve which when the pump stops cuts the pump off from the freeze dryer unit and keeps it under vacuum while atmospheric pressure is re established inside the pump so that the oil cannot flow back It also has an exhaust filter e One cooling system cooling the condenser coil down to working temperature The condensation surface is designed to a size that ensures condensation of the vapour given off by the product being freeze dried preventing it from reaching the vacuum pump CRYODOS 50 one air condensing one stage hermetic compressor CRYODOS 80 two air condensing one stage hermetic compressors At the top there is a stainless steel cylinder with 8 3 4 18 7 mm cocks and key The cylinder has a top cover made of a transparent acrylic material to enable inspection of the condenser during the process Each of the 8 cocks is equipped with its 3 way valve providing cutting off and re establishing atmospheric pressure in each individual vial These enable emery ground vial mouths to be connected with the tapering adapter they hold Outside diameter 29 32 mm Inside diameter 18 mm Tubes and vials can be inserted directly when this adapter is removed On the front there is the control panel composed of a
12. e alarm does not disappear contact the Technical Service Dept 7 6 2 VACUUM PROBE ALARM If the vacuum reading falls below 1x10 mbar this shows that the vacuum gauge is broken or disconnected The following message will appear ALARM lt VACUUM PROBE Fig 10 Review the probe and replace it in case is broken Once it is verified connect again by pressing the ENTER key 7 6 3 TEMPERATURE PROBE ALARM If the temperature probe is broken or disconnected the following message will appear ALARM lt TEMP PROBE Fig 11 Review the probe and replace it in case is broken Once it is verified connect again by pressing the ENTER key teTELSTAR Page 18 of 20 8 ATTACHED 8 1 WORKING PRINCIPLE CRYODOS V3 1 50 TELSTAR c Y VAC 0 010 mBar ON OFF IR 4 SYSTEM READY ALARMS TEMP 045 0 C 3 Seg AV Y Y Y COOL VACUUM ON HOUR COUNTER ALARM TIME 11 23 45 PUMP 00150 H VACUUM SYSTEM A Y HOUR COUNTER ALARM COMP El 00160 H VACUUM PROBE A Y HOUR COUNTER ALARM lt COMP E2 00099 H TEMP PROBE X Y SELECT LANGUAGE English CRYODOS V3 1 v TECHNICAL ASISTANCE PROGRAM v COOL OFF v PUMP OFF v HOUR COUNTER COMP El 00160 H v HOUR COUNTER COMP E2 00160 H v HOUR COUNTER PUMP 00160 H ON OFF ON O
13. e is indicated when the flask is at ambient temperature showing that the process has finished When it has finished the appropriate manifold cocks are closed and air enters in the flask or flasks so they can be removed CONNECTING VALVE m 24 a AAA TIRA Air inlet to flask Vacuum to flask tv TEISTAR Page 12 of 20 The length of the main drying process during freeze drying depends essentially on The heating temperature that can be applied to product outside the equipment The maximum heating temperature accepted by the product The final degree of humidity desired The percentage of solid material in the product The vacuum level obtained The total amount of product to be dried each time Condenser temperature 5 3 AIR ENTERING DRYING CHAMBER AT END OF THE PROCESS Stop the process by pressing the ON OFF key which stops the pump and cooling unit and opens to let air in through some of the taps Place a recipe at the end of the draining tube and remove the stopper De freezing can be sped up by applying hot air to the condenser coil In any case it is advisable to remove the cylinder with the valves to accelerate coil ice de freezing Before starting a new process ensure that the condenser is totally defrost there are no remains of water in the drainpipe and that the valve is once again closed te TEISTAR Page 13 of 20 6 ACCESSORIES 1 Stoppering chamber Ref 7801 Glass cylind
14. lways be kept cleaned and greased Avoid dirtiness accumulation 4 7 CONNECTION OF THE VACUUM PUMP DISCHARGE In the event that smoke from the vacuum pump is ducted outside connect this tube to the vacuum unit discharge avoiding the installed filter 4 8 LONG STORAGE PERIODS OF NON USE In the event that the freeze dryer is placed in storage for a long time the vacuum pump oil must be changed to ensure that there is no corrosive waste that could damage it Disconnect the unit from the electricity supply Clean the inside of the chamber check that the condenser has been completely emptied and lubricate the chamber and the condenser s gaskets TELSTAR Page 11 of 20 5 WORKING PRINCIPLE 5 1 FREEZING Products must be frozen before they are freeze dried The layer of product should be as thin as possible recommended inferior than 20 mm The length the freeze drying process depends essentially on this height and the solid composition of the product Fully recommended are even loading of the freeze dryer and equal heights in different containers of product to dry For the same reason a mixture of products to dry should be avoided Freezing temperature is proportionate to product solidifying point Freezing speed influences the size of the crystals and consequently sublimation speed Therefore the most suitable freezing parameters for each product must be determined It is advisable to freeze products at a temperature below 2
15. on equipment operation 1 0 15 7 6 Alarms O 16 7 6 1 Vacuum system alarm 16 7 6 2 Vacuum probe alarm ___________________________________________ 17 7 6 3 Temperature probe alarm _______________________________________ 17 8 ATTACHED 18 8 1 ag principle ee ee et 8 2 Guarantee certificate 19 8 3 teTEISTAR 1 GENERAL DETAILS This Operation Manual is valid for laboratory Freeze dryer models CRYODOS 50 CRYODOS 80 WARNING A e Itis mandatory to read and fully understand this manual before using the unit e All safety instructions contained herein must be respected e Before carrying out any maintenance work on the equipment it must be disconnected from the energy source e Use or application of the equipment that does not conform to the recommendations in this manual may cause danger and lead to the loss of the manufacturer s guarantee MANUFACTURER TELSTAR INDUSTRIAL S L Josep Tapiolas 120 08226 TERRASSA BARCELONA Telf 34 93 736 16 00 Fax 34 93 785 93 42 Web www etelstar com E mail telstar etelstar com teTEISTAR 2 DETAILS OF THE FREEZE DRYER 2 1 AIM OF THIS MANUAL The main aim of this manual is to give the user guidelines for the handling and operation of the TELSTAR CRYODOS 50 and CRYODOS 80 2 2 DESCRIPTION The CRYODOS freeze dryer in a compact desktop version The basic unit comprises a metal cabinet with a door at the back whi
16. rical chamber 200 mm with 3 non thermostatized shelves and manual vial closing device Includes 3 trays for vials and serum 2 Chamber Ref 8956 Glass cylindrical chamber 200 mm with 3 shelves and 3 trays for vials serum bottles and raw material 3 8 port manifold Ref 70205 Including 8 rubber three way valves CN29 32 for flasks 4 40 port manifold Ref 7917 Manifold with 40 ports for tubes of 13 mm REMARK To install this manifold is necessary to install the adapter plate for manifolds 5 Adapter plate for manifold Ref 7820 Adapter to place manifolds with connection DN 50 tv TEISTAR Page 14 of 20 7 OPERATING INSTRUCTI ONS 7 1 PREVIOUS OPERATI ONS BEFORE START UP e Check that all the water remains from de freezing during the previous operation has been removed by opening the draining valve Close again e Check that the condenser transparent cover is on e Check that the all the cocks of the chamber are turned off 7 2 CONTROL PANEL 7 3 INSTRUCTIONS FOR START UP To start the equipment proceed as follows Set the switch on placed in the back side just above the electric inlet plug to position 1 The following screen will appear CRYODOS V 3 1 50 TELSTAR c Fig 1 After a few seconds the main screen will show SYSTEM READY Fig 2 Press ON OFF key and the screen will show VAC 0 000 mBar TEMP 000 0 2 C
17. washer Filter Elbow racord Black pipe 4 Connect the black pipe to the elbow racord placed in the connection filter base Pour new oil into the filling hole Verify the level Vacuum pump oil capacity 0 5 litres see paragraph 2 1 3 maintenance manual It is recommended to open Y4 the gas ballast during the lyophilisation cycle in order to prevent product vapours not to sublimate in the condenser If this occurs the vacuum pump oil can contaminate The vacuum pump is equipped with an exhaust filter which job is to retain oils vapours The electrical connection of the vacuum pump has to be connected to the base placed in the backside of the unit Furthermore the vacuum pump admission has to be connected to the base unit through the supplied pipe 4 4 ICE CONDENSER Before each operation open the condenser water drain valve to ensure that the condensed ice from the previous operation has been totally removed If any water remains in the condenser or drainpipe it will freeze as a result of the vacuum thus possibly compromising work conditions tv TEISTAR Page 10 of 20 4 5 REFRIGERATI NG UNIT In order to ensure that the refrigerating unit works properly refrigeration via forced air circulation by means of a fan all vents must be separated minimum 20 cms away from other equipment or the wall 4 6 LUBRICATI ON Slightly grease the airtight seals with the silicone grease The contact surfaces should a
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