Thermo Scientific ModulyoD User manual

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Section Section Title — Technical Data Page
2.0 Technical Data 13
2.1 General 13
2.2 Refrigeration System 13
2.3 Electrical Data 13
2.4 Construction Details 14
2.4.1 Legislation and Standards 14
2.4.2 Constructions Materials 14
2.5 Vacuum Pump Requirements 14
©2001 Thermo
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Table of Contents
Section Section Title — Introduction Page
1.0 Introduction 4
1.1 Scope of the Manual 4
1.2 General Description 4
1.2.1 The ModulyoD 4
Figure 1-ModulyoD 5
Figure 2-ModulyoD Back view 5
1.2.1.1 The Accessory Flange & Condenser Chamber 6
1.2.1.2 The Refrigeration System 5
Figure 3-Inside ModulyoD 7
Figure 4- Refrigeration Circuit Diagram 7
1.2.1.3 User Interface 8
Table 1-Control Panel Description 8
Figure 5-ModulyoD Control Panel 9
Figure 6-Temperature Progress Bar 9
Figure 7-Vacuum Progress Bar 9
1.2.1.4 Front Fascia 9
1.2.1.5 Connections 10
Table 2-Drain Outlet Description 10
1.2.1.6 Condenser Extension Assembly 10
Figure 8-The Condenser Extension Tube 11
1.3 Protection Devices 11
1.4 Applications 11
1.4.1 Introduction 11
1.4.2 The Freezing Process 12
1.4.3 The Drying Process 12
1.4.4 Vapor Trapping 12

Table of Contents
Section Section Title — Installation Page
3.0 Installation 15
3.1 Unpack and Inspect 15
Table 3- Checklist of Components 15
3.2 Site Preparation 15
3.3 Connect the ModulyoD to the Electrical Supply 16
3.4 Connect the Vacuum Pump 16
3.5 Connect a Vacuum Pump to the ModulyoD 16
Figure 9-Connect a VLP195FD or VLP120 Pump to the ModulyoD 17
3.6 Pump Outlet Safety 17
3.7 Test After Installation 17-18
Section Section Title — Operation Page
4.0 Operation 19
4.1 Safety 19
4.2 Sequence of Operation 19
Table 4-Sequence of Operation 19
4.3 Prepare the ModulyoD 20
4.4. Fit the Sample Container and Other Accessories 20
4.5 Pre-Cool the ModulyoD 20-21
4.6 Drying 21-22
4.7 Shut Down 22
4.8 Defrost the ModulyoD 23
4.9 Operation With No Load 24
Section Section Title — Maintenance Page
5.0 Maintenance 24
5.1 Safety 24
5.2 Precautions 24
5.3 Refrigerant Leaks 25
Section Section Title — Accessories Page
6.0 Accessories/Drying Accessories 25
Section Section Title — Warranty & Appendices Page
7.0 Warranty and Liability 26
Appendix A - Using the ModulyoD as a Cold Trap 26
Appendix B - Decision Tree 27
Freeze Drying User’s Log28
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Caution - refer to accompanying documents
Caution - risk of electric shock
Caution - hot surface
This manual provides installation and operation instructions for the Thermo Electron
ModulyoDFreeze Dryer, abbreviated to ModulyoD in the remainder of this manual. You
must use the ModulyoD as specified in this manual.
Read this manual before installing and operating the ModulyoD. Important safety infor-
mation is highlighted as WARNING and CAUTION instructions; you must obey these
instructions. The use of WARNINGS and CAUTIONS is defined below.
WARNING: Warnings are given where failure to observe the instruction could
result in injury or death to people.
CAUTION: Cautions are given where failure to observe the instruction could
result in damage to equipment, associated equipment and process.
In accordance with the recommendations of IEC1010, the following warning symbols
may appear on the freeze dryer:
1.0 INTRODUCTION
1.1 SCOPE OF THE MANUAL
The ModulyoD is the ice condenser section of a freeze drying system. It is designed
specifically for freeze drying biological samples and pharmaceutical preparations in a
laboratory environment. The ModulyoD, when used in conjunction with a vacuum source
and manifold or other sample container, forms a complete freeze drying system. The
ModulyoD may also be suitable for use as a low temperature (-50 °C.) vapor trap.
Please refer to Appendix A for specific limitations regarding the use of the ModulyoD as
a vapor trap.
The ModulyoD is used with a variety of optional accessories to freeze materials in bulk
trays, flasks, tubes, vials or ampules. These optional accessories are described in
Section 6.0 and depicted inAppendix B. The ModulyoD may also be used as a low tem-
perature vapor trap (cold trap) for a variety of devices. These include vacuum concen-
trators, rotary evaporators and vacuum ovens.
The ModulyoD itself is made of three basic parts, the condenser chamber, a refrigera-
tion system and the user interface. The refrigerant used in the ModulyoD is CFC free.
All ModulyoD components are housed in a steel cabinet that is designed for bench-top
use. The major components of the ModulyoD are described in the following sections.
(Please refer to Figures 1 and 2 on page 4 for the location of each component.)
1.2 GENERAL DESCRIPTION
1.2.1 THE MODULYOD

Figure 1 – MODULYOD
1. Condenser Chamber Accessory Flange & Condenser Chamber
2. Steel Cabinet with Refrigeration System
3. User Interface
4. Front Fascia
5. Drain Outlet
6. Drain Valve
7. Vacuum Port
5
47
6
5
2
Figure 2 – MODULYOD BACK VIEW
2
Power IEC Outlet
to Vacuum Pump
1
Power IEC Inlet 3
RS232 Port
4
Power Switch
with Circuit Breaker
3
1

6
Refer to Figure 3, on page 6 for the location of components of the refrigeration system
on the ModulyoD.
NOTE: There are no longer user-serviceable parts inside the ModulyoD refrigeration
system.
The condenser chamber is cooled by refrigerant, which evaporates in the copper cool-
ing coil wound externally around the chamber. The thermo expansion valve (item2) pro-
vides excellent performance to the system. The compressor (item1) is a high-capacity,
air-cooled, hermetically sealed unit.
A suction-line accumulator (item 3) in the return line from the cooling-coil to the com-
pressor prevents slugs of liquid refrigerant, which might cause damage, from reaching
the compressor.
A filter dryer (item 4) in the line between the liquid receiver (item 5) and the expansion
valve absorbs any residual particulate and water contamination in the system. The fil-
ter dryer does not need to be serviced or replaced.
The electrical fan (item 6) simultaneously cools down the condenser coil (item 7) and
the compressor.
See Section 2.2 on page 12 for refrigerant type and charge.
1.2.1.2 THE REFRIGERATION SYSTEM
The accessory flange and condenser chamber are made entirely of stainless steel.
The chamber itself is a thin walled cylinder with a dish shaped bottom. It has a total
capacity of 5 liters of ice. The accessory flange is a large diameter flat circular plate
located immediately above the chamber. The accessory flange is designed to accept
a wide variety of accessory items. A large opening in the center of the accessory
flange provides easy inspection, cleaning and defrosting of the condenser chamber. It
also facilitates high vacuum pumping rates. Acircular cooling coil wrapped around the
outside of the condenser chamber cools the walls of the chamber. This coil is cooled
to approximately -50 °C under normal operating conditions with no load applied. At
this temperature most water vapor will condense and freeze on the chamber walls.
1.2.1.1 THE ACCESSORY FLANGE & CONDENSER CHAMBER

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Figure 3 – INSIDE MODULYOD
3
2
4
5
7
16
1. Compressor
2. Thermo Expansion Valve
3. Suction-line Accumulator
4. Filter Dryer
5. Liquid Receiver
6. Fan
7. Condenser Coil
Figure 4 – REFRIGERATION CIRCUIT DIAGRAM

Table 1 – CONTROL PANEL DESCRIPTION
Control Figure # Item # Use
The user interface is a membrane panel with two indicator bars, two digital displays and
two pushbutton actuators. It is located on the upper sloping surface of the front fascia of
the ModulyoD. Through this interface the user will switch on and off and moving refrig-
eration and vacuum. Figure 5, Figure 2 and Table 1 (below) locate and describe, in
detail, the function of each item.
1.2.1.3 USER INTERFACE
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To switch refrigeration system on and off.
To show temperature of the condenser chamber in °C.
When the temperature of the condenser chamber is equal to
or higher than ambient temperature, ‘rt’ is displayed, which
stands for ‘room temperature’.
The lamp is on when the refrigeration system is on.
The temperature indicator bar is a multicolored display
designed to indicate operating status from a distance. Green
indicates a temperature at or near minimum (approximately -
40 °C.). Amber bars indicate temperatures progressing from
approximately -40° to -7°. Red bars indicate temperatures pro-
gressing from -7° to ambient (see Figure 6, page 8).
To switch vacuum pump on and off if the pump is plugged
into auxiliary power outlet of the ModulyoD (see Section 3.5,
page 15).
The lamp is on when the vacuum pump is on.
To show absolute pressure in the condenser chamber.
Readings start when pressure is less then 50 mbar and are
in millibars down to 1.0 millibar. When the vacuum pressure
drops below 1.0 millibar, the pressure will then be displayed
in micro-bars. When pressure is above 50 mbar, ‘Hpr’ is dis-
played, which stands for ‘High pressure’.
The vacuum indicator bar is a multicolored display designed
to indicate operating status from a distance. Green indicates
a pressure at or below 1mbar. Amber bars indicate
pressures progressing from approximately 1 to 13 mbar.
Red bars indicate pressures progressing from 13 to 52
mbar, (see Figure 7, page 8).
To switch the ModulyoD on and off.
Fridge button 5 1
Fridge On lamp 5 2
Vacuum progress bar 5 8
Mains switch with 2 4
circuit breaker
Vacuum level display 5 7
Vacuum pump on lamp 5 6
Vacuum pump button 5 5
Temperature progress 5 4
Temperature display 5 3

1
2
4375
6
Figure 5 – MODULYOD CONTROL PANEL
See Table 1, page 7, for description of items.
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The front fascia forms the front of the ModulyoD cabinet. The user interface is
located on the upper right-hand portion of this surface. The drain outlet, drain
valve and vacuum port are located on the lower left-hand portion.
1.2.1.4 FRONT FASCIA
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Temperature Color
°C
Figure 6
TEMPERATURE
PROGRESS BAR
Pressure Color
mbar
Figure 7
VACUUM
PROGRESS BAR
T<-40
-40<T<-34
-34<T<-21
-21<T<-7
-7 <T<+7
7 <T
Green
Amber
Amber
Amber
Red
Red
H<1.0
1 <H<3.95
3.95 <H<6.58
6.58 <H<13.16
13.16<H<52.6
52.6 <H
Green
Amber
Amber
Amber
Red
Red

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Figure 1 (Page 4) and Table 2 locate and describe, in detail, the function of the drain out-
let, drain valve and vacuum port. Figure 2 and Table 2 locate and describe the electrical
connections.
1.2.1.5 CONNECTIONS
The ModulyoDis shipped with the condenser extension assembly installed (see Figure 8).
This extension assembly is necessary to prevent the formation of ice in the vacuum pump
connection. The extension assembly should only be removed when working with the Spin
Freezer 96 freeze drying accessory (part numbers F05637000 or F05637115).
1.2.1.6 CONDENSER EXTENSION ASSEMBLY
Table 2 – DRAIN OUTLET DESCRIPTION
Connection Figure # Item # Use
Vacuum port 1 7 To connect your vacuum pump to the ModulyoD
Drain valve 1 6 Close the valve (turn it fully clockwise) to isolate the
condenser chamber from the drain outlet. Open the
valve (turn it anti-clockwise) to admit air into the
vacuum system, and to drain water from the condenser
chamber after it has been defrosted.
Drain outlet 1 5 This outlet is used to drain water from the ModulyoD
during defrosting of the condenser chamber. The outlet
is also used to admit air into the vacuum system.
Power IEC 320 inlet 2 1 To connect the ModulyoD to an external power source.
Auxiliary power 2 2 To connect your vacuum pump to the IEC 320 outlet
power supply which will enable the pump to be
operated directly from the ModulyoD.
RS232 port 2 3 To connect the ModulyoD to a computer or chart
recorder.