Labconco Corporation
8811 Prospect Avenue
Kansas City, MO 64132-2696
800-821-5525, 816-333-8811
FAX 816-363-0130
E-MAIL labconco@labconco.com
HOME PAGE www.labconco.com
Please read the User’s Manual before operating the equipment.
Warranty
Labconco provides a warranty on all parts and factory workmanship. The warranty includes areas of
defective material and workmanship, provided such defect results from normal and proper use of the
equipment. Glassware is not warranted from breakage when dropped or mishandled.
The warranty for FreeZone® Freeze Dry Systems will expire one year from date of installation or two
years from date of shipment from Labconco, whichever is sooner. Warranty is non-transferable and
only applies to the owner (organization) of record.
This limited warranty covers parts and labor, but not transportation and insurance charges. In the
event of a warranty claim, contact Labconco Corporation or the dealer who sold you the product. If
the cause is determined to be a manufacturing fault, the dealer or Labconco Corporation will repair or
replace all defective parts to restore the unit to operation. Under no circumstances shall Labconco
Corporation be liable for indirect, consequential, or special damages of any kind. This statement may
be altered by a specific published amendment. No individual has authorization to alter the provisions
of this warranty policy or its amendments. Lamps and filters are not covered by this warranty.
Damage due to corrosion or accidental breakage is not covered.
The information contained in this manual and the accompanying products are copyrighted and all rights
reserved by Labconco Corporation. Labconco Corporation reserves the right to make periodic design
changes without obligation to notify any person or entity of such change.
Returned or Damaged Goods
Do not return goods without the prior authorization from Labconco. Unauthorized returns will not be
accepted. If your shipment was damaged in transit, you must file a claim directly with the freight carrier.
Labconco Corporation and its dealers are not responsible for shipping damages.
The United States Interstate Commerce Commission rules require that claims be filed with the delivery
carrier within fifteen (15) days of delivery.
Limitation of Liability
The disposal and/or emission of substances used in connection with this equipment may be governed by
various federal, state, or local regulations. All users of this equipment are required to become familiar with
any regulations that apply in the user’s area concerning the dumping of waste materials in or upon water,
land, or air and to comply with such regulations. Labconco Corporation is held harmless with respect to
user’s compliance with such regulations.
Contacting Labconco Corporation
If you have questions that are not addressed in this manual, or if you need technical assistance, contact
Labconco’s Customer Service Department or Labconco’s Product Service Department at 1-800-821-5525
or 1-816-333-8811, between the hours of 7:00 a.m. and 6:00 p.m., Central Standard Time.
Congratulations on your purchase of a Labconco FreeZone® Freeze Dry System,
which is designed for laboratory lyophilization procedures. The refrigerant used in
the refrigeration system is CFC-free so it will not endanger the environment. The
unit is easy to install and maintain. Proper care and maintenance of this product
will result in many years of dependable service.
Freeze Dry Process
Freeze drying is an important process in sample preparation and for the
preservation and storage of biologicals, pharmaceuticals and foods. Of the various
methods of dehydration, freeze drying (lyophilization) is especially suited for
substances that are heat sensitive. Other than food processing (e.g., coffee, whole
dinners), freeze drying has been extensively used in the development of
pharmaceuticals (e.g., antibiotics) and preservation of biologicals (e.g., proteins,
plasma, viruses and cell lines). The nondestructive nature of this process has been
demonstrated by the retention of viability in freeze dried viruses and
microorganisms.
Freeze drying is a process whereby water or other solvent is removed from frozen
material by converting the frozen water directly into vapor without the
intermediate formation of liquid water. The basis for this sublimation process
involves the absorption of heat by the frozen sample in order to vaporize the ice;
the use of a vacuum pump to enhance the removal of water vapor from the surface
of the sample; the transfer of water vapor to a collector; and the removal of heat by
the collector in order to condense the water vapor. In essence, the freeze dry
process is a balance between the heat absorbed by the sample to vaporize the ice
and the heat removed from the collector to convert the water vapor into ice.
Product Service 816-333-8811 or 1-800-522-7658
Chapter 1: Introduction
2
SAFE TEMPERATURE AND DRYING TIMES
FOR SELECTED MATERIALS
Material
10mm Thick
Safe
Temperature
°C
Collector
Temperature
°C
Hours
(Approx.)
Milk
-5
-40
10
Urea
-7
-40
10
Blood Plasma
-10 to -25
-40
16
Serum
-25
-40
18
Vaccinia
-30 to -40
-50
22
Influenza Vaccine
-30
-50
24
Human Tissue
-30 to -40
-50
48
Vegetable Tissue
-50
-80
60
Table 1
Freeze Dry Rates
The efficiency of the freeze drying process is dependent upon the surface area and
the thickness of the sample, the collector temperature and vacuum obtained, the
eutectic point and solute concentration of the sample. It is important to remember
these factors when trying to obtain efficient utilization of your freeze dry system.
A listing of selected materials and their approximate drying times are shown in
Table 1 for your reference.
*Total sample quantities are contingent on various freeze dryer capacities.
Up to the point of overloading the system, the greater the surface area of the
sample, the faster the rate of freeze drying. By contrast, for a given surface area,
the thicker the sample the slower the rate of freeze drying. This is based on the
fact that the heat of sublimation is usually absorbed on one side of the frozen
sample and must travel through the frozen layer to vaporize water at the other
surface. In addition, as the sample is freeze dried, the water vapor must travel
through the layer of dried material. The thicker the sample, the greater the chance
that the dried layer may collapse, which would cause an additional decrease in the
rate of freeze drying.
The surface area and thickness of the sample can usually be ignored when each
sample contains only a few milliliters. However, for larger volumes, the samples
should be shell frozen to maximize the surface area and minimize the thickness of
the sample. The volume of the freeze dry flask should be two to three times the
volume of the sample.
Product Service 816-333-8811 or 1-800-522-7658
Chapter 1: Introduction
3
In order for lyophilization to occur, ice must be removed from the frozen sample
via sublimation. This is accomplished by the collector and the vacuum pump. The
collector, which should be at least 15 to 20°C colder than the eutectic temperature
(melting temperature) of the sample, traps vapor as ice. Since the vapor pressure
at the collector is lower than that of the sample, the flow of water vapor is from the
sample to the collector. Since this vapor diffusion process occurs very slowly
under normal atmospheric conditions, a good vacuum is essential to maintain an
efficient rate. In many applications, the maintenance of a vacuum of 0.133 mBar
or less is recommended.
The rate of freeze drying is directly proportional to the vapor pressure and the
vapor pressure is dependent upon both eutectic temperature and solute
concentration of the sample. For example, a solution of sodium chloride and water
would freeze dry at a slower rate than pure water. The eutectic temperature of a
sodium chloride solution is about –21°C and at this temperature the vapor pressure
is about 1/16 that of water at 0°C. Although the eutectic temperature is not
dependent upon the concentration of sodium chloride, the vapor pressure of the
water would decrease as the concentration of sodium chloride increased. This is
due to the fact that as the solute concentration increases, less of the surface area of
the frozen sample is occupied by water. In general, most solutions or biological
samples will have a eutectic temperature of –10 to –25°C. However, if the sample
contains a simple sugar such as glucose or if the sample is animal or plant tissue,
the eutectic temperature may be as low as –30° to –50°C.
Freeze Dry Capacity
The volume of a sample that can be freeze dried at one time is related to factors
discussed previously and the size and design of the freeze dry system. With any
given instrument, the capacity is based on the surface area of the sample; the
eutectic temperature and concentration of the sample; and the rate and amount of
heat transferred to the frozen sample. Of these factors, the eutectic temperature is
the most important factor in determining the amount of sample that can be freeze
dried at one time, particularly when flasks are used. This is because as the eutectic
temperature decreases, the vapor pressure decreases but the rate of heat absorption
by the sample does not change. This tends to promote melting of the sample,
which leads to a marked increase in vapor pressure and ultimately overloads the
collector and vacuum pump. Samples that have eutectic temperatures of –20°C or
lower should be placed on the freeze dry system one flask at a time so that the
vacuum in the system may recover before adding another sample to the system. If
the vacuum does not recover, the capacity of the freeze dry system has been
exceeded and the sample should be removed.
Product Service 816-333-8811 or 1-800-522-7658
Chapter 1: Introduction
4
If there is a problem with a particular type of sample melting when placed on the
freeze dry system, dilution of the sample with more water or providing some
insulation around the flask to decrease the rate of heat absorption by the sample
may help. If the eutectic temperature of the sample is –40 to –60°C, the freeze dry
system selected for use must be equipped with cascade type refrigeration so that
the collector temperature can be cooled to below –75°C, or a dry ice/solvent trap
may be used between the collector and the vacuum pump.
Samples Containing Volatile Substances
In certain cases the solvent in a sample to be freeze dried may contain volatile
components such as acetonitrile, methanol, acetic acid, formic acid or pyridine. In
addition to these substances having an effect on the eutectic temperature, they may
increase the vapor pressure at the surface of the sample. Also, compared to water,
they will require the absorption of less heat for sublimation to occur. Hence,
samples that contain volatile substances will have a greater tendency to melt,
particularly when placed in flasks or exposed to room temperature. If a sample
containing a volatile substance tends to melt when placed on a freeze dry system,
dilution of the sample with more water will help keep the sample frozen. For
example, a 0.2M solution of acetic acid is much easier to freeze dry than a 0.5M
solution.
Safety Symbols
Your freeze dry system was designed with safety in mind, however conditions may
exist that could be hazardous.
Product Service 816-333-8811 or 1-800-522-7658
Chapter 1: Introduction
5
Throughout this manual potentially hazardous conditions are identified using the
following words and symbols.
It is important that you understand the warnings listed throughout this manual
before you operate the freeze dry system.
Product Service 816-333-8811 or 1-800-522-7658
6
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Before you install your freeze dryer, you need to prepare your site for
installation. Carefully examine the location where you intend to install your
freeze dryer. You must be certain that the area is level and of solid
construction. An electrical source must be located near the installation site.
Carefully read this chapter to learn:
the electrical supply requirements.
the vacuum pump requirements.
Refer to Appendix C: Freeze Dryer Specifications for complete freeze dryer
electrical and environmental conditions, specifications and requirements.
Electrical Requirements
The freeze dryer requires a dedicated electrical outlet. This outlet requires a
20 Amp circuit breaker or fuse for models rated at 115V (60 Hz). An outlet
equipped with a 15 Amp circuit breaker or fuse is required for models rated
at 230V (50/60 Hz). See Freeze Dryer Components in Chapter 3 for detail
plug specifications. If the plug supplied with the Freeze Dryer does not
match the available receptacle, remove this plug and replace it with an
approved plug of the suitable style.
Location Requirements
The freeze dryer should be located in an area that provides an unobstructed
flow of air around the cabinet. This air cools the refrigeration system. The
refrigeration system draws air through the rear panel and exhausts it through
the sides. A minimum of 3" must be allowed between the back and both
sides of the freeze dryer and adjacent wall surfaces. Restriction of airflow
during operation could adversely affect performance.
Product Service 816-333-8811 or 1-800-522-7658
Chapter 2: Prerequisites
7
Refer to Appendix C: Freeze Dryer Specifications for dimensional drawings
of the Freeze Dryer. The space for benchtop models must be large enough to
accommodate the vacuum pump, which will be used with the freeze dryer.
Vacuum Pump Requirements
A vacuum pump must be provided by the user. A vacuum pump with a
displacement of 86 liters per minute and 0.002 mBar ultimate pressure is
adequate for most samples. The inlet fitting on the vacuum pump must be
suitable for 3/4" ID vacuum hose, which is provided. It is recommended that
the vacuum pump is equipped with an exhaust filter to minimize oil mist
exhausting from the vacuum pump. The operating vacuum level may be set
on the freeze dryer. The higher the pressure is set, the more likely it is that
oil mist will be exhausted.
Vacuum pumps used with 115V models should be equipped with a 115V, 15
Amp NEMA 5-15P plug. Vacuum pumps used with 230V models should be
equipped with a reverse IEC plug. This plug is included with 230V models.
This will allow the vacuum pump to be plugged into the receptacle on the
back panel of the freeze dryer. See Appendix D: Freeze Dryer Accessories
for vacuum pumps available from Labconco.
Chamber or Manifold Requirements
A 12-port drying chamber is included with the unit. This allows samples to
be attached to the freeze dryer. See Appendix D: Freeze Dryer Accessories
for available chambers and manifolds.
Product Service 816-333-8811 or 1-800-522-7658
8
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Now that the site for your freeze dryer is properly prepared, you are ready to
unpack, inspect, install and test your freeze dryer. Read this chapter to learn
how to:
unpack and move your freeze dryer.
set up your freeze dryer.
connect the electrical supply source to your freeze dryer.
properly exhaust your freeze dryer.
safely use solvents with your freeze dryer.
Product Service 816-333-8811 or 1-800-522-7658
Chapter 3: Getting Started
9
Power Cords
Catalog #
Description
Volts
Hz
PTFE
Coated
Chamber
1336400
1336500
1342100
1332601
1332701
7386020
4.5L Benchtop Cascade Freeze Dryer
115
60 X
7386021
4.5L Benchtop Cascade Freeze Dryer
115
60 X X
7386030
4.5L Benchtop Cascade Freeze Dryer
230
50 X
7386031
4.5L Benchtop Cascade Freeze Dryer
230
50 X X
7386040
4.5L Benchtop Cascade Freeze Dryer
230
60 X
7386041
4.5L Benchtop Cascade Freeze Dryer
230
60 X X
7386060
4.5L Benchtop Cascade Freeze Dryer
230
50 X
7386061
4.5L Benchtop Cascade Freeze Dryer
230
50 X X
7386070
4.5L Benchtop Cascade Freeze Dryer
230
50 X
7386071
4.5L Benchtop Cascade Freeze Dryer
230
50 X X
Unpacking Your Freeze Dryer
Carefully unpack your freeze dryer and inspect it for damage that may have
occurred in transit. If your freeze dryer is damaged, notify the delivery
carrier immediately and retain the entire shipment intact for inspection by the
carrier.
The Benchtop FreeZone Plus Cascade 4.5 Liter Freeze Dry System weighs
over 125 lbs. (57 Kg). The Console FreeZone Plus Cascade 4.5 Liter Freeze
Dry System weighs over 176 lbs. (80 Kg). If you must lift the freeze dryer
manually, use at least two (2) persons and follow safe lifting guidelines.
If your freeze dryer was damaged in transit, you must file a claim directly
with the freight carrier. The United States Interstate Commerce Commission
rules require that claims be filed with the delivery carrier within fifteen (15)
days of delivery. Labconco Corporation and its dealers are not responsible
for shipping damage.
Do not return goods without the prior authorization of Labconco.
Unauthorized returns will not be accepted.
Do not discard the carton or packing material for your freeze dryer until you
have checked all of the components and installed and tested the freeze dryer.
Freeze Dryer Components
Locate the model of FreeZone Plus Cascade 4.5 Liter Freeze Dry System you
received in the following table. Verify that the components listed are present
and undamaged.
Product Service 816-333-8811 or 1-800-522-7658
Chapter 3: Getting Started
10
Power Cords
Catalog #
Description
Volts
Hz
PTFE
Coated
Chamber
1336400
1336500
1342100
1332601
1332701
7387020
4.5L Console Cascade Freeze Dryer
115
60 X
7387021
4.5L Console Cascade Freeze Dryer
115
60 X X
7387030
4.5L Console Cascade Freeze Dryer
230
50 X
7387031
4.5L Console Cascade Freeze Dryer
230
50 X X
7387040
4.5L Console Cascade Freeze Dryer
230
60 X
7387041
4.5L Console Cascade Freeze Dryer
230
60 X X
7387060
4.5L Console Cascade Freeze Dryer
230
50 X
7387061
4.5L Console Cascade Freeze Dryer
230
50 X X
7387070
4.5L Console Cascade Freeze Dryer
230
50 X
7387071
4.5L Console Cascade Freeze Dryer
230
50 X X
7382020
4.5L -105C Benchtop Freeze Dryer
115
60 X
7382021
4.5L -105C Benchtop Freeze Dryer
115
60 X X
7382030
4.5L -105C Benchtop Freeze Dryer
230
50 X
7382031
4.5L -105C Benchtop Freeze Dryer
230
50 X X
7382032
4.5L -105C Benchtop Freeze Dryer
230
50 X
7382033
4.5L -105C Benchtop Freeze Dryer
230
50 X X
7382034
4.5L -105C Benchtop Freeze Dryer
230
50 X
7382035
4.5L -105C Benchtop Freeze Dryer
230
50 X X
7382040
4.5L -105C Benchtop Freeze Dryer
230
60 X
7382041
4.5L -105C Benchtop Freeze Dryer
230
60 X X
Part #
Component Description
7387900
User’s Manual
7373450
Vacuum Hose
1488800
Hose Clamps (2)
7395801
Chamber Lid
7395800
Lid Gasket
7522800
Drying Chamber (12-port)
1291000
Plug
Plus the following:
If you did not receive one or more of the components listed for your freeze
dryer, or if any of the components are damaged, contact Labconco
Corporation immediately for further instructions.
Product Service 816-333-8811 or 1-800-522-7658
Chapter 3: Getting Started
11
Setting Up Your Freeze Dryer
After you verify receipt of the proper components, move your freeze dryer to
the location where you want to install it. Then, follow the steps listed below.
Vacuum Pump Connection
A vacuum pump as described in Chapter 2: Prerequisites is required to
operate your freeze dry system properly. The freeze dryer is equipped with a
3/4" ID, heavy wall, vacuum hose for connecting the collector chamber to the
vacuum pump.
Place the vacuum pump near the benchtop freeze dryer models. For console
models, from the back of the unit, place the vacuum pump on the floor of the
cabinet.
Connect the vacuum pump power cord to the receptacle on the back of the
cabinet labeled “vacuum pump.” If the vacuum pump has an off/on switch,
turn the switch on. The vacuum pump will be controlled by the freeze dryer.
Connect the vacuum pump inlet port to the vacuum tube on the back of the
cabinet with the vacuum hose and clamps provided. If necessary, cut the
hose to proper length to allow for gentle bends without kinks.
Models rated for use on 230V have a reverse IEC connector for attaching the
vacuum pump power cord. A plug is supplied that can be installed on the
vacuum pump power cord if necessary. Make certain that the oil in the
vacuum pump is at the proper level.
Electrical Connection
Plug the power cord into the receptacle on the back of the freeze dryer and
plug the other end into a suitable power receptacle.
Drying Chamber or Drying Manifold Installation
Install the clear lid with 3.0 inch hole on top of the collector chamber.
The supplied drying chamber or drying manifold, which may be purchased
separately, may be positioned directly above the 3-inch hole in the collector
chamber lid. Center the rubber gasket that came with the chamber over the
hole in the lid. Then place the chamber over the gasket. When vacuum is
applied to the system, the chamber will be held securely in place.
Product Service 816-333-8811 or 1-800-522-7658
Chapter 3: Getting Started
12
Acids
Buffers Solvents
Component
Material
Acetic Acid 20%
Formic Acid
Trifluoroacetic Acid (TFA) Calcium Chloride
Sodium Phosphate Acetone
Acetonittirle
Carbon Tetrochloride
Cyclohexane
Dioxane
Methyl t-Butyl Ether (BTBE)
Pyridine
Valve Stem
Acetal
C D D D D Collector Lid
Acrylic
D D D D
Hoses, Gaskets
& Valve
Bodies
Neoprene
C D D C C D D D C
D
Flask Top
Silicon Rubber
C D D D D D C
D
Chamber &
Fittings
Stainless Steel
C
Chemical Resistance of Freeze Dryer
Components
The FreeZone Freeze Dry System is designed to be chemically resistant to
most compounds that are commonly used in freeze drying processes.
However, by necessity, the freeze dryer is comprised of a number of different
materials, some of which may be attacked and degraded by certain chemicals.
The degree of degradation is dependent on the concentration and exposure
duration. Some of the major components of the FreeZone Freeze Dry System
that are susceptible to degradation are as follows:
C – Moderate degradation; Limited use
D – Severe degradation; infrequent use recommended; immediate thorough
cleaning required.
Most common compounds used in freeze drying processes, if allowed to
enter the vacuum pump, will degrade the oil and cause damage to the
vacuum pump.
Sugars and proteins typically will have minimal negative effect on any of
the materials of construction.
When using compounds in the freeze dryer that are hostile to the materials of
construction, it is imperative the equipment is thoroughly cleaned after use.
Rubber and plastic components that have been exposed to damaging
compounds should be removed and flushed with water.
Product Service 816-333-8811 or 1-800-522-7658
Chapter 3: Getting Started
13
The oil in the vacuum pump should be checked often. It must be changed
if it is cloudy, shows particles or is discolored. The useful life of vacuum
pump oil can be extended if the vacuum pump is operated for an extended
period of time after a freeze dry run. This allows contaminants to be
purged from the hot oil. This must be done with the inlet to the pump
blocked off to prevent air from free flowing through the pump. If the
pump is operated at an elevated vacuum level (> 10mBar), oil may be
expelled from the pump and damage could occur.
Another way to extend the life of the vacuum pump is to install an optional
secondary trap in the line between the freeze dryer and the vacuum pump.
Contact Labconco for ordering information.
With prudent maintenance the FreeZone Freeze Dry System will provide
years of service. Warranty on the affected parts will be voided if
maintenance has been obviously neglected. If you have questions about
using specific compounds in the freeze dryer, contact Labconco Technical
Service at 1-800-821-5525 or 816-333-8811 or e-mail:
labconco@labconco.com.
Solvent Safety Precautions
Solvents used in the freeze dryer may be flammable or hazardous to
your health. Use extreme caution and keep sources of ignition away
from the solvents. When using flammable or hazardous solvents, the
vacuum pump must be vented to or operated inside a fume hood.
Hazardous materials such as strong acids or bases, radioactive
substances and volatile organics must be handled carefully and promptly
cleaned up if spilled. If a sample is spilled in the collector chamber it
must immediately be cleaned up.
NOTE: The disposal of substances used in connection with this
equipment may be governed by various Federal, State or local
regulations. All users of this equipment are urged to become familiar
with any regulations that apply in the user’s area concerning the
dumping of waste materials in or upon water, land or air and to comply
with such regulations.
Product Service 816-333-8811 or 1-800-522-7658
14
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After your Freeze Dryer has been installed as detailed in Chapter 3: Getting
Started, you are ready to begin using your Freeze Dryer. Read this chapter to
learn how to:
operate the controls.
understand the display.
connect samples.
Do not use the freeze dryer in a manner not specified by the
manufacturer (refer to Appendix C: Freeze Dryer Specifications). The
electrical protection properties of the freeze dryer may be impaired if the
freeze dryer is used inappropriately.
Product Service 816-333-8811 or 1-800-522-7658
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