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Labconco FreeZone 780601 Series User Manual

Bulk tray dryer
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Original instructions
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780601*** Series

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Summary of Contents for Labconco FreeZone 780601 Series

  • Page 1 Original instructions Models 780601*** Series...
  • Page 3 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.
  • Page 5 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 Bulk Tray Dryer Bulk Tray Dryer Components Setting Up Your Bulk Tray Dryer...
  • Page 6 Original instructions Programs Creating a New Program Starting a Program Stopping a Program Freeze Drying Using the Manifold Valves Alerts Power Fail Shelf Temp Variation Shelf Temp Set Point Program Complete CHAPTER 5: MAINTAINING YOUR BULK TRAY DRYER Service Safety Precautions Routine Maintenance Schedule Decontamination CHAPTER 6: TROUBLESHOOTING...
  • Page 7 Proper care and maintenance of this product will result in many years of dependable service. Intended Use The Bulk Tray Dryer is intended to be used in conjunction with Labconco Console Freeze Dryers in a laboratory setting to facilitate the lyophilization process. Freeze Dry Process Freeze drying is an important process in sample preparation and for the preservation and storage of biologicals, pharmaceuticals and foods.
  • Page 8 Original instructions Chapter 1: Introduction SAFE TEMPERATURE AND DRYING TIMES FOR SELECTED MATERIALS Material 10mm Thick Safe Temp °C Collector Temp °C Hours (Approx.) Milk Urea Blood Plasma -10 to -25 Serum Vaccinia -30 to -40 Influenza Vaccine Human Tissue -30 to -40 Vegetable Tissue *Total sample quantities are contingent on various freeze dryer capacities.
  • Page 9 Original instructions Chapter 1: Introduction Freeze Dry Capacity The volume of a sample that can be freeze dried at one time is related to factors discussed previously and the size and design of the Freeze Dryer. With any given instrument, the capacity is based on the surface area of the sample, the eutectic temperature and concentration of the sample and the rate and amount of heat transferred to the frozen sample.
  • Page 10 Appendix A: Components contains labeled diagrams of the components of the Bulk Tray Dryer. Appendix B: Dimensions contains diagrams showing the dimensions for the Bulk Tray Dryer. Appendix C: Specifications contains product specifications. Appendix D: Accessories see www.labconco.com for a complete list of Bulk Tray Dryer accessories. Product Service 1-800-522-7658...
  • Page 11 Original instructions Chapter 1: Introduction Typographical Conventions Recognizing the following typographical conventions will help you understand and use this manual: • Book, chapter, and section titles are shown in italic type (e.g., Chapter 3: Getting Started). • Steps required to perform a task are presented in a numbered format. •...
  • Page 12 Original instructions Chapter 2: Prerequisites Before you install your Bulk Tray Dryer, you need to prepare your site for installation. The Bulk Tray Dryer will mount on top of a FreeZone 6, 12 or 18 liter Freeze Dryer. Carefully examine the location where you intend to install your Bulk Tray Dryer.
  • Page 13 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 back panel of the Console Freeze Dryer.
  • Page 14 IF YOUR BULK TRAY DRYER WAS DAMAGED IN  (15) days of TRANSIT, YOU MUST FILE A CLAIM DIRECTLY WITH THE delivery. FREIGHT CARRIER. LABCONCO CORPORATION AND ITS DEALERS ARE NOT RESPONSIBLE FOR SHIPPING DAMAGE.  DO NOT DISCARD THE CARTON OR PACKING MATERIAL...
  • Page 15 See parts list (Appendix A) If you did not receive one or more of the components listed for your Bulk Tray Dryer, or if any of the components are damaged, contact Labconco Corporation immediately for further instructions. Setting Up Your Bulk Tray Dryer After you verify receipt of the proper components, move your Bulk Tray Dryer to the location where you want to install it.
  • Page 16 Original instructions Chapter 3: Getting Started Lift the Bulk Tray Dryer into place on your Freeze Dryer while centering the vacuum coupling over the vacuum connection port. Align the four mounting holes in the Bulk Tray Dryer support stand with the four holes in the top of the Freeze Dryer.
  • Page 17 Original instructions Chapter 3: Getting Started Testing System Vacuum Integrity The Bulk Tray Dryer is now installed and must be tested to make certain the system is free of leaks. Refer to Chapter 4 on how to operate the Bulk Tray Dryer. To test the vacuum integrity of the system, turn on the Freeze Dryer refrigeration and allow the temperature to reach –40°C or lower.
  • Page 18 Another way to extend the life of the vacuum pump is to install an optional secondary trap in the line between the Freeze Dryer and the vacuum pump. Contact Labconco for ordering information. Product Service 1-800-522-7658...
  • Page 19 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 Dryer, 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 Bulk Tray Dryer may be flammable or hazardous to your health.
  • Page 20 Original instructions Chapter 4: Using Your Bulk Tray Dryer After your Bulk Tray Dryer has been installed as detailed in Chapter 3: Getting Started, you are ready to begin using your Bulk Tray Dryer. Read this chapter to learn how to: •...
  • Page 21 Original instructions Chapter 4: Using Your Bulk Tray Dryer Component Identification POWER / STANDBY LED Indicator IN PROCESS LED Indicator Vacuum Release Valve Sample Probe Port (one on each shelf) Power Switch Door Latch / Handle Heated Shelf (up to 5 shelves) 6-Port Manifold (optional) Product Service 1-800-522-7658...
  • Page 22 Original instructions Chapter 4: Using Your Bulk Tray Dryer Power Switch - Located on left side of cabinet. Turns all AC power to the Bulk Tray Dryer ON or OFF. POWER / STANDBY LED Indicator – Indicates if the power switch is ON or OFF. IN PROCESS LED Indicator –...
  • Page 23 Original instructions Chapter 4: Using Your Bulk Tray Dryer Operating the Bulk Tray Dryer 1. Adjust the shelf spacing - Prior to loading the shelves with the product to be freeze dried, adjust the shelf spacing to accommodate the size and quantity of the samples.
  • Page 24 Original instructions Chapter 4: Using Your Bulk Tray Dryer The main features that are used to control the Bulk Tray Dryer will be described in this manual. For a complete description of the Freeze Dryer operating system, consult the Freeze Dryer User’s Manual. Drying Accessory Screen If the Bulk Tray Dryer is NOT connected to the Freeze Dryer (via the communication cable), the Drying Accessory icon will NOT appear in the main...
  • Page 25 Original instructions Chapter 4: Using Your Bulk Tray Dryer Manual Mode Manual mode can be used to control the shelf temperature to a single set point value between -20°C and +60°C.  THE SHELVES HAVE NO COOLING MECHANISM, THEREFORE ANY COOLING BELOW ROOM TEMPERATURE IS DONE BY THE FROZEN SAMPLES AND THE COOLING FROM THE SUBLIMATION PROCESS THAT IS OCCURRING.
  • Page 26 Original instructions Chapter 4: Using Your Bulk Tray Dryer Changing the Shelf Temp Set Point Value If the Tray Dryer is already running in MANUAL mode and you want to change the current Shelf Temp Set Point value: 1. Go to the Drying Accessory screen. 2.
  • Page 27 Original instructions Chapter 4: Using Your Bulk Tray Dryer Programs The Programs screen will allow you to create and store programs that are used to control the shelf temperature and vacuum level. Programs can be designed that take the product through both primary and secondary drying phases. When no program has been selected the “New”...
  • Page 28 Original instructions Chapter 4: Using Your Bulk Tray Dryer When a program is currently in progress, a “running man” icon will appear to the left side of the program name. If the running program is selected (highlighted), the “Stop” button will be active, and the “Delete” button will be inactive. Creating a New Program When the “New”...
  • Page 29 Original instructions Chapter 4: Using Your Bulk Tray Dryer • Time – This time represents how long the system will hold at the Shelf Temp. that has been programmed for each Step. The time can be set from 00:01 to 99:59 (1 min to 99 hrs 59 min). It can also be set to an indefinite amount of time, which is represented by the infinity symbol (∞).
  • Page 30 Original instructions Chapter 4: Using Your Bulk Tray Dryer Freeze Drying Using the Manifold Valves Some Bulk Tray Dryers are equipped with a 6-Port Manifold. The procedure below should be followed when freeze drying samples using the manifold. 1. Close and latch the Bulk Tray Dryer door. 2.
  • Page 31 Original instructions Chapter 4: Using Your Bulk Tray Dryer 8. To remove a container after drying is complete, turn the plastic knob on the valve to the “VENT” position, which closes the valve and vents the container. Should backfilling with an inert gas be required, simply connect the gas supply line to the vent port on the valve.
  • Page 32 Original instructions Chapter 4: Using Your Bulk Tray Dryer Power Fail If a power failure to the Bulk Tray Dryer occurs while a run is in progress, the “Power Fail – BT” alert will be displayed when power is restored. If the failure is of a short duration and the Freeze Dryer collector does not warm up above -30°C, when power is restored the Freeze Dryer and Bulk Tray Dryer will restart and resume operation of the refrigeration and vacuum systems.
  • Page 33 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 34 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...
  • Page 35 Troubleshooting Refer to the following if your Freeze Dryer fails to operate properly. If the suggested corrective actions do not solve your problem, contact Labconco for additional assistance. FreeZone Freeze Dryers that are clean, dry and without samples attached should reach a vacuum of 0.133 mbar within 30 minutes and should achieve an ultimate...
  • Page 36 Original instructions Chapter 6: Troubleshooting 4. Isolate the pump by disconnecting the vacuum hose from the Freeze Dryer. Deadhead the pump by inserting the vacuum sensor from a secondary vacuum gauge into the end of the vacuum hose and observe the vacuum reading obtained.
  • Page 37 Original instructions Chapter 6: Troubleshooting The illustration below shows how the sample valve installs on a manifold. Manifold Assembly Trim Ring Knob & Stem Valve Body 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 38 Original instructions Chapter 6: Troubleshooting The next test will allow you to determine if the vacuum leak is in the Bulk Tray Dryer or in the Console Freeze Dryer. 1. Remove the coupling and spacer connecting the Bulk Tray Dryer to the Freeze Dryer.
  • Page 39 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. Bulk Tray Dryer • Inspect the door and door gasket. • Inspect the coupling between the freeze dryer and the Bulk Tray Dryer. •...
  • Page 40 Original instructions Chapter 6: Troubleshooting 2. The door hinges can be adjusted to move the door in towards the chamber sealing surface. a. Loosen the screws to the hinge covers and rotate the hinge cover out of the way. b. Turn on the vacuum pump using the Freeze Dryer controls. c.
  • Page 41 Original instructions Appendix A: Components The following pages list components that are available for your Bulk Tray Dryer. The parts shown are the most common replacement parts. If other parts are required, contact Product Service. Item Part No. Description 1302301 Switch 7317000 Printed Circuit Board...
  • Page 42 Original instructions Appendix A: Components Product Service 1-800-522-7658...
  • Page 43 Original instructions Appendix B: Dimensions 20.4 51.7 32.3 82.0 19.5 49.4 27.1 68.8 SHOWN WITH 6 PORT MANIFOLD INCHES (CENTIMETERS) Product Service 1-800-522-7658...
  • Page 44 Original instructions Appendix B: Dimensions 2.4" 62.2 mm 2.2" 56.9 mm 5.2" 131.2 mm 2.2" 14.1" 56.9 mm 359.3 mm 2.2" 56.9 mm 5.2" 131.2 mm 2.2" 56.9 mm Product Service 1-800-522-7658...
  • Page 45 Original instructions Appendix C: Specifications 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 Bulk Tray 780601*00 115V 103 - 127 50/60 Dryer 780601*10...
  • Page 46 Original instructions Appendix D: Accessories For a complete list of accessories offered for the Bulk Tray Dryer please consult our website at www.labconco.com. Product Service 816-333-8811...

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