DYNAVAC NovaDryer-DHF400 Owner's manual
Vacuum Freeze Dryer
NovaDryer-DHF400/ DHF600
(PLC Control System)
Quick Installation & Operation Guide
(Version202003)
www.dynapumps.com.au • 1300 788 579 • [email protected]
2
3
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9
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Contents
Pageno.
Part 1. Unpacking ………………………………………………………………….
Part 2. Preparation before operation …………………………………….
Part 3. Basic knowledge about this freeze dryer ………………….
Part 4. System operation ………………………………………………………….
Part 5. System Working Flow Chart ………………………………………….
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-1-
Before you use this freeze dryer for the first time, please read all the
documents and complete the training course listed below:
‐UserManual
‐QuickinstallationandOperationGuide
‐ParameterSettingChartforDifferentMaterials
‐VideoTrainingCourse
‐TechnicalBulletin
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Part 1. Unpacking
When receiving the goods:
1. Ifanydamageisfound,pleasecontactinsurancecompanyforcompensationclaim.
*ForCIF,CIPandDDP,pleasecontactSenovatoobtainnecessaryassistance.
2. Afterunpacking,pleasecheckthefreezerandalltheaccessoriesarereceivedingoodcondition
accordingtoyourorder.
3. Afterunpacking,pleaseremovetheprotectivebufferfoamfilledinsidethechamber(Pic‐1)
Pic‐1 Pic‐2 Pic‐3
4. Removetheblackdust‐proofplasticcap(Pic‐4)ondischargeoutletofthevacuumpump
beforeusing.
Caution:
Thereisanexternaltemperaturesensor(Pic‐5)insidethechamber.Donotdamageit!
Pic‐4 Pic‐5
protectivebufferfoam
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Part 2. Preparation before operation
1. Findpowercord,metalsoftvacuumtube,andconnectors.Connectthevacuumpumptothe
freezedryer(Pic‐2&3)
2. Vacuumpumpoil:
2‐1.Pleasefindvacuumpumpoilinsidethepackage.
2‐2.Additintothevacuumpumptotheoillevelor2/3positionofthesidewindow.
2‐3.Ifthefreezedryerisshipped by air,vacuumpumpoilis removedbeforeshipmentaccordingtocivil
aviationsecurityregulation.Pleasepurchasevacuumpumpoil(#100or#68forvacuumpump2XZ‐2/4and
#46or#68forvacuumpumpDRV‐10)foranybrandlocally.MobilandShellarerecommended.
2‐4. Vacuum pump oil is consumable and needs to be replaced after running for 100‐200 hours, please
preparesomevacuumpumpoilforspareuse.
2‐5.Vacuumpumpoilcanberecycledafterfrozenandsedimentationsoastosavecost.Fordetails,please
contactus.
Pic‐6 Pic‐7
3. Connectthefreezedryertoproperpowersupply(220V/50Hz,220V/60Hzor110V/60Hz)asmarkedonthelabelonthe
sideofthefreezedryer.
Pic‐8 Pic‐9
4. Openthedoor,loadthetraysontotherack.
5. Externaltemperaturesensor:
Insertthesensorintothematerialssoastodetectmaterialtemperatureduringfreezedrying.
Pic‐10 Pic‐11
6. Closethedoor.Checkandmakesurethereisnoairleakagewiththevacuumtube,connectorsanddoor
2/3Position
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7. Rotatethevacuum/waterdrainingvalvetothecloseposition.
*This valve is combined with functions as a vacuum valve for chamber pressure and a water draining valve after
defrosting
vacuum/waterdrainingvalve OpenPosition ClosePosition
8. Turnonmainpower.Switchonthefreezedryer.Thefreezedryerisreadytousenow.
Pic‐12
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Part 3. Basic knowledge about this freeze dryer
1. Thereare5workingstagesinthefreezedryingprocess.
Ittakesafreezedryer24‐30hourstofinishthecompleteprocessincluding:
Pre‐freeze,ColdTrapCooling,VacuumPumping,DryingandTemperaturekeeping.
Totalfreezedryingtime(24‐30hours)dependsonsugarcontents,oilcontents,water
contents,sizeofthematerials,androomtemperature.
If‐45Cdeepfreezerisavailable,pleaseuseittopre‐freezethematerialsforabout9
hourssothefreezedryercanskipthepre‐freezestage(setpre‐freezetime:1minute)
toreducefreezedryer'stotalworkingtimetoabout18hours(Coldtrapcooling
needstobestartedbeforethepre‐frozenmaterialsareloadedintothechamberto
coolthechambertolowtemperaturerequestedforthenextstage‐vacuumpumping)
2. Theworkingstageindicatorkeepsflashingineachstageallthetime.Thisflashingisnormalanddoesnotmeanany
alarm.
3. Thereare2controlmodesforthisfreezedryer:VacuumControlandProgramControl.
Bothmodessharethesamesettingsinthefirst3stages(pre‐freeze,coldtrapcoolingandpre‐vacuum)buthave
differentsettingsatdryingstage.
VacuumControlmode:Parametersatdryingstageispresetandtheuserisnotallowedtomodifyparameters.
ProgramControlmode:Parametersatdryingstageisnotpresetandtheuserisallowedtomodifyparameters
accordingtodifferentmaterials.
ProgramControlModeisrecommendedbecausethismodecanbeusedforallthematerialswhileVacuumControl
Modeisnotsuggestedforsomematerialssuchasmilkandflowers.
4. Aparametersettingchartisofferedbyusaccordingtoourtestsondifferentmaterials.Theusercantrytomodify
it afterthebestparametersettingisfoundaftersometrialrunning.
5. Afterstarted,thefreezedryerandvacuumpumpcanrunautomaticallyaccordingtothesetparameters.
6. ThevacuumpumpdoesNOTstartatthefirst2stages(pre‐freeze,coldtrapcooling).Itwillbestarted
automatically fromvacuumpumpingstageandwillkeeprunninginworkingstatusuntilendoffreezedrying
(exceptitisstopped bytheuser).
7. Afterstarted,thevacuumpumpwillinitially be a little noisy(about60‐70dB),
togetherwithwhitesmokedischargefromoutletofthevacuumpump.Thiswill
lastforafewminutes.Itisnormal.
Afterthat,noisewillbereducedandwhitesmokewilldisappear.
Itisnormalthatthevacuumpumpfeelshotallthetime.
8. Thereare3workingstatusdisplayedonthemainmenu:
NormalStatus VacuumAlarm PleaseRemoveMaterials
Referto8‐2:
Refertopoint9forsolution:
“HowtoEliminateVacuumAlarm”
Indicatingthefreezedryerisworking
ingoodcondition.
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8‐1.NormalStatus:Thefreezedryerisworkingingoodcondition.
8‐2.PleaseRemoveMaterials:
Materialshavefinishedfreezedryingandcanberemovedfromthefreezedryer.
[Caution]Beforeremovingmaterials,pleaseconfirmmaterialsareinstablestatusfirst:
GotoMainMenu,press“Temp.Control”tocheckifvacuumrecordinthepastonehourhasbeenkeepingstable.
Whenvacuumrecordinthepastonehourisstable,stopthefreezedryer,openthewaterdrainingvalve,removematerials
fromthechamber,andrun“Defrost”in“OPERATION”menu.
*Beforerunningthenextfreezedryingcycle,checkandmakesuretherearenofrost,iceorwaterinthechamber.
8‐3.VacuumAlarm:
Thisalarmiscausedsomereasonsrelatedtothematerialitselfandairleakage.Refertopoint9forsolutions.
9. HowtoEliminateVacuumAlarm
When“VacuumAlarm”keepsflashingonthemainmenu,pleasetrythe
2solutionsgivenbelow:
9‐1.Ifvacuumdegreeonthemainmenuisbetween900‐1000(Pa)(Pic‐9)
when“VacuumAlarm”keepsflashingontheMainMenu.
☞Itmeanscriticalleakagewhichcausesfailureofvacuumpumping.
Step1.Stopthefreezedryer.
Step2.Checkandmakesurethedoorisclosedtightly,andthereis
noleakagewithallthevacuumtubesoutside/insidethefreezedryer
andconnectors.
*Ifnecessary,somepartsneedtobereplacedtofixleakage.
Step3.Re‐startthefreezedryer
Step4.GotoMainMenu,Press“FORMULA”.Modify“Pre‐freezeTime”from600(minutes)into1(minute).
*Thisisbecausepre‐freezestagehascompletedbeforere‐startanditneedstoskipthisstageafterre‐start.Sothe
pre‐freezestagecanrunonlyfor1minutethengotovacuumpumpingstagequickly.
Step5.GotoMainMenu,press“OPERATION”.OnOPERATIONmenu,press“StopVacu.Alarm”toeliminatevacuumalarm.
Step6.OnOPERATIONmenu,press“Start”torunthefreezedryeringoodconditionwithoutvacuumalarm.
TheProblemissolved.
Pic‐9
600 1
950
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9‐2.Ifvacuumdegreeonthemainmenuislowerthan900(Pa)buthigherthanPre‐vacuumpressuresetbytheuser(for
sample.30Pa)when“VacuumAlarm”keepsflashingonthemainmenu.
Forexample.Vacuumdegreedisplayedonthemainmenuis45Pa(Pic‐10)andpressuresetforPre‐vacuumis30Pa(Pic‐11).
Thereare2reasons:
☞Reason1:Thereisminorleakage.
Solution:
Step1.DoNOTstopthefreezedryer.
Step2.Checkandmakesurethedoorisclosedtightly,andthereisnoleakagewithallthevacuumtubesoutside/inside
thefreezedryerandconnectors.
Step3.GotoMainMenu,Press“FORMULA”.Modify“Pre‐VacuumPressurefrom30(Pa)intoavalue(e.g.60Pa)higher
thanvacuumdegree(e.g.45Pa)asdisplayedonthemainmenu
*Thisisbecausepre‐freezestagehascompletedbeforere‐startanditneedstoskipthisstageafterre‐start.Sothe
pre‐freezestagecanrunonlyfor1minutethengotovacuumpumpingstagequickly.
Step4.GotoMainMenu,press“OPERATION”.OnOPERATIONmenu,press“StopVacu.Alarm”toeliminatevacuumalarm.
Thenthefreezedryercancontinuetoruningoodconditionwithoutvacuumalarm.
TheProblemissolved.
45
30
Pic‐10 Pic‐11
30 60
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☞Reason2:Characteristics(suchaswatercontents)ofthematerialsitselfdoesnotallowtoreachapressure(e.g.30Pa)
assetforpre‐vacuumwhichislowerthanthevacuumdegree(e.g.45Pa)displayedontheMainMenu.
Itmeansthematerialscanfinishfreezedryinginthevacuumdegree(e.g.45Pa)displayedontheMainMenu.Anditis
impossibletoreachthelowerpressure(e.g.30Pa)assetforpre‐vacuum.
Solution:
Step1.DoNOTstopthefreezedryer.
Step2.GotoMainMenu,Press“FORMULA”.Modify“Pre‐VacuumPressurefrom30(Pa)intoavalue(e.g.60Pa)higher
thanvacuumdegree(e.g.45Pa)asdisplayedonthemainmenu
*Thisisbecausepre‐freezestagehascompletedbeforere‐startanditneedstoskipthisstageafterre‐start.Sothe
pre‐freezestagecanrunonlyfor1minutethengotovacuumpumpingstagequickly.
Step4.GotoMainMenu,press“OPERATION”.OnOPERATIONmenu,press“StopVacu.Alarm”toeliminatevacuumalarm.
Thenthefreezedryercancontinuetoruningoodconditionwithoutvacuumalarm.
TheProblemissolved.
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Part 4. System Operation
1.Afterpower‐onThesystementersintoMainMenu(MonitoringInterface)withparametersincludingtimethefreeze
dryerhasrunfromstart,real‐timevacuumdegree(1000Paisshownifhigherthan1000Pa),temperatureofshelves,
coldtrap(workingchamber)andmaterials,currentsectionatcurrentstage,andcurrentworkingstage.
2.Click"FORMULA"forrecipemanagement.Setparametersaccordingtomaterialstobefreezedried.
i. SetPre‐freezingtime(600minutesisrecommended).
ii.Setcoldtraptemperatureandtime(Timingstartswhencoldtrapreachestemperaturesetbytheuser).‐30℃ and3
minutesarerecommended.
iii.Setpre‐vacuumpumpingvalueandtime(Timingstartswhenvacuumreachesvaluesetbytheuser).30Paand30
minutesarerecommended.Ifvacuumdoesnotreachthesetvaluewithin30minutes,thesystemwilldisplayvacuum
abnormalalarm.Insuchsituation,checkdoor,drainvalveandvacuumpumpconnectors.
iv. Setvacuumlimitfordryingstage(Ifvacuumindryingstageexceedsthislimit,heatingisstopped).
Afterfinishingabovesetting,youwillhave2controlmodes(VacuumControlandProgramControl)tochoose.
ProgramControlModeisrecommendedbecausethisModecanbeusedforallthematerialswhileVacuumControl
Modeisnotsuggestedforsomematerialssuchasmilkandflowers.
Pleaserefertodetailsonthenextpage.
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IfVacuumControlModeischosen:
i.PleasesetVacuumUpperLimit,VacuumLowerLimit(Ininitialvacuumprocess.Whenchamberpressure≤VacuumLower
Limit,thesystemstartsheatingandinflating.Whenchamberpressure≧VacuumUpperLimit,thesystemstopsheatingand
inflating.VacuumUpperLimit66PaandVacuumLowerLimit33Paarerecommended.
ii.Settimeforinitialdryingstage.600minutesisrecommended.Wheninitialdryingtimeisreached,thesystementersinto
secondarydryingstage.
iii.Setkeeping(maintaining)pressureandtime.Whenchamberpressure<keepingpressure,timingstarts.Whentimereaches
keepingtimesetbytheuser,thesystementersintothesecondarydryingstage.
iv. Setkeeping(maintaining)temperaturewhichcanbeunderstoodaskeeping(maintaining)timefortheinitialdrying.60℃is
recommended.
Afterfinishingabovesetting,press"Next"tosetparametersforthesecondarydrying.
v. Settimeforsecondarydrying.600minutesisrecommended.
vi.Settemperatureforsecondarydrying.40℃ isrecommended.
IfProgramControlModeischosen:
Theusercanprogramupto18sections.Settemperatureandheatkeeping(maintaining)time.Pleaseinputtotalnumberofall
thesectionsinRUNSECTIONNOaftersettingisfinished.
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3.Temperature‐keeping(maintaining)Stage.Setkeepingtime999min,keeptemperature30℃.
4.AfterfinishingFORMULAsetting,returntoMonitoringMenu(MainInterface),press"OPERATION".
i. Choosecontrolmode(ProgramControlorVacuumControl).Refertoprocedureaboveonthepreviouspageforsetting.
ii. Loadmaterialsintothechamber,closethedoor,checkiftheinflation/drainvalveisclosedtightlyandvacuumpump
tubeisconnectedproperly.
iii. Press"Start'.Thesystembeginsfreezedryingprocess.
iv. Afterautomaticprogramrunningisfinished,Rotatethevacuum/waterdrainingvalvetotheopenposition,then
openthedoorandunloadthefreezedriedmaterials.
OpenPosition
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v. Setdefrosttimeandtemperature,press"DefrostON".120minutesand60℃ arerecommended.
Thissystemallowstheusertocheckandoutputhistoryrecordoftemperatureandvacuum.
InMonitoringMenu(MainMenu),press"TEMP.CONTROL"toviewhistorytemperatureandvacuumchart.Press
"NEXT"and"PREVIOUS"tocheckhistoryrecordatspecifictime.TheusercanalsoinsertaFlashDisk(thisfeatureis
availablesoon)tooutputdatainExcelformat.DONOTsavetoomanyfilesintheflaskdisk. ☞Contactusforvideo.
Itissuggestedtocleardatamonthlysoastoensuredataintegrity.Ifmemoryforthetouch‐screencontrollerisfull,the
systemwillreplacetheearliestdatawithlatestdata.
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Part 5.
HF400/600PLCFreezeDryingSystemAutomaticWorkingFlowChart
预冻
捕水器制冷
预抽真空
一次干燥
解析干燥
Temp.
ProgramOver
满足预冻时间
满足捕水器温度及时间
InProgramTemperatureControlmode：It is allowed to set max. 18 sections of temperature
controlprogram.Aftertemperaturecontrolprogramfinishesrunning, it skips into Secondary
DryingStage.Inthismode,itisallowedtocreateformulaandmaterialname,delete,uploador
downloadtheformula.
In Vacuum Control Mode: When present vacuum is less than vacuum lower limit，it starts
heating.Whenvacuumexceedsvacuumupperlimit,itstopsheating.
When initial drying time is finished, it skips into Secondary Drying stage. Ifpresent vacuum≤
keeping/maintainingpressure,andalsoreacheskeeping/maintainingtime, itskipsdirectlyinto
SecondaryDryingstagewithoutfinishingremainingtimeatinitialdryingstage
Temperatureupperlimit:ItisthemaximumtemperatureallowedforshelfheatingintheInitial
Dryingstage.
Secondary Drying Time: It is running time in the Secondary drying stage. After
secondarydryingtimeisfinished,thevacuumpumpstopsrunninganditentersinto
heat‐keeping/maintainingstage
Heat‐Keeping/MaintainingTemperature: Itisshelfcontroltemperaturein
SecondaryDryingstage.
Heat‐Keeping/Maintainingtime:
Itisdesignedtostopheatingandkeeprefrigerationincasethefreezedryeris
unattendedafterfreezedryingprogramisfinished.
Opentheinflationvalveanddoor,unloadthefreezedriedmaterialsfromthechamber.
Defrost:Setdefrosttimeandtemperature.Shelvesstartsheatingtodefrostautomatically.
ReachPre‐FreezingTime
Pre‐Freezing
ColdTrap
StartsCooling
ReachWater‐CapturingTemperature&Time
Pre‐Vacuum
Reach Pre‐VacuumValue&Time
InitialDrying
SecondaryDrying
Heat‐Keeping/Maintaining
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-35℃ PLC Controller Freeze Dryer (NovaDryer-HF400)
Parameter Setting Formula/Recipe for Various Materials
(Version 20190901)
Fruit &
Vegetable Meat Fruit Juice Milk Seafood
Microbial
Products
& Strain
Flower
&
Blueberry
Leaf Soup Placenta
10 10 10 10 10 10 10 10 10 10
Parameters
(Temp,℃/Time,min)
Pre-Freezing Time (Hr)
Section1 Temp/Time -30/120 -30/120 -30/120 -30/120 -30/120 -30/120 -30/120 -30/120 -30/120 -30/120
Section 2 Temp/Time -10/120 -10/120 -20/60 -30/60 -20/60 -30/30 -33/60 -30/60 -30/60 -20/60
Section 3 Temp/Time -5/60 0/60 -10/120 -25/60 -10/120 -25/60 -32/60 -25/60 -25/60 -10/120
Section 4 Temp/Time 0/60 20/60 -5/120 -20/60 0/120 -20/60 -30/60 -20/60 -20/60 0/60
Section 5 Temp/Time 10/60 30/30 10/120 -15/60 10/60 -15/60 -28/60 -15/120 -15/120 10/120
p
Section 6 Temp/Time 20/30 40/30 20/30 -10/180 20/30 -10/180 -26/60 -10/240 -10/180 20/30
Section 7 Temp/Time 30/30 50/30 30/60 -5/60 30/30 -5/60 -23/60 -5/120 -5/60 30/30
Section 8 Temp/Time 55/720 60/600 45/800 0/60 55/800 0/60 -20/120 0/60 0/60 50/750
Section 9 Temp/Time 45/180 45/180 40/180 5/60 45/180 5/60 -18/120 5/30 5/30 55/180
Sti 10 T /Ti 25/999 35/999 25/999 10/120 30/999 10/120 15/120 10/60 10/120 45/999
Section 10 Temp/Time 25/999 35/999 25/999 10/120 30/999 10/120 -15/120 10/60 10/120 45/999
Section 11 Temp/Time 15/60 15/30 -13/120 20/30 15/60
Section 12 Temp/Time 20/60 20/30 -10/240 30/60 20/30
Section 13 Temp/Time 25/30 25/30 -8/120 40/300 30/30
Section 14 Temp/Time 30/30 30/30 -5/120 45/240 40/300
Section 15 Temp/Time 35/600 35/600 -3/120 35/999 50/800
Section 16 Temp/Time 25/999 25/999 0/180 40/999
Section 17 Temp/Time 3/240
Section 18 Temp/Time 5/300
Section 19 Temp/Time 7/120
Section 19 Temp/Time 7/120
Section 20 Temp/Time 4/999
*A video training course is available upon request.
Note: In case of machine being unattended at completion of cycle, the duration of the final section is set at 999 minutes.
However, it is not necessary to run the final section for 999 minutes. At any time during the final section, the user can remove
the dried materials from the freeze dryer.
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Phone 1300 788 579
Sales & Service Centre
Unit 3, 94 Belgravia Street,
Belmont WA 6104
(08) 9424 2000
For more information and to request a quote contact
one of the Dynapumps offices Australia-wide
Perth - Head Office
88 Belgravia Street,
Belmont, WA 6104
(08)08) 9424 2000
Sydney
Unit 5 / 6 Stanton Road,
Seven Hills, NSW 2147
(02)02) 9624 7888
Brisbane
Unit 7/ 14 Hopper Ave
Ormeau, QLD 4208
(07)07) 5546 7777
Melbourne
Unit 5/39 Heyington Ave
Thomastown, VIC 3074
(03)03) 9464 3039
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