Telstar Cryodos Cryostat Service Manual
Contents
1. LA 0 or 8 ee SEIS ale PST 2S eros x 9 gs I i Su 09 09 09 2 i i OL eo Ep s ros Ox 4 06 So 001 dis 72 SS i o m n AQ M iss 00 001 te TEISTAR Page 20 of 20 Dr 2 8A2. tv TELSTAR Page 15 of 20 6 ATTACHED DOCUMENTATI ON 6 1 CRYODOS 50 REFRIGERATING SYSTEM P amp ID 6 2 LEGEND CRYODOS 50 REFRI GERATI NG SYSTEM DESCRI PCI N CODI GO D 7 tv TELSTAR Page 16 of 20 6 3 CRYODOS 80 REFRIGERATING SYSTEM P amp ID te TEISTAR Page 17 of 20 6 4 LEGEND CRYODOS 80 REFRI GERATI NG SYSTEM P amp ID o Bh UN BIO e e e e e N H O DESCRIPTION Hermetic compressor R 404 a Loading valve Condenser R 404 a Refrigerating tank R 404 a Drying filter Thermostatic valve R 404 a Exchanger heat Liquid tank R 23 Drying filter Thermostatic valve R 23 Ice condenser Suction separator Hermetic compressor R 23 Desuperheater High pressure switch Expansion tank R 23 Electrovalve CODE 3484 3023 3428 7072 19813 3485 19534 222718 19557 19657 26844 26462 3522 23438 3514 3384 3510 te TEISTAR Page 18 of 20 6 5 LEGEND OF CRYODOS ELECTRI C DI AGRAMS ID DESCRI PTI ON CODE 1 Filter FTO 6A 70237 9 Lyologger connection optional 16965 15 tv TELSTAR Page 19 of 20 6 6 ELECTRIC DIAGRAMS mj Cl ad dd OL 02 02 8
3. 6 ATTACHED DOCUMENTATION 15 6 1 CRYODOS 50 Refrigerating system P amp ID __ 15 6 2 CRYODOS 80 Refrigerating system P amp ID ________________ 16 6 3 Legend of cryodos electric diagrams ______________________________ 18 6 4 Electric diagrams _____________________________________________ 19 teTEISTAR Page 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 teTEISTAR 2 MAINTENANCE INSTRUCTI ONS WARNING A 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 MAI NTENANCE 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 i
4. Compressor E2 only for CRYODOS 80 This shows hours running of compressor 2 and provides for resetting them HOUR COUNTER COMP E2 00070 H Vacuum pump ENTER gt This shows pump running hours and provides for resetting them HOUR COUNTER PUMP 00060 H ENTER gt RESET 2 lt COMP E2 00070 H RESET lt PUMP 00060 H teTEISTAR Page 8 of 20 Working diagram CRYODOS V3 1 50 TELSTAR c v ON OFF VAC 0 010 mBar TECHNICAL ASISTANCE TEMPS SYSTEM READY ALARMS P856 X 3 Seg AV AV Y Y COOL VACUUM ON HOUR COUNTER ALARM lt COOL OFF ON OFF COOL M TIME 11 23 45 PUMP 00150 H VACUUM SYSTEM TEMP 091 0 AN HOUR COUNTER ALARM lt PUMP OFF ON OFF PUMP gt 1 00160 H VACUUM PROBE VAC 0 010 mBar X v v HOUR COUNTER ALARM lt HOUR COUNTER ENTER RESET lt gt 2 00099 H TEMP PROBE COMP El 00160 H COMP 1 00160 H AV AV v SELECT LANGUAGE HOUR COUNTER ENTER RESET lt 5 4 0 English COMP E2 00160 H COMP 2 00099 H X AV v HOUR COUNTER ENTER RESET lt PUMP 00160 H PUMP 00150 H CRYODOS V
5. 3 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 te TEISTAR Page 9 of 20 OPERATI ON VACUUM UNIT nspection of oil conditions Oil level control A First oil change Oil change Check the performance of the vacuum unit particularly the standard time for reaching vacuum throughout the unit using the cold condenser Visual inspection of oil loss PERIODICITY Before each operation Before each operation After the first 150 hours of service Minimum every 500 hours of service Every 6 months Every 6 months REFRIGERATING UNIT Cleaning of the condenser panel Check the performance of the refrigerating system by comparing the standard chamber plate and condenser cooling times Every 6 months Every 6 months FREEZE DRYER Seals cleaning and greasing Every 6 months tv TELSTAR Page 10 of 20 3 TROUBLESHOOTI NG 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 Check the corresponding circuit breaker Check that the working temperature is not too high gt 352C as this might have caused the circuit breakage The pump s starter prote
6. MAINTENANCE MANUAL Laboratory Freeze Dryer CRYODOS te TEISTAR Telstar Industrial S L Josep Tapiolas 120 08226 TERRASSA Spain Tel 34 937 36 16 00 CRYODOS rev0105 MA Fax 34 937 85 93 42 telstar etelstar com www etelstar com ts TELSTAR Page 2 of 20 CONTENTS 1 INTRODUCTION __________________________________________________ 3 2 MAINTENANCE 0 00 0000000 4 2 1 Vacuum unit maintenance __________________________ 4 2 1 1 Inspection of oil condition 4 2 1 2 Oil level control 4Z 4 2 1 3 ___________________________________________________ 4 2 1 4 Control visual de p rdidas de aceite eee 5 2 1 5 Gas ballast situation 40 0 2Z2 Z 40 3 5 2 2 Refrigerating system maintenance 5 2 3 Technical assistance 5 2 4 Maintenance chart eee 8 3 TROUBLESHOOTING See 10 3 1 Vacuum unit 10 3 2 Refrigerating unit ____________________________________ 11 3 3 _________________________________ 11 4 UNIT SPARE PART 5 22 12 4 1 Vacuum group 12 4 2 Refrigerating system ee 12 4 3 _____________________________________________________ 12 5 5__________________________________________ 13 5 1 Time counters eee 13 5 2 Other 14
7. ctor is Check that the condenser temperature is sufficient to permit blocked as result of thej 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 1 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 1 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 1 SOLUTION Lack of ventilation or extremely Position of the vacuum pump in an area with better high temperature above 352C in ventilation the pump area Problem Mist leak from the emission channel CAUSE Air ballast open too far Close the air ballast There is a leak in the unit Locate the leak tv TELSTAR Page 11 of 20 3 2 REFRIGERATING UNIT Problem The refrigerating unit does not start SOLUTI ON 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 t
8. first pour 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 P RDI DAS 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
9. he 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 I ntermittent compressor stoppage CAUSE SOLUTION Insufficient refrigeration of the the freeze dryer a better ventilated spot condensing component Check that the room temperature is below 24 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 249C 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 1 1 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 the
10. n 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 ASSISTANCE ON OFF OPERATION PROGRAM s 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 2C TEMP 033 2 9C 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 gt 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 te TEISTAR Page 7 of 20 Compressor E1 This shows hours running of compressor 1 and provides for resetting them HOUR COUNTER RESET lt ENTER gt COMP E1 00080 H COMP E1 00080 H
11. re 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 SOLUTION Vacuum gauge short circuit Check wiring Replace the gauge tv TELSTAR 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 DESCRI PTI ON 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 DESCRI PTI ON 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 DESCRI PTI ON CODE Low condenser reservoir seal 60098 Top condenser reservoir seal 8652 tv TELSTAR Page 13 of 20 5 MAI NTENANCE 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 OPERATI ON DONE BY COOLING COMPRESSOR DATE HOURS OPERATI ON DONE BY te TEISTAR Page 14 of 20 5 2 OTHER OPERATIONS DATE OPERATION DONE BY
12. s 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 Admission 2 Gas Ballast 3 Gas Ballast key 4 Oil filter exhaust 5 Suck back pipe 6 Filling cap 7 Sight glass 8 Emptying cap 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 teTEISTAR 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
13. 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 800gr 5 80 800 8 kg cm 2 3 TECHNICAL ASSISTANCE PROGRAM This is a menu incorporated in the equipment which provides for come of the maintenance work WARNING N This program is only for maintenance and technical assistance tasks it should never be used for normal equipment operations teTEISTAR The Technical Assistance program provides for e Working on the vacuum unit independently e Working on the cooling unit independently e 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 scree
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