Summary of Contents for DYNAVAC NovaDryer-DHF400
- Page 1 Vacuum Freeze Dryer NovaDryer-DHF400/ DHF600 (PLC Control System) Quick Installation & Operation Guide (Version202003) www.dynapumps.com.au • 1300 788 579 • sales@dynapumps.com.au...
- Page 2 Contents Page no. Part 1. Unpacking …………………………………………………………………. Part 2. Preparation before operation ……………………………………. Part 3. Basic knowledge about this freeze dryer …………………. Part 4. System operation …………………………………………………………. Part 5. System Working Flow Chart …………………………………………. www.dynapumps.com.au • 1300 788 579 • sales@dynapumps.com.au...
- Page 3 Before you use this freeze dryer for the first time, please read all the documents and complete the training course listed below: ‐User Manual ‐Quick installation and Operation Guide ‐Parameter Setting Chart for Different Materials ‐Video Training Course ‐Technical Bulletin www.dynapumps.com.au • 1300 788 579 • sales@dynapumps.com.au - 1-...
- Page 4 Part 1. Unpacking When receiving the goods: 1. If any damage is found, please contact insurance company for compensation claim. *For CIF,CIP and DDP, please contact Senova to obtain necessary assistance. 2. After unpacking, please check the freezer and all the accessories are received in good condition according to your order. 3. After unpacking, please remove the protective buffer foam filled inside the chamber(Pic‐1) protective buffer foam Pic‐1 Pic‐2 Pic‐3 4. Remove the black dust‐proof plastic cap(Pic‐4) on discharge outlet of the vacuum pump before using. Caution: There is an external temperature sensor (Pic‐5) inside the chamber. Do not damage it! Pic‐4 Pic‐5 www.dynapumps.com.au • 1300 788 579 • sales@dynapumps.com.au...
- Page 5 Part 2. Preparation before operation 1. Find power cord, metal soft vacuum tube, and connectors. Connect the vacuum pump to the freeze dryer(Pic‐2 & 3) 2. Vacuum pump oil: 2‐1. Please find vacuum pump oil inside the package. 2‐2. Add it into the vacuum pump to the oil level or 2/3 position of the side window. 2‐3. If the freeze dryer is shipped by air, vacuum pump oil is removed before shipment according to civil aviation security regulation. Please purchase vacuum pump oil (#100 or #68 for vacuum pump 2XZ‐2/4 and #46 or #68 for vacuum pump DRV‐10) for any brand locally. Mobil and Shell are recommended. 2‐4. Vacuum pump oil is consumable and needs to be replaced after running for 100‐200 hours, please prepare some vacuum pump oil for spare use. 2‐5. Vacuum pump oil can be recycled after frozen and sedimentation so as to save cost. For details, please contact us. 2/3 Position Pic‐6 Pic‐7 ...
- Page 6 7. Rotate the vacuum /water draining valve to the close position. *This valve is combined with functions as a vacuum valve for chamber pressure and a water draining valve after defrosting vacuum /water draining valve Open Position Close Position 8. Turn on main power. Switch on the freeze dryer. The freeze dryer is ready to use now. Pic‐12 www.dynapumps.com.au • 1300 788 579 • sales@dynapumps.com.au...
- Page 7 Part 3. Basic knowledge about this freeze dryer 1. There are 5 working stages in the freeze drying process. It takes a freeze dryer 24‐30 hours to finish the complete process including: Pre‐freeze, Cold Trap Cooling, Vacuum Pumping, Drying and Temperature keeping. Total freeze drying time (24‐30 hours) depends on sugar contents, oil contents, water contents, size of the materials, and room temperature. If ‐45C deep freezer is available, please use it to pre‐freeze the materials for about 9 hours so the freeze dryer can skip the pre‐freeze stage (set pre‐freeze time: 1 minute) to reduce freeze dryer's total working time to about 18 hours (Cold trap cooling needs to be started before the pre‐frozen materials are loaded into the chamber to cool the chamber to low temperature requested for the next stage‐vacuum pumping) 2. The working stage indicator keeps flashing in each stage all the time. This flashing is normal and does not mean any alarm. 3. There are 2 control modes for this freeze dryer: Vacuum Control and Program Control. Both modes share the same settings in the first 3 stages (pre‐freeze, cold trap cooling and pre‐vacuum) but have different settings at drying stage. Vacuum Control mode: Parameters at drying stage is preset and the user is not allowed to modify parameters. Program Control mode:Parameters at drying stage is not preset and the user is allowed to modify parameters according to different materials. Program Control Mode is recommended because this mode can be used for all the materials while Vacuum Control Mode is not suggested for some materials such as milk and flowers. 4. A parameter setting chart is offered by us according to our tests on different materials. The user can try to modify it after the best parameter setting is found after some trial running. 5. After started, the freeze dryer and vacuum pump can run automatically according to the set parameters. 6. The vacuum pump does NOT start at the first 2 stages (pre‐freeze, cold trap cooling). It will be started automatically from vacuum pumping stage and will keep running in working status until end of freeze drying (except it is stopped by the user).
- Page 8 8‐1. Normal Status: The freeze dryer is working in good condition. 8‐2. Please Remove Materials: Materials have finished freeze drying and can be removed from the freeze dryer. [Caution]Before removing materials, please confirm materials are in stable status first: Go to Main Menu, press “Temp.Control” to check if vacuum record in the past one hour has been keeping stable. When vacuum record in the past one hour is stable, stop the freeze dryer, open the water draining valve, remove materials from the chamber, and run “Defrost” in “OPERATION” menu. *Before running the next freeze drying cycle, check and make sure there are no frost, ice or water in the chamber. 8‐3. Vacuum Alarm: This alarm is caused some reasons related to the material itself and air leakage. Refer to point 9 for solutions. 9. How to Eliminate Vacuum Alarm When “Vacuum Alarm” keeps flashing on the main menu, please try the 2 solutions given below: 9‐1. If vacuum degree on the main menu is between 900‐1000 (Pa)(Pic‐9) when “Vacuum Alarm” keeps flashing on the Main Menu. ☞ It means critical leakage which causes failure of vacuum pumping. Step 1. Stop the freeze dryer. Step 2. Check and make sure the door is closed tightly, and there is no leakage with all the vacuum tubes outside/inside the freeze dryer and connectors. Pic‐9 *If necessary, some parts need to be replaced to fix leakage. Step 3. Re‐start the freeze dryer Step 4. Go to Main Menu, Press “FORMULA”. Modify “Pre‐freeze Time” from 600(minutes) into 1(minute). *This is because pre‐freeze stage has completed before re‐start and it needs to skip this stage after re‐start. So the pre‐freeze stage can run only for 1 minute then go to vacuum pumping stage quickly. 600 Step 5.Go to Main Menu, press “OPERATION”. On OPERATION menu, press “Stop Vacu. Alarm” to eliminate vacuum alarm. Step 6. On OPERATION menu, press “Start” to run the freeze dryer in good condition without vacuum alarm. The Problem is solved. www.dynapumps.com.au • 1300 788 579 • sales@dynapumps.com.au...
- Page 9 9‐2. If vacuum degree on the main menu is lower than 900 (Pa) but higher than Pre‐vacuum pressure set by the user(for sample. 30Pa) when “Vacuum Alarm” keeps flashing on the main menu. For example. Vacuum degree displayed on the main menu is 45Pa (Pic‐10) and pressure set for Pre‐vacuum is 30Pa(Pic‐11). Pic‐10 Pic‐11 There are 2 reasons: ☞ Reason 1:There is minor leakage. Solution: Step 1. Do NOT stop the freeze dryer. Step 2. Check and make sure the door is closed tightly, and there is no leakage with all the vacuum tubes outside/inside the freeze dryer and connectors. Step 3. Go to Main Menu, Press “FORMULA”. Modify “Pre‐Vacuum Pressure from 30(Pa) into a value (e.g. 60Pa) higher than vacuum degree (e.g. 45Pa) as displayed on the main menu *This is because pre‐freeze stage has completed before re‐start and it needs to skip this stage after re‐start. So the pre‐freeze stage can run only for 1 minute then go to vacuum pumping stage quickly. 30 Step 4.Go to Main Menu, press “OPERATION”. On OPERATION menu, press “Stop Vacu. Alarm” to eliminate vacuum alarm. Then the freeze dryer can continue to run in good condition without vacuum alarm. The Problem is solved. www.dynapumps.com.au • 1300 788 579 • sales@dynapumps.com.au...
- Page 10 ☞ Reason 2: Characteristics (such as water contents) of the materials itself does not allow to reach a pressure (e.g. 30Pa) as set for pre‐vacuum which is lower than the vacuum degree (e.g. 45Pa) displayed on the Main Menu. It means the materials can finish freeze drying in the vacuum degree (e.g. 45Pa) displayed on the Main Menu. And it is impossible to reach the lower pressure (e.g. 30Pa) as set for pre‐vacuum. Solution: Step 1. Do NOT stop the freeze dryer. Step 2. Go to Main Menu, Press “FORMULA”. Modify “Pre‐Vacuum Pressure from 30(Pa) into a value (e.g. 60Pa) higher than vacuum degree (e.g. 45Pa) as displayed on the main menu *This is because pre‐freeze stage has completed before re‐start and it needs to skip this stage after re‐start. So the pre‐freeze stage can run only for 1 minute then go to vacuum pumping stage quickly. Step 4.Go to Main Menu, press “OPERATION”. On OPERATION menu, press “Stop Vacu. Alarm” to eliminate vacuum alarm. Then the freeze dryer can continue to run in good condition without vacuum alarm. The Problem is solved. www.dynapumps.com.au • 1300 788 579 • sales@dynapumps.com.au...
- Page 11 Part 4. System Operation 1.After power‐on The system enters into Main Menu (Monitoring Interface) with parameters including time the freeze dryer has run from start, real‐time vacuum degree (1000Pa is shown if higher than 1000Pa) , temperature of shelves, cold trap (working chamber) and materials, current section at current stage, and current working stage. 2.Click "FORMULA" for recipe management. Set parameters according to materials to be freeze dried. i. Set Pre‐freezing time (600 minutes is recommended). ii.Set cold trap temperature and time (Timing starts when cold trap reaches temperature set by the user). ‐30℃ and 3 minutes are recommended. iii.Set pre‐vacuum pumping value and time (Timing starts when vacuum reaches value set by the user). 30Pa and 30 minutes are recommended. If vacuum does not reach the set value within 30 minutes, the system will display vacuum abnormal alarm. In such situation, check door, drain valve and vacuum pump connectors. iv. Set vacuum limit for drying stage (If vacuum in drying stage exceeds this limit, heating is stopped). After finishing above setting, you will have 2 control modes(Vacuum Control and Program Control) to choose. Program Control Mode is recommended because this Mode can be used for all the materials while Vacuum Control Mode is not suggested for some materials such as milk and flowers. Please refer to details on the next page. www.dynapumps.com.au • 1300 788 579 • sales@dynapumps.com.au...
- Page 12 If Vacuum Control Mode is chosen: i.Please set Vacuum Upper Limit, Vacuum Lower Limit (In initial vacuum process. When chamber pressure≤Vacuum Lower Limit, the system starts heating and inflating. When chamber pressure≧Vacuum Upper Limit, the system stops heating and inflating. Vacuum Upper Limit 66Pa and Vacuum Lower Limit 33Pa are recommended. ii.Set time for initial drying stage. 600 minutes is recommended. When initial drying time is reached, the system enters into secondary drying stage. iii.Set keeping (maintaining) pressure and time. When chamber pressure<keeping pressure, timing starts. When time reaches keeping time set by the user, the system enters into the secondary drying stage. iv. Set keeping (maintaining) temperature which can be understood as keeping (maintaining) time for the initial drying. 60℃ is recommended. After finishing above setting, press "Next" to set parameters for the secondary drying. v. Set time for secondary drying. 600 minutes is recommended. vi.Set temperature for secondary drying. 40℃ is recommended. If Program Control Mode is chosen: The user can program up to 18 sections. Set temperature and heat keeping (maintaining) time. Please input total number of all the sections in RUN SECTION NO after setting is finished. www.dynapumps.com.au • 1300 788 579 • sales@dynapumps.com.au...
- Page 13 3.Temperature‐keeping (maintaining) Stage. Set keeping time 999 min, keep temperature 30℃. 4.After finishing FORMULA setting, return to Monitoring Menu (Main Interface) , press "OPERATION". i. Choose control mode (Program Control or Vacuum Control). Refer to procedure above on the previous page for setting. ii. Load materials into the chamber, close the door, check if the inflation/drain valve is closed tightly and vacuum pump tube is connected properly. iii. Press "Start'. The system begins freeze drying process. iv. After automatic program running is finished, Rotate the vacuum /water draining valve to the open position, then open the door and unload the freeze dried materials. Open Position www.dynapumps.com.au • 1300 788 579 • sales@dynapumps.com.au...
- Page 14 v. Set defrost time and temperature, press "Defrost ON". 120 minutes and 60℃ are recommended. This system allows the user to check and output history record of temperature and vacuum. In Monitoring Menu (Main Menu), press "TEMP. CONTROL" to view history temperature and vacuum chart. Press "NEXT" and "PREVIOUS" to check history record at specific time. The user can also insert a Flash Disk (this feature is ☞ available soon) to output data in Excel format. DO NOT save too many files in the flask disk. Contact us for video. It is suggested to clear data monthly so as to ensure data integrity. If memory for the touch‐screen controller is full, the system will replace the earliest data with latest data. www.dynapumps.com.au • 1300 788 579 • sales@dynapumps.com.au...
- Page 15 Part 5. HF400/600 PLC Freeze Drying System Automatic Working Flow Chart Pre‐Freezing 预冻 满足预冻时间 Reach Pre‐Freezing Time Cold Trap 捕水器制冷 Starts Cooling 满足捕水器温度及时间 Reach Water‐Capturing Temperature & Time Pre‐Vacuum 预抽真空 Reach Pre‐Vacuum Value & Time In Program Temperature Control mode：It is allowed to set max. 18 sections of temperature Initial Drying control program. After temperature control program finishes running, it skips into Secondary 一次干燥 ...
- Page 16 -35℃ PLC Controller Freeze Dryer (NovaDryer-HF400) Parameter Setting Formula/Recipe for Various Materials (Version 20190901) Note: In case of machine being unattended at completion of cycle, the duration of the final section is set at 999 minutes. However, it is not necessary to run the final section for 999 minutes. At any time during the final section, the user can remove the dried materials from the freeze dryer.
- Page 17 For more information and to request a quote contact one of the Dynapumps offices Australia-wide Phone 1300 788 579 Perth - Head Office Brisbane sales@dynapumps.com.au 88 Belgravia Street, Unit 7/ 14 Hopper Ave Belmont, WA 6104 Ormeau, QLD 4208 (08) 08) 9424 2000 (07) 07) 5546 7777...
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