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Christ ALPHA 1-2 LDplus - User Manual

Christ ALPHA 1-2 LDplus
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Version 11.2006 – English
Revision 1.2
Operating Manual
Freeze Dryer
ALPHA 1-2 LDplus
Part. No. 101521

Table of Contents

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Summary

1. General Information

1.1. Introduction

Defines freeze drying (Lyophilisation) as extraction of water from frozen material via sublimation.

1.2. Applications

Lists applications of the ALPHA 1-2 LDplus for laboratory and pre-production freeze drying.

1.3. Technical Specifications of Freeze Dryer ALPHA 1-2 LDplus

Provides performance, physical, and electrical specifications for the ALPHA 1-2 LDplus freeze dryer.

1.4. Standards and Regulations

Refers to the enclosed EU Declaration of Conformity for standards and regulations.

1.5. Safety Instructions

Details critical safety warnings including disconnecting mains, handling solvents, cleaning, and transport.

1.5.1. CAUTION! Disconnect Mains Plug!

Warns to disconnect the mains plug before opening panels or for maintenance.

1.5.2. CAUTION! Solvents!

Advises caution with solvents, especially azides, due to explosion risks and unit damage.

1.5.3. ADVICE! Cleaning and Maintenance of the Unit!

Mentions observing safety regulations for infectious, toxic, pathogenic, and radioactive substances.

1.5.4. WARNING! Freezing of Limbs to Surfaces!

Warns about limbs freezing to surfaces in the ice condenser chamber during operation.

1.5.5. ADVICE! Transport Instructions!

Provides instructions for safe transport, advising two-person carrying and avoiding the control panel.

1.6. Prohibited Freeze Drying Processes

Lists prohibited freeze drying processes including incorrect installation and hazardous substances.

2. General Information on Freeze Drying

2.1. General Information on Freeze Drying

Explains freeze drying (sublimation) as a gentle process, detailing components.

2.2. Preparation

Details pre-operation steps, including warming up the vacuum pump and its importance.

2.3. Freezing

Describes freezing methods for small and large quantities, including shell or spin freezing.

2.4. Main Drying

Explains the main drying phase, factors affecting duration, and the role of the vacuum pump.

2.5. Final Drying

Describes the final drying phase, its dependence on ice condenser temperature and vacuum.

2.6. End of Drying and Aeration

Explains how to determine the end of drying and the aeration process to vent the chamber.

2.7. Defrosting

Details the process of defrosting the ice condenser using room temperature or warm water.

3. Description of the Freeze Drying Processes

3.1. Separate Freezing and Drying Outside the Ice Condenser Chamber (Process B) on Shelves

Describes drying products on shelves outside the ice condenser chamber after pre-freezing.

3.2. Separate Freezing and Drying Outside the Ice Condenser Chamber (Process B) with Sealing Device

Details drying and sealing injection bottles under vacuum or inert gas using a sealing device.

3.3. Separate Freezing and Drying of Liquids in Flasks (Process B)

Explains drying liquids in flasks outside the chamber using manifolds and rubber valves.

3.4. Separate Freezing and Drying of Liquids in Ampoules (Process B)

Describes the process of freezing and drying liquids in ampoules outside the chamber.

4. Installation and Commissioning of the Unit

4.1. Site of Installation

Advises on proper placement, alignment, ambient temperature, and air circulation for the freeze dryer.

4.2. Mains Electricity

States that the supply voltage must match the nameplate and the unit is safety class I.

4.3. Fuses on Site

Specifies that the freeze dryer should be protected with a 16 AG fuse.

4.4. Checking the Earth Connection

Describes checking the earth connection using a screw and a measuring device.

4.5. Aeration

Explains the use of the aeration and drain valve for venting or flooding the ice condenser chamber.

4.6. Condensate and Defrosting Water

Details draining condensate and defrosting water via the aeration/drain valve, ensuring proper hose setup.

4.7. Vacuum Pump Exhaust

Advises on managing vacuum pump exhaust, recommending an exhaust filter for oil mist.

4.8. Initial Start-up

Provides a caution to ensure correct installation before initial start-up.

4.8.1. Functional Components and Control Elements

Identifies and labels the functional components and control elements of the freeze dryer.

4.8.2. Connection of vacuum sensor vacuum Pump, and pressure control valve

Illustrates connection diagrams for vacuum sensor, pump, and pressure control valve.

4.8.3. Switching-on

Explains how to switch on the unit and the initial tutorial sequence for the LDplus control system.

5. LDplus Control System

5.1. Introduction

Introduces the LDplus system as a user interface for controlling freeze drying processes.

5.2. LDplus control panel

Identifies the components of the LDplus control panel: display, softkeys, and navigation keys.

5.3. Brief Guide - Handling

Explains how to operate the LDplus control system using the touch-sensitive panel and navigation keys.

5.4. Visual components of the LDplus control system

Describes the three areas of the LC display: Main window, Status bar, and Softkey function.

5.4.1. Main window

Explains that the main window shows set values, actual values, menus, and process information.

5.4.2. Status bar

Details the status bar's function in showing operating mode, active phase, and other relevant information.

5.4.2.1. Operating mode

Describes the operating modes: Standby, Run mode (timer deactivated/activated).

5.4.2.2. Active phase

Details the active phases: Freezing, WarmUp VP, Main drying, and Final drying.

5.4.2.3. Info icon

Explains the function of the info icon for error and process messages.

5.4.3. Softkey function

Explains that softkeys have dynamic functions displayed next to them for easy operation.

5.5. Values window

Describes the values window, showing measuring channels like time and vacuum.

5.6. Mode

Explains how to select modes and phases (Freezing, Warm-up, Main drying, Final drying).

5.6.1. Starting a drying process

Guides on starting a drying process from standby mode, including vacuum pump warm-up inquiry.

5.6.2. Changing the phase

Explains how to change phases or stop the process while it is running.

5.6.3. Timer

Describes the timer function and user inquiries for continuing or stopping phases.

5.7. Main menu

Explains how to access the main menu using the right softkey to navigate options.

5.7.1. Change set values

Details how to define set values for freezing, main drying, and final drying phases.

5.7.1.1. Set values for freezing

Explains setting the timer for the freezing phase, including infinite duration.

5.7.1.2. Set values for main drying & final drying

Explains setting timer and vacuum values for main and final drying phases.

5.7.2. Special functions

Describes accessing special functions for accessories like defrosting or lifting devices.

5.7.3. Process and equipment information system

Refers to a chapter for detailed information on error messages and the process/equipment information system.

5.7.4. Options

Lists options available in the menu: Contrast, Language, Settings, and Service.

5.7.4.1. Contrast

Explains how to adjust the LC display contrast to suit local lighting conditions.

5.7.4.2. Language

States the LDplus system supports German, English, French, Spanish, and Polish.

5.7.4.3. Settings

Covers settings for warm-up time and automatic phase change.

5.7.4.4. Service menu

Describes the service menu for LDplus configuration and loading default settings.

5.7.5. Tutorial

Explains how to start the LDplus control system tutorial.

5.8. Process and equipment information system

Explains the display of the process & equipment information window for messages and status.

5.8.1. Information status

Describes the different status indicators for information messages (acknowledged, not acknowledged).

5.9. LDplus special functions

Details special functions like defrosting the ice condenser and using the electrical lifting device.

5.9.1. Defrost ice condenser (option)

Explains the process of defrosting the ice condenser using electrical heating.

5.9.2. Electrical lifting device (option)

Describes using the electrical lifting device to move the drying chamber.

6. Error Correction

6.1. Power Failure

Discusses the impact of power failure on the drying process and how to handle it.

6.2. Insufficient Vacuum

Provides troubleshooting steps for insufficient vacuum, checking valves and connections.

6.3. Unit does not function

Offers checks for when the unit display does not work after operating the mains switch.

6.4. Insufficient Ice Condenser Temperature

Explains reasons for insufficient ice condenser temperature, such as ambient conditions or air circulation.

6.5. Process and Equipment Information System

Refers to a chapter for error messages and details on the process and equipment information system.

6.5.1. Error Messages

Lists and explains various error messages, their causes, and recommended actions.

7. Maintenance

7.1. Ice Condenser Chamber

Advises ensuring the ice condenser chamber is free of residue before start-up and drying.

7.2. Heat Exchanger

Recommends checking and cleaning the heat exchanger periodically to maintain performance.

7.3. Adjustment and Maintenance of the Vacuum Sensor VSP62

Details the maintenance and adjustment procedures for the VSP62 vacuum sensor.

7.3.1. Maintenance of the Vacuum Sensor:

Explains the limited service life of the tungsten wire in vacuum sensors and how to avoid damage.

7.3.2. Replacement and adjustment

Describes when to replace the vacuum sensor and how to perform its adjustment and calibration.

7.3.2.1. Vacuum sensor adjustment

Provides detailed steps for adjusting the vacuum sensor using its buttons.

7.3.2.2. Adjustment to a specific zero reference value

Explains how to adjust the sensor to a specific zero reference value.

7.4. Rubber Valves

Emphasizes checking rubber valves and maintaining them by dismantling, cleaning, and greasing.

7.5. Vacuum Pump

Refers to the separate manual for vacuum pump maintenance and highlights oil level checks and oil changes.

7.6. Exhaust Filter

Advises on managing condensate in the exhaust filter and refers to its manual.

7.7. Cleaning

Details cleaning procedures for the freeze dryer and its accessories.

7.7.1. Cleaning of the Freeze Dryer

Recommends using mild agents for cleaning the freeze dryer and leaving the lid open.

7.7.2. Cleaning of Accessories

Stresses considering safety measures for accessories and regular cleaning to prevent damage.

7.7.3. Maintenance of the Aeration Valve and the Drain Valve

Highlights the importance of maintaining aeration and drain valves to prevent faulty operation.

7.7.4. Disinfection of Drying Chamber, Lid and Accessories

Lists suitable disinfectants and notes checking material compatibility for disinfection.

7.7.5. Checks by Operator

Outlines essential safety checks for the operator, including lid, seals, and accessories.

8. Options

8.1. Process Control System LPC-32, Software

Mentions the LPC-32 software as an available option.

8.2. Process Control System LPC-32, Software with PC hardware

Mentions the LPC-32 software with PC hardware as an available option.

8.3. LyoLog LL-1 (Documentation Software)

Mentions LyoLog LL-1 documentation software as an available option.

8.4. LDplus Simulation Tool (Training Software)

Mentions the LDplus Simulation Tool as a training software option.

Christ ALPHA 1-2 LDplus Specifications

General IconGeneral
TypeCondenser dryer
Capacity8 kg
Energy efficiency classA++
Noise level65 dB
Number of programs16
ColorWhite
Dimensions (H x W x D)85 cm x 60 cm x 60 cm

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