Telstar LyoQuest Guide de dépannage

USER & SERVICE MANUAL

MANUAL DE USUARIO Y MANTENIMIENTO

Laboratory Freeze Dryers

Liofilizadores de laboratorio

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INDEX / ÍNDICE

GENERAL DATA ..................................................................................................................................... 6

DETAILS OF THE FREEZE-DRYER ............................................................................................................. 7

2.1. Aim of this manual ................................................................................................................................................... 7

2.2. Application ............................................................................................................................................................... 7

2.3. Requirements ........................................................................................................................................................... 7

2.4. Description ............................................................................................................................................................... 7

TECHNICAL CHARACTERISTICS ............................................................................................................... 9

TRANSPORT AND PACKING ................................................................................................................. 10

BEFORE START- P ............................................................................................................................... 10

5.1. Placing on site ........................................................................................................................................................ 10

5.2. Electrical connection .............................................................................................................................................. 10

5.3. acuum pump ........................................................................................................................................................ 10

5.4. Refrigerating unit ................................................................................................................................................... 11

RECOMMENDATIONS .......................................................................................................................... 11

6.1. Ice condenser ......................................................................................................................................................... 11

6.2. Greasing ................................................................................................................................................................. 11

6.3. Long stoppage ........................................................................................................................................................ 11

WORKING PRINCIPLE .......................................................................................................................... 12

7.1. Freeze ..................................................................................................................................................................... 12

7.2. Lyophilization ......................................................................................................................................................... 12

7.2.1. In manifold .......................................................................................................................................................... 12

7.2.2. In chamber .......................................................................................................................................................... 13

7.2.3. End of the process ............................................................................................................................................... 14

7.3. Lyophilization modes ............................................................................................................................................. 14

7.4. Selectable processes .............................................................................................................................................. 14

OPTIONAL ACCESORIES (COMPILATION AT THE END OF THE MAN AL) ................................................ 15

8.1. Chambers ............................................................................................................................................................... 15

8.2. Manifolds ............................................................................................................................................................... 16

8.3. Flasks condensations collector (Drip tray) ............................................................................................................. 16

8.4. Lyoquestlogger software ....................................................................................................................................... 17

INSTR CTIONS FOR SE ...................................................................................................................... 18

9.1. Start up ................................................................................................................................................................... 18

9.2. Semiautomatic mode ............................................................................................................................................. 19

9.3. Automatic mode .................................................................................................................................................... 19

9.4. Defrosting mode .................................................................................................................................................... 20

9.5. Menu ...................................................................................................................................................................... 20

9.6. Hours counter vacuum pump ................................................................................................................................ 21

9.7. Stop of the freeze-dryer ......................................................................................................................................... 21

9.8. No Plus version ...................................................................................................................................................... 22

10.

RECIPES .............................................................................................................................................. 23

11.

ALARMS .............................................................................................................................................. 23

12.

MAINTENANCE PLAN .......................................................................................................................... 25

12.1. acuum unit maintenance ..................................................................................................................................... 25

12.2. Refrigerating system maintenance ........................................................................................................................ 27

12.3. Surface cleaning and disinfection .......................................................................................................................... 27

12.4. Maintenance table ................................................................................................................................................. 27

13.

TRO BLESHOOTING ............................................................................................................................ 28

13.1. acuum unit ........................................................................................................................................................... 28

13.2. Refrigerating unit ................................................................................................................................................... 28

13.3. Freeze-dryer kit ...................................................................................................................................................... 29

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DATOS GENERALES ............................................................................................................................. 31

DATOS DEL LIOFILIZADOR .................................................................................................................... 32

2.1. Objetivo del manual ............................................................................................................................................... 32

2.2. Aplicación ............................................................................................................................................................... 32

2.3. Requerimientos ...................................................................................................................................................... 32

2.4. Descripción ............................................................................................................................................................. 32

CARACTERÍSTICAS TÉCNICAS ............................................................................................................... 34

TRANSPORTE Y EMBALAJE .................................................................................................................. 35

ANTES DE LA P ESTA EN MARCHA ...................................................................................................... 35

5.1. Emplazamiento del equipo .................................................................................................................................... 35

5.2. Conexión eléctrica .................................................................................................................................................. 35

5.3. Bomba de vacío ...................................................................................................................................................... 35

5.4. Grupo frigorífico ..................................................................................................................................................... 36

RECOMENDACIONES ........................................................................................................................... 36

6.1. Condensador de hielo ............................................................................................................................................ 36

6.2. Engrase ................................................................................................................................................................... 36

6.3. Paro prolongado .................................................................................................................................................... 36

PRINCIPIO DE F NCIONAMIENTO ........................................................................................................ 37

7.1. Congelación ............................................................................................................................................................ 37

7.2. Liofilización............................................................................................................................................................. 37

7.2.1. En manifold ......................................................................................................................................................... 37

7.2.2. En cámara ........................................................................................................................................................... 38

7.2.3. Finalización del proceso ...................................................................................................................................... 39

7.3. Modos de liofilización ............................................................................................................................................ 39

7.4. Procesos seleccionables ......................................................................................................................................... 39

ACCESORIOS OPCIONALES (RECOPILATORIO AL FINAL DEL MAN AL) ................................................... 40

8.1. Cámaras ................................................................................................................................................................. 40

8.2. Manifolds ............................................................................................................................................................... 41

8.3. Recogedor de las condensaciones de los frascos (Drip tray) ................................................................................. 41

8.4. Lyoquestlogger software ....................................................................................................................................... 42

INSTR CCIONES DE SO ..................................................................................................................... 43

9.1. Puesta en marcha .................................................................................................................................................. 43

9.2. Modo de funcionamiento semiautomático ........................................................................................................... 44

9.3. Modo de funcionamiento automático ................................................................................................................... 44

9.4. Modo de funcionamiento descarche ..................................................................................................................... 45

9.5. Menú ...................................................................................................................................................................... 45

9.6. Contador horas bomba de vacío ............................................................................................................................ 46

9.7. Parada del liofilizador ............................................................................................................................................ 46

9.8. ersión No Plus ...................................................................................................................................................... 47

10.

RECETAS ............................................................................................................................................. 48

11.

ALARMAS ........................................................................................................................................... 48

12.

PLAN DE MANTENIMIENTO ................................................................................................................. 50

12.1. Mantenimiento del grupo de vacío ....................................................................................................................... 50

12.2. Mantenimiento del grupo frigorífico ..................................................................................................................... 52

12.3. Limpieza y desinfección superficial ........................................................................................................................ 52

12.4. Tabla de mantenimiento ........................................................................................................................................ 52

13.

ANOMALÍAS DE F NCIONAMIENTO .................................................................................................... 53

13.1. Bomba de vacío ...................................................................................................................................................... 53

13.2. Grupo frigorífico ..................................................................................................................................................... 54

13.3. Conjunto liofilizador ............................................................................................................................................... 54

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14.

ANNEXES /ANEXOS ............................................................................................................................. 55

14.1. Equipment spare part codes / Códigos de los recambios de la instalación ........................................................... 55

14.2. Examples of recipes / Ejemplos de recetas ............................................................................................................ 56

14.3. Maintenance records / Histórico de mantenimiento ........................................................................................... 58

14.4. Decontamination declaration / Declaración de descontaminación ...................................................................... 60

14.5. Refrigerating system P&ID / P&ID Sistema de refrigeración (Lyoquest -55) ......................................................... 61

14.6. Refrigerating system P&ID / P&ID Sistema de refrigeración (Lyoquest -85) ......................................................... 62

14.7. acuum system P&ID / P&ID Sistema de vacío ..................................................................................................... 63

14.8. Electric diagrams / Esquemas eléctricos (Lyoquest -55) ........................................................................................ 64

14.9. Electric diagrams key / Leyenda esquemas eléctricos (Lyoquest -55) ................................................................... 69

14.10. Electric diagrams / Esquemas eléctricos (Lyoquest -85) .................................................................................... 70

14.11. Electric diagrams key / Leyenda esquemas eléctricos (Lyoquest -85) ............................................................... 75

14.12. Warranty certificate / Certificado de garantía ................................................................................................... 76

14.13. Declaration of conformity / Declaración de conformidad ................................................................................. 77

14.14. Accessories configuration / Configuraciones de accesorios ............................................................................... 78

14.15. LyoQuest standard codification / Codificación estándar LyoQuest ................................................................... 79

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1. GENERAL DATA

This instruction manual is valid for the laboratory freeze-dryers models:

LYOQUEST -55 (PLUS / NO PLUS)

LYOQUEST -85 (PLUS / NO PLUS)

C UTION

•The readin and comprehension of this manual are mandatory before the start up of the freeze-dryer.

•All safety instructions that are mentioned in this manual must be respected.

•Before any maintenance operations can be in the freeze-dryer must be disconnected from the power supply.

•A use or an application not accordin to the recommendations expressed in the manual can enerate a risk

situation and means the loss of the manufacture uarantee.

The European Union issued the Directive 2012/19/EU on Waste of Electrical and Electronic Equipment (WEEE).

This product is required to comply with the European Union’s Waste Electrical & Electronic

Equipment (WEEE) Directive. Mark symbol is shown at the ri ht.

Azbil Telstar sells products throu h distributors throu hout Europe. Contact your local distributor for

recyclin /disposal.

The name plate & CE mark sticker is located at the back of the freeze-drier.

M NUF CTURER: ZBIL TELST R TECHNOLOGIES, S.L.U.

Av. Font i Sa ué, 55

Parc Científic i Tecnolò ic Orbital 40

08227 TERRASSA (SPAIN)

Telf (+34) 93 736 16 00

Fax (+34) 93 786 13 80

e-mail: [email protected]

http://www.telstar.com

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2. DETAILS OF THE FREEZE-DRYER

2.1. AIM OF THIS MANUAL

The main aim of this manual is to act as a uideline for the handlin , operation and maintenance of the equipments

LYOQUEST -55 and LYOQUEST -85.

2.2. APPLICATION

This model of freeze-dryer can be used for the freeze-dryin in flasks, vials, ampoules or in bulk, by means of the

different confi urations of the basic unit and the possibility of couplin several accessories.

W RNING

•This freeze dryer is NOT a sterilizable unit.

•This freeze dryer consists of methacrylate parts. Not followin the instructions about the disinfection of the unit

(chapter 12.3) or in the event of freeze dryin methacrylate corrosive products can dama e the parts, bein

excluded of the uarantee of the unit.

•Under no circumstances may the unit be used with corrosive, flammable or explosive ases.

•In the event of freeze dryin products containin corrosive or explosive solvents, please contact the Customer

Service, to take the specific preventive actions for the specific product.

•Certain freeze-dryin cycles increase the required preventive maintenance actions on the vacuum pump. See

chapter 12.1.

2.3. REQUIREMENTS

Electrical supply: 230V monophase + PE, 50 Hz / 230V monophase +PE, 60 Hz

Installed power: LYOQUEST –55: 2.5 kW

LYOQUEST –85: 3.5 kW

Consumption in amperes: LYOQUEST –55: 7A (11A max)

LYOQUEST –85: 9A (15A max)

Maximum environmental temperature to work: 25ºC

2.4. DESCRIPTION

The LYOQUEST freeze-dryer is constructed as a compact desktop version. The basic unit consists of a metallic box

with lateral access doors to perform maintenance tasks. The vacuum pump is supplied separately and is optional.

The control panel is located at the front.

LYOQUEST components:

•A two-sta e vacuum pump provided with a as ballast or a bubbler ( as pur in apparatus). When the pump is

switched off a closin valve isolates the pump from the freeze-dryer, preservin the latter’s vacuum while

atmospheric pressure is re-established in the interior of the vacuum pump, so backlash of oil is avoided. An

exhaust filter is also included.

•A refri eratin system, which cools the condenser coil to the workin temperature. The condensation surface

has been dimensioned ensurin the condensation of the water vapor released by the products that are bein

freeze dried. This prevents vapors from enterin the vacuum pump. The refri eratin system is formed by:

- Compressor:

LYOQUEST-55: one-sta e hermetic compressor, condensed by air.

LYOQUEST-85: two one-sta e hermetic compressors, condensed by air.

- Condenser:

Material: AISI 316L stainless steel.

LYOQUEST models:

•PLUS: Prepared to work with all accessories and heated plates.

•NO PLUS: Prepared to work with all accessories, but not with heated plates.

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1. Manifold with 8 inlets 5. Connection RS232 for Lyolo er

2. Touch screen 6. Vacuum pump

3. Drainin 7. Electrical connection of the vacuum pump

4. Electrical connection and switch 8. Chamber with heated plates

Fi . 1

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3. TECHNICAL CHARACTERISTICS

V CUUM PUMP (optional) ULVAC GLD 136C ILMVAC P6Z-101

Dimensions (len th x width

hei ht)

mm 487.5x170x249.5 500 x 300 x 340

Wei ht k 27 25.4

Suction flow (50Hz/60Hz) m

/h 8.1/9.72 5.8/6.6

Vacuum at the pump inlet mbar See user manual of the pump

Motor velocity r.p.m. - 1500

Motor power kW 0.4 0.4

Oil

Capacity liters 1 1

Type (standard

applications) AV-30 LABOVAC 10

ICE CONDENSER LYOQUEST -55 LYOQUEST -85

Condensation surface m

0.25

Minimum temperature (T

room

≤ +21ºC) ºC -55 -85

Ice capacity k 8 (4 k /24 h) 8 (6 k /24 h)

Material AISI – 316L

REFRIGER TING UNIT LYOQUEST -55 LYOQUEST -85

Number of compressors 1 2

hermetic type One sta e

Refri eration power (at -35ºC) W 495 800

Refri erant (free of CFCs) R-507 R-507/ R-23

Refri eration of the unit By air circulation

EQUIPMENT LYOQUEST -55 LYOQUEST -85

Electrical connection V, ph, Hz

230, 1, 50 / 230, 1, 60

Total installed power kW 2.5 3.5

Process vacuum. Unloaded, T

room

≤ 21ºC,

condenser temperature: -55ºC (LYOQUEST -55),

condenser temperature: -85ºC (LYOQUEST -85)

mbar < 5 x 10

-2

< 3 x 10

–2

Dimensions

(hei ht x width x depth) mm 480 x 425 x 575

Vacuum au e DIGITAL

PT100 Temperature probe DIGITAL

Wei ht k 65 70

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4. TRANSPORT AND PACKING

The freeze-dryer is delivered to ether with the optional accessories and documentation in a sin le pack; it is packed in

a suitable way to prevent it from bein dama ed durin transportation. The freeze-dryer and the accessories are also

packed in an individual packa e.

The pack includes a tube of silicone rease, to carry-out the maintenance of the equipment seals.

The unit has to be shipped in vertical position accordin to the crate indications (adhesive labels).

After havin unpacked the freeze-dryer, it is necessary to verify that the pack includes all the optional accessories

shown in the order.

5. BEFORE START-UP

Before proceedin with the start-up of the freeze-dryer the followin instructions must be followed step by step.

5.1. PLACING ON SITE

The unit must be placed on a table that has a smooth and horizontal surface. The basic unit must be firmly settled to

prevent vibrations.

W RNING

•When assemblin the chamber to the Lyoquest, do not for et to assembly the methacrylate base. It is required for

proper workin when chamber is installed.

5.2. ELECTRICAL CONNECTION

W RNING

•Before switchin the Freeze-Dryer on, check that the supply volta e is the same as the one mentioned on the

specification plate.

•Installation in the place where the Freeze-Dryer is connected to must meet the safety re ulations in force and be

accordin to the local re ulations of the country or customer facilities.

Connect the cable of the vacuum pump to the basic unit.

Connect the electrical cable of the basic unit to the power supply (the plu wire is supplied with a European plu ).

5.3. VACUUM PUMP

ULVAC GLD-136C / ILMVAC P6Z-101 vacuum pumps (Fi . 2 & 3):

The pump is supplied with the oil loaded. Verify the oil level (see section Vacuum unit maintenance).

In order to prevent the non-condensable vapors of the product of contaminatin the oil of the pump, the system has

Gas-Ballast function (see section Vacuum unit maintenance).

The vacuum pump is equipped with an exhaust filter, whose function is to retain oil vapors.

The electrical connection of the vacuum pump has to be connected to the base placed at the side of the unit.

Furthermore, the vacuum pump admission has to be connected to the basic unit throu h the supplied pipe.

Connection of the vacuum pump expulsion:

To direct the vapors outside of the pump, connect the pipe to vacuum pump exhaust, removin the installed filter.

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