MAINTENANCE MANUAL

Laboratory Freeze Dryer

CRYODOS

Telstar Industrial, S.L.

Josep Tapiolas, 120
08226 TERRASSA (Spain)
Tel. +34 937 36 16 00
CRYODOS_I_rev0105MA Fax: +34 937 85 93 42
[email protected]
www.etelstar.com
 Page 2 of 20

CONTENTS

1. INTRODUCTION __________________________________________________ 3
2. MAINTENANCE INSTRUCTIONS ______________________________________ 4
2.1. Vacuum unit maintenance ______________________________________ 4
2.1.1. Inspection of oil condition_______________________________________ 4
2.1.2. Oil level control _______________________________________________ 4
2.1.3. Oil change ___________________________________________________ 4
2.1.4. Control visual de pérdidas de aceite _______________________________ 5
2.1.5. Gas ballast situation ___________________________________________ 5
2.2. Refrigerating system maintenance ________________________________ 5
2.3. Technical assistance program ____________________________________ 5
2.4. Maintenance chart_____________________________________________ 8
3. TROUBLESHOOTING _______________________________________________ 10
3.1. Vacuum unit _________________________________________________ 10
3.2. Refrigerating unit _____________________________________________ 11
3.3. Freeze-dryer assembly _________________________________________ 11
4. UNIT SPARE PART CODES __________________________________________ 12
4.1. Vacuum group________________________________________________ 12
4.2. Refrigerating system___________________________________________ 12
4.3. General _____________________________________________________ 12
5. MAINTENANCE RECORDS ___________________________________________ 13
5.1. Time counters ________________________________________________ 13
5.2. Other operations ______________________________________________ 14
6. ATTACHED DOCUMENTATION________________________________________ 15
6.1. CRYODOS –50 Refrigerating system P&ID __________________________ 15
6.2. CRYODOS –80 Refrigerating system P&ID __________________________ 16
6.3. Legend of cryodos electric diagrams ______________________________ 18
6.4. Electric diagrams _____________________________________________ 19
 Page 3 of 20

1. INTRODUCTION

The aim of a maintenance plan is to provide a guide for operating on all installed components that
require maintenance.

The success of a maintenance plan basically depends on how detailed the information is and on the
correct analysis of this information. The maintenance plan must therefore be an active document to be
modified according to user requirements.

The maintenance plan sets out a series of inspections and operations that range from being carried out
on a daily basis to up to once every six months. The corresponding information should be compiled and
noted in detail in order to be of use for the following maintenance operations.
 Page 4 of 20

2. MAINTENANCE INSTRUCTIONS

WARNING

• Before beginning any maintenance operation or work on the freeze-dryer, disconnect it from the
power supply.
• In general, a regular inspection of the correct operation of all the unit components should be
performed once a year.

2.1. VACUUM UNIT MAINTENANCE

The revision and maintenance operations to be done in the vacuum unit are as follows:

2.1.1. INSPECTION OF OIL CONDITION

The visual inspection is performed through the sight glass (7). The pump must be switched off but at
working temperature.

The usual state of the oil is normally clear and transparent. Oil draining and changing is recommended
when it looks dirty or milky (water contaminated).

1
2

4 1.- Admission.
3 2.- Gas-Ballast.
3.- Gas-Ballast key.
6 4.- Oil filter (exhaust).
5.- Suck-back pipe.
6.- Filling cap.
5 7.- Sight glass.
8.- Emptying cap.

8
7

2.1.2. OIL LEVEL CONTROL

The correct level for oil is shown when it is seen half way up the sight glass (7). If it falls below this
point, top up with the necessary amount through the filler hole when the pump is not running.

2.1.3. OIL CHANGE

This operation has to be done with pump switched off but at working temperature (the pump must
have been running for at least 20 minutes to ensure proper viscosity of the oil).

To change vacuum pump oil proceed as follows:

1. Unscrew the emptying cap (8) and leave the dirty oil flow out. When there is any oil remaining,
start up the vacuum pump for some seconds and stop it. Screw the emptying cap (8). REMARK:
comply with current environmental standards and regulations when disposing of the used oils.
2. Take out the filling cap (6).
 Page 5 of 20

3. Pour new oil into the filling hole into the filling hole until the level is half way up the sight glass (7).
4. Screw the filling cap (6).

It is advisable to carrying out a periodic interior cleaning of oil and of pump body. To do this, first pour
¼ in the normal amount of oil for normal pump working, run the pump for 30 seconds to empty it out.
Next repeat this operation with the same amount of oil and the same time, empty it out again and
then pour in the final filling to half way up the level sight glass.

As the pump may be damaged by being idle for long periods with dirty oil in it, it is advisable to
change the oil before the beginning of the idle period.

The recommended TELSTAR Oils are:

- AV-30, mineral oil for general industry and laboratory applications.
- CHEMOIL-500, specially designed for use at high temperatures.
- WETOIL-8r, specially designed for moisture absorbing applications.
Vacuum pump oil capacity: 0,5 litres.

2.1.4. CONTROL VISUAL DE PÉRDIDAS DE ACEITE

Make sure that there is no oil remaining around the vacuum pump. Presence of oil drops means oil loss
through the seals, caps or level. Proceed to clean the area and locate the origin of the loss.

2.1.5. GAS BALLAST SITUATION

The gas-ballast (2) is placed in the suck-back pipe (5) communicating this pipe with the gas exhaust
filter of the vacuum pump (includes a gas ballast key (3), that allows its regulation).

2.2. REFRIGERATING SYSTEM MAINTENANCE

The refrigerating system needs practically no maintenance. If, by accident or due to any refrigerating
circuit damage, oil or cooling liquid has to be added, consult our technical service.

To ensure proper cooling of the refrigerating system, all the grids must beat a suitable distance from
the equipment and the wall (minimum distance of 20 cm.).

Periodic cleaning away of dust accumulated in the cooling unit condensing battery at the back of the
base unit is recommended. To clean this, the cover must be opened and a small paintbrush used to
remove the dust. This should be done particularly before summer.

When the switch is off, the compressor continues working for the time set by the collecting timer (2
min.) in order to suck up the gas from the evaporator. If the compressor fails to stop after this period,
the equipment must be inspected, as it is not good for the compressor to continue working without
circulating gas.

Refrigerating loads:

R-404a R-23
CRYODOS-50 800 gr. -----
CRYODOS-80 800 gr. 8 kg/cm2

2.3. TECHNICAL ASSISTANCE PROGRAM

This is a menu incorporated in the equipment, which provides for come of the maintenance work.

WARNING

This program is only for maintenance and technical assistance tasks; it should never be used for
normal equipment operations.
 Page 6 of 20

The Technical Assistance program provides for:

• Working on the vacuum unit independently.
• Working on the cooling unit independently.
• Setting to 0 /Resetting the timetable counters.
- Vacuum Pump
- Compressor E1
- Compressor E2 (only CRYODOS –80)
To access the Technical Assistance Program, proceed as follows:

Switch on the equipment; the initial screen will appear, then hold the ENTER key during 10 seconds till
access to the Technical Assistance Program. To exit and go back to the normal operation program,
press the ON/OFF key.

Diagram

TECHNICAL
NORMAL
INITIAL SCREEN ENTER ASSISTANCE ON/OFF
OPERATION
PROGRAM

SCREENS

The Technical Assistance Program has several screens forming options viewed by use of the UP/DOWN
keys.

Cooling unit operation

This option provides for working independently on the cooling unit. The screen shows condenser
temperature and whether the process is on “ON” or “OFF”.

COOLING OFF COOLING ON

ON/OFF
TEMP: -033.2 ºC TEMP: -033.2 ºC

Vacuum unit operation

This option provides for working independently on the vacuum unit. The screen shows the vacuum
level and whether the process is running, “ON” or not, “OFF”.

PUMP OFF PUMP ON

ON/OFF
VACUUM: 1.0 10+3 mB VACUUM: 1.0 10+3 mB

Resetting time counters

The time counters can be reset by pressing the ENTER key, giving access to the confirmation screen,
and then pressing ENTER again. To leave the confirmation screen, press the UP/DOWN key.

If any other key is pressed, it will not reset.

 Page 7 of 20

Compressor E1

This shows hours running of compressor 1 and provides for resetting them.

HOUR COUNTER RESET ? [< - ]

ENTER
COMP E1 00080 H COMP E1 00080 H

Compressor E2 (only for CRYODOS-80)

This shows hours running of compressor 2 and provides for resetting them.

HOUR COUNTER RESET ? [< - ]

ENTER
COMP E2 00070 H COMP E2 00070 H

Vacuum pump

This shows pump running hours and provides for resetting them.

HOUR COUNTER RESET ? [< - ]

ENTER
PUMP 00060 H PUMP 00060 H
 Page 8 of 20

Working diagram

CRYODOS V3.1 -50

TELSTAR (c)

ON/OFF
VAC: 0.010 mBar TECHNICAL ASISTANCE
SYSTEM READY ALARMS
TEMP: -045.0ºC PROGRAM

3 Seg.

COOL + VACUUM ON HOUR COUNTER ALARM [<-] COOL OFF ON/OFF COOL ON
TIME: 11:23:45 PUMP 00150 H VACUUM SYSTEM TEMP: -091.0ºC

HOUR COUNTER ALARM [<-] PUMP OFF ON/OFF PUMP ON

COMP E1 00160 H VACUUM PROBE VAC: 0.010 mBar

HOUR COUNTER ALARM [<-] HOUR COUNTER ENTER RESET ? [<-]

COMP E2 00099 H TEMP PROBE COMP E1 00160 H COMP E1 00160 H

SELECT LANGUAGE HOUR COUNTER ENTER RESET ? [<-]

English COMP E2 00160 H COMP E2 00099 H

HOUR COUNTER ENTER RESET ? [<-]

PUMP 00160 H PUMP 00150 H

CRYODOS V3.1

2.4. MAINTENANCE CHART

The following frequencies for each task, and particularly that for oil changes, as shown on the
Maintenance Chart below, are for guidance with normal freeze dryer work. Very severe work conditions
may indicate a reduction of these intervals on the Chart.
 Page 9 of 20

OPERATION PERIODICITY

VACUUM UNIT

- Inspection of oil conditions Before each operation

- Oil level control Before each operation
- First oil change After the first 150 hours of service
- Oil change Minimum every 500 hours of service
- Check the performance of the vacuum Every 6 months
unit, particularly the standard time for
reaching vacuum throughout the unit
using the cold condenser.
- Visual inspection of oil loss Every 6 months

REFRIGERATING UNIT

- Cleaning of the condenser panel Every 6 months

- Check the performance of the
refrigerating system by comparing the
standard chamber plate and condenser
cooling times Every 6 months

FREEZE DRYER
- Seals cleaning and greasing Every 6 months
 Page 10 of 20

3. TROUBLESHOOTING

3.1. VACUUM UNIT

Problem: The vacuum pump does not start.

CAUSE SOLUTION
The pump motor is not receiving Check the pump's electrical terminals
voltage Check the corresponding circuit-breaker
Check that the working temperature is not too high
(>35ºC), as this might have caused the circuit breakage.

The pump's starter protector is Check that the condenser temperature is sufficient to permit
blocked, as a result of the the start-up of the vacuum pump.
condenser not reaching the
appropriate temperature.

Pump wheel seizure. The motor Contact the Technical Assistance Department. Send the
axis will not turn pump to TELSTAR for inspection

Problem: A vacuum cannot be obtained in the unit

CAUSE SOLUTION
The motor turns but does not Motor/pump coupling broken. Send the pump to TELSTAR
create a vacuum. for inspection

Problem: The pump is not creating the maximum vacuum pressure.

CAUSE SOLUTION
Lack of oil Check the level of oil in the pump and add if necessary

Contaminated oil Empty the oil from the pump and fill it with new oil

Problem: Abnormal pump heating

CAUSE SOLUTION
Lack of ventilation or extremely Position of the vacuum pump in an area with better
high temperature (above 35ºC) in ventilation.
the pump area

Problem: Mist leak from the emission channel

CAUSE SOLUTION
Air ballast open too far Close the air ballast

There is a leak in the unit Locate the leak

 Page 11 of 20

3.2. REFRIGERATING UNIT

Problem: The refrigerating unit does not start

CAUSE SOLUTION
The compressors are not receiving Check the compressors' electrical terminals
a voltage Check the circuit breaker corresponding to each compressor.

Problem: The chamber plates or the condenser are not reaching the minimum temperature.

CAUSE SOLUTION
Refrigerant leak Notify the TELSTAR Technical Assistance Department in
order to locate the leak, repair it and load gas.

Lack or insufficient water supply Verify water source and pressure.

Problem: Intermittent compressor stoppage.

CAUSE SOLUTION
Insufficient refrigeration of the Place the freeze-dryer in a better ventilated spot
condensing component Check that the room temperature is below 24ºC
Clean the area formed by the condensing component with
compressed air and a brush
Check that there is adequate circulation of fan forced air

Problem: The compressor stops after a series of intermittent stoppages

CAUSE SOLUTION
Disconnection of the compressor Place the freeze-dryer in a better ventilated area
motor thermal protector Check that the room temperature is below 24ºC
Clean the area formed by the condensing component with
compressed air and a brush
Check that there is adequate circulation of fan forced air
Wait 30 minutes for the motor to cool down and for the
protector to become unblocked in order for operation to
resume.

3.3. FREEZE-DRYER ASSEMBLY

Problem: A working vacuum cannot be achieved in the chamber

CAUSE SOLUTION
There is a leak in the unit Check that the unit is watertight
Lubricate the chamber and condenser joints with silicon
Check that all the connection taps are closed. Check that
the condenser discharge valve is closed
Check that there is no condenser defrosts water remaining
from the last operation in the discharge tube.

Problem: The vacuum gauge indicates gauge short circuit on the display

CAUSE SOLUTION
Vacuum gauge short-circuit Check wiring
Replace the gauge
 Page 12 of 20

4. UNIT SPARE PART CODES

Only original parts and accessories will guarantee correct operation of the freeze-dryer.

4.1. VACUUM GROUP

DESCRIPTION CODE

Vacuum Pump VARIAN DS 102 21978

Vacuum transducer 19658

Exhaust filter 91015

Silicone grease 4716

Fluid oil AV-30 for Vacuum Pump (1 litre) 15263

Set of gaskets for VARIAN DS 102 Vacuum Pump 23074

4.2. REFRIGERATING SYSTEM

DESCRIPTION CODE

Refrigerating fluid R-404-A 12728

Refrigerating fluid R-23 70256

Compressor R-404 (-50) 3484

Compressor R-23 (-80) 3522

Compressor R-404 (-80) 3484

4.3. GENERAL

DESCRIPTION CODE

Low condenser reservoir seal 60098

Top condenser reservoir seal 8652

 Page 13 of 20

5. MAINTENANCE RECORDS

5.1. TIME COUNTERS

Note down in the following tables the number of hours operated before resetting the time meters.

VACUUM PUMP

DATE HOURS OPERATION DONE BY:

COOLING COMPRESSOR

DATE HOURS OPERATION DONE BY:

 Page 14 of 20

5.2. OTHER OPERATIONS

DATE OPERATION DONE BY:

 Page 15 of 20

6. ATTACHED DOCUMENTATION

6.1. CRYODOS –50 REFRIGERATING SYSTEM P&ID

6.2. LEGEND. CRYODOS 50 REFRIGERATING SYSTEM

ID. DESCRIPCIÓN CODIGO

1 R-404-A Compressor 3484
2 Ice condenser 26844
3 Thermostatic valve R-404a 3485
4 Drying filter 3252
5 Refrigerating tank R-404a 7072
6 Condenser R-404a 3428
7 Exchanger heat
8 Loading valve 3023
 Page 16 of 20

6.3. CRYODOS –80 REFRIGERATING SYSTEM P&ID

 Page 17 of 20

6.4. LEGEND CRYODOS –80 REFRIGERATING SYSTEM P&ID

ID. DESCRIPTION CODE

1 Hermetic compressor R-404-a 3484
2 Loading valve 3023
3 Condenser R-404-a 3428
4 Refrigerating tank R-404-a 7072
5 Drying filter 19813
6 Thermostatic valve R-404-a 3485
7 Exchanger heat 19534
8 Liquid tank R-23 222718
9 Drying filter 19557
10 Thermostatic valve R-23 19657
11 Ice condenser 26844
12 Suction separator 26462
13 Hermetic compressor R-23 3522
14 Desuperheater 23438
15 High pressure switch 3514
16 Expansion tank R-23 3384
17 Electrovalve 3510
 Page 18 of 20

6.5. LEGEND OF CRYODOS ELECTRIC DIAGRAMS

ID. DESCRIPTION CODE

1 Filter FTO 6 A 70237
2 Card E/S 19074
3 High pressure switch R404 3514
4 Compressor R-23 (CRYODOS –80) 3522
5 Electrovalve (CRYODOS –80) 3510
6 Condenser fan 3428
7 Plug 1852
8 Compressor R404 3484
9 Lyologger connection(optional) 16965
10 Controller Cryodos 19073
11 Vacuum transducer 19658
12 Conversor Wika 21249
13 Temperature gauge PT100 20070
14 Input/output
15 Configuration port CRYODOS
 C1 1

3
PS

6.6.

6
1

6
1
2 2

2 1 1

6
1
6 5 4 3 2 1
ELECTRIC DIAGRAMS

F6 F5 F4 F3 F2 F1

12 11 10 9 8 7 6 5 4 3 2 1

L1
N1
100
90
80
70
60
50
40
30
20
10

100
90
PE
80
70
60
50
20
10
PE

2 2 2 2 2 2 2 2 2 2

1 1 1 1 1 1 1 1 1 1

100
90
PE
80
70
60
50
40
30
20
10
PE
Page 19 of 20

L
N
M 4 5 6 7 M 8

L
N
2 2

1~ 2 1~
1 1
 10

- +
9 12
1 2 3

11 13

1
C1
2/8A
Page 20 of 20