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Operating Manual Freeze-dryer

Alpha 1-2 LDplus from serial no. 101521

Translation of the original operating manual

sb Version 11/2006 Rev. 2.0 of 02/12/2014 Alpha 1-2 LDplus; ;

http://donaulab.ru/components/martin-liofilnye-sushki-s-kontrollerom-ld-plus/

Freeze-dryer Alpha 1-2 LDplus

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стр.2034, Москва, Турчанинов пер, д.6, Адрес: 119www.donaulab.ru Тел. +7 (495)-255-33-89в Россииtin Christ GmbH Донау Лаб. Москва/ «Donau Lab. Moscow» - дилер Mar


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In case of inquiries, please state the following numbers: Order number Serial number © Copyright by Martin Christ Gefriertrocknungsanlagen GmbH An der Unteren Söse 50 37520 Osterode am Harz Germany Tel.: +49 (0) 5522 / 5007-0 Fax: +49 (0) 5522 / 5007-12 Web: www.martinchrist.de E-mail: [email protected]


Table of contents

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1 General information ............................................................................................................. 9 1.1 Importance of the operating manual .................................................................................. 9 1.2 Intended use ..................................................................................................................... 9 1.3 Warranty and liability ....................................................................................................... 10 1.4 Copyright ........................................................................................................................ 10 1.5 Explanation of symbols ................................................................................................... 10 1.6 Standards and regulations .............................................................................................. 10 1.7 Scope of supply .............................................................................................................. 11

2 Layout and mode of operation .......................................................................................... 12 2.1 Layout of the freeze-dryer ............................................................................................... 12

2.1.1 Functional and operating elements ............................................................................ 12 2.1.2 Name plate ................................................................................................................ 14

2.2 Mode of operation ........................................................................................................... 15 2.2.1 General information on freeze-drying ......................................................................... 15 2.2.2 Freeze-drying process ............................................................................................... 18

2.2.2.1 Preparation ........................................................................................................ 18 2.2.2.2 Freezing ............................................................................................................. 18 2.2.2.3 Main drying ........................................................................................................ 19 2.2.2.4 Final drying ........................................................................................................ 20 2.2.2.5 End of drying and aeration ................................................................................. 20 2.2.2.6 Defrosting .......................................................................................................... 20

3 Safety .................................................................................................................................. 21 3.1 Marking of the unit .......................................................................................................... 21 3.2 Explanation of the symbols and notes ............................................................................. 22 3.3 Responsibility of the operator .......................................................................................... 23 3.4 Operating personnel ....................................................................................................... 23 3.5 Informal safety instructions ............................................................................................. 23 3.6 Safety instructions........................................................................................................... 24

3.6.1 Electrical safety ......................................................................................................... 24 3.6.2 Mechanical safety ...................................................................................................... 25 3.6.3 Fire prevention ........................................................................................................... 25 3.6.4 Thermal safety ........................................................................................................... 26 3.6.5 Chemical and biological safety................................................................................... 26

3.7 Safety devices ................................................................................................................ 27 3.7.1 System check ............................................................................................................ 27 3.7.2 Earth conductor check ............................................................................................... 27

3.8 Procedures in the event of hazards and accidents .......................................................... 27 3.9 Remaining hazards ......................................................................................................... 28


Table of contents

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4 Storage and transport ....................................................................................................... 29 4.1 Dimensions and weight ................................................................................................... 29 4.2 Storage conditions .......................................................................................................... 29 4.3 Notes on transport .......................................................................................................... 30 4.4 Packaging ....................................................................................................................... 31 4.5 Transport safety device ................................................................................................... 31

5 Set-up and connection ...................................................................................................... 32 5.1 Installation site ................................................................................................................ 32 5.2 Power supply .................................................................................................................. 32

5.2.1 Connection ................................................................................................................ 32 5.2.2 Customer-provided fuses ........................................................................................... 32

5.3 Aeration and media drain valve ....................................................................................... 33 5.4 Vacuum sensor ............................................................................................................... 33 5.5 Vacuum pump ................................................................................................................. 35 5.6 Pressure control valve .................................................................................................... 35

6 Operation ............................................................................................................................ 36 6.1 Initial start-up .................................................................................................................. 36 6.2 Installation of accessories ............................................................................................... 36 6.3 Preparation ..................................................................................................................... 36 6.4 Switching the freeze-dryer on ......................................................................................... 36 6.5 LDplus control system ..................................................................................................... 37

6.5.1 User interface ............................................................................................................ 37 6.5.2 Mode ......................................................................................................................... 40 6.5.3 Main menu ................................................................................................................. 42

6.5.3.1 Changing set values........................................................................................... 42 6.5.3.2 Special functions ................................................................................................ 44 6.5.3.3 Process and equipment information ................................................................... 45 6.5.3.4 Options .............................................................................................................. 46 6.5.3.5 Tutorial ............................................................................................................... 48

6.6 Switching the freeze-dryer OFF ...................................................................................... 49

7 Malfunctions and error correction .................................................................................... 50 7.1 General malfunctions ...................................................................................................... 50

7.1.1 Power failure .............................................................................................................. 50 7.1.2 Insufficient vacuum .................................................................................................... 50

7.1.2.1 Small flange connections ................................................................................... 50 7.1.2.2 Aeration and media drain valve .......................................................................... 51 7.1.2.3 Pressure control valve ........................................................................................ 52 7.1.2.4 Rubber valves .................................................................................................... 52 7.1.2.5 Vacuum sensor .................................................................................................. 52

7.1.3 Insufficient ice condenser temperature ...................................................................... 53 7.2 Process and equipment messages ................................................................................. 54 7.3 Service contact ............................................................................................................... 55


Table of contents

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8 Maintenance and service................................................................................................... 56 8.1 Maintenance ................................................................................................................... 56

8.1.1 Freeze-dryer .............................................................................................................. 56 8.1.1.1 Ice condenser chamber ...................................................................................... 57 8.1.1.2 Drying chamber .................................................................................................. 57 8.1.1.3 Aeration valve, media drain valve....................................................................... 57 8.1.1.4 Heat exchanger (only for air-cooled freeze-dryers) ............................................ 58

8.1.2 Vacuum pump ........................................................................................................... 58 8.1.3 Exhaust filter (oil mist separator) ................................................................................ 59 8.1.4 Vacuum sensor .......................................................................................................... 59 8.1.5 Accessories ............................................................................................................... 60

8.2 Disinfection of the drying chamber and accessories........................................................ 60 8.3 Service............................................................................................................................ 61 8.4 Return of defective parts ................................................................................................. 62

9 Disposal .............................................................................................................................. 63 9.1 Disposal of the freeze-dryer ............................................................................................ 63 9.2 Disposal of the packaging ............................................................................................... 63

10 Technical data .................................................................................................................... 64 10.1 Ambient conditions.......................................................................................................... 65 10.2 Technical documentation ................................................................................................ 65

11 Appendix ............................................................................................................................ 66 11.1 Brief operating instructions.............................................................................................. 66 11.2 EC declaration of conformity ........................................................................................... 71 11.3 Resistance to stress cracking and chemical influences "Plexiglas" ................................. 73

12 Glossary ............................................................................................................................. 91

13 Index ................................................................................................................................... 93


1 General information

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1 General information Pos: 2 /2 00 C hrist/ 360 GT-BA Lab or-Pilot (STANDARDM ODULE)/ 010 Allg emei ne I nfor mati one n/01 0-0 010 Stelle nwert de r Betri ebsa nleitu ng @ 25\ mod _14 049 832 092 48_6 8.d ocx @ 182 935 @ 2 @ 1

1.1 Importance of the operating manual A fundamental requirement for the safe and trouble-free operation of the unit is to be familiar with the fundamental safety instructions and all possible hazards. The operating manual includes important information concerning the safe operation of the freeze-dryer. This operating manual, and in particular the notes on safety and hazards, must be observed by all persons operating the unit. In addition, the local rules and regulations for the prevention of accidents must be complied with.

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1.2 Intended use CHRIST freeze-dryers have been solely designed for the freeze-drying of solid or liquid products in ampoules, vials or dishes. They are, therefore, solely intended for these applications. The freeze-dryer is suitable • for freeze-drying materials such as bacteria and virus cultures, blood

plasma, serum fractions, antibodies, sera, vaccines, and pharmaceutical products

• for freeze-drying plant extracts, e.g. for biochemical tests • for freeze-drying inorganic materials, e.g. nanoparticles • for freeze-drying numerous other products (for further information

please contact our qualified personnel) Any other use beyond this area of application is regarded as improper use. Martin Christ Gefriertrocknungsanlagen GmbH cannot be held liable for any damage resulting from such improper use. The intended use also includes: • observation of all the notes and instructions included in the operating

manual • compliance with the inspection and maintenance instruction • prohibition of any type of extensions to, or conversions of the unit.

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1.3 Warranty and liability The warranty and liability are subject to our "General Terms and Conditions" that were distributed to the operator upon the conclusion of the contract. Warranty and liability claims are excluded if they are due to one or several of the following reasons: • improper use • non-compliance with the safety instructions and hazard warnings in the

operating manual • improper installation, start-up, operation, and maintenance of the

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1.4 Copyright The copyright concerning the operating manual remains with Martin Christ Gefriertrocknungsanlagen GmbH. The operating manual is solely intended for the operator and their personnel. It includes instructions and information that may not be • duplicated, • distributed, or • communicated in any other way neither in full nor in parts. Non-compliance may be prosecuted under criminal law.

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1.5 Explanation of symbols In this operating manual, specialist terms that are explained in the glossary (see chapter 12 - "Glossary") are marked by an arrow and printed in italics (e.g. sublimation).

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1.6 Standards and regulations EC declaration of conformity (see chapter 11.2 - "EC declaration of conformity").

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1.7 Scope of supply The scope of supply comprises: • 1 tube of high-vacuum grease • 1 drain hose 0.5 m (silicone 8 x 12 mm) • 1 open spanner (size 19) • 1 operating manual In addition, if a vacuum pump is included: • 1 litre of vacuum pump oil • 1 hexagon socket key (size 6) Accessories and commissioning According to your order, our order confirmation, and our delivery note.

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2 Layout and mode of operation

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2 Layout and mode of operation Pos: 18 / 200 Christ /36 0 GT-BA La bor -Pilot (S TANDARDMODULE) /02 0 Aufb au u nd Wirk ungs weise/ 020 -00 10 Au fba u de r Ge frie rtr ocknu ngsa nlag e-- --- -- --- -- --- -- --- --- -- --- -- --- --- -- --- -- --- -- - @ 2 5\m od_ 140 4983 236 941 _68 .docx @ 18 303 3 @ 2 @ 1

2.1 Layout of the freeze-dryer

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2.1.1 Functional and operating elements

1 Ice condenser chamber

with an internal ice condenser

2 Aeration and media drain valve

Fig. 1: Left side of the freeze-dryer

3 Pipe connection of the

vacuum pump (behind the cover plate)

4 Ice condenser Fig. 2: Ice condenser chamber



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5 User interface (see

chapter 6.5.1 - "User interface")

6 Mains power switch Fig. 3: Front and right side of the freeze-dryer

7 Name plate (see chapter

2.1.2 - "Name plate") 8 Power supply of the

pressure control valve 9 Power supply of the

vacuum pump 10 Equipotential bonding

screw 11 Mains connection 12 Vacuum connection 13 Connection of the

vacuum sensor 14 Option: data interface for

further accessories 15 Heat exchanger of the

refrigeration unit Fig. 4: Rear view of the freeze-dryer Pos: 20 / 010 Unive rsalm odul e/Seite nwechs el @ 0 \mo d_1 202 116 244 312_ 0.d ocx @ 105 @ @ 1



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2.1.2 Name plate

1 Manufacturer 2 Registered office 3 Type 4 Serial number 5 Power rating 6 Nominal voltage 7 Rated current 8 Degree of

interference suppression

9 Refrigerant data of the 1st stage

10 Part number 11 Year of manufacture

(month/year) 12 Country of origin

Fig. 5: Name plate (example, enlarged photo) Pos: 22 / 010 Unive rsalm odul e/Seite nwechs el @ 0 \mo d_1 202 116 244 312_ 0.d ocx @ 105 @ @ 1



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2.2 Mode of operation

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2.2.1 General information on freeze-drying What is freeze-drying? Freeze-drying or lyophilisation is a procedure for the gentle drying of high-quality products. The product is dried by sublimation without passing through the liquid phase. What are typical applications for freeze-drying? As far as their sheer quantity is concerned, foodstuffs are the major application for freeze-drying. One widely known example is the production of granulated instant coffee or the drying of fruit, e.g. for breakfast cereals. Other areas of application are the restoration of water-damaged documents or the drying of archaeological artefacts. Another important area of application is the drying of biotechnological and pharmaceutical products, e.g. tissues and tissue extracts, bacteria, vaccines, and sera. Products that would not keep well when they are dissolved in water can be preserved by freeze-drying. During this process, the biological properties of these sensitive substances are preserved. The compounds remain unchanged from a qualitative and quantitative point of view. After the addition of water, the products will have the same characteristics as the original products. How does freeze-drying work? Freeze-drying is a very gentle procedure for the extraction of water from a product in the frozen state. The drying process takes place through sublimation, i.e. the direct transition of a product from the solid phase to the gas phase. This happens under vacuum. The following section describes the process of sublimation based on the example of water, since most products that are processed by freeze-drying are aqueous solutions. Their behaviour is based on identical fundamental principles. The vapour pressure curve above ice describes the phase transition as a function of the pressure and temperature. The higher the temperature is, the higher the vapour pressure. • If the vapour pressure is higher than 6.11 mbar (A), water passes

through all three phases: solid, liquid, and gas (see the illustration). • If the vapour pressure is below 6.11 mbar (B) and energy is added, the

ice will be directly converted into water vapour once the sublimation curve is reached. This transition is called “sublimation”. If thermal energy is added to pure ice with a temperature of less than –30°C at a pressure of 0.37 mbar, it will be converted into water vapour once it reaches –30°C (see figure).

The vacuum prevents the melting of ice when energy is added. If thermal energy is added to a frozen product under vacuum, thawing of the product will be prevented and the water that is contained within the product will be released in the form of water vapour.



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Fig. 6: Vapour pressure curve above ice

From a physical point of view, the freeze-drying process covers three phases (see figure below): (1) Freezing: The product to be dried is frozen under atmospheric pressure. This can be done either directly in the freeze-dryer or in a separate deep-freeze. The freezing temperature should be approximately 10°C below the solidification point of the product. (2) Evacuation: When the product is sufficiently frozen, the vacuum pump is activated. The pressure inside the drying chamber will be lowered to the value that corresponds to the freezing temperature in accordance with the vapour pressure curve above ice. (3) Sublimation: Thermal energy is added to the product, thus starting the sublimation process. Due to the added energy, the water in the product is converted into water vapour. Since the ice condenser is much colder than the product that is to be dried, the vapour pressure in the ice condenser is considerably lower than above the product. As a result, the water vapour that is released by the product streams to the ice condenser, where it condenses on the condenser coils. Once the free water has been extracted from the product during the main drying phase, the last traces of bound water will also be removed at a final pressure that is as low as possible and at higher temperatures. This takes place by way of desorption. This drying phase is also called final drying.

6.11 mbar

0.37 mbar

-30°C

B

AVapour pressure curve

Vapo

ur pr

essu

re cu

rve f

or ic

e =

Sublim

ation

pres

sure

curve

Melting

SublimationTriple point

SOLID

LIQUID

GASEOUS

Evaporation

Mel

ting

poin

tpr

essu

re c

urve

Pressure(mbar)

Temperature (°C)



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Fig. 7: Freeze-drying phases

NOTE

Please find further information about basic principles, optimum procedures and applications in the brochure "Smart freeze-drying", which can be downloaded at www.martinchrist.de [Applications].


1

2

1 bar

20°C

Vapour pressure curve

Vapo

ur pr

essu

re cu

rve f

or ic

e =

subli

mation

pres

sure

curv

e

Triple point

SOLID

LIQUID

GASEOUS

Mel

ting

poin

tpr

essu

re c

urve

Pressure(mbar)

Temperature (°C)



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2.2.2 Freeze-drying process The main components of a freeze-dryer are: • vacuum drying chamber with a temperature control system for adding

thermal energy • vacuum pump for generating a vacuum inside the drying chamber • ice condenser for binding the water vapour that is released by the

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2.2.2.1 Preparation The ice condenser chamber must be clean and dry. Any water residues from a preceding drying run must be removed. The media drain valve and the aeration valve must be closed. In the case of units that are equipped with a pressure control valve (standard on LSCplus units), the vacuum pump should be warmed up (“warm-up”) for at least 15 minutes prior to the start of the main drying phase. Do not subject the vacuum pump to condensable gases until the operating temperature is reached. In this way, the service life of the vacuum pump can be extended. At the same time, the ice condenser is pre-cooled ("cool-down"). The ice condenser temperature does not have any influence on the product temperature. The sole purpose of the ice condenser is to bind the released water vapour.


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2.2.2.2 Freezing First, the product that is to be dried is frozen. This can be carried out either directly in the freeze-dryer or in a separate deep-freeze. Especially in the case of small filling quantities, we recommend pre-cooling the shelves as well in order to prevent the product from thawing during the evacuation. Two very different structures of the frozen material can be distinguished: • crystalline structures with clearly distinguishable crystals • amorphous structures with no crystal junctions at all (e.g. glass) The majority of the freeze-drying products have a crystalline form. When freezing these kinds of products, one must take into consideration that too deep and too quick freezing leads to smaller ice crystals, which has a negative effect on the duration of the drying process. For every product to be dried, the solidification point must be determined as a first step. This is the point at which the water that is contained in the product has completely crystallised. In order to ensure an optimum freeze-drying process, the product temperature should be approximately 10°C below the solidification point. A layer thickness of the product of 1-2 cm should not be exceeded, since otherwise the drying duration would be negatively affected. If liquids are to be dried in bottles with a layer thickness of more than 1 cm, we recommend freezing them in a cooling bath with the aid of a shell or spin freezing device (see figure). Due to the centrifugal force, the liquid to be frozen will rise on the inner wall of the bottle and freeze. This procedure reduces the layer thickness and, thereby, the total drying time will be shortened to a considerable extent (see figures on the right side).



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Fig. 8: Shell freezing

Fig. 9: Cooling bath with spin freezing device Fig. 10: Spin freezing

NOTE

If the product that is to be dried contains solvents or high salt concentrations, it may start to thaw during the drying process, which is indicated by clearly visible foaming. In order to prevent this, the product must be frozen as deeply as possible, e.g. with the aid of liquid nitrogen, prior to putting it into the unit.



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2.2.2.3 Main drying When the product is frozen to a sufficiently deep extent, the main drying phase commences. The vacuum pump is switched on. The pressure inside the drying chamber will be lowered to the value that corresponds to the freezing temperature in accordance with the vapour pressure curve above ice. At the same time, thermal energy will be added to the product. In the case of products in round-bottom flasks, wide-neck bottles, etc., this is realised through the environment that is considerably warmer (direct contact heat), in the case of unheated shelves by way of thermal radiation from the environment, and in the case of temperature-controlled shelves directly via the shelves. As a result, the sublimation process starts. At the beginning of the drying process, the maximum drying rate will be reached. The more the sublimation area recedes into the product, the further the produced water vapour must pass through the layers that have already been dried. Under certain conditions, it is possible that the vacuum inside the ice condenser chamber increases during the main drying phase (e.g. from 0.63 mbar to 0.47 mbar) although the valve towards the vacuum pump is closed. From a physical point of view, this is due to the pumping effect of the ice condenser ("cryo-pumping effect"). The required drying time depends strongly on the drying vacuum. At 1.0 mbar, one gram of ice takes up a volume of 1 m3 of vapour, at 0.1 mbar a volume of 10 m3 of vapour, and at 0.001 mbar a volume of 100 m3. The closer the vacuum is to the solidification point, the smaller is the resulting vapour volume. The drying rate increases and the drying time decreases.



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The end of the main drying phase is reached, when the product temperature and the shelf temperature are nearly identical. The temperature difference between the shelf and the product should be approximately 3 K to 5 K.


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2.2.2.4 Final drying Final drying is an option whenever one requires a product with minimal residual moisture. In the physical sense, this process is a desorption process, i.e. the removal of adsorptively bound water. Final drying is performed under the lowest possible final pressure that depends on the ice condenser temperature in accordance with the vapour pressure curve above ice as well as on the final vacuum of the vacuum pump that is used. The process is supported by a higher shelf temperature.


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2.2.2.5 End of drying and aeration The end of the drying process is reached when both the product and shelf temperature are clearly in the positive range (+15 to +20°C) and if their difference is not greater than 5 K. Another indication of the end of the drying process is the behaviour of the vacuum and of the ice condenser temperature. The ice condenser is no longer subject to load and reaches the final temperature of approximately -55°C or -85°C. The pressure in the drying chamber decreases in accordance with the ice condenser temperature. The vacuum pump will be switched off and the drying chamber will be aerated via a rubber valve or via the aeration valve. The aeration valve can also be used to flood the unit with nitrogen or another inert gas instead of ambient air. Then, the product can be removed from the unit.


Pos: 39 / 200 Christ /36 0 GT-BA La bor -Pilot (S TANDARDMODULE) /02 0 Aufb au u nd Wirk ungs weise/ 020 -00 20- 002 0-0 061 Abta uen H eißg as @ 25\ mod _14 049 8326 342 6_6 8.d ocx @ 1831 73 @ 4 @ 1

2.2.2.6 Defrosting Defrosting with hot gas As standard, the freeze-dryer is equipped with a hot-gas defrosting system. In order to defrost the ice condenser, heated refrigerant is fed through the heating coil. In addition, the bottom of the ice condenser chamber is heated by way of a heating collar. In order to avoid damage, the condensate must be drained off through the media drain valve directly after the completion of the defrosting process. Then, any residual water must be removed from the ice condenser chamber by way of a cloth.




3 Safety

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Pos: 42 / 200 Christ /36 0 GT-BA La bor -Pilot (S TANDARDMODULE) /03 0 Sicher heit/ 030 Siche rheit == === == == === == == == === == == === == == === @ 2 5\m od_ 1404 983 296 098 _68. docx @ 18 320 1 @ 1 @ 1

3 Safety Pos: 43 / 200 Christ /36 0 GT-BA La bor -Pilot (S TANDARDMODULE) /03 0 Sicher heit/ 030 -00 10 B eschilde ru ng d es Ge räts @ 2 5\mo d_1 404 983 297 040 _68. docx @ 18 321 5 @ 2 @ 1

3.1 Marking of the unit The following symbols are used for CHRIST freeze-dryers:

Gefährliche elektrische Spannung Dangerous voltage Courant haute tension

Achtung, Betriebsanleitung lesen Attention, consult the instruction manual Attention, consulter le mode d'emploi

I

Ein (Netzverbindung) On (Power) Marche (mise sous tension)

0

Aus (Netzverbindung) Off (Power) Arrêt (mise hors tension)

Schutzleiteranschluss Protective earth (ground) Raccord à la terre

Erde Earth (ground) Terre

Netzstecker ziehen Unplug the mains plug Débrancher la prise

Vorsicht Quetschgefahr Caution! Risk of bruising Attention ! Risque de blessure

Drehrichtungspfeil Arrow indicating the direction of rotation Flèche de sens de rotation

Heiße Oberfläche Hot surface Surface chaude

CE-Zeichen gemäß Richtlinie 2006/42/EG CE mark in compliance with the directive 2006/42/EC Symbole CE conforme à la directive 2006/42/CE



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Pos: 45 / 200 Christ /36 0 GT-BA La bor -Pilot (S TANDARDMODULE) /03 0 Sicher heit/ 030 -00 20 Sy mbol - un d Hinw eiserkl äru nge n @ 2 5\m od_ 140 498 3298 133 _68 .docx @ 1 8322 9 @ 2 @ 1

3.2 Explanation of the symbols and notes This operating manual uses the following names and symbols to indicate hazards:

DANGER

This symbol stands for a direct hazard to the life and health of persons. Non-observance of these symbols causes serious health problems up to life-endangering injuries.

DANGER

This symbol stands for a direct hazard to the life and health of persons due to electrical voltage. Non-observance of these symbols causes serious health problems up to life-endangering injuries.

WARNING

This symbol stands for a potential hazard to the life and health of persons. Non-observance of these symbols can cause serious health problems up to life-endangering injuries.

CAUTION

This symbol indicates a potentially hazardous situation Non-observance of these notes can cause minor injuries or damage to property.

NOTE

This symbol indicates important information.



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Pos: 47 / 200 Christ /36 0 GT-BA La bor -Pilot (S TANDARDMODULE) /03 0 Sicher heit/ 030 -00 30 V era ntwor tun g des Betr eiber s @ 2 5\m od_ 140 498 3299 227 _68 .docx @ 1 8324 3 @ 2 @ 1

3.3 Responsibility of the operator The operator is responsible to authorise only qualified personnel to work on the freeze-dryer (see chapter 3.4 - "Operating personnel"). The areas of responsibility of the personnel concerning the operation, maintenance, and care of the unit must be clearly defined. The safety-conscious work of the personnel in compliance with the operating manual and the relevant EC and national health and safety regulations as well as with the accident prevention regulations must be checked at regular intervals (e.g. every month). The operator is responsible to check the chemical compatibility of all substances to be used inside the freeze-dryer (product to be processed, cleaning media, etc.) with the material of the chamber walls, shelves, pipes, and gaskets. Substances that may damage the material an degrade the mechanical strength must not be used. The freeze-dryer has to be maintained regularly (see chapter 8 - "Maintenance and service"). Components that are not in a perfect state mus be replaced immediately.


Pos: 49 / 200 Christ /36 0 GT -BA La bor -Pilot (S TANDARDMODULE) /03 0 Sicher heit/ 030 -00 40 B edien per sonal @ 2 5\m od_1 404 983 300 275 _68. docx @ 18 325 7 @ 2 @ 1

3.4 Operating personnel Persons operating the unit must • be familiar with the fundamental regulations concerning workplace

safety and accident prevention • have read and understood this operating manual (and in particular the

safety sections and warning notes) and confirmed this with their signature.


Pos: 51 / 200 Christ /36 0 GT-BA La bor -Pilot (S TANDARDMODULE) /03 0 Sicher heit/ 030 -00 50 Info rm elle Siche rheits hinweis e @ 25\m od_ 140 498 330 128 4_6 8.docx @ 1 832 71 @ 2 @ 1

3.5 Informal safety instructions This operating manual is a part of the product. • The operating manual must be kept at the location of use of the freeze-

dryer. Ensure that it is accessible at all times. • The operating manual must be handed over to any subsequent owner

or operator of the freeze-dryer. • Any changes made must be added to the operating manual. • In addition to the operating manual, the general and local rules and

regulations concerning the prevention of accidents and the protection of the environment must also be supplied.

• Safety and danger indications on the freeze-dryer must be kept readable at all times. If necessary, they must be replaced.



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Pos: 53 / 200 Christ /36 0 GT-BA La bor -Pilot (S TANDARDMODULE) /03 0 Sicher heit/ 030 -00 60 Sic her heitshi nweise ++ +++ ++ ++ +++ ++ ++ +++ ++ ++ ++ +++ + @ 25\ mod _14 0498 330 236 1_6 8.do cx @ 1 832 85 @ 2 @ 1

3.6 Safety instructions The following instructions must be observed prior to every drying process:

WARNING

• Ensure that the freeze-dryer was set up and connected properly (see chapter 5 - "Set-up and connection").

• Connections to customer-provided pipes must be force- and torque-free.

• Maintain a safety distance of at least 30 cm (12 inches) around the freeze-dryer.

• Do not store any dangerous goods in the safety area of the freeze-dryer.

• Do not stay in the safety area longer than what is absolutely necessary for the operation of the freeze-dryer.

• Only use accessories that have been approved by the manufacturer (except for commercial vessels made of glass or synthetic materials). We explicitly warn against the use of equipment of poor quality. Breaking glass or bursting vessels can cause dangerous situations.

• Observe the instructions on the installation of accessories (see the separate document).



Pos: 56 / 200 Christ /36 0 GT-BA La bor -Pilot (S TANDARDMODULE) /03 0 Sicher heit/ 030 -00 60- 001 0 Elekt rische Sicher heit @ 25\ mo d_1 4049 833 034 48_ 68.d ocx @ 183 299 @ 3 @ 1

3.6.1 Electrical safety CHRIST freeze-dryers are units of safety class I. Please comply with the following points in order to preserve the safety features:

DANGER

• Ensure that the local mains voltage matches the nominal voltage that is stated on the name plate.

• Do not place any dangerous material, e.g. glass vessels containing liquid substances, within the safety area of 30 cm around the freeze-dryer. Spilled liquids may get into the freeze-dryer and damage the electrical or mechanical components.

• Work on the power supply system must only be performed by certified electricians.

• Inspect the electrical equipment of the unit regularly. Defects such as loose or burnt cables must be eliminated immediately.



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Pos: 58 / 200 Christ /36 0 GT-BA La bor -Pilot (S TANDARDMODULE) /03 0 Sicher heit/ 030 -00 60- 002 0 Mech anisch e Siche rheit @ 25 \mo d_1 404 983 304 593 _68. docx @ 18 331 3 @ 3 @ 1

3.6.2 Mechanical safety In order to ensure the safe operation of the freeze-dryer, please comply with the following points:

WARNING

• Do not use the freeze-dryer if it was installed incorrectly. • Do not use the freeze-dryer without panels. • Do not use the freeze-dryer with accessories that shows signs of

damage. • Only use the freeze-dryer with accessories that have been approved by

the manufacturer. In case of doubt, contact the manufacturer (see chapter 7.3 - "Service contact").

• Do not hit or move the freeze-dryer during its operation. • Do not lean against or rest on the freeze-dryer during its operation. • Check the freeze-dryer and the accessories before every start-up for

any visible signs of damage. • Do not dry any substances that could damage the material of the ice

condenser chamber, drying chamber, lid, or accessories in any way, e.g. highly corrosive substances such as hydrogen chloride (HCl).

• Stop the freeze-dryer immediately in the event of a malfunction. Eliminate the malfunction (see chapter 7 - "Malfunctions and error correction") or contact the after-sales service of Firma Martin Christ Gefriertrocknungsanlagen GmbH (see chapter 7.3 - "Service contact").

• Ensure that all repairs are performed only by authorised and specialised personnel.



Pos: 61 / 200 Christ /36 0 GT-BA La bor -Pilot (S TANDARDMODULE) /03 0 Sicher heit/ 030 -00 60- 003 0 Br andsc hutz @ 25 \mo d_1 404 983 3057 08_ 68. docx @ 18 3327 @ 3 @ 1

3.6.3 Fire prevention Fuses protect certain electrical circuits within the freeze-dryer against over-current conditions.

DANGER

• Always use fuses of the same type and rating. • Do not dry explosive or inflammable substances. • Do not use the freeze-dryer within hazardous locations where there is a

risk of explosion. Pos: 62 / 010 Unive rsalm odul e/Seite nwechs el @ 0 \mo d_1 202 116 244 312_ 0.d ocx @ 105 @ @ 1


3 Safety

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Pos: 63 / 200 Christ /36 0 GT-BA La bor -Pilot (S TANDARDMODULE) /03 0 Sicher heit/ 030 -00 60- 004 0 The rmisc he Siche rhei t @ 2 5\m od_ 140 498 3306 816 _68 .docx @ 18 334 1 @ 3 @ 1

3.6.4 Thermal safety During the operation of the freeze-dryer, the ice condenser can reach surface temperatures of –85°C depending on the power.

DANGER

• Wear suitable protective gloves when installing or removing accessories. Do not reach into the ice condenser chamber without this protection – your limbs may freeze onto the chamber walls!



Pos: 66 / 200 Christ /36 0 GT-BA La bor -Pilot (S TANDARDMODULE) /03 0 Sicher heit/ 030 -00 60- 005 0 Ch emisc he u nd biologisc he Sich erh eit @ 25\ mod_ 140 498 330 794 9_6 8.docx @ 1 833 55 @ 3 @ 1

3.6.5 Chemical and biological safety

If infectious, toxic, pathogenic, or radioactive substances are intended to be dried, it is in the responsibility of the user to ensure that all necessary safety regulations, guidelines, precautions, and practices are adhered to accordingly.

DANGER

• Infectious, toxic, pathogenic, and radioactive substances must be dried in suitable accessories. Take suitable precautions for your own safety!

• Do not dry products with a high solvent concentration or acidic products without special protective measures or device-based precautions (e.g. an additional cooling trap to protect the vacuum pump). It is absolutely necessary to consult the manufacturer in these cases (see chapter 7.3 - "Service contact").

• Special caution is necessary when handling azides, as a dangerous explosive develops in combination with copper or nonferrous metals! It is absolutely necessary to contact the manufacturer (see chapter 7.3 - "Service contact").

WARNING

• Keep informed about local measures to avoid harmful emissions (depending on the substances to be dried).

• As personal protective equipment, safety gloves are required for the use of the freeze-dryer. The materials to be dried may, however, require additional special safety measures (e.g. drying of infectious, toxic, radioactive, or pathogenic substances)



3 Safety

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Pos: 68 / 200 Christ /36 0 GT-BA La bor -Pilot (S TANDARDMODULE) /03 0 Sicher heit/ 030 -00 70 Sic her heitsei nricht ung en- -- --- -- --- --- -- --- -- --- -- --- --- -- --- -- --- --- -- --- -- -- @ 25\ mod _14 049 833 091 10_6 8.d ocx @ 183 369 @ 2 @ 1

3.7 Safety devices

Pos: 69 / 200 Christ /36 0 GT-BA La bor -Pilot (S TANDARDMODULE) /03 0 Sicher heit/ 030 -00 70- 001 0 Syst emko ntr olle LD plus @ 31\ mod _14 085 1550 885 6_6 8.do cx @ 2 097 72 @ 3 @ 1

3.7.1 System check An internal system check system monitors the data transfer and sensor signals with regard to plausibility. Errors are detected by continuous self-monitoring of the system. Error messages are displayed in the main window under "Process & equipment messages" ((see chapter 6.5.3.3 - "Process and equipment information")).


Pos: 71 / 200 Christ /36 0 GT-BA La bor -Pilot (S TANDARDMODULE) /03 0 Sicher heit/ 030 -00 70- 002 0 Sch utzleite rp rüfu ng Alph a - Ga mma, Epsilon 1-4 _2- 4 @ 25\ mod _14 0498 331 146 3_6 8.do cx @ 1 833 97 @ 3 @ 1

3.7.2 Earth conductor check For the earth conductor check, there is an equipotential bonding screw on the rear panel of the freeze-dryer. An earth conductor check can be carried out with the aid of a suitable measuring instrument.



Pos: 74 / 200 Christ /36 0 GT-BA La bor -Pilot (S TANDARDMODULE) /03 0 Sicher heit/ 030 -00 80 V erh alten bei G efah re n un d Unf ällen Alp ha-G am ma @ 25\ mo d_14 049 833 124 51_ 68.d ocx @ 183 411 @ 2 @ 1

3.8 Procedures in the event of hazards and accidents

DANGER

Fire: • A fire in the electrical control system must be extinguished with a CO2

fire extinguisher! • Burning oil must be extinguished with a CO2 fire extinguisher or powder

fire extinguisher! Hazardous electrical incident: • Set the mains power switch of the control system to the "0" position in

order to interrupt the power supply completely. Burns: • Small-area burns (e.g. finger) should be cooled immediately with

lukewarm water for approximately 2 minutes. • Large-area burns should not be cooled because of the resulting risk of

hypothermia. • Cover the burns loosely and in a sterile manner (e.g. with a sterile

dressing). • Cover the injured person with a blanket. IF IN DOUBT, CALL THE EMERGENCY PHYSICIAN (AMBULANCE)!



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Pos: 76 / 200 Christ /36 0 GT-BA La bor -Pilot (S TANDARDMODULE) /03 0 Sicher heit/ 030 -00 90 R estrisik en @ 25\ mod _14 049 833 155 77_ 68.d ocx @ 183 453 @ 2 @ 1

3.9 Remaining hazards All CHRIST freeze-dryers were built state-of-the-art and according to the accepted safety rules. Danger to life and limb of the operator, or of third parties, or impairments of the units or other material assets, however, cannot be completely excluded when the units are being used. Use the freeze-dryer • only for the purpose that it was originally intended for (see chapter 1.2 -

"Intended use") and • only if it is in a perfect running state. • Immediately eliminate any problems that can affect safety.




4 Storage and transport

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Pos: 79 / 200 Christ /36 0 GT-BA La bor -Pilot (S TANDARDMODULE) /04 0 La ger ung und Tr ans port /040 L age run g un d T rans por t= === == == === == == === == == === == @ 2 5\mo d_1 404 983 713 664 _68. docx @ 18 346 7 @ 1 @ 1


Pos: 80 / 200 Christ /36 1 GT-BA La bor -Pilot (PROJEKTE )/Alpha 1- 2 LDpl us/0 40 L age run g un d T ran spo rt/0 40- 0010 Ab messu nge n un d Gewic ht Alph a 1 -2 LD plus @ 31\ mod _14 080 840 602 55_ 68.d ocx @ 209 327 @ 2 @ 1

4.1 Dimensions and weight Values for the freeze-dryer without a vacuum pump:

Alpha 1-2 LDplus

Height: 345 mm

Width: 315 mm

Depth (including vacuum flange connection): 460 mm

Weight: approx. 28 kg Pos: 81 / 010 Unive rsalm odul e/Le erzeil e @ 0\mo d_1 202 116 244 500 _0.d ocx @ 114 @ @ 1


Pos: 83 / 200 Christ /36 0 GT-BA La bor -Pilot (S TANDARDMODULE) /04 0 La ger ung und Tr ans port /040 -00 20 La ger bedin gun gen @ 2 5\mo d_1 404 983 714 695 _68. docx @ 18 348 1 @ 2 @ 1

4.2 Storage conditions In order to ensure the protection against mechanical and climatic influences, the guidelines of the German Federal Association for Wooden Packages, Pallets, and Export Packaging (Bundesverband Holzpackmittel, Paletten, Exportverpackung e.V.), the so-called HPE packaging guidelines, must be applied when packing and storing the freeze-dryer. The storage must be: • dust-free • dry • free from excessive temperature fluctuations • free from a mechanical load.




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Pos: 85 / 200 Christ /36 1 GT-BA La bor -Pilot (PROJEKTE )/Alpha 1- 2 LDpl us/0 40 L age run g un d T ran spo rt/0 40- 0030 Tra nspo rthinw eise Alp ha 1 -2 LD plus @ 31\ mo d_1 4080 840 605 47_ 68.d ocx @ 209 341 @ 2 @ 1

4.3 Notes on transport • Use suitable packaging for the transport, and if at all possible, the

original packaging. • Install all transport safety devices (see chapter 4.5 - "Transport safety

device"). • Over short distances, the freeze-dryer can be transported by a suitable

number of persons who reach under it from the sides. • When lifting the freeze dryer, always reach under the freeze-dryer from

the side. Do not grab the unit at the plastic control panel (see figures below).

correct incorrect

Fig. 11: Lifting the freeze-dryer

CAUTION

The freeze-dryer Alpha 1-2 LDplus weighs approx. 28 kg!

• When setting the unit down, ensure that the feet are upright (see figures

below).

Fig. 12: Unit feet




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Pos: 87 / 200 Christ /36 1 GT-BA La bor -Pilot (PROJEKTE )/Alpha 1- 2 LDpl us/0 40 L age run g un d T ran spo rt/0 40- 0040 Ver pack ung Alp ha 1 -2 LDplus @ 31 \mo d_1 408 084 061 156 _68. docx @ 20 935 5 @ 2 @ 1

4.4 Packaging The freeze-dryer is packaged in a cardboard box or in a wooden crate, depending on the scope of supply. • After opening the packaging, take out the box containing the

accessories. • Remove the packaging material. • Lift the freeze-dryer upwards and out of the crate/cardboard box. When

lifting the unit, always reach under the freeze-dryer from the side.

CAUTION

The freeze-dryer Alpha 1-2 LDplus weighs approx. 28 kg!

• Retain the packaging for any possible future transport of the freeze-

dryer. Pos: 88 / 010 Unive rsalm odul e/Le erzeil e @ 0\mo d_1 202 116 244 500 _0.d ocx @ 114 @ @ 1

Pos: 89 / 200 Christ /36 1 GT-BA La bor -Pilot (PROJEKTE )/Alpha 1- 2 LDpl us/0 40 L age run g un d T ran spo rt/0 40- 0050 Tra nspo rtsich eru ng Alph a 1 -2 LD plus @ 31\ mod _14 080 840 614 20_6 8.d ocx @ 209 369 @ 2 @ 1

4.5 Transport safety device Prior to start-up, the vacuum sensor must be installed (see chapter 5.4 - "Vacuum sensor").

NOTE

Prior to any transport, the vacuum sensor must be deinstalled.




5 Set-up and connection

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Pos: 92 / 200 Christ /36 0 GT-BA La bor -Pilot (S TANDARDMODULE) /05 0 Aufstell ung und Anschlus s/05 0 Aufs tellun g u nd Ansc hluss= == == === == == === == == == === == @ 25 \mo d_1 404 983 7372 44_ 68. docx @ 18 3495 @ 1 @ 1


Pos: 93 / 200 Christ /36 0 GT-BA La bor -Pilot (S TANDARDMODULE) /05 0 Aufstell ung und Anschlus s/05 0-0 010 Aufst ellort (Alpha -Delt a) @ 25\ mod _14 049 837 381 97_ 68.d ocx @ 183 509 @ 2 @ 1

5.1 Installation site Operate the freeze-dryer only in closed and dry rooms. • The table must be stable and have a solid, even tabletop. • Ensure sufficient ventilation. Do not place any paper, cloth, or similar

material behind or under the unit, since otherwise the air circulation will be impaired.

• Keep a safety distance of at least 30 cm from the wall so that the vents in the unit remain fully effective.

• The ambient temperature must be in the range of +10°C to +25°C. • Do not subject the freeze-dryer to thermal stress, e.g. by positioning it

near heat generators. • Avoid direct sunlight (UV radiation).


Pos: 95 / 200 Christ /36 0 GT-BA La bor -Pilot (S TANDARDMODULE) /05 0 Aufstell ung und Anschlus s/05 0-0 020 Ene rgiev erso rgu ng- -- --- --- -- --- -- --- --- -- --- -- --- -- --- -- @ 25\ mo d_14 049 837 400 08_ 68.d ocx @ 183 537 @ 2 @ 1

5.2 Power supply

Pos: 96 / 200 Christ /36 1 GT-BA La bor -Pilot (PROJEKTE )/Alpha 1- 2 LDpl us/0 50 Aufs tellun g un d Anschl uss/0 50- 002 0-0 010 Anschl ussar t Alpha 1- 2 LDpl us @ 31\ mod _140 808 408 036 5_6 8.doc x @ 2 093 98 @ 3 @ 1

5.2.1 Connection

DANGER

The operating voltage on the name plate must correspond to the local supply voltage!

CHRIST freeze-dryers are units of safety class I. Alpha 1-2 LDplus units have a three-wire power cord with an IEC C13 connector (see chapter 10 - "Technical data"). An equipotential bonding screw is located on the back below the mains power input (see chapter 2.1.1 - "Functional and operating elements"). This equipotential bonding screw can be used to perform an earth conductor check.


Pos: 98 / 200 Christ /36 0 GT-BA La bor -Pilot (S TANDARDMODULE) /05 0 Aufstell ung und Anschlus s/05 0-0 020 -00 20 Sic her unge n b auseits @ 2 5\m od_ 140 4983 741 015 _68. docx @ 18 355 1 @ 3 @ 1

5.2.2 Customer-provided fuses Typically, the freeze-dryer must be protected with 16 Amp G fuses that are to be provided by the customer.




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Pos: 100 /20 0 Ch rist/3 61 G T-BA L abo r-Pilot (PROJEKTE)/Alph a 1 -2 LD plus/ 050 Au fstellu ng u nd Ansc hluss/ 050 -00 30 B elüftu ngs - un d M edien abla ufve ntil Alpha 1- 2 LDpl us @ 31\m od_ 140 808 408 064 5_68 .docx @ 2 094 12 @ 2 @ 1

5.3 Aeration and media drain valve The aeration and media drain valve is located on the left side of the unit. After the end of a freeze-drying process, the unit will be aerated via the aeration valve. Additionally, it is used to drain off the condensate and the defrosting water. • Connect the drain hose (included in the scope of supply) to the hose

connector. • Place a collecting vessel under the unit. The hose must be laid with a continuous slope and the end of the hose must always be above the liquid level in the collecting vessel. This prevents water and dirt residues from being sucked into the ice condenser chamber if there is negative pressure when the media drain valve is opened. (see chapter 2.1.1 - "Functional and operating elements")

Pos: 101 /01 0 Univ ersal mod ule/L eerz eile @ 0\m od_ 120 211 624 450 0_0. docx @ 11 4 @ @ 1

Pos: 102 /20 0 Ch rist/3 61 G T-BA L abo r-Pilot (PROJEKTE)/Alph a 1 -2 LD plus/ 050 Au fstellu ng u nd Ansc hluss/ 050 -00 50 V akuu mm essson de Alp ha 1 -2 LDplus @ 31\ mo d_1 4080 840 813 43_ 68.d ocx @ 209 440 @ 2 @ 1

5.4 Vacuum sensor

NOTE

Please refer to the separate operating manual of the vacuum sensor!

In order to protect the vacuum sensor against transport damage, it comes supplied in its original packaging. Prior to commissioning the freeze-dryer, the sensor must be installed.

1 Vacuum sensor 2 Clamping rings 3 Connection socket

Fig. 13: Position of the vacuum sensor and the connection socket

• Switch the unit off by actuating the mains power switch. • Take the vacuum sensor out of its original packaging and fasten it to the

connector with a bow-shaped connecting piece, two clamping rings (DIN16KF) and two centring rings (included in the scope of supply).

• Plug the connector to the connection socket and hand-tighten the screws on the connector.



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NOTE

It is absolutely essential to comply with the manufacturer’s instructions in the separate operating manual of the vacuum sensor!

Thyracont VSP62/63

MKS 722B

Pfeiffer TPR 280/281

Fig. 14: Installed vacuum sensors of different manufacturers

NOTE

The vacuum sensor comes supplied in a calibrated state.

After the freeze-dryer has been switched on, the vacuum sensor needs several minutes until it is ready for operation.

Pos: 103 /01 0 Univ ersal mod ule/Seit enwec hsel @ 0\m od_ 120 211 624 4312 _0. docx @ 10 5 @ @ 1



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Pos: 104 /20 0 Ch rist/3 61 G T-BA L abo r-Pilot (PROJEKTE)/Alph a 1 -2 LD plus/ 050 Au fstellu ng u nd Ansc hluss/ 050 -00 60 V akuu mpu mpe Alpha 1-2 LDpl us @ 3 1\m od_ 140 808 408 1959 _68 .docx @ 2 094 54 @ 2 @ 1 5.4.6 Vakuum pum pe

5.5 Vacuum pump

NOTE

Please refer to the separate operating manual of the vacuum pump and the exhaust filter!

The vacuum pump must be connected to the vacuum connector of the unit and its plug must be plugged into the IEC C14 connector on the back of the unit (see chapter 2.1.1 - "Functional and operating elements"). The oil mist that escapes when the pump is in operation must be retained or carried off by way of an oil mist separator. • We recommend using an oil mist separator. This filter prevents air

pollution by oil mist. • In order to carry off the oil mist, connect a suitable hose to the exhaust

port of the vacuum pump (RZ-2.5 and RC-6: ½", DUO 5 or DUO 10 ¾"). • The hose must be laid so that the condensate cannot flow back into the

pump. In the case of upward leading hoses, we recommend using a separator (Woulfe's bottle or wash bottle).


Pos: 106 /20 0 Ch rist/3 61 G T-BA L abo r-Pilot (PROJEKTE)/Alph a 1 -2 LD plus/ 050 Au fstellu ng u nd Ansc hluss/ 050 -00 70 D rucks teu erve ntil Alpha 1- 2 LDpl us @ 31\ mod _140 808 408 233 1_6 8.doc x @ 2 094 68 @ 2 @ 1

5.6 Pressure control valve The pressure control valve is integrated in the suction pipe between the vacuum pump and ice condenser chamber. During certain, specified process phases, it interrupts the volume flow to the vacuum pump (see chapter 2.2.1 - "General information on freeze-drying").

CAUTION

Observe the installation direction of the pressure control valve!

1 Pressure control valve

Fig. 15: Installation of the pressure control valve

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6 Operation Pos: 110 /20 0 Ch rist/3 60 G T-BA L abo r-Pilot (STANDARDMODU LE)/0 60 Bet rieb/ 060 -00 10 E rste I nbe trie bnah me ++ +++ ++ ++ +++ ++ ++ +++ ++ ++ ++ + @ 2 5\m od_ 140 4983 760 674 _68. docx @ 18 359 2 @ 2 @ 1

6.1 Initial start-up

WARNING

Before the initial start-up, please ensure that your freeze-dryer is properly set up and installed (see chapter 5 - "Set-up and connection")


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6.2 Installation of accessories The accessories must be completed in accordance with the drying method that is applied as well as in accordance with the scope of supply. The installation instructions can be found in a separate document. Please contact our sales department if you have any queries.


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6.3 Preparation The ice condenser chamber must be clean and dry. • Remove any water residues from the preceding run. • Close the media drain valve and the aeration valve. • Ensure that all of the valves of the accessories are closed. • Switch the vacuum pump on.


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6.4 Switching the freeze-dryer on • Actuate the mains power switch. The control unit performs a self-test and an initialisation. This may take several seconds. • Follow the safety instructions and hazard warnings (see chapter 3 -

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6.5 LDplus control system The control system LDplus ("Lyo Display plus") was specifically developed for the control of freeze-drying processes. The clear user interface enables the intuitive operation of the unit.

Fig. 16: Start screen of the LDplus control system


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6.5.1 User interface

1 Left function key 2 Right function key 3 "Up" key 4 "Down" key 5 Display

Fig. 17: User interface of the LDplus control system

Function keys (1+2) Function keys are keys whose function depends on the menu and operating state of the unit. The current function is displayed directly next to the key in the field with a black background.

Fig. 18: Indication of the current functions of the function keys; here, on the left, the "mode" function and on the right the "menu" function.

"Up" and "down" keys (3+4) These keys are used to select the functions and values that are available in the menu or to change the selected parameters. In addition, these keys also control the indication of the measurement value channels in the value windows. The "up" key is assigned to the left value window, whereas the "down" key controls the right value window. • For a selection, press the "up" or "down" key repeatedly until the

desired measurement value channel is indicated in the respective value window.


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Display (5) The main window of the display is divided into the value windows, an area indicating the current function of the function keys, and a status line. The main window displays all of the relevant process data, such as set and actual values, menus, and process information (see the illustration).

6 Value window 7 Current function of the

function keys 8 Status line

Fig. 19: Layout of the LDplus control system display

Value windows (6) The value windows are displayed after the initialisation of the control system. There are two value windows with an identical layout. The indication of the measurement value channels is controlled by way of the "up" and "down" keys (see above).

9 Measurement value channel

10 Set value (only in the run mode)

11 Unit of the measurement value

12 Actual value

Fig. 20: Value windows

The available measurement values can be displayed in the left as well as in the right value window so that a combination of the following values can be selected: • Total time (indicates the total runtime of the process) • Section time (indicates the runtime of an individual phase, e.g. freezing,

warm-up of the vacuum pump, or main drying) • Ice condenser temperature • Vacuum in mbar (indicates the vacuum in the drying chamber; only

possible if a vacuum sensor is installed) • Vacuum converted into °C (indicates the vacuum inside the drying

chamber, converted based on the vapour pressure curve for ice and water, see chapter 2.2.1 - "General information on freeze-drying"; only possible if a vacuum sensor is installed)

Current function of the function keys (7) See function keys (1+2)


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Status line (8) The status line at the bottom of the screen indicates the current operating state, active phase, and any pending information. The status line is visible at all times.

13 Symbol of the operating state

14 Active phase 15 Symbol of pending

information

Fig. 21: Status line

Operating state (13)

The freeze-dryer is in the standby mode. All of the various units are switched off.

The freeze-dryer is in the run mode. The unit performs a continuous run.

The freeze-dryer is in the run mode. The timer is activated.

Active phases (14)

Freezing The ice condenser is cooled.

Warm-up VP

The ice condenser is cooled and the vacuum pump is activated while the pressure control valve is closed. If no pressure control valve is integrated, the drying chamber must be separated from the vacuum pump by way of a manual valve or similar.

Main drying The drying chamber is evacuated while the ice condenser is cooled. If a vacuum control system is included, the vacuum is controlled based on the corresponding set value for the main drying phase.

Final drying The final drying phase is only available if a vacuum control system is included. It is possible to define different control parameters (set vacuum, timer) for the main drying and final drying phases.

Pending information (15)

The symbol flashes every second if there is pending information concerning the process or the freeze-dryer (error messages, process messages, or general information). The information can be viewed under "Process & equipment info" (see chapter 6.5.3.3 - "Process and equipment information")



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6.5.2 Mode The mode can be called up with the left function key if a value window is active. The individual phases can be selected as follows: • Press the left function key "mode". The menu "Start with phase..." will

be displayed (see the illustration). • Select the desired menu item by way of the up/down keys. • Confirm with the right function key "enter".

Fig. 22: Selecting a mode

Starting the freeze-drying process The freeze-drying process comprises four phases: • Freezing • Warm-up vacuum pump • Main drying • Final drying If "main drying" or "final drying" is selected, the system enquires as to whether the vacuum pump shall warm up beforehand.

Changing the phase The freeze-dryer is in the run mode. In order to switch over to the next phase or to stop the process by way of "standby": • Press the left function key "mode". The menu "Select mode" will be

displayed (see the illustration).

Fig. 23: Selecting a mode

• Select the menu item "Continue with phase..." by way of the up/down

keys and confirm the selection with the right function key "enter". • Select the desired phase by way of the up/down keys and confirm the

selection with the right function key "enter".

Fig. 24: Continuing the freeze-drying process


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Warm-up vacuum pump Prior to a freeze-drying process, the vacuum pump usually needs to warm up in order to reach its operating temperature. For this purpose, the warm-up phase can be started. The desired duration can be preselected (see chapter 6.5.3.4 - "Options"). The following processes take place during the warm-up phase. • The ice condenser is cooled. • The vacuum pump is activated while the pressure control valve is

closed. If no pressure control valve is integrated, the drying chamber must be separated from the vacuum pump by way of a manual valve or similar.

After the preset warm-up time, the following information will be displayed:

Fig. 25: Message at the end of the warm-up phase

• Confirm the message and continue the process with the desired phase. Aborting the warm-up phase During the warm-up phase, the functions "Continue with phase" or "Standby" can be selected by way of the left function key "mode". Selecting one of these functions will abort the warm-up phase.



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6.5.3 Main menu The main menu can be selected from the main window by way of the right function key "menu". It includes the following submenus: • Change set values (see chapter 6.5.3.1 - "Changing set values") • Special functions (see chapter 6.5.3.2 - "Special functions") • Process & equipment info (see chapter 6.5.3.3 - "Process and

equipment information") • Options (see chapter 6.5.3.4 - "Options") • Tutorial (see chapter 6.5.3.5 - "Tutorial")

1 Menu bar 2 Menu title 3 Selection frame 4 Scroll bar 5 Function key "exit

menu" 6 Function key "open

menu item"

Fig. 26: Layout of the main menu Pos: 125 /01 0 Univ ersal mod ule/L eerz eile @ 0\m od_ 120 211 624 450 0_0. docx @ 11 4 @ @ 1

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6.5.3.1 Changing set values • Select the "Change set values" function in the main menu.

Fig. 27: Menu "Change set values"

• Select the set value by way of the up/down keys. The selected value will be displayed in a selection frame.

Fig. 28: Manual mode – set value selection

• Confirm with the right function key "edit". The selected value will be displayed in inverted form.

Fig. 29: Inverted indication of the selected set value

• Change the set value by way of the up/down keys. • Confirm with the right function key "ok". The modification of the set value is now complete.


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Set values for the "freezing" phase Timer The timer is used to define the duration of the phase. Settings between one minute and 200 hours are possible. If, when starting at 00:00 h:m, the "down" key is pressed, the symbol will appear. It indicates that the timer is deactivated and that the freeze-dryer is in the continuous mode. After the preselected time has elapsed, the system enquires as to whether the next phase is to be started.

NOTE

It is possible to specify an automatic phase change from "Freezing" to "Warm-up vacuum pump" (seechapter 6.5.3.4 - "Options" / Settings / Automatic phase change).

Set values for the phases "Main drying" and "Final drying"

NOTE

The set values for the "Final Drying" phase are only available if the optional pressure control system is installed.

Timer The timer is used to define the duration of the phase. Settings between one minute and 200 hours are possible. If, when starting at 00:00 h:m, the "down" key is pressed, the symbol will appear. It indicates that the timer is deactivated and that the freeze-dryer is in the continuous mode.

NOTE

It is possible to specify an automatic phase change from "Main drying" to "Final drying" (seechapter 6.5.3.4 - "Options" / Settings / Automatic phase change).

Vacuum

NOTE

For this set value, the optional vacuum control system must be installed.

The range of possible values goes from 6.1 mbar to 0.0010 mbar, converted into steps of 1°C in accordance with the vapour pressure curve for ice and water (see chapter 2.2.1 - "General information on freeze-drying").



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6.5.3.2 Special functions The freeze-dryer is equipped with one or several optional accessories. The components can be controlled by way of this function. • Select the "Special functions" function in the main menu. • Select the option by way of the up/down keys. The selected value will

be displayed in a selection frame.

Fig. 30: "Special functions" menu

• Confirm with the right function key "enter". The possible functions will be

displayed. • If an option is selected that is not installed, a corresponding message

will be displayed:

Fig. 31: Message if an option is not available

Defrosting the ice condenser As standard, the freeze-dryer is equipped with a defrosting system. The ice condenser chamber is supplied with heat that melts the ice off the ice condenser. The freeze-dryer must be in the standby mode and completely aerated.

NOTE

During the defrosting process, the chamber should not be covered in order to prevent the deactivation of the system due to overheating.

• The defrosting time and temperature can be set in the main menu under "Options" (see chapter 6.5.3.4 - "Options").

• Select the function "Defrosting ice condenser" under "Special functions" in the main menu (see above).

• Start the defrosting process by way of the right function key "start". The progress of the defrosting process will be displayed in a dialogue box.

Fig. 32: Progress bar of the defrosting process

When the specified defrosting time has elapsed, the defrosting process will be stopped. The dialogue box disappears automatically.


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Option: Electrical lifting hoist The freeze-dryer can be retrofitted with an electrical lifting hoist that facilitates the attachment and removal of drying chambers. The freeze-dryer must be in the standby mode and completely aerated.

NOTE

The drying chamber cannot be moved in the "Main drying" and "Final drying" phases.

• Select the function "Lifting hoist" under "Special functions" in the main menu (see above).

• Move the drying chamber by way of the up/down keys.

Fig. 33: Operation of the electrical lifting hoist

• After the completion of the process, exit the menu via the left function key "back".


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6.5.3.3 Process and equipment information The menu "Process & equipment info" provides the user with information concerning error, process, and system messages. In the event of a message, a sound signal will be issued, the symbol " " will appear on the status line, and the process and equipment information window will be displayed. If the user is currently in a menu, the window will not be displayed until the user exits the main menu.

1 Message 2 Status of the

information 3 Number of active

messages 4 Function key "exit

menu" 5 Function key

"acknowledge message"

Fig. 34: Structure of the "Process & equipment info" menu

Regardless of the presence of a message, the menu can be activated at all times in order to view any messages that are present. • Select the "Process & equipment info" function in the main menu.

NOTE

The error messages are listed in detail under chapter 7 - "Malfunctions and error correction".


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Status of the information All of the information that is displayed receives a certain status:

Information present, not acknowledged

Information present, acknowledged

Cause of the message no longer present, information not acknowledged

The sound signal is issued until all of the information has been acknowledged.

If the cause of the message is no longer present and if the information has been acknowledged it will be removed from the process and equipment information window. The menu cannot be exited by way of the left function key "back" until all of the information has been acknowledged.


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6.5.3.4 Options The following values can be adjusted in the "Options" menu: • Display contrast • Language • Settings • Service menu

Fig. 35: "Options" menu

Changing the display contrast • Select the menu "Change display contrast". • Adjust the contrast by way of the up/down keys. • Confirm the entry with the right function key "ok".

Fig. 36: Menu for changing the display contrast

Selecting a language The LDplus control system can be used in various language versions. • Select the menu "Select language". • Select the desired language by way of the up/down keys. • Confirm the entry with the right function key "enter".


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Fig. 37: Menu for selecting a language

Settings This menu can be used to adapt the operation and process control of the freeze-dryer's control system to your specific requirements. • Select the desired menu. • Change the value by way of the up/down keys. • Confirm the entry with the right function key "ok".

Fig. 38: "Settings" menu

Warm-up vacuum pump This item is used to adjust the duration of the warm-up phase. Values between 5 and 60 minutes are possible. Automatic phase change If the "Change phase automatically" option is selected, the system will automatically switch over to the next phase after a preset time (see chapter 6.5.3.1 - "Changing set values" / Timer). Click at button push If this setting is active, a confirmatory sound signal will be issued whenever a key/button is pressed. High temperature resolution If this setting is active, temperatures will be displayed in the value window with a resolution of 1/10°C (instead of 1°C). Time defrosting Here, the time that is needed for defrosting the ice condenser can be preselected. Settings between one minute and 200 hours are possible.

Temperature defrosting This value defines the maximum temperature of the ice condenser chamber or ice condenser during the defrosting process. Values between 10 and 60°C are possible.


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Service menu

Fig. 39: Service menu

LDplus configuration Here, the following accessory components (options) can be configured: • Vacuum sensor • Vacuum control system

NOTE

• Installed options must be activated with "yes". • Options that are not installed must be deactivated with "no".

Load default settings This menu item is used to reset all of the set values and parameters to the delivery state of the freeze-dryer. The system will issue a corresponding enquiry prior to performing this step. Extended service menu The extended service menu is reserved for service technicians. This area is protected by a password and is not accessible to the user.


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6.5.3.5 Tutorial The tutorial provides information concerning the most important functions of the LDplus control system. The tutorial is available in German, English, and French.

Fig. 40: Tutorial

• Select the "Tutorial" function in the main menu. • Browse the tutorial by way of the up/down keys. • Click the left function key repeatedly in order to exit the tutorial.



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6.6 Switching the freeze-dryer OFF The freeze-dryer must be in the standby status. • Switch the freeze-dryer off by pressing the mains power switch.




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7 Malfunctions and error correction Malfunctions are displayed in the dialog box "Process & equipment messages" (see chapter 6.5.3.3 - "Process and equipment information"). An acoustic signal sounds when an error message is generated. • Eliminate the source of the problem (see the following chapter). • Acknowledge the error message.


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7.1 General malfunctions Pos: 142 /20 0 Ch rist/3 60 G T-BA L abo r-Pilot (STANDARDMODU LE)/0 70 Stö run gen und Fe hlers uche /07 0-0 010 -00 10 N etzau sfall @ 25\ mod _14 049 840 5896 4_6 8.d ocx @ 1841 53 @ 3 @ 1

7.1.1 Power failure The control system continues with the process after a power failure. The preselected conditions remain saved even during a process run. In the event of a power failure in the drying phase, the batch may become unusable. Whether the batch can be saved or not depends on the drying phase in which the product was when the power failure occurred. • In the final drying phase, the product has reached a residual moisture

content of approx. 5%. Below this value, the product is generally not damaged even if the power failure lasts for a longer period of time.

• If the product is in the main drying phase, we recommend aerating the unit, removing the product, and storing it in a deep-freeze. The defrosted condensate must be drained off prior to the next start.


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7.1.2 Insufficient vacuum

NOTE

The vacuum checks must be carried out when the ice condenser is frozen.


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7.1.2.1 Small flange connections Leakages are often due to improper small flange connections between the various components and hose connections or to leakages in the valves. • Loosen the connection and place the centring ring (with sealing ring

inside) in a centred manner between the flange connections. • Seal the connection with the clamping ring by tightening the wing nut. • Ensure that the centring ring neither slips out of place nor gets jammed.



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Fig. 41: Small flange and centring ring Fig. 42: Small flange with centring ring

and small flange

Fig. 43: Attaching the clamping ring Fig. 44: Tightened clamping ring


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7.1.2.2 Aeration and media drain valve A malfunction of the aeration and media drain valve may have several causes. One potential source are contaminants such as product residues within the valve. • Switch the freeze-dryer off and disconnect the mains plug. • Clean the valve (see chapter 8.1.1.3 - "Aeration valve, media drain

valve"). • Put the freeze-dryer into operation again. If there is still a leakage, the freeze-dryer must be checked by qualified specialist personnel (see chapter 7.3 - "Service contact").


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7.1.2.3 Pressure control valve A malfunction of the pressure control valve may have several causes.

NOTE

The inspection of the valve must be carried out by qualified specialist personnel (see chapter 7.3 - "Service contact").

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7.1.2.4 Rubber valves In order to identify a leaking rubber valve, the valves must be checked individually: • Remove the rubber valve and seal the connection at the drying

chamber with a rubber stopper. • Check the tightness under vacuum until the leaking valve has been

localised. • Clean the valve or replace it if necessary.


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7.1.2.5 Vacuum sensor Vacuum sensors have a limited service life and can be ordered as spare parts (e.g. VSP62/63, order no. 125468). Functional test: • Connect the vacuum sensor directly to the suction side connector of the

vacuum pump. If a final pressure of at least 0.011 mbar is reached (with a vacuum pump that has reached its operating temperature), the sensor and the vacuum pump are OK.


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7.1.3 Insufficient ice condenser temperature

CAUTION

Ensure sufficient ventilation. Do not place any paper, cloth, or similar material behind or under the unit, since otherwise the air circulation will be impaired.

The refrigeration unit is equipped with a protective device against overpressure in the refrigeration system and with a thermal motor protection switch. The protective devices trip • when the ambient temperature is too high • when the air circulation of the heat exchanger of the refrigeration

system is insufficient • when the refrigeration system is overloaded. In these cases, the refrigeration unit will be switched off automatically. If the permissible operating conditions are re-established after a cool-down phase of several minutes, the refrigeration unit will be switched on again automatically. The malfunctions are displayed in the process and equipment information window. The minimum ice condenser temperature of approx. -55°C or approx. –85°C (depending on the type of freeze-dryer) is reached when the ice condenser is not loaded and the ice condenser chamber is evacuated.




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7.2 Process and equipment messages

Error message Possible cause Remedy

Vacuum 6.11 mbar not reached The value of 6.11 mbar is not reached within 15 minutes with an open pressure control valve. The pressure control valve will be closed and the vacuum pump will be switched off.

• The aeration and media drain valves are soiled.

• The small flange connections are not properly connected.

• A seal is soiled or damaged. • The cover or drying chamber is

not properly attached. • The ground-in stopper is not

inserted correctly or it is missing.

• The vacuum pump is switched off or defective.

• Clean the valve (see chapter 8.1.1.3 - "Aeration valve, media drain valve") and replace it if necessary.

• Loosen the connection. Place the centring ring with the inner sealing ring in a centred manner between the flange connections and connect it with the clamping ring. Ensure that the centring ring neither slips out of place nor gets jammed.

• Clean the seal and replace it if necessary.

• Check the cover and drying chamber.

• Grease the ground-in stopper evenly and over the entire sealing surface with vacuum grease and install it.

• Switch the vacuum pump on. Refer to the separate instruction manual of the vacuum pump.

Defective vacuum sensor The control system registers an invalid measurement value.

• The vacuum sensor is not connected correctly.

• The calibration is faulty.

• The vacuum sensor is soiled (e.g. due to water residues).

• The vacuum sensor is defective.

• Check the vacuum sensor connectors.

• Calibrate the vacuum sensor (see the separate operating instructions of the vacuum sensor).

• Clean the vacuum sensor.

• Check the vacuum display with the aid of a reference device (if available).

• See chapter 7.1.2.5 - "Vacuum sensor".

Overpressure of refrigeration unit 1 • The overpressure switch of the refrigeration unit has tripped.

• Let the freeze-dryer cool down. • Ensure sufficient air circulation

(see chapter 7.1.3 - "Insufficient ice condenser temperature").

Overpressure of refrigeration unit 2 • The overpressure switch of the refrigeration unit has tripped.

• Let the freeze-dryer cool down. • Ensure sufficient air circulation

(see chapter 7.1.3 - "Insufficient ice condenser temperature").

Ice condenser overtemperature Ice condenser temperature > +65°C. All of the units will be switched off and the freeze-dryer will be automatically set to standby.

• The defrosting process has been performed with the cover closed.

• Remove the cover and let the freeze-dryer cool down.



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Error message Possible cause Remedy

Ice condenser temperature 20°C The ice condenser temperature rises to a non-permissible value during the freeze-drying process. The pressure control valve will close automatically in order to prevent the vacuum pump from being damaged.

• Insufficient cooling. • Observe the behaviour of the refrigeration system. If necessary, inform the service department (see chapter 7.3 - "Service contact").

Defective ice condenser temperature sensor

• The temperature sensor is not connected or it is defective.

• Inform the service department (see chapter 7.3 - "Service contact").

Defective temperature sensor of the defrosting heater

• The temperature sensor is not connected or it is defective.

• Inform the service department (see chapter 7.3 - "Service contact").

Mains power failure (see chapter 7.1.1 - "Power failure")

• The power supply has been interrupted.

• The mains power connector is not connected.

• The fuses have tripped.

• The mains power switch has been switched off.

• Check the mains fuse.

• Connect the mains power connector firmly.

• Check the customer-provided fuses.

• Switch the mains power switch on.

Default settings loaded All of the settings have been reset to the delivery state of the freeze-dryer.

• Error in the parameter memory. • Manual execution in the service

menu.

• No measure required.

IO communication error (0x20) • Error in the LDplus IO module. • Inform the service department (see chapter 7.3 - "Service contact").



Pos: 161 /20 0 Ch rist/3 60 G T-BA L abo r-Pilot (STANDARDMODU LE)/0 70 Stö run gen und Fe hlers uche /07 0-0 030 Kont akt im S ervice fall_L abo r-RVC @ 25\ mod _14 049 8406 875 8_6 8.do cx @ 1 842 79 @ 2 @ 1

7.3 Service contact In the event of queries, malfunctions, or spare part enquiries:

From Germany: Contact Martin Christ Gefriertrocknungsanlagen GmbH An der Unteren Söse 50 37520 Osterode (Germany) Tel. +49 (0) 55 22 / 50 07-44 44 E-mail: [email protected]

Outside Germany: Contact our agency in your country. All agencies are listed at www.martinchrist.de [Sales Partners]

NOTE

If you would like to utilise our after-sales-service, please state the type of your freeze-dryer and its serial number.

Pos: 162 /01 0 Univ ersal mod ule/Absc hnittsw echsel @ 0\ mod _12 021 245 140 62_ 0.docx @ 4 18 @ @ 1 Pos: 163 /01 0 Univ ersal mod ule/Seit enwec hsel @ 0\m od_ 120 211 624 4312 _0. docx @ 10 5 @ @ 1


8 Maintenance and service

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Pos: 164 /20 0 Ch rist/3 60 G T-BA L abo r-Pilot (STANDARDMODU LE)/0 80 Wa rtun g u nd In stan dhalt ung/ 080 Wa rtun g un d Ins tan dhalt ung == === == == === == == === == == == == @ 25\ mod _14 049 840 9570 4_6 8.d ocx @ 184 307 @ 1 @ 1

8 Maintenance and service The freeze-dryer and the accessories are subject to high mechanical stress. Thorough maintenance performed by the user extends the service life and prevents premature failure.

CAUTION

If corrosion or other damage occurs due to improper care, the manufacturer cannot be held liable or subject to any warranty claims.

• Use soap water or other water-soluble, mild cleaning agents for cleaning the freeze-dryer and the accessories.

• Do not use corrosive and aggressive substances. • Do not use solvents. • Do not use agents with abrasive particles. • Do not expose the freeze-dryer or its accessories to intensive UV

radiation (e.g. sunlight) or thermal stress (e.g. by heat generators). • Do not turn the unit upside down in order to clean it.


Pos: 166 /20 0 Ch rist/3 60 G T-BA L abo r-Pilot (STANDARDMODU LE)/0 80 Wa rtun g u nd In stan dhalt ung/ 080 -00 10 Wart ungs arb eiten -- --- -- --- --- -- --- -- --- -- --- --- -- --- -- --- --- -- --- -- --- -- --- --- -- --- -- --- - @ 25\ mod_ 140 498 409 668 0_6 8.doc x @ 1 843 21 @ 2 @ 1

8.1 Maintenance Pos: 167 /20 0 Ch rist/3 60 G T-BA L abo r-Pilot (STANDARDMODU LE)/0 80 Wa rtun g u nd In stan dhalt ung/ 080 -00 10- 001 0 G efri ertr ockn ungs anla ge @ 25\ mod _14 0498 409 783 2_6 8.do cx @ 1 843 35 @ 3 @ 1

8.1.1 Freeze-dryer • Switch the freeze-dryer off by actuating the mains power switch and

disconnect the power cord from the wall outlet before cleaning. • Remove product residues thoroughly with a cloth. • If the freeze-dryer has been contaminated with toxic, radioactive, or

pathogenic substances, clean the inside immediately with a suitable decontamination agent (depending on the type of contamination, see (see chapter 8.2 - "Disinfection of the drying chamber and accessories")).

WARNING

Take suitable precautions for your own safety if there is a risk of toxic, radioactive, or pathogenic contamination.

• Open the lid/drying chamber when the freeze-dryer is not in use so

moisture can evaporate. Pos: 168 /01 0 Univ ersal mod ule/Seit enwec hsel @ 0\m od_ 120 211 624 4312 _0. docx @ 10 5 @ @ 1



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Pos: 169 /20 0 Ch rist/3 60 G T-BA L abo r-Pilot (STANDARDMODU LE)/0 80 Wa rtun g u nd In stan dhalt ung/ 080 -00 10- 001 0-0 010 Eiskon dens ato rkam me r (a ußer Epsil on 2 -4) @ 2 5\m od_ 1404 984 098 898 _68. docx @ 18 434 9 @ 4 @ 1

8.1.1.1 Ice condenser chamber Before each start-up, ensure that the ice condenser chamber is free from water residues. • Open the media drain valve to drain off any liquid. Then, close the

valve. • If necessary, wipe the ice condenser chamber dry with a cloth.


Pos: 171 /20 0 Ch rist/3 60 G T-BA L abo r-Pilot (STANDARDMODU LE)/0 80 Wa rtun g u nd In stan dhalt ung/ 080 -00 10- 001 0-0 020 T rock nun gska mme r La bor @ 2 5\m od_ 140 4984 100 052 _68. docx @ 18 436 3 @ 4 @ 1

8.1.1.2 Drying chamber Some drying chambers are equipped with the LYO CHAMBER GUARD splinter protection film. • In order to prevent the film from being damaged, only use water and

commercially available window cleaning agents as well as synthetic sponges, soft tissues or a rubber wiper for cleaning.

• Do not dry-clean any drying chambers that are equipped with LYO CHAMBER GUARD film!

Fig. 45: Identification label on a drying chamber with a splinter protection film

Pos: 172 /01 0 Univ ersal mod ule/Seit enwec hsel @ 0\m od_ 120 211 624 4312 _0. docx @ 10 5 @ @ 1 Pos: 173 /20 0 Ch rist/3 60 G T-BA L abo r-Pilot (STANDARDMODU LE)/0 80 Wa rtun g u nd In stan dhalt ung/ 080 -00 10- 001 0-0 030 Belüf tung s- u nd Medi ena blaufv entil LD plus @ 31\ mo d_14 084 423 160 92_ 68.d ocx @ 209 746 @ 4 @ 1

8.1.1.3 Aeration valve, media drain valve Contaminants such as product residues may lead to an insufficient vacuum. In this case, the aeration valve and the media drain valve must be cleaned. • Switch the freeze-dryer off and disconnect the mains plug. • Remove the valve core. • Clean the valve core and the opening with a moist cloth. • Clean the O-rings and inspect them for any damage. Damaged O-rings

must be replaced. 1 Valve opening 2 Valve core 3 O-rings

Fig. 46: Valve opening and valve core with O-rings (example, varies depending of the type of freeze-dryer)



58 Version 11/2006, Rev. 2.0 of 02/12/2014 • sb


• Reinsert the valve core. • Put the freeze-dryer into operation again. If the vacuum is still insufficient, the freeze-dryer must be checked by qualified specialist personnel (see chapter 7.3 - "Service contact").


Pos: 175 /20 0 Ch rist/3 60 G T-BA L abo r-Pilot (STANDARDMODU LE)/0 80 Wa rtun g u nd In stan dhalt ung/ 080 -00 10- 001 0-0 040 Wä rmet ausc her @ 25 \mo d_1 404 984 102 436_ 68. docx @ 18 439 1 @ 4 @ 1

8.1.1.4 Heat exchanger (only for air-cooled freeze-dryers) A lamellar heat exchanger is used for cooling the refrigerant that is compressed by the refrigeration unit. This air-cooled heat exchanger is located at the back of the unit (see chapter 2.1.1 - "Functional and operating elements"). Dust and dirt impair the cooling effect of the air flow. Dust on the lamellas prevents the exchange of heat and, thereby, impairs the performance and power of the refrigeration unit. Strong soiling may cause the unit to fail. This is why the selected set-up location should be as clean as possible. • Check the heat exchanger at least once per month for soiling and clean

it if necessary. • Please contact the Christ service department if you have any queries

(see chapter 7.3 - "Service contact").

Pos: 176 /01 0 Univ ersal mod ule/Seit enwec hsel @ 0\m od_ 120 211 624 4312 _0. docx @ 10 5 @ @ 1 Pos: 177 /20 0 Ch rist/3 60 G T-BA L abo r-Pilot (STANDARDMODU LE)/0 80 Wa rtun g u nd In stan dhalt ung/ 080 -00 10- 002 0 Vak uum pu mpe @ 25 \mo d_1 404 984 1034 28_ 68. docx @ 18 4405 @ 3 @ 1

8.1.2 Vacuum pump

NOTE

Please refer to the separate operating manual of the vacuum pump!

The stress of the vacuum pump in conjunction with a freeze-dryer is usually not very high. This is why the recommendations in this operating manual may differ from the information that is provided by the pump manufacturers. Under normal operating conditions, the following maintenance tasks concerning the vacuum pump must be performed at regular intervals: • Check the oil level of the vacuum pump once per week. If necessary,

top it up with oil. • Check the running pump for any unusual noise. • Ensure that the pump has reached its operating temperature prior to

changing the oil. • Perform the first oil change after approximately 100 operating hours. • The other oil changes depend on the operating conditions. In general,

an interval of 500 to 1,000 operating hours is sufficient. • Please contact the Christ service department if you have any queries

(see chapter 7.3 - "Service contact"). Pos: 178 /01 0 Univ ersal mod ule/L eerz eile @ 0\m od_ 120 211 624 450 0_0. docx @ 11 4 @ @ 1

Pos: 179 /20 0 Ch rist/3 60 G T-BA L abo r-Pilot (STANDARDMODU LE)/0 80 Wa rtun g u nd In stan dhalt ung/ 080 -00 10- 003 0 Öl neb elabsc heid er (Auspuf ffilter ) @ 25\ mod _14 049 8410 452 1_6 8.d ocx @ 1844 19 @ 3 @ 1



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8.1.3 Exhaust filter (oil mist separator)

NOTE

Please refer to the separate operating manual of the vacuum pump and the exhaust filter!

The oil mist that is emitted by the vacuum pump in quantities that depend on the working pressure must be led to the outside or to an exhaust hood or similar. If this is not possible, the pump must be equipped with an exhaust filter (oil mist separator). • Observe the liquid level in the collecting vessel of the filter. • Remove the condensate in time (please refer to the information

provided by the manufacturer in the separate operating manual).

Pos: 180 /01 0 Univ ersal mod ule/Seit enwec hsel @ 0\m od_ 120 211 624 4312 _0. docx @ 10 5 @ @ 1 Pos: 181 /20 0 Ch rist/3 60 G T-BA L abo r-Pilot (STANDARDMODU LE)/0 80 Wa rtun g u nd In stan dhalt ung/ 080 -00 10- 004 0 Vak uum mess sond e @ 25\ mod _14 0498 410 561 0_6 8.do cx @ 1 844 33 @ 3 @ 1

8.1.4 Vacuum sensor

NOTE

Please refer to the separate operating manual of the vacuum sensor!

The vacuum sensor has only a limited service life. Especially carbon-containing substances, e.g. alcoholic compounds, reduce the service life extremely. • The vacuum sensor is maintenance-free. • Remove any soiling on the outside with a cloth.


Pos: 183 /20 0 Ch rist/3 60 G T-BA L abo r-Pilot (STANDARDMODU LE)/0 80 Wa rtun g u nd In stan dhalt ung/ 080 -00 10- 005 0 Zub ehö r @ 25\ mod_ 140 498 410 669 3_6 8.doc x @ 1 844 47 @ 3 @ 1



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8.1.5 Accessories

CAUTION

For the care of the accessories, special safety measures must be considered as these are measures that will ensure operational safety at the same time.

Chemical reactions as well as stress-corrosion (combination of oscillating pressure and chemical reaction) can affect or destroy the metal and plastic parts. Barely detectable cracks on the surface can expand and weaken the material without any visible signs. • Check the material regularly (at least once a month) for

– cracks – visible damage of the surface – pressure marks – signs of corrosion – other changes.

• Replace any damaged components immediately for your own safety. • Immediately rinse off the accessories if any liquids that may cause

corrosion come into contact with them. • Clean the accessories outside the freeze-dryer once a week or

preferably after each use.

Pos: 184 /01 0 Univ ersal mod ule/Seit enwec hsel @ 0\m od_ 120 211 624 4312 _0. docx @ 10 5 @ @ 1 Pos: 185 /20 0 Ch rist/3 60 G T-BA L abo r-Pilot (STANDARDMODU LE)/0 80 Wa rtun g u nd In stan dhalt ung/ 080 -00 20 Desinf ektion von Tr ockn ungsk am mer und Zu beh ör @ 25\ mo d_1 4049 841 078 51_ 68.d ocx @ 184 461 @ 2 @ 1

8.2 Disinfection of the drying chamber and accessories • Use commercially-available disinfectants such as, for example, Incidur ,

Meliseptol , Sagrotan , Buraton , or Terralin (available at specialised trade).

• The freeze-dryers and the accessories consist of various materials. A possible incompatibility must be considered.

• Before using cleaning or decontamination agents that were not recommended by us, contact the manufacturer to ensure that such a procedure will not damage the freeze-dryer.

• Please contact us if you have any queries (see chapter 7.3 - "Service contact").

DANGER

If dangerous materials (e.g. infectious and pathogenic substances) are used, the freeze-dryer and accessories must be disinfected.



Pos: 188 /20 0 Ch rist/3 60 G T-BA L abo r-Pilot (STANDARDMODU LE)/0 80 Wa rtun g u nd In stan dhalt ung/ 080 -00 30 Inst and haltu ngsa rbeit en Labo r @ 25\ mod _14 049 8410 899 8_6 8.do cx @ 1 844 75 @ 2 @ 1



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8.3 Service

DANGER

In the event of service work that requires the removal of the panels, there is a risk of electric shock or mechanical injury. Only qualified specialist personnel is authorised to perform this service work.

The freeze-dryer is subject to high mechanical stress. In order to be able to withstand this high level of stress, high-quality components were used during the production of the freeze-dryer. Nevertheless, wear cannot be excluded and it may not be visible from the outside. This is why we recommend having the freeze-dryer checked by the manufacturer during an inspection once per year. Information and appointments: From Germany: Contact Martin Christ Gefriertrocknungsanlagen GmbH An der Unteren Söse 50 37520 Osterode (Germany) Tel. +49 (0) 55 22 / 50 07-44 44 E-mail: [email protected] Outside Germany: Contact our agency in your country. All agencies are listed at www.martinchrist.de [Contacts] [Foreign agencies]

NOTE

If you would like to utilise our after-sales-service, please state the type of your freeze-dryer and its serial number.



Pos: 191 /20 0 Ch rist/3 60 G T-BA L abo r-Pilot (STANDARDMODU LE)/0 80 Wa rtun g u nd In stan dhalt ung/ 080 -00 40 Rückse ndu ng defek ter Teile @ 2 5\m od_ 1404 984 111 088 _68. docx @ 18 450 3 @ 2 @ 1



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8.4 Return of defective parts

Although we exercise great care during the production of our products, it may be necessary to return a unit or accessory to the manufacturer. In order to ensure the quick and economical processing of returns of freeze-dryers, rotational vacuum concentrators, spare parts, or accessories, we require complete and extensive information concerning the process. Please fill in the following forms completely, sign them, enclose them with the return package, and send them together with the product to: Martin Christ Gefriertrocknungsanlagen GmbH

An der Unteren Söse 50 37520 Osterode (Germany)

1. Declaration of decontamination As a certified company and due to the legal regulations for the protection of our employees and of the environment, we are obliged to certify the harmlessness of all incoming goods. For this purpose, we require a declaration of decontamination. • The form must be filled in completely and signed by authorised and

specialised personnel only. • Affix the original form in a clearly visible manner to the outside of the

packaging.

NOTE

If no such declaration is enclosed in the return package, we will perform the decontamination at your expense!

2. Form for the return of defective parts This form is for the product-related data. They facilitate the assignment, and they enable the quick processing of the return. If several parts are returned together in one packaging, please enclose a separate problem description for every defective part. • A detailed problem description is necessary in order to perform the

repair quickly and economically. • Please note on the form if you would like to receive a cost estimate.

Cost estimates are only prepared upon request and against charge. If an order is placed, these charges will be offset.

NOTE

The unit must be packaged in a transport-safe manner. Please use the original packaging, if at all possible. If the product is dispatched to us in unsuitable packaging, you will be charged the cost for returning it to you in new packaging.




9 Disposal

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Pos: 194 /20 0 Ch rist/3 60 G T-BA L abo r-Pilot (STANDARDMODU LE)/0 90 Ents org ung/ 090 Ents org ung === == == == === == == === == == === == == === == == === == @ 2 5\mo d_1 404 984 138 903 _68. docx @ 18 451 7 @ 1 @ 1

9 Disposal Pos: 195 /20 0 Ch rist/3 60 G T-BA L abo r-Pilot (STANDARDMODU LE)/0 90 Ents org ung/ 090 -00 10 Entso rgu ng d er G efri ertr ockn ungs anlag e @ 25\ mod _140 498 414 112 2_6 8.doc x @ 1 845 31 @ 2 @ 1

9.1 Disposal of the freeze-dryer Martin Christ Gefriertrocknungsanlagen GmbH is a registered manufacturer of electric and electronic devices that are solely intended for commercial use. • Comply with all local rules and regulations.


Pos: 197 /20 0 Ch rist/3 60 G T-BA L abo r-Pilot (STANDARDMODU LE)/0 90 Ents org ung/ 090 -00 20 Entso rgu ng d er Ve rpack ung @ 2 5\m od_1 404 984 143 017 _68. docx @ 18 454 5 @ 2 @ 1

9.2 Disposal of the packaging • Dispose of the packaging, after having separated the individual

materials. • Comply with all local rules and regulations.




10 Technical data

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Pos: 200 /20 0 Ch rist/3 61 G T-BA L abo r-Pilot (PROJEKTE)/Alph a 1 -2 LD plus/ 100 Tec hnisch e Dat en/1 00 Tec hnisch e Dat en Alp ha 1 -2 LDplus == === == == === == == === == == @ 31\ mo d_1 408 0840 934 61_ 68.d ocx @ 209 483 @ 1 @ 1

10 Technical data Manufacturer: Martin Christ

Gefriertrocknungsanlagen GmbH An der Unteren Söse 50 37520 Osterode (Germany)

Type: Alpha 1-2 LDplus

Part number: 101521

Performance data

Ice condenser - capacity: - performance: - temperature: - chamber volume:

2.5 kg max. 2 kg / 24 h max. approx. –55°C approx. 3.5 l

Shelf or product temperature during freezing in the ice condenser chamber

approx. –25°C

Max. shelf surface ( process B): drying outside the ice condenser chamber drying in injection vials with sealing under vacuum or nitrogen atmosphere outside the ice condenser chamber drying in round bottom flasks

3 shelves, Ø 200 mm, Atotal=0.092m2 distance up to 80 mm, with accessory, part no. 120893 2 shelves, 200 mm, Atotal=0.054 m2 distance 25-70 mm, with accessory, part no. 121015 8 pieces, with accessory, part no. 121450

Connection requirements (without vacuum pump and accessories)

Electrical connection: 1 x 230 V / 50-60 Hz

Protection class: I

IP protection category according to DIN 60529: 11

Nominal power: 0.66 kVA

Nominal current: 3.0 A

Mains fuse: 6.3 A T

Pressure control valve connection: 230 V, 50/60 Hz, 20 VA / 0.5 A max.

Vacuum pump connection: 230 V, 50/60 Hz, 2.5 A max.

Filling quantity

Refrigerant: see name plate


10 Technical data

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Physical data (without vacuum pump and accessories)

Dimensions - height: - width: - depth:

345 mm 315 mm 460 mm (incl. vacuum flange connection)

Weight: approx. 28 kg

Noise level according to DIN 45635:

49 dB(A)

EMC according to EN 55011: Class B

Heat emission: 0.51 kW min. 0.91 kW max.

Equipment connections

Vacuum connection: Small flange connection DN25KF (ISO 28403, DIN 2861)

Aeration and media drain valve: Hose nozzle DN10 (outside diameter 12 mm)

Mains input: IEC C13 connector

Vacuum sensor: SUB D-9 VSP 62/63

Option: Data interface (LAN): RJ 45 Pos: 201 /01 0 Univ ersal mod ule/L eerz eile @ 0\m od_ 120 211 624 450 0_0. docx @ 11 4 @ @ 1


Pos: 203 /20 0 Ch rist/3 60 G T-BA L abo r-Pilot (STANDARDMODU LE)/1 00 Tech nische D ate n/10 0-0 010 Um geb ungs bedin gun gen -- --- --- -- --- -- --- --- -- --- -- --- -- --- --- -- --- -- @ 25 \mo d_1 404 9841 557 72_ 68.d ocx @ 184 573 @ 2 @ 1 10.1 Umgeb ungs bedi ngu nge n

10.1 Ambient conditions Pos: 204 /20 0 Ch rist/3 60 G T-BA L abo r-Pilot (STANDARDMODU LE)/1 00 Tech nische D ate n/10 0-0 010 Um geb ungs bedin gun gen Tex t @ 2 5\m od_ 140 498 415 4817 _68 .docx @ 1 845 59 @ @ 1

10.1 Umgeb ungs bedi ngu nge n

• The figures are valid for an ambient temperature of +20°C. • Allowable ambient temperature +10 °C to +25 °C. • Max. humidity 85% (non-condensing) at +25°C.



Pos: 207 /20 0 Ch rist/3 60 G T-BA L abo r-Pilot (STANDARDMODU LE)/1 00 Tech nische D ate n/10 0-0 020 Technisc he D okum ent ation @ 25 \mo d_1 404 984 156 884_ 68. docx @ 18 458 7 @ 2 @ 1

10.2 Technical documentation The technical documentation of this freeze-dryer (e.g. circuit diagram, cooling system ) and the safety data sheets of the manufacturers of refrigerant and heat transfer medium is not attached to this operating manual. You can order these documents from our service department.




11 Appendix

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Pos: 210 /20 0 Ch rist/3 60 G T-BA L abo r-Pilot (STANDARDMODU LE)/1 10 Anh ang /011 0 Anh ang == == === == == == === == == === == == === == == === == == === == == = @ 25\m od_ 140 498 417 799 4_68 .docx @ 1 846 01 @ 1 @ 1

11 Appendix Pos: 211 /20 0 Ch rist/3 61 G T-BA L abo r-Pilot (PROJEKTE)/Alph a 1 -2 LD plus/ 110 An han g/0 110 -002 0 Ku rzbe dien ungs anleitu ng Alp ha 1 -2 LDplus @ 31 \mo d_1 408 084 1091 22_ 68. docx @ 20 9498 @ 2 @ 1

11.1 Brief operating instructions Functional and operating elements

1 Ice condenser chamber

with an internal ice condenser

2 Aeration and media drain valve

Fig. 47: Left side of the freeze-dryer

3 Pipe connection of the

vacuum pump (behind the cover plate)

4 Ice condenser Fig. 48: Ice condenser chamber


11 Appendix

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5 User interface 6 Mains power switch Fig. 49: Front and right side of the freeze-dryer

7 Name plate 8 Power supply of the

pressure control valve 9 Power supply of the

vacuum pump 10 Equipotential bonding

screw 11 Mains connection 12 Vacuum connection 13 Connection of the

vacuum sensor 14 Option: data interface for

further accessories 15 Heat exchanger of the

refrigeration unit Fig. 50: Rear view of the freeze-dryer


11 Appendix

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Step-by-step instructions – shelf drying 1 Freeze the sample separately, e.g. in a deep-freeze.

NOTE

Ensure that the layer thickness of 1 to 2 cm is not exceeded, since otherwise the drying time needs to be extended.

2 Check the ice condenser chamber and ensure that it is completely free

from water residues. 3 Close the media drain valve and install the base plate. 4 Switch the unit on 20 to 30 minutes prior to the start of the drying

process in order to let the vacuum pump warm up. 5 Place the plate rack on the base plate. 6 Transport the frozen samples as quickly as possible from the deep-

freeze to the freeze-dryer and place them on the shelves.

NOTE

Recommendation: Store the product vessels on the aluminium shelves or, if possible, the entire rack with the shelves in the deep- freeze. The advantage is that due to the higher cold storage capacity of the aluminium material, the product will remain frozen for a longer period of time so that the sample will not thaw.

7 nstall the drying chamber. Prior to doing so, check whether the O-ring

is completely free of dirt particles. The ground-in stopper of the acrylic glass bell must be greased with high-vacuum grease.

8 Ensure that all of the valves of the acrylic glass bell are closed. 9 Ensure that the aeration valve is closed. 10 Ensure that the media drain valve is closed. 11 Start the main drying process either by opening the manual shut-off

valve or by waiting for the electromagnetic valve to open. Vacuum is applied to the chamber and the freeze-drying process commences.

NOTE

The vacuum pump always runs with maximum power. With this type of freeze-dryer, the power of the vacuum pump cannot be controlled.

12 The operating panel displays the vacuum, the ice condenser

temperature, and the current operating mode. 13 The end of the process is reached when the ice condenser is no longer

loaded and when it again reaches a final temperature of approximately -50°C to -54°C. The pressure decreases as a function of the ice condenser temperature.

14 Switch the vacuum pump off and aerate the drying chamber via the media drain valve or via a rubber valve.

15 Switch the unit off by actuating the mains power switch and take the product out of the freeze-dryer.


11 Appendix

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16 Switch the unit on again and start the defrosting process.

CAUTION

Ensure that no water gets into the pipe connection of the vacuum pump or vacuum sensor.

17 Drain the defrosting water via the media drain valve on the left-hand

side of the unit. To do so, connect a hose to the hose connector and collect the defrosting water in a suitable vessel.

18 Keep the freeze-dryer open (i.e. without the lid or drying chamber) when it is not in use so that moisture can evaporate. This increases the service life of the vacuum sensor.

Step-by-step instructions – drying in a flask 1 Freeze the sample separately, e.g. in a deep-freeze.

NOTE

Ensure that the layer thickness of 1 to 2 cm is not exceeded, since otherwise the drying time needs to be extended.

2 Check the ice condenser chamber and ensure that is completely free

from water residues. 3 Install the drying chamber. Prior to doing so, check whether the O-ring

is completely free of dirt particles. The ground-in stopper of the acrylic glass bell must be greased with high-vacuum grease.

4 Ensure that all of the valves are closed. 5 Let the vacuum pump warm up 20 to 30 minutes before the freeze-

drying processes commences. 6 Connect a frozen sample to a valve.

CAUTION

After the pressure has fallen below 1.030 mbar, a frozen sample can be connected to a valve. The next frozen sample cannot be connected to another valve until the pressure is again lower than 1.030 bar.

NOTE

The vacuum pump always runs with maximum power. With this type of freeze-dryer, the power of the vacuum pump cannot be controlled.

7 The operating panel displays the vacuum, the ice condenser

temperature, and the current operating mode. 8 The end of the process is reached when the ice condenser is no longer

loaded and when it again reaches a final temperature of approximately -


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50°C to -54°C. The pressure decreases as a function of the ice condenser temperature.

NOTE

The drying time depends on the layer thickness of the sample, the solids content of the sample, and the amount of heat that is supplied during the drying process. In the case of a layer thickness of 1 cm, the freeze-drying process usually takes 24 hours.

9 Switch the vacuum pump off and aerate the drying chamber via the

media drain valve or via a rubber valve. 10 Switch the unit off by actuating the mains power switch and take the

product out of the freeze-dryer. 11 Switch the unit on again and start the defrosting process.

CAUTION

Ensure that no water gets into the pipe connection of the vacuum pump or vacuum sensor.

12 Drain the defrosting water via the defrosting water valve on the left-hand

side of the unit. To do so, connect a hose to the hose connector and collect the defrosting water in a suitable vessel.

13 Keep the freeze-dryer open (i.e. without the lid or drying chamber) when it is not in use so that moisture can evaporate. This increases the service life of the vacuum sensor.



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Pos: 213 /20 0 Ch rist/3 61 G T-BA L abo r-Pilot (PROJEKTE)/Alph a 1 -2 LD plus/ 110 An han g/0 110 -030 Kon for mitäts erklä run g Alph a 1- 2 LDpl us @ 31\ mod _14 0808 411 076 0_6 8.do cx @ 2 095 10 @ 2 @ 1

11.2 EC declaration of conformity



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Pos: 215 /20 0 Ch rist/3 60 G T-BA L abo r-Pilot (STANDARDMODU LE)/1 10 Anh ang /011 0-0 040 Spa nnu ngsriss - u nd Ch emik alienb estä ndigk eit Plexiglas @ 2 5\m od_1 404 984 180 960 _68. docx @ 18 464 3 @ 2 @ 1


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11.3 Resistance to stress cracking and chemical influences "Plexiglas"


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Pos: 218 /01 0 Univ ersal mod ule/9 00 Gl ossa r GT La bor LDplus == == === == == === == == === == == == === == == === == == === @ 3 1\m od_ 1411 375 072 732 _68. docx @ 21 048 0 @ 1 @ 1


12 Glossary

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12 Glossary Desorption Desorption (from Latin de-sorbere, sorbere = sup up, suck in) describes a phenomenon whereby molecules are released from the surface of a solid. In order to be able to desorb, the particle must have, or be provided with, a sufficient amount of energy in order to overcome the binding energy. Eutectic point The eutectic point is the point at which a homogenous mixture (e.g. a eutectic alloy) passes directly from the liquid to the solid phase without the formation of a crystal mixture that consists of different phases. Single-chamber method At the single-chamber method, the freezing as well as the subsequent drying of the product are both performed in the ice condenser chamber. The sample is frozen as a result of the low temperature of the ice condenser (–55°C in the case of one-stage systems or –85°C in the case of two-stage systems). The inside of the chamber can be cooled to approximately –20°C or –40°C. The moderate supply of the frozen sample with energy, which is necessary during the main drying phase, is ensured by heatable shelves on which the product is placed. Double-chamber method Drying on shelves outside the ice condenser chamber is referred to as a double-chamber system. The advantage compared to the single-chamber method is the considerably higher product capacity. In addition, the product chamber can be isolated from the ice condenser chamber by an intermediate valve in order to perform a so-called pressure increase test for determining the end of the drying process. In freeze-dryers without an active shelf cooling, the samples need to be pre-frozen externally, e.g. in a deep-freeze or freezer cabinet. After the transfer of the product into the freeze-dryer, the actual sublimation is started. Reference designator During the service life of industrial systems, a standardised reference designation system is required for the planning, design, realisation, maintenance, and disassembly stages in order to be able at all times to identify every single component within the system in an unambiguous manner. The reference designators) are affixed to the components and entered into the technical documentation (e.g. circuit diagrams). Sublimation Sublimation (from Latin "sublimis" = high up in the air, raised), is a thermodynamic process of the direct transition of a substance from the solid phase to the gas phase.

=== E nde der Liste für Tex tma rke I nhal t = ==


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Index

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13 Index

A

Aborting the warm-up phase ...................... 41 Accessories ................................... 11, 25, 60 Accident prevention ................................... 23 Active phases ............................................ 39 Aeration valve ................................ 12, 33, 65 Aeration valve, cleaning and care .............. 57 Aeration valve, malfunction ........................ 51 Ambient conditions ..................................... 65 Ambient temperature ................................. 65 Automatic phase change ............................ 47

B

Brief operating instructions ......................... 66

C

CE mark in compliance with the directive 2006/42/EC ............................................ 21

Changing set values .................................. 42 Changing the display contrast .................... 46 Changing the phase ................................... 40 Chemical and biological safety ................... 26 Chemical reactions .................................... 60 Circuit diagram ........................................... 65 Cleaning agents ................................... 56, 60 Cleaning the freeze-dryer and the

accessories ............................................ 56 Click at button push ................................... 47 Commissioning .......................................... 11 Connection................................................. 32 Connection of the vacuum sensor .............. 13 Connection requirements ........................... 64 Contamination ............................................ 56 Cooling system .......................................... 65 Copyright ................................................... 10 Corrosion ............................................. 56, 60 Country of origin......................................... 14 Cracks ....................................................... 60 Current function of the function keys .......... 38 Customer-provided fuses ........................... 32

D

Dangerous goods....................................... 24 Dangerous materials .................................. 60

Data interface ............................................ 13 Data interface (LAN) .................................. 65 Declaration of decontamination .................. 62 Decontamination agents ............................ 60 Defrosting .................................................. 20 Defrosting the ice condenser...................... 44 Defrosting with hot gas............................... 20 Degree of interference suppression ........... 14 Desorption ................................................. 91 Dimensions .......................................... 29, 65 Direct hazard to the life and health ............. 22 Disinfectants .............................................. 60 Disinfection of the drying chamber and

accessories ............................................ 60 Display ....................................................... 38 Disposal of the freeze-dryer ....................... 63 Disposal of the packaging .......................... 63 Double-chamber method ............................ 91 Drying chamber.......................................... 57

E

Earth conductor check ............................... 27 EC declaration of conformity ................ 10, 71 Electrical connection .................................. 64 Electrical lifting hoist .................................. 45 Electrical safety .......................................... 24 EMC according to EN 55011 ...................... 65 Emissions .................................................. 26 End of drying and aeration ......................... 20 Equipment connections .............................. 65 equipotential bonding screw ....................... 27 Equipotential bonding screw ...................... 13 Error correction .......................................... 50 Error messages.................................... 27, 54 Eutectic point ............................................. 91 Exhaust filter .............................................. 59 Explanation of symbols .............................. 10 Explanation of the symbols and notes ........ 22 Extended service menu.............................. 48

F

Filling quantity ............................................ 64 Final drying ................................................ 20


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Fire prevention ........................................... 25 Form for the return of defective parts ......... 62 Freeze-dryer, cleaning and care ................ 56 Freeze-drying phases ................................ 17 Freeze-drying process ............................... 18 Freezing ..................................................... 18 Function keys ............................................. 37 Functional and operating elements ............ 12 Fuses ......................................................... 25

G

General conditions ..................................... 10 General information on freeze-drying ......... 15

H

Hazard warnings .................................... 9, 10 Heat emission ............................................ 65 Heat exchanger ......................................... 58 Heat exchanger of the refrigeration unit ..... 13 High temperature resolution ....................... 47 Highly corrosive substances ...................... 25 Hot-gas defrosting ...................................... 20

I Ice condenser ............................................ 64 Ice condenser chamber.............................. 12 Ice condenser chamber, cleaning and care 57 Importance of the operating manual ............. 9 Important information ................................. 22 Infectious substances .......................... 26, 60 Inflammable substances ............................ 25 Informal safety instructions ........................ 23 Initial start-up ............................................. 36 Inspection by the manufacturer .................. 61 Installation of accessories .......................... 36 Installation site ........................................... 32 Insufficient ice condenser temperature ....... 53 Insufficient vacuum .................................... 50 Intended use ................................................ 9 IP protection category according to DIN

60529 ..................................................... 64

K

Keys "up" and "down" ................................ 37

L

Layout of the freeze-dryer .......................... 12 LDplus configuration .................................. 48

LDplus control system ................................ 37 Lifting hoist, electrical ................................. 45 Load default settings .................................. 48 LYO CHAMBER GUARD splinter protection

film ......................................................... 57

M

Main drying ................................................ 19 Main menu ................................................. 42 Mains fuse ................................................. 64 Mains power switch .................................... 13 Maintenance and service ........................... 56 Malfunctions ............................................... 50 Manufacturer ........... 14, 24, 26, 56, 60, 63, 64 Marking of the unit ..................................... 21 Max. humidity ............................................. 65 Mechanical safety ...................................... 25 Media drain valve ........................... 12, 33, 65 Media drain valve, cleaning and care ......... 57 Media drain valve, malfunction ................... 51 Mode.......................................................... 40 Mode of operation ...................................... 15

N

Name plate .............................. 13, 14, 24, 32 Noise level ................................................. 65 Nominal current.......................................... 64 Nominal power ........................................... 64 Nominal voltage ................................... 14, 24 Notes on safety and hazards........................ 9 Notes on transport ..................................... 30

O

Oil mist separator ................................. 35, 59 Operating elements .................................... 12 Operating personnel .................................. 23 Operating state .......................................... 39 Operating voltage....................................... 32 Operational safety ...................................... 60 Option: data interface ................................. 13 Option: electrical lifting hoist ...................... 45 Options ...................................................... 46

P

Packaging ............................................ 31, 63 Part number ......................................... 14, 64 Pathogenic substances .................. 26, 56, 60


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Pending information ................................... 39 Performance data ...................................... 64 Physical data ............................................. 65 Potential hazard to the life and health ........ 22 Potentially hazardous situation................... 22 Power failure .............................................. 50 Power rating ............................................... 14 Power supply ............................................. 32 Power supply of the pressure control valve 13 Power supply of the vacuum pump ............ 13 Preparation .......................................... 18, 36 Pressure control valve................................ 35 Pressure control valve, malfunction............ 52 Pressure marks .......................................... 60 Prevention of accidents .......................... 9, 23 Procedures in the event of hazards and

accidents ................................................ 27 Process and equipment information ........... 45 Process and equipment messages ............ 54 Protection class.......................................... 64 Protection of the environment .................... 23 Protective gloves........................................ 26

R

Radioactive substances ....................... 26, 56 Rated current ............................................. 14 Reference designator ................................. 91 Refrigerant ................................................. 64 Refrigerant data ......................................... 14 Registered office ........................................ 14 Remaining hazards .................................... 28 Resistance to stress cracking and chemical

influences "Plexiglas" ............................. 73 Responsibility of the operator ..................... 23 Return of defective parts ............................ 62 Rubber valves ............................................ 52

S

Safety area ................................................ 24 Safety class ......................................... 24, 32 Safety data sheets ..................................... 65 Safety devices ........................................... 27 Safety distance .................................... 24, 32 Safety instructions ............................ 9, 10, 24 Safety-conscious work ............................... 23 Scope of supply ......................................... 11

Selecting a language ................................. 46 Serial number ................................ 14, 55, 61 Service ....................................................... 61 Service contact .......................................... 55 Service life ................................................. 56 Service menu ............................................. 48 Service work .............................................. 61 Settings ...................................................... 47 Set-up and connection ............................... 32 Signs of corrosion ...................................... 60 Single-chamber method ............................. 91 Small flange connections ........................... 50 Solvents. .................................................... 56 Special functions ........................................ 44 Specialist personnel ................................... 61 Splinter protection film................................ 57 Standards and regulations ......................... 10 Starting the freeze-drying process ............. 40 Status line .................................................. 39 Status of the information ............................ 46 Step-by-step instructions – drying in a flask 69 Step-by-step instructions – shelf drying ...... 68 Storage ...................................................... 29 Storage and transport ................................ 29 Storage conditions ..................................... 29 Stress-corrosion ......................................... 60 Sublimation ................................................ 91 Supply voltage ........................................... 32 Switching the freeze-dryer OFF ................. 49 Switching the freeze-dryer on..................... 36 System check ............................................ 27

T

Technical data ........................................... 64 Technical documentation ........................... 65 Temperature defrosting .............................. 47 Thermal safety ........................................... 26 Thermal stress ........................................... 56 Time defrosting .......................................... 47 Timer ......................................................... 43 Toxic substances ................................. 26, 56 Transport ................................................... 29 Transport safety device .............................. 31 Type..................................................... 14, 64


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U

User interface ...................................... 13, 37 UV radiation ......................................... 32, 56

V

Vacuum ..................................................... 43 Vacuum connection ............................. 13, 65 Vacuum pump ...................................... 26, 35 Vacuum pump connection .......................... 64 Vacuum pump, cleaning and care .............. 58 Vacuum sensor ........................ 33, 52, 59, 65

Value windows ........................................... 38 Vapour pressure curve above ice ............... 16 Ventilation ............................................ 32, 53

W

Warm-up .................................................... 41 Warm-up vacuum pump ............................. 47 Warranty and liability .................................. 10 Weight ................................................. 29, 65

Y

Year of manufacture .................................. 14

стр.2034, Москва, Турчанинов пер, д.6, Адрес: 119www.donaulab.ru Тел. +7 (495)-255-33-89в Россииtin Christ GmbH Донау Лаб. Москва/ «Donau Lab. Moscow» - дилер Mar

tin Christ GmbHПосмотреть каталог оборудования Mar

http://donaulab.ru/manufacturer/martin-christ-gefriertrocknungsanlagen-gmbh/

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