FTS LYOSTAR 3 - User Manual

Questions and Answers

J
Jose TaylorAug 6, 2025
What to do if my FTS Dryer vacuum pump runs but there's no vacuum?
- R
  Rebekah SchneiderAug 6, 2025
  If the vacuum pump on your FTS Dryer is running but the unit isn't pulling a vacuum, there could be several reasons: * The condenser drain might be open. Ensure the plug is properly inserted in the drain hose. * The door gaskets may not be sealing correctly. Make sure the door latches are closed snugly. A properly sealed door should have a distinctive ¼“ to ½“ wide dark ring where the gasket contacts the acrylic door. * Accessory ports, valves, or filters might not be closed tightly. Check all connections to ensure they are secure. * There might be water under the door gasket. Remove the door gasket and wipe away any condensation. The gasket should be dry and grease-free on the inside.
J
Jasmine SmithAug 11, 2025
Why my FTS Dryer system does not respond to computer commands?
- J
  Jennifer ReillyAug 11, 2025
  If your FTS Dryer system isn't responding to commands from the computer, there are a couple of potential causes: * The lyophilizer might not be powered on. Check that it's plugged in and the circuit breaker on the rear of the system is switched on. * There could be a data communications problem. Ensure the communication cable is properly connected between the computer and the freeze-dryer. Try shutting down the computer and powering off the LyoStar. Then, restart both the LyoStar™ 3 and the computer.
C
Christina WilsonAug 17, 2025
How to troubleshoot a vacuum pump that won't start on my FTS Dryer?
- D
  Denise Harris MDAug 17, 2025
  If the vacuum pump on your FTS Dryer isn't starting, consider these possibilities: 1. There may be no power to the pump motor. Check if the vacuum pump motor circuit breaker has tripped. Also, verify that the automatic control is in the vacuum or heat phase. Check the power source in the electrical box at the Solid State Relay or Contactor. 2. If there is power to the motor, but the pump still won't start, the vacuum pump may be seized. Remove the motor and start it without the pump attached to determine if the problem lies within the motor or the pump. If the pump module is seized, it should be rebuilt or replaced.
I
ibatesAug 25, 2025
What to do if my FTS Dryer pulls vacuum but pressure doesn't register?
- J
  Jessica RileyAug 25, 2025
  If your FTS Dryer is pulling a vacuum, but the system pressure isn't registering on the display or other vacuum gauges, here’s what you can check: * The probe might be defective. Test it with a McLeod gauge or remote vacuum gauge, and replace the probe if necessary. * The vacuum level may not be low enough to register. If the pump has been running for at least 30 minutes, test for vacuum leaks.
D
Dana RothAug 30, 2025
Why does my FTS Dryer start hard and make chugging noises?
- E
  Elizabeth RasmussenAug 30, 2025
  If your FTS Dryer starts with difficulty, roughly, and makes chugging noises, it could be due to a low voltage supply. Check the voltage and amperage supplied to the unit against the freeze-dryer’s serial tag. If the supply is low, contact a certified electrician to evaluate.

Summary

Original Instructions

Important Symbols

Freeze Dryer Safety Warnings

Warranty Information

Limited Warranty

Details the terms and conditions of the product warranty.

Introduction

Standard Features

Details the key features and capabilities of the LyoStar™™ 3 lyophilizer.

Equipment Options

Lists optional features and configurations available for the LyoStar™™ 3 lyophilizer.

Getting Started

Initial Inspection

Procedure for inspecting the lyophilizer for shipping damage upon receipt.

Setup Procedure

Step-by-step guide for installing and setting up the LyoStar™™ 3 lyophilizer.

Vacuum Pump Oil

Instructions for checking and maintaining vacuum pump oil levels and condition.

Oil Mist Eliminator

Ensuring the proper attachment of the oil mist eliminator.

Workstation Power Configuration

Verify workstation voltage selector switch configuration before connecting to power.

Connecting Control System Cables

Connecting data communication cables between the lyophilizer and workstation.

The Freeze-Drying System

Components and Subsystems

Overview of the main components and subsystems of the LyoStar™™ 3 lyophilizer.

Product Drying Chamber

Details the standard and ControLyo™™ chambers and their respective doors.

Product Shelves

Describes product shelves, shelf stack, latching, stoppering, and trays.

Shelf Heat-Transfer System

Explains the system for circulating heat transfer fluid through shelves.

TDLAS Spool Piece

Information on the vapor port for TDLAS apparatus installation.

Isolation Valve

Details the butterfly-type isolation valve and its function.

Condenser System

Describes the condenser chamber, cooling, door, and defrosting.

Refrigeration System

Explains the cascade refrigeration system and its utility requirements.

Aeration and Vacuum Level Control

Describes methods for controlling vacuum and aeration in the chambers.

Vacuum System

Details the vacuum pump, its function, and exhaust system.

Control System

Overview of the LyoS™ Control System and PLC.

Operating your Lyophilizer

Leak Rate and Function Testing

Procedure for performing automatic leak rate and function tests for the lyophilizer.

Preparation and Pretreatment

Ensures the product chamber, shelves, and condenser are clean and dry before operation.

Product Temperature-Monitoring Probes

Details probes, placement in bulk samples, vials, and unusual containers.

Thermocouple Connection

Ensures correct copper-to-copper connection for accurate thermocouple readings.

Pre-Freezing

Product samples must be frozen before the drying process begins.

Stoppers

Describes the system for seating stoppers in vials at the end of a cycle.

Freeze Drying

Overview of the two-phase freeze-drying cycle: freezing and drying.

Freezing; Thermal Treatment

Covers freezing methods and the use of ControLyo™™ technology.

Drying Steps 1-16

Details the primary drying phase where moisture sublimes.

Drying Step 17

Additional step for removing residual bound water from the product.

Completing the Cycle

Procedure for shutting down systems and unloading product.

Defrost

Instructions for defrosting the condenser after each cycle.

Liquid Nitrogen Trap

Operation

Step-by-step instructions for operating the auto-fill liquid nitrogen trap.

Cleaning

Procedure for cleaning the liquid nitrogen trap, including defrosting if needed.

Sample Extractor Assemblies

Standard Sample Extractor Assembly (Acrylic)

Details the components of the standard acrylic sample extractor assembly.

Sample Extractor Installation

Instructions for removing the standard door and installing the sample extractor.

Standard Sample Extractor Operation

Step-by-step guide for operating the standard acrylic sample extractor.

ASME-Coded Stainless Steel Sample Extractor Assembly

Describes the components of the ASME-coded stainless steel sample extractor.

ASME-Coded Sample Extractor Operation

Step-by-step guide for operating the ASME-coded stainless steel sample extractor.

Shelf Spacing

Adjusting shelf spacing using latching kits for larger vials.

Stoppering

Main Components

Details the main components of the LyoStar™™ 3 stoppering system.

Stoppering Procedure

Step-by-step instructions for operating the hydraulic stoppering mechanism.

Inert Gas Backfill

Process for backfilling the chamber with inert gas prior to stoppering.

Shelf-Latching

Shelf-Latching Kit Installation

Procedure for installing shelf-latching kits to adjust shelf spacing.

Praxairs ControLyo Nucleation On-Demand Technology

ControLyo Process Overview

Explains the pressurization, depressurization, and purging steps of the ControLyo™™ process.

Importance of Controlled Nucleation

Discusses the benefits of controlled nucleation on lyophilization outcomes.

Key Steps for ControLyo

Outlines the essential steps for utilizing the ControLyo™™ technology.

Mechanism

Discusses hypotheses regarding the mechanism by which ControLyo™™ induces nucleation.

Guidelines and Performance Expectations

Provides guidelines and expected performance for ControLyo™™ technology.

General Maintenance

Vacuum System Maintenance

Covers vacuum pump oil checks, changes, and oil mist eliminator.

Scheduling Vacuum Pump Oil Changes

Guidelines for determining the frequency of vacuum pump oil changes.

Gas Ballast Valve Maintenance

Explains the function and maintenance of the gas ballast valve.

Door Gasket Inspection

Instructions for inspecting and maintaining chamber and condenser door gaskets.

Air-Cooled Condenser Maintenance

Procedures for cleaning and maintaining the air-cooled condenser and compressor.

Water-Cooled Condenser Maintenance

Information on maintaining water-cooled condensers and water supply.

Condenser Chamber Cleaning

Guidelines for cleaning the condenser chamber, especially after processing corrosive materials.

Chemical Resistance Chart for Acrylic

Table showing acrylic resistance to various chemicals.

Recommended Monthly Maintenance Schedule

Tasks to be performed monthly for routine lyophilizer maintenance.

Recommended Quarterly Maintenance Schedule

Tasks to be performed quarterly for routine lyophilizer maintenance.

Recommended Annual Maintenance Schedule

Tasks to be performed annually for lyophilizer maintenance.

Recommended Five-Year Maintenance Schedule

Tasks to be performed every five years for comprehensive lyophilizer maintenance.

Appendix A: Sample Recipe

Sample Recipe: Freezing; Thermal Treatment

Sample recipe parameters for the freezing and thermal treatment phases.

Sample Recipe: Drying Phase

Sample recipe parameters for the drying phase of lyophilization.

Sample Recipe: Product Storage

Sample recipe parameters for product storage and backfill/stoppering.

Appendix B: Troubleshooting

Troubleshooting Chart

A guide to diagnosing and resolving common freeze-dryer issues.

Vacuum System Troubleshooting

Steps for diagnosing and resolving vacuum system related problems.

Chamber Vacuum Leak Check

Procedure for checking product and condenser chambers for vacuum leaks.

Appendix C: Stainless Steel Cleaners

Cleaning Heat Tint and Discoloration

Methods for cleaning heat tint and heavy discoloration on stainless steel.

Cleaning Stubborn Deposits and Stains

Recommended cleaners for tenacious deposits and atmospheric stains.

Cleaning Hard Water Spots and Scale

Procedure for removing hard water spots and scale from stainless steel.

FTS LYOSTAR 3 Specifications

General

Brand	FTS
Model	LYOSTAR 3
Category	Dryer
Language	English

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