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Summary of Contents for Labconco FreeZone 794801 Series
- Page 1 Original instructions Models 794801*** Series...
- Page 2 Warranty Labconco Corporation provides a warranty to the original buyer for the repair or replacement of parts and reasonable labor as a result of normal and proper use of the equipment with compatible chemicals. Broken glassware and maintenance items, such as filters, gaskets, light bulbs, finishes and lubrication are not warranted.
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Page 3: Table Of Contents
Original instructions ABLE ONTENTS CHAPTER 1: INTRODUCTION Intended Use Freeze Dry Process Freeze Dry Rates Freeze Dry Capacity Samples Containing Volatile Substances About This Manual Typographical Conventions CHAPTER 2: PREREQUISITES Electrical Requirements Location Requirements Vacuum Pump Requirements CHAPTER 3: GETTING STARTED Unpacking Your Stoppering Tray Dryer Stoppering Tray Dryer Components Setting Up Your Stoppering Tray Dryer... - Page 4 Original instructions Programs Creating a New Program Starting a Program Stopping a Program Freeze Drying Using the Manifold Valves Shelf Spacing Adjustment Shelf Loading Sample Freezing Freeze Drying Stoppering Vacuum Break/Backfilling Alerts Power Fail Line Voltage Range System Temp Variation Vacuum Variation System Temp Set Point Program Complete...
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Page 5: Chapter 1: Introduction
The unit is easy to install and maintain. Proper care and maintenance of this product will result in many years of dependable service. Intended Use The Stoppering Tray Dryer is intended to be used in conjunction with Labconco Console Freeze Dryers in a laboratory setting to facilitate the lyophilization process. -
Page 6: Freeze Dry Rates
Original instructions Chapter 1: Introduction Freeze Dry Rates The efficiency of the Freeze Drying process is dependent upon the surface area and the thickness of the sample, the collector temperature and vacuum obtained, the eutectic point and solute concentration of the sample. It is important to remember these factors when trying to obtain efficient utilization of your Freeze Dry system. -
Page 7: Freeze Dry Capacity
Original instructions Chapter 1: Introduction essential to maintain an efficient rate. In many applications, the maintenance of a vacuum of 0.133 mbar or less is recommended. The rate of freeze drying is directly proportional to the vapor pressure and the vapor pressure is dependent upon both eutectic temperature and solute concentration of the sample. -
Page 8: Samples Containing Volatile Substances
Original instructions Chapter 1: Introduction Samples Containing Volatile Substances In certain cases the solvent in a sample to be freeze dried may contain volatile components such as acetonitrile, methanol, acetic acid, formic acid or pyridine. In addition to these substances having an effect on the eutectic temperature, they may increase the vapor pressure at the surface of the sample. -
Page 9: Typographical Conventions
Appendix B: Dimensions contains comprehensive diagrams showing the dimensions for the Stoppering Tray Dryer. Appendix C: Specifications contains product specifications. Appendix D: Accessories see www.labconco.com for a complete list of Stoppering Tray Dryer accessories. Typographical Conventions Recognizing the following typographical conventions will help you understand and use this manual: •... -
Page 10: Chapter 2 Prerequisites
Original instructions HAPTER REREQUISITES Before you install your Stoppering Tray Dryer, you need to prepare your site for installation. The Stoppering Tray Dryer will mount on top of a FreeZone 6, 12 or 18 liter Console Freeze Dryer. Carefully examine the location where you intend to install your Stoppering Tray Dryer. -
Page 11: Location Requirements
Vacuum pumps used with 115V models should be equipped with a 115V, 15 Amp NEMA 5-15P plug. Vacuum pumps used with 230V models should be equipped with a reverse IEC plug (included with 230V pumps purchased from Labconco). This will allow the vacuum pump to be plugged into the receptacle on the rear electrical panel of the Console Freeze Fryer. -
Page 12: Chapter 3 Getting Started
Commerce by the carrier. Commission rules require DO NOT RETURN GOODS WITHOUT THE PRIOR that claims be AUTHORIZATION OF LABCONCO. UNAUTHORIZED filed with the delivery carrier RETURNS WILL NOT BE ACCEPTED. within fifteen (15) days of delivery. Product Service 1-800-522-7658... -
Page 13: Stoppering Tray Dryer Components
Screw, ¼ - 20 x .75 long If you did not receive one or more of the components listed for your Stoppering Tray Dryer, or if any of the components are damaged, contact Labconco Corporation immediately for further instructions. Setting Up Your Stoppering Tray Dryer After you verify receipt of the proper components, move your Stoppering Tray Dryer to the location where you want to install it. -
Page 14: Electrical Connection
Original instructions Chapter 3: Getting Started 3. Loosen both clamps on the lower rubber coupling and slide the coupling upward so the bottom edge of the coupling is above the lower edge of the stainless steel tube. Snug both clamps on the coupling to hold them in place. -
Page 15: Communication Cable
Original instructions Chapter 3: Getting Started Communication Cable The Freeze Dryer power cord should be unplugged before connecting the communication cable. Connect one end of the communication cable (7364601) to the port on the back of the Stoppering Tray Dryer labeled “OUTPUT TO FREEZE DRYER”. -
Page 16: Venting The Vacuum Pump
Original instructions Chapter 3: Getting Started Venting the Vacuum Pump If any materials will be placed in the Stoppering Tray Dryer that can liberate hazardous gases when heated, the vacuum pump exhaust must be vented to a fume hood or other ventilation device. -
Page 17: Solvent Safety Precautions
Warranty on the affected parts will be voided if maintenance has been obviously neglected. If you have questions about using specific compounds in the Freeze Dry System, contact Labconco Technical Service at 1-800-821-5525 or 816-333-8811 or e-mail: labconco@labconco.com. Solvent Safety Precautions Solvents used in the Stoppering Tray Dryer may be flammable or hazardous to your health. -
Page 18: Chapter 4 Using Your Stoppering Tray Dryer
Original instructions HAPTER SING TOPPERING RYER After your Stoppering Tray Dryer has been installed as detailed in Chapter 3: Getting Started, you are ready to begin using your Stoppering Tray Dryer. Read this chapter to learn how to: • Operate the controls. •... -
Page 19: Component Identification
Original instructions Chapter 4: Using Your Stoppering Tray Dryer Component Identification POWER / STANDBY LED Indicator IN PROCESS LED Indicator Stoppering Control Valve Vacuum Release Valve Backfill Port (3) Sample Probe Ports (3) Shelves Power Switch Door Latch / Handle Stoppering Bladder 6 Port Manifold (optional) -
Page 20: Operation Checklist
Original instructions Chapter 4: Using Your Stoppering Tray Dryer Power Switch – Turns all AC power to the Tray Dryer ON or OFF. POWER / STANDBY LED Indicator – Indicates if the power switch is ON or OFF. IN PROCESS LED Indicator – This light will be ON if the Stoppering Tray Dryer is running in either MANUAL or PROGRAM mode. -
Page 21: Operating The Stoppering Tray Dryer
Original instructions Chapter 4: Using Your Stoppering Tray Dryer DISCONNECT THE QUICK CONNECT DRAIN FITTING BEFORE STARTING THE VACUUM PUMP. FAILURE TO REMOVE THE FITTING WILL RESULT IN A LARGE VACUUM LEAK. 4. Wipe the interior of the collector chamber and baffle (if equipped) with a soft cloth or paper towel to remove any remaining moisture. -
Page 22: Manual Mode
Original instructions Chapter 4: Using Your Stoppering Tray Dryer Freeze Dryer, the Drying Accessory icon will appear in the main menu bar and you will be able to control and monitor the Drying Accessory from this screen. Drying Accessory Sensor Table – The middle section of the screen displays a list of all the sensors that are available for the connected Drying Accessory. -
Page 23: Starting Manual Mode
Original instructions Chapter 4: Using Your Stoppering Tray Dryer Starting MANUAL Mode BEFORE STARTING THE TRAY DRYER, ENSURE THAT THE COLLECTOR IS “ON” AND HAS COOLED TO -40°C OR BELOW. 1. Turn the Stoppering Tray Dryer power switch ON. The POWER / STANDBY LED Indicator will turn ON. -
Page 24: Stopping Manual Mode
Original instructions Chapter 4: Using Your Stoppering Tray Dryer Stopping MANUAL Mode 1. Go to the Drying Accessory screen 2. Press the “MANUAL” button 3. Press the “Stop” button 4. The Tray Dryer refrigeration system will stop and the IN PROCESS LED Indicator will turn OFF. - Page 25 Original instructions Chapter 4: Using Your Stoppering Tray Dryer • New – Use this button to add a new program to the program list. The new program name will be defaulted to a two-digit sequential number (starting with “Program 01”) that will be incremented as new programs are added to the list (i.e., Program 02, Program 03…).
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Page 26: Creating A New Program
Original instructions Chapter 4: Using Your Stoppering Tray Dryer Creating a New Program When the “New” button is selected, the following screen will be displayed. Lock or unlock program editing Delete Step Step Pressing the program name field will allow you to edit the program name. The “Add”... -
Page 27: Starting A Program
Original instructions Chapter 4: Using Your Stoppering Tray Dryer Illustration of a simple 3 Step Program Starting a Program BEFORE STARTING A PROGRAM, ENSURE THAT THE COLLECTOR IS “ON” AND HAS COOLED TO -40°C OR BELOW. 1. Go to the Programs screen. You can access the Programs screen in two different ways, both lead to the same location. -
Page 28: Freeze Drying Using The Manifold Valves
Original instructions Chapter 4: Using Your Stoppering Tray Dryer 2. To stop before the completion of the last programmed step • Go to the Programs screen • Select (highlight) the program that is currently running • Press the STOP button 3. - Page 29 Original instructions Chapter 4: Using Your Stoppering Tray Dryer Valve in Vacuum or Run Position Note location of bevel on knob in vacuum position 6. Before adding another sample, allow system vacuum to return to 0.133 mbar or lower. Any combination of valves and sample sizes may be utilized at one time provided that the system vacuum and collector temperature remain sufficiently low to prevent melting of the frozen sample.
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Page 30: Shelf Spacing Adjustment
Original instructions Chapter 4: Using Your Stoppering Tray Dryer Valve in Vent Position Note location of bevel on knob in vent position 9. Ampules may be flame sealed while connected to a valve by using a sealing torch. Care must be taken not to burn the valve. An insulation material placed between the valve and the torch is recommended. -
Page 31: Shelf Loading
Original instructions Chapter 4: Using Your Stoppering Tray Dryer To unlatch the shelves, press the latch protruding from the side of the shelf support structure and move the latch until it clears the shelf and allows the shelf to drop. The top shelf has one latched position, the middle shelf has two latched positions, and the bottom shelf should not latch in any position. -
Page 32: Freeze Drying
Original instructions Chapter 4: Using Your Stoppering Tray Dryer Freeze Drying Turn on the FreeZone Freeze Dryer. See Freeze Dryer User’s Manual for complete instructions on operating the Freeze Dryer.Following the instructions for the unit, this may be accomplished in either the auto or manual mode. When the Freeze Dryer collector temperature is less than –40°C and the vacuum has reached the desired level, the MANUAL mode set point temperature may be adjusted or PROGRAM mode may be initiated. -
Page 33: Alerts
Original instructions Chapter 4: Using Your Stoppering Tray Dryer vacuum pump is turned off, air will enter the system through the vacuum break valve located between the vacuum pump and the collector chamber. Alerts A number of events may occur during a lyophilization procedure that will cause an alert to be displayed on the Freeze Dryer touch screen. -
Page 34: System Temp Set Point
Original instructions Chapter 4: Using Your Stoppering Tray Dryer System Temp Set Point If during a Ramp segment the system temperature stabilizes without reaching the Shelf Temp Set Point, the control will automatically enter the next Hold segment and the “System Temp Set Point” alert will be displayed. Program Complete When the last step of a running program has been completed, the “Program Complete”... -
Page 35: Chapter 5: Maintaining Your Stoppering Tray Dryer
Alcohol may craze the acrylic door. Before using any cleaning or decontamination method except those recommended by Labconco, users should check with Labconco that the proposed method will not damage the equipment. 2. Clean up all spills; remove liquids from the chamber. - Page 36 When freeze drying biological substances, it may be necessary to decontaminate the system. A surface decontaminant should be used to clean the accessible surfaces. The use of ethylene oxide is not recommended because of its hazardous and corrosive nature. Contact Labconco for additional information. Product Service 1-800-522-7658...
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Page 37: Chapter 6: Troubleshooting
ROUBLESHOOTING Refer to the following if your Freeze Dry System fails to operate properly. If the suggested corrective actions do not solve your problem, contact Labconco for additional assistance. FreeZone Freeze Dry Systems that are clean and dry and without samples attached should reach a vacuum of 0.133 mbar within 30 minutes and should... -
Page 38: Gaskets, Tubing, Connections, Sample Valves
Original instructions Chapter 6: Troubleshooting If vacuum problems continue, consider obtaining a second vacuum gauge capable of reading a vacuum of 0.010 mbar. It is often useful in determining if the vacuum pump is operating properly and the vacuum sensor reading is accurate. 4. -
Page 39: System Components & Collector Chamber Isolation
Original instructions Chapter 6: Troubleshooting The illustration below shows how the sample valve installs on a manifold. Manifold Assembly Knob & Stem Valve Body Trim Ring Assembly System Components and Collector Chamber Isolation The following test allows you to check the pump and the connections from the pump to the vacuum tube. - Page 40 Original instructions Chapter 6: Troubleshooting The next test will allow you to determine if the vacuum leak is in the Stoppering Tray Dryer or in the Console Freeze Dryer. 1. Remove the coupling and spacer connecting the Tray Dryer to the Freeze Dryer.
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Page 41: Stoppering Tray Dryer
Original instructions Chapter 6: Troubleshooting still present at the bulkhead fittings, loosen the bulkhead fittings and apply vacuum grease to the O-rings, then reassemble and test. Stoppering Tray Dryer • Inspect the door and door gasket. • Inspect the coupling between the freeze dryer and the Stoppering Tray Dryer. •... -
Page 42: Refrigeration Module Operation
If any repairs are required on the refrigeration module, contact your local laboratory supply dealer. If your laboratory supply dealer is unable to provide assistance, please call Labconco. Repairs should only be undertaken by a competent refrigeration technician or through an authorized Labconco service agency. -
Page 43: Shelf And Stoppering System Removal
Original instructions Chapter 6: Troubleshooting Grasp the left and right edges of the front panel and pull forward to release the spring loaded latches that hold the panel in place. Disconnect the ribbon cable from the connection at the PC board. Disconnect the wires to the power switch. -
Page 44: Filling The Fluid System
Original instructions Chapter 6: Troubleshooting The assembly is now ready for repairs. Whenever possible, do not break the fluid system. Reverse the removal procedures for installation of the shelf and stoppering system. Make sure the fluid inlet and outlet tubes are routed on top of the assembly. -
Page 45: Heat Transfer Fluid Precautions
Original instructions Chapter 6: Troubleshooting 7. Open the fluid circulation valve by completely “down-seating” (turn top valve stem completely clockwise) to direct fluid to by-pass through tubing to fluid reservoir. 8. Temporarily re-install the left cover and secure it to the base plate with (3) hex head screw. -
Page 46: Heat Transfer Fluid First Aid Procedures
Original instructions Chapter 6: Troubleshooting Heat Transfer Fluid First Aid Procedures Eye Contact: Immediately flush eyes with fresh water for at least 15 minutes. If irritation persists, get medical attention. Skin Contact: Wash contaminated areas with soap and water. Remove contaminated clothing and footwear. -
Page 47: Appendix A Components
Original instructions PPENDIX OMPONENTS The following pages list components that are available for your Stoppering Tray Dryer. The parts shown are the most common replacement parts. If other parts are required, contact Product Service. Item Part No. Description Compressor 115V – 60 Hz 7592002 Compressor 230V –... - Page 48 Original instructions Appendix A: Components Product Service 1-800-522-7658...
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Page 49: Appendix B Dimensions
Original instructions PPENDIX IMENSIONS 23.7 60.1 32.3 82.0 19.3 49.1 27.1 68.8 SHOWN WITH 6 PORT MANIFOLD INCHES (CENTIMETERS) Product Service 1-800-522-7658... - Page 50 Original instructions Appendix B: Dimensions Serum Bottle Capacity of the Stoppering Tray Dryer Size Labconco No. Shelf Capacity No. of Shelves Total Capacity 2 ml 7575010 1290 3 ml 7575210 1449 5 ml 7573010 10 ml 7573210 20 ml 7573410...
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Page 51: Appendix C Specifications
Original instructions PPENDIX PECIFICATIONS This Appendix contains technical information about the Freeze Dryer including electrical specifications and environmental operating conditions. Electrical Specifications Current Voltage Frequency Rating Operating Catalog # Description Nominal (Hz) Amps Range Stoppering 794801*00 115V 103 - 127 Tray Dryer 794801*10 Stoppering... -
Page 52: Appendix D Accessories
Original instructions PPENDIX CCESSORIES Labconco offers a full line of accessories to enhance your Stoppering Tray Dryer’s operation and usability. For a complete list of these accessories, please consult our website at www.labconco.com. Product Service 1-800-522-7658...
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