Yamato DC801 User manual

Freeze Dryer
DC801
Instruction Manual
- Fourth Edition -
Yamato Scientific Co. Ltd.
Printed on recycled paper
Thank you for choosing the DC801 freeze
dryer from Yamato Scientific Co., Ltd.
For proper equipment operation, please read
this instruction manual thoroughly before
use. Always keep equipment documentation
safe and close at hand for convenient future
reference.
WARNING!:
Read instruction manual warnings and
cautions carefully and completely before
proceeding.

Contents
1. SAFETY PRECAUTIONS.....................................................................1
Explanation of Safety Symbols...................................................................................... 1
Symbol Glossary ........................................................................................................... 2
Warnings & Cautions..................................................................................................... 3
2. PRE-OPERATION PROCEDURES......................................................5
Installation Precautions & Preparations ........................................................................ 5
Installation Procedures.................................................................................................. 8
3. COMPONENT NAMES & FUNCTIONS ...............................................9
Unit Overview ................................................................................................................ 9
Control Panel............................................................................................................... 10
4. OPERATION PROCEDURES.............................................................11
Pre-freezing................................................................................................................. 11
Main Operation............................................................................................................ 12
Defrost......................................................................................................................... 16
5. HANDLING PRECAUTIONS..............................................................18
6. MAINTENANCE PROCEDURES .......................................................21
Inspection & Maintenance ........................................................................................... 21
7. STORAGE & DISPOSAL....................................................................22
Disposal Considerations.............................................................................................. 22
8. TROUBLESHOOTING........................................................................23
Troubleshooting Guide ................................................................................................ 23
9. SERVICE & REPAIR...........................................................................24
10. SPECIFICATIONS ............................................................................25
Main Unit ..................................................................................................................... 25
Optional Accessories................................................................................................... 26
11. WIRING DIAGRAM...........................................................................27
DC801 ......................................................................................................................... 27
12. REPLACEMENT PARTS..................................................................28
13. LIST OF HAZARDOUS SUBSTANCES...........................................29

1
1. SAFETY PRECAUTIONS
Explanation of Safety Symbols
A Word Regarding Symbols
Various symbols are provided throughout this text and on equipment to
ensure safe operation. Failure to comprehend the operational hazards and
risks associated with these symbols may lead to adverse results as explained
below. Become thoroughly familiar with all symbols and their meanings by
carefully reading the following text regarding symbols before proceeding.
Warning
Caution Signifies a situation which may result in minor injury (Note 2)
and/or property damage (Note 3)
(Note 1) Serious injury is defined as bodily wounds, electrocution, bone
breaks/fractures or poisoning, which may cause debilitation requiring
extended hospitalization and/or outpatient treatment.
(Note 2) Minor injury is defined as bodily wounds or electrocution, which will not
require extended hospitalization or outpatient treatment.
(Note 3) Property damage is defined as damage to facilities, equipment, buildings or
other property. （Note 1 ）Serious injury is defined as bodily wounds,
Symbol Meanings
Signifies warning or caution.
Specific explanation will follow symbol.
Signifies restriction.
Specific restrictions will follow symbol.
Signifies an action or actions which operator must undertake.
Specific instructions will follow symbol.
Signifies a situation which may result in serious
injury or death (Note 1)

2
1. SAFETY PRECAUTIONS
Symbol Glossary
Warning
General
Warning
Danger!: High
Voltage
Danger!:
Extremely Hot
Danger!: Moving
Parts
Danger!: Blast
Hazard
Caution
General Caution Caution:
Shock Hazard!
Caution: Burn
Hazard!
Caution: Do Not
Heat Without
Water!
Caution: May
Leak Water!
Caution: Water
Only
Caution: Toxic
Chemicals
Restriction
General
Restriction No Open Flame Do Not
Disassemble Do Not Touch
Action
General Action
Required
Connect Ground
Wire
Level Installation
Required Disconnect Power Inspect Regularly

3
1. SAFETY PRECAUTIONS
Warnings & Cautions
WARNING!
Never operate equipment near combustible gases/fumes.
Do not install or operate this unit near flammable or explosive gases/fumes. Unit is NOT fire or blast
resistant. Negligent use could cause fire/explosion. Refer to “List of Hazardous Substances” (P.29).
Always ground equipment.
Always ground this unit properly to avoid electric shock.
DO NOT operate equipment when abnormalities are detected.
If smoke or unusual odors begin emitting from unit, or if any other abnormalities are detected, terminate
operation immediately, turn off main power switch (Earth Leakage Breaker - “ELB”) and disconnect
power cable. Continued operation under such conditions may result in fire or electric shock.
DO NOT operate with bundled or tangled power cable.
Operating unit with the power cable bundled or otherwise tangled, may cause power cable to overheat
and/or catch fire.
DO NOT damage power cable.
Damaging the power cable by forcibly bending, pulling or twisting may cause fire or electric shock to the
operator.
DO NOT handle flammable substances without proper ventilation.
Be sure there is adequate ventilation when working with certain flammable substances (such as
ethanol, etc.), which evaporate quickly at or below room temperature, and emit flammable fumes.
Insufficient ventilation may cause a fire or explosion. Refer to “List of Hazardous Substances” (P.29).
DO NOT disassemble or modify equipment.
Attempting to dismantle or modify unit in any way, may cause malfunction, fire or electric shock.
Keep unit upright.
Never attempt to turn or place unit on its side while moving or transporting. Damage to refrigeration
system may result. If briefly tilting unit to one side or the other is unavoidable during transport, refrain
from turning power on for at least 24 hours after positioning unit upright.

4
1. SAFETY PRECAUTIONS
Warnings & Cautions
CAUTION!
DO NOT operate equipment during thunderstorms.
In the event of a thunderstorm, terminate operation and turn off main power switch (ELB) immediately. A
direct lightning strike may cause damage to equipment, or result in fire or electric shock.
DO NOT touch condensate in cold trap.
Condensate and inner surfaces of cold trap may become extremely cold during operation or right after
operation. Avoid contact with bare hands/fingers in order to prevent severe frostbite.
DO NOT touch cooling fins.
Edges of cooling fins are very sharp. Do not contact with bare hands or skin. Laceration injuries may
result.

5
2. PRE-OPERATION PROCEDURES
Installation Precautions & Preparations
WARNING!
1. Choose an appropriate installation site.
● Do not install unit:
・ where installation surface is not
completely level, not even or not clean.
・ in excessively humid or dusty locations.
・ where power supply is erratic.
・ where ventilation is not sufficient
・ where flammable or corrosive
gases/fumes will be generated.
・ where external temperature will exceed
30ºC, will fall below 5ºC or will fluctuate.
・ where there is constant vibration.
・ in direct sunlight or outdoors
Install unit in a location with sufficient space as specified below.
More than
20cm
More than
20cm
Front side
More than 40cm
2. Install unit in a safe, well-ventilated area.
In the event of an earthquake or other unforeseen incident, equipment may unexpectedly shift or
fall, causing injury. Taking preventative steps to install unit in a safe location, away from room
access doors and out of other danger is strongly recommended.
This unit is equipped with an air-cooled refrigerator. Install unit in a well-ventilated or
air-conditioned place so that unit is allowed to sufficiently diffuse heat. Failure to do so may
cause ambient temperature to rise, resulting in possible degraded cooling performance, overload
on the refrigerator, or equipment malfunction.
3. Install in a location free of flammables and explosives.
● Never install near flammables or
explosives. This unit is NOT fire or blast
resistant. Simply switching the main
power switch (ELB) “ON” or “OFF” can
produce a spark, which can relay during
operation, causing a fire or explosion
when near flammable or explosive
fluids, chemicals or gases/fumes.
Refer to “List of Hazardous Substances”
(P.29).
Main
Unit
Explosives
Flammables

6
2. PRE-OPERATION PROCEDURES
Installation Precautions & Preparations
4. Never disassemble or modify. 5. Install on a level surface.
Attempting to disassemble or modifiy this
unit in any way may result in malfunction,
fire or electric shock.
Install unit on a level and even surface.
Failure to do so may result in abnormal
vibrations or noise and damage to the
refrigeration system.
Approximate unit weight is 65kg.
Handle with care. Transport and
installation should always be
performed by two or more people.
6. Ensure adequate amount of unit ventilation.
Do not operate unit with ventilating openings (front, side, rear) obstructed.
Doing so may cause excessive temperatures inside unit, resulting in degraded performance,
malfunction or fire.
7. Install in a dry location.
Install unit where it will be free from fluid spray and other moisture. Failure to do so may result in
malfunction, electrical shock and/or fire.
8. Connect to a proper power supply.
Connect power cable to a suitable facility outlet or terminal, according to the following
electrical requirements.
Electrical
requirements: AC100V±5% 7/6.5A 50/60Hz (15/14.5A when optional pump & heater is
used)
NOTE)
Check the line voltage on outlet or terminal to be used and properly evaluate whether to
utilize a line being shared by other equipment. If unit is not activated by turning on the
main power switch (ELB), take an appropriate course of action, such as connecting unit
to a dedicated power source.
If multiple power cables are connected to a single outlet, input voltage to unit may drop,
causing degraded cooling and temperature control performance.
Modification

7
2. PRE-OPERATION PROCEDURE
Installation Precautions & Preparations
CAUTION!
9. Handle power cable with care.
Never operate unit with power cable bundled or tangled; and do not modify, bend, forcibly
twist or pull on power cable. Doing so may cause fire and/or electrical shock.
Do not risk damage to power cable by positioning it under desks or chairs, or by pinching
it between objects. Doing so may cause fire and/or electrical shock.
Do not place power cable near kerosene/electric heaters or other heat-generating
devices. Doing so may cause power cable insulation to overheat, melt and/or catch fire,
which may result in electric shock.
Turn off main power switch (ELB) immediately and disconnect from facility terminal or
outlet, if power cable becomes partially severed or damaged in any way. Failure to do so
may result in fire or electric shock.
Contact a local dealer or Yamato sales office for information about replacing power cable
if it is damaged.
Always connect power cable to appropriate facility outlet or terminal.
10. Equipment MUST always be grounded properly.
Where no grounding terminal is provided, contact a local dealer, electrician or Yamato sales
office for location-specific electrical requirements.
･Connect terminals securely to facility terminal or to an appropriate connector.
Plugs and connectors are not included with this
unit. Ground unit properly to facility outlet or
terminal as required.
Never connect ground wire to gas lines, water pipes, telephone grounding lines or lightening
rods. Doing so may result in malfunction, fire or electrical shock.
11. Observe wire color designation. See table below.
Confirm that the facility main breaker is OFF before
connecting the round terminals from the power cable. No
power plugs or connectors of any kind are included with
this unit. Where required, purchase an appropriate plug
and properly connect using the round terminals.
Color Facility
Black Live/Hot side
White Neutral side
Green Ground
3(three) Round Terminal for M5 screws
Green (to grounding terminal)
Black (to facility terminal)
White (to facility terminal)

8
2. PRE-OPERATION PROCEDURES
Installation Procedures
1. Unlock caster.
Pull up on lever to release caster lock
(only two front casters are equipped with
locks).
2. Move unit into place for installation.
Wheeling unit over large bumps or crevices
may cause excessive shock to unit or
damage to casters. Use care when moving
unit and obtain assistance, when necessary,
to lift unit over bumps and crevices.
Do not turn or position unit on its side when
lifting.
3. When unit is in place, place caster stops
under casters and push down on lever to
lock caster.
4. Check drain cap
Check to make sure cap is installed on
drain outlet hose.
5. Connect power cable
Be sure main power switch (ELB) is turned OFF. Connect power cable to grounded outlet.
6. Use a vacuum pump having a displacement of 50L/min or more, maximum pressure of 1.0X10-1Pa and
a current rating of 6A or less. Vacuum pump must have a check-valve.
7. Install vacuum valves on all valve openings in the vacuum chamber.
8. Be sure a freezer is available which can maintain samples sufficiently below their eutectic (solidification)
point. Refer to P.11 for explanation on eutectic point.
Caster
Caster Lock
Release
Lock
Drain
Caster Stops

9
3. COMPONENT NAMES & FUNCTIONS
Unit Overview
Front View
Rear View
Cold Trap
Main Power Switch
Serial No. & Rating Sticker
Casters
(two casters in front have stoppers)
Vacuum Gauge
Control Panel
Cooling Vent
Dust Filter
Compound Gauge
Vacuum Port
Drain Outlet
Service Outlets
(for vacuum pump
and optional heater)
Service Outlet Fuse
Power Cable

10
3. COMPONENT NAMES & FUNCTIONS
Control Panel
Part Name Function
①Refrigeration Switch
Activates/deactivates refrigeration system.
Protection delay timer activates system 3 minutes after switch is set
to ON.
May be used to stop defrost function mid-way through process
②Vacuum Pump Switch Activates service outlets, solenoid valve in vacuum line and vacuum
gauge.
③Temperature Display Displays temperature of inner wall in cold trap.
④Vacuum Gauge Decompression (vacuum) strength meter.
⑤Defrost Switch Loosens ice buildup in cold trap.
Operable only with REFRIGERATION switch ON.
⑥Refrigeration Error Lamp Lights when refrigeration system is in overload or when temperature
sensor fails.
④
①
②
③
⑤
⑥

11
4. OPERATION PROCEDURES
Pre-freezing
For the pre-freezing process, freeze samples quickly and completely through, at a temperature
sufficiently lower than sample eutectic (solidification) point*. Freeze as thinly as possible so that
sample will not have a chance to melt before the drying process can dry it. Likewise, external heat
may influence and begin melting samples with a low eutectic table, if it is frozen too thickly in the
container.
Be advised that if throughput is too high, or if the eutectic point of samples is low, melting may give
way to sudden boiling (bumping) which may scatter samples.
When installing containers during a freeze-dry process, following pre-freeze, wait 3-4 minutes
(varies with container and sample types) before installing the next container and opening the
next valve for the next process, and so on until the whole process for all containers is complete.
Making intervals shorter between each individual container process or attempting to install all
containers at once, will cause samples to melt before vacuum pressure is able build again to dry
them.
Eutectic (solidification) Point
If pure water freezes at 0 degree Celsius, a mixed solution of water and other fluids may not
freeze immediately below 0 degrees Celsius, and may simply become soft ice, or not freeze at all,
because of being mixed with fluid(s) having a freezing point below 0.
If temperature continues to fall, the value at which the entire solution uniformly freezes solid is
called the “eutectic point” of that solution.

12
4. OPERATION PROCEDURES
Main Operation
Prepare dryer manifold, vacuum pump, vacuum hose, tandem tube, and other equipment necessary to
operation process.
Example vacuum pump: PD52 (from YAMATO Scientific)
Displacement volume: 50L/min, maximum vacuum pressure: 6.7×10-2Pa,
inlet pipe diameter: 18mm (or equivalent)
1. Turn power ON
ON
Turn "ON" main power switch (ELB).
2. Start refrigeration
Turn "ON" refrigeration switch. Refrigeration system
activates after 3 minutes.
3. Install vacuum chamber.
1. Be sure there is no dust or other contaminants on the trap
seal or vacuum chamber before flask installation.
Damage to or contaminants on chamber and seal weaken
vacuum pressure.
2. Gently place flask mounting vacuum chamber on trap seal.
If vacuum chamber does not sufficiently adhere to trap seal, a
vacuum leak may result.
The above holds true for Manifolds A & B, etc. as well
REFRIG
Flask Mounting
Vacuum Chamber
(Optional)
Trap seal
Manifold A
(Optional)

13
4. OPERATION PROCEDURES
Main Operation
4. Connect vacuum pump
Connect vacuum hose from pump to the vacuum port on
left side of unit.
(Vacuum port outer diameter: 17mm)
(Inside dia. of applicable vacuum hose: 12mm X outer
diameter 30mm)
Connect the opposite end of the vacuum hose to vacuum
pump inlet.
Seal strength may be improved by applying vacuum seal
grease (silicon grease compound manufactured by TORAY,
H.V.G, etc) to the inside of vacuum hose opening.
5. Connect vacuum pump to power
outlet on back of unit
6
A
2
A
Connect vacuum pump power cable to the 6A power outlet
on back of DC unit.
Keep vacuum pump switch ON.
Do not go above 8A total on 6A outlet.
6. Close valves.
Turn all valves so that surface reading “VENT” is in the top
position, closing chamber side path.
7. Turn pump switch ON
When the trap is sufficiently cooled (time required to reach
minimum temp has passed), start the vacuum pump.
Time required to minimum temperature (-80°C):
DC801: 60 minutes or less
Base on external temperature of 20°C, no load
This time is a guideline and may vary. (There will be
condensation near the bottom of vacuum chamber when
sufficient time has passed)
"VENT"
VAC PUMP

14
4. OPERATION PROCEDURES
Main Operation
8. Check vacuum gauge
Confirm by looking at the vacuum gauge, that vacuum
chamber has sufficiently decompressed. (20Pa or less)
9. Install sample container and open
valve
Install the pre-frozen sample container on the vacuum
valve, turn the valve knob so that “VAC” is in the top
position, opening the chamber side path.
Sample container is decompressed and drying process
begins.
10. Install the next container
When a vacuum valve is set from “VENT” to “VAC”, the
chamber interior is pressurized. To process multiple
samples, wait (approx. 3-4 min.) until the pressure has
returned before turning the next vacuum valve from
“VENT” to “VAC”.
If multiple samples are processed at one time,
decompression will decrease and pre-frozen samples will
begin melting, possibly causing container to break.
11.End process
Process may be ended after confirming sample status and
making sure process has finished normally.
"VAC"
First
Next

15
4. OPERATION PROCEDURES
Main Operation
12. Close vacuum valve
When process has finished, turn valve from “VAC” to
“VENT” (“VENT” in the top position) to normalize
pressure in the sample container and remove the
container.
Hold container securely when removing, so that it is not
dropped.
13. Normalize chamber pressure
When the drying process has completed for all
samples, and all containers have been removed, turn
one of the vacuum valves gradually until “VAC” is in the
top position. This returns pressure inside the chamber
to normal.
14.Turn vacuum pump OFF
Turn the vacuum pump switch OFF, after chamber
pressure has normalized.
"VENT"
"VAC"
VAC PUMP

16
4. OPERATION PROCEDURES
Defrost
1. Remove chamber
Remove the flask mounting vacuum chamber from
the trap.
If ice has formed on trap wall, press the defrost
button with the REFRIG switch ON.
2. Remove ice from trap
When ice has melted sufficiently to remove, do so
by pulling up on handle and turn OFF the defrost
switch.
Defrost auto stop activates after approximately 45
minutes and the defrost lamp goes out.
To terminate the defrost function mid-way, turn the
REFRIG switch OFF.
3. Drain water
Remove the drain hose cap, and drain remaining
water from the trap into a drain basin or other
receptacle.
Drain Hose
Handle
Ice
Flask mounting
vacuum chamber

17
5. HANDLING PRECAUTIONS
Defrost
4. Stop refrigeration system
OFF
1. Turn "OFF" the refrigeration switch.
2. Turn "OFF" the main power switch (ELB).
Cooling curve (reference data)
Display temperature with the trap empty (no load)
REFRIG REFRIG
Room temp
Room temp
100V AC 50Hz
Time (min)
Temperature (℃)

18
5. HANDLING PRECAUTIONS
WARNING!
DO NOT operate equipment when abnormalities are detected.
If unit begins emitting smoke or abnormal odors for reasons unknown, turn off main power (ELB)
immediately, disconnect power cable from power supply, and contact Yamato sales office for
assistance. Continuing to operate without addressing abnormalities may cause fire or electric
shock, resulting in serious injury or death. Never attempt to disassemble or repair unit. Repairs
should be always be performed by a certified technician.
DO NOT handle flammable substances without proper ventilation.
Be sure there is adequate ventilation when working with certain flammable substances (such as
ethanol, etc.), which evaporate quickly at or below room temperature, and emit flammable fumes.
Little or no ventilation may cause a fire or explosion resulting in serious injury or death. Refer to
“List of Hazardous Substances” (P.29).
CAUTION!
Cold trap capacity.
Maximum cold trap capacity for DC801 is approximately 1.0L. Exceeding this capacity may
severely degrade performance.
DO NOT climb on equipment.
Do not attempt to climb onto unit or substitute it for a proper step ladder. Units are not designed
to support bodily weight and damage may result. In addition, unit may become unstable and tip
over or fall resulting in equipment damage, serious injury or death.
DO NOT place objects on equipment.
Do not place any objects on unit, which may fall and cause personal injury.
DO NOT operate equipment during thunderstorms.
In the event of a thunderstorm, turn off main power switch (ELB), and disconnect power cable
immediately. A direct lightning strike may cause equipment damage, fire or electric shock,
resulting in serious injury or death.
Overnight and extended storage.
Whenever unit is not in operation, stored overnight or placed in storage, always turn off main
power switch and disconnect power cable. Drain any fluid collected in the cold trap if unit is going
to be out of service for an extended period.
Power supply voltage.
Power supply voltage must be within +/-5% of the rated voltage.
DO NOT use solvents.
The seals contained in this unit is made from chloroprene rubber and may be damaged by acids,
halogens, aromatics, esters, and oxo solvents. Do not use these compounds with unit.
Starting/restarting refrigeration
When the refrigeration switch is turned from OFF to ON or when refrigeration is resumed by
turning ON the main power switch, a timer delays operation for three minutes to protect the
refrigeration system. Note that this is NOT a failure.