Lyophilizer Manual

Operators Manual
for
VirTis Model:
FREEZEMOBILE™ 25 and 35
Freeze Drying Systems
SP INDUSTRIES
815 Route 208
Gardiner, NY 12525
800-431-8232 z 845-255-5000 z Fax 845-255-5338
Virtis Freezemobile 25 and 35 Freeze Drying System Manual: Rev 3a 8/05
Operators Manual - Freezemobile 25 or 35
TABLE OF CONTENTS
Page
Inspection upon arrival 2
Warranty Policy 3
Introduction 4
Operating Principles 5-7
Installation Requirements 8
Sentry 2.0 Control 11
Operating Instructions 20
Optional Accessories 22
General Maintenance 30
Trouble Shooting 32
Spare Parts List 34
1
SP Industries
815 Route 208, Gardiner, NY 12525
Phone 800-431-8232 • 845-255-5000 • Fax 845-255-5338
Rev: 3a, 8/05
INSPECTION
1. Inspect contents of this shipment immediately upon arrival. Check packing material
for possible small accessory items. If damage is obvious, DO NOT ACCEPT ship-
ment from carrier without a signed notification of damages.
2. When concealed damage and/or loss is discovered, contact the delivering carrier
immediately to make an inspection report. Keep the contents and packing material
and any paperwork intact until the written report is obtained.
a. If your shipment is F.O.B. destination, file your claim with SP

Industries at the address below with the inspection report and other
supporting documents.
b. If you shipment is F.O.B. factory, file your claim with the delivering
carrier, accompanied by an inspection report and other supporting
documents.
SP Industries will cooperate in the matter of collecting your claims, but we are not re-
sponsible for the collection or free replacement of the material. Replacement parts will
be shipped and invoiced to you, making them a part of your claim.
2
SP Industries
Phone 800-431-8232 • 845-255-5000 • Fax 845-255-5338
Rev: 3a, 8/05
LIMITED WARRANTY
SP Industries warrants, that the product will be free from defects in material and work-
manship when properly installed in accordance with written instructions and operated
under normal and proper use and service, for a period of twelve months from the date of
installation of the product or 15 months from the date of shipment, whichever occurs
sooner. Additionally, the refrigeration system will be warranted for a period of 24
months under normal and proper use.
SP Industries sole responsibility under this warranty will be to repair or replace, at SP

Industries option, any product which SP Industries determines to be nonconforming or
defective within the warranty period, provided that Buyer notifies SP Industries of the
defect immediately in writing. SP Industries shall have no responsibility for unauthorized
repairs, replacements, or product modifications or any product failures resulting from
such unauthorized repairs, replacements or product modifications negligently or other-
wise made by persons other than SP Industries’ employees or SP Industries’ authorized
representatives. SP Industries shall have no responsibility for ordinary wear and tear,
erosion, corrosion, unintended use, misuse, abuse or improper handling, operation,
storage or maintenance by Buyer or any third party.
This warranty covers the costs of parts and labor to repair or replace defective product
at Seller’s factory. This warranty does not cover transportation charges to ship the
product to and from Seller’s factory or the costs of travel, room and board if SP Indus-
tries’ employees conduct repair at Buyer’s location. In lieu of repair or replacement at
SP Industries’ factory, SP Industries may, in its discretion, authorize a third party to per-
form the repair or replacement at Buyer’s location, at SP Industries’ sole expense. No
product should be returned to SP Industries without prior approval of SP Industries.
Except as expressly set forth above, SP Industries does not make and expressly
disclaims any and all warranties of merchantability or fitness for a particular pur-
pose and any other warranty, express or implied, with respect to the sale, installa-
tion, design or use of its products, and SP Industries shall not be liable for any
punitive, incidental or consequential damages resulting from the use of or any
defects in its products.
3
SP Industries
Phone 800-431-8232 • 845-255-5000 • Fax 845-255-5338
Rev: 3a, 8/05
INTRODUCTION
Thank you for choosing a VirTis FreezemobileTM for your freeze drying needs. In keep-
ing with our traditions of quality, reliability, and technical innovation, your new
Freezemobiles have many exclusive features for convenient and trouble-free operation.
The microprocessor based Sentry 2.0 monitor system with “Auto” Feature controls your
drying process with the touch of a button. You’ll have full visibility of our smooth wall
stainless steel condenser. And, whichever refrigeration system you chose, you can rest
assured knowing that you have our exclusive two year refrigeration system warranty.
All our designs are sodium azide proof and we have many valuable options. All of this
combines to make a system that is standardized yet flexible to suit your particular
needs.
This rugged, easy-to-use VirTis Freezemobile will give years of dependable, trouble-free
service. Your VirTis Freezemobile has been carefully designed, built and tested to
make sure you get a quality, high performance freeze dryer.
Please take the time to read the INSTALLATION and OPERATION sections of this
manual before attempting operation, and refer to the MAINTENANCE section to keep
your freeze dryer in top running condition. The OPERATING PRINCIPLE SECTION is
a helpful outline of mechanical functions -- especially useful when training a new opera-
tor.
The Freezemobile is a service module designed to operate with a wide variety of prod-
uct manifolds or chambers. Please consult the separate instructions that came with
your manifold or chamber for complete information.
It’s a good idea to keep this booklet on hand for quick reference, but if you can’t find the
answer to your problem here, please call and we’ll be glad to help.
4
SP Industries
Phone 800-431-8232 • 845-255-5000 • Fax 845-255-5338
Rev: 3a, 8/05
OPERATING PRINCIPLE
The VirTis Freezemobiles are designed to remove the aqueous solution or other sol-
vents of product materials under controlled conditions. The four basic requirements in
this process are:
FREEZING
The rapid cooling of the product, to a point below its eutectic or collapse temperature.
(A compound’s eutectic is the common freezing point for all of its components).
VACUUM
Removal of air and other non-condensable vapors from the chamber to facilitate vapor
migration.
HEATING
Heat input to the frozen product to speed the drying process.
CONDENSING
Trapping of water vapor molecules in the form of ice on the condenser surface.
The following is a brief description of the four basic requirements of freeze drying.
1. FREEZING
The main reason to pre-freeze a product is to lock its particles into a solid
matrix so that water and other solvents can be removed without causing
physical or chemical changes to the compound. Freezing the product to
below -40°C is usually sufficient.
Depending on the drying manifold being used, pre-freezing for this unit is
done by one of two methods. Chamber units with shelves (Virtis Unitop™)
have the ability to pre-freeze right on the shelf, while manifold heads re-
quire separate pre-freezing. Instructions for freezing on the chamber
shelves are given in the manual supplied with the chamber. Instructions
for shell freezing of flasks are found later in this manual.
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SP Industries
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Rev: 3a, 8/05
2. VACUUM
The purpose of the vacuum system is to evacuate all non-condensable
gasses from the drying chamber. This reduces the resistance encoun-
tered by water vapor molecules migrating from the product to the con-
denser. It also encourages the vapor pressure differential necessary for
sublimation and helps to prevent oxidation by removing air.
Your vacuum pump is equipped with two stages for generating the high
vacuum required in the freeze drying process. The two stages are repre-
sented inside the pump by two cylindrical chambers containing off-set,
concentrically driven rotors. As the rotors are driven, sliding vanes fitting
into slots in each rotor allow a volume of gas to be captured, compressed
and then exhausted.
The pumping unit (2 stage) is submerged in a high quality, specially com-

pounded, low pressure oil. This insures a vacuum-tight seal between
stages and acts as a coolant and lubricant for the pump’s moving parts. A
conveniently located sight glass makes quick checks on the oil level easy,
and the gas ballast (see pump booklet) helps prevent oil contamination
while pumping condensable vapors, reducing the number of necessary oil
changes.
3. HEATING
Controlled heat is supplied to the frozen product in the drying chamber
and is not directly controlled by the base unit. When flasks are dried on a
manifold, the ambient (or room temperature) air surrounding the flasks will
normally supply enough heat.
Heat is applied to the frozen product to maintain vapor migration from the
product to the condenser -- supplying the necessary energy to drive off
vapors, insuring continued sublimation.
4. CONDENSING
When water vapor molecules leave the product ice, they migrate toward
the low pressure areas in the vacuum system -- first to the area just above
the product ice, then to the low pressure area surrounding the condenser.
Upon contacting the condenser, the vapors give up their heat energy and
turn to ice.
The Freezemobile’s condenser is fully visible through its clear acrylic door.
The condensing surface is cylindrical in shape, made of 316L stainless
steel and has refrigeration coils wrapped around its outer surface.
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Rev: 3a, 8/05
Heavily insulated with polyurethane foam, it is further enclosed by a metal

shield. The air cooled refrigeration unit draws air through the grille at the
front of the cabinet and warmed air exits at the back.
The refrigeration system automatically seeks the lowest possible tempera-

ture commensurate with the load. There are, however, certain solvents
and acids that can’t be trapped at normal condenser temperatures. If
these are encountered in large quantities a unit with a lower temperature
refrigeration system may be necessary.
7
SP Industries
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Rev: 3a, 8/05
INSTALLATION
1. Check voltage, phase, frequency and amperage as listed on the serial tag,
against your available electric supply; your power supply must be adequate
and match that of your unit.
2. Position unit on a firm level floor, and in an area providing adequate air circu-
lation. Its back should be at least 4 inches away from the wall. The ideal
maintained room temperature is a constant 20°C (68°F) for efficient operation.
Warmer ambient temperatures may affect system performance.
SET UP for all Freezemobile 25 and 35 Liter Freeze Dryers
1. The refrigeration system compressors may be mounted on shock absorbent

springs. Check to see if you have compressor spring mounts. If so, use a ½”
wrench to loosen shipping hex nuts on the spring mount bolts. These were
tightened prior to shipment. To do this, turn them counterclockwise until the
top of the nut is flush with the top of its bolt. This will float the compressor on
the springs preventing vibration from extending to the cabinet. To reach all of
them, it may be convenient to work through the back, front grille and/or side
panels.
2. If your unit was purchased with a vacuum pump, it is installed inside the op-
tional vacuum pump module. Remove the shipping plug in the exhaust port
and make sure the vacuum pump is plugged into the receptacle marked
VACUUM. Unbolt and discard the shipping hold-down bolts, leaving the
pump free to be moved if necessary.
3. Check the vacuum pump oil level. The pump is shipped with oil in it. Add oil
only if necessary. DO NOT OVERFILL! The oil level normally should be
halfway up the sight glass.
NOTE: For your protection and well-being, we suggest your facility make ar-
rangements for an adequate vacuum pump exhaust system. Pump vapors
can be quite unpleasant in the lab and cannot be tolerated in a cleanroom.
Exhaust lines should have an I.D. size no smaller than that of the pump. Oil
mist reducing filters are available, a hood may be used, or the pump can be
vented to the outside.
The exhaust line should go horizontally from the pump to a “T” with drainable
trap, then 90 vertical to outside vent. Place trap as close to the pump as pos-
sible.
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SP Industries
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Rev: 3a, 8/05
4. Open the condenser door. A very light film of High Vacuum Grease was ap-
plied to the front contact surface of the condenser gasket prior to factory test-
ing. Only a “sheen” on the surface is needed. There should be no visible
layer. Check often to make sure this film is intact. Never grease the inside of
the gasket where it grips the condenser lip.
5. Check one final time that voltage, amperage and frequency of your power line
match those specified on the serial tag. Connect the line cord to the proper
electrical outlet.
6. Turn main power switch (located at the rear of the unit near the power cord
connection) to “on” position. The Sentry 2.0 monitor will now display the Syn-
optic Screen.
7. The Sentry displays condenser temperature, vacuum (microbar (µBar),

millitorr (mTorr), and/or Pascals (Pa), ambient temperature. If your unit is
equipped with a shell bath, its temperature will also display.
8. The system has a Synoptic LCD display and a graphical LED display that
visually reflects condenser temperature and vacuum level.
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SP Industries
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Rev: 3a, 8/05
1. Condenser Temperature:
The following temperatures are represented by each LED on the

graphical display.
LED Temp. Color
1 10 Red
2 0 Red
3 -10 Red
4 -20 Amber
5 -30 Amber
6 -40 Green
7 -50 Green
2. Vacuum
The following vacuum set points are reflected graphically.
LED Vacuum (MT) Color
1 2000 Red
2 1000 Red
3 500 Amber
4 200 Amber
5 100 Green
6 50 Green
7 20 Green
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SP Industries
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Rev: 3a, 8/05
Sentry 2.0 CONTROL
The Sentry 2.0 is the central control center for your new freeze mobile. It’s powerful mi-
croprocessor and custom programming offers a wealth of user-customized features as
well as intuitively easy operation.
The interface membrane and display is broken into three primary areas. The first is the
graphical wave and alarm LED, provide the user with a quick and easily identifiable
method for checking the system status. Second, the tactile buttons located on the front
of the membrane allows the user to activate specific functions and navigate through the
menus located within the LCD display. Third is the LCD display, which shows the cur-
rent status of the unit as well as allows adjustment of alarm and control parameters as
well as system configurations.
Button Functions
Up\Down (+/-) Buttons

The up and down buttons allow the user to navigate within the menus and to increase
and decrease the set point values located within the LCD display.
MENU Button
The MENU button performs a number of functions. During an alarm condition pressing
the MENU button will temporarily silence, but not clear the alarm. If the synoptic screen
is displayed within the LCD display, pressing the MENU button brings up the main
menu. While in the user menu, the MENU button acts as an enter key and allows fields
to be adjusted (MENU = ENTER).
COND Button
The COND button activates the refrigeration system. This will provide cooling of the va-
por condenser as well as the optional shell bath, if provided.
VAC Button
The VAC button starts the vacuum pump and opens the VBS valve allowing the system
to be evacuated. Vacuum level control can be selected and set within the user options
screens.
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SP Industries
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Rev: 3a, 8/05
AUTO Button
AUTO button starts the refrigeration and vacuum systems in a proper sequence. The
vapor condenser refrigeration will cool to the condenser setpoint and then automatically
start the vacuum pump.
DEFR Button
DEFR button activates the condenser defrost. The hot gas defrost, contained in this Freezemo-
bile unit, is directed to the condenser walls to loosen the ice. This permits the quick removal of
the ice plug(s) for fast turnaround. This will also activate the refrigeration system.
Note: Defrost is “locked out” while any other function is on.
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SP Industries
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Rev: 3a, 8/05
LCD display functions

The LCD display will by default display the system synoptic screen.
Note: The actual synoptic screen as well as any other screen depicted may vary slightly from those
displayed within your unit based upon purchased option.
Main Menu
The synoptic screen gives a visual display of the current operation and status of the
unit. Alarm messages, run time and system status are conveniently displayed. Pressing
the Menu button while in the synoptic screen brings you to the main menu. If the unit is
idle within any menu for more than three minutes the system will default back to the
synoptic screen.
∧ Main Menu
User Options >

Alarms >
Set Points >
Vacuum Control 0000
Purge Off
Bath Off
Navigation within the menu screens is accomplished by using the Up/Down (+/-) arrow
buttons as well as the MENU button. The up/down (+/-) buttons allows the user to scroll
the flashing cursor to their desired function or allows the value of a set point to be
changed. The MENU button is used to select the desired item or is used as an ENTER
key. The ∧ symbol located within the upper left corner of the screen allows the user to
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SP Industries
Phone 800-431-8232 • 845-255-5000 • Fax 845-255-5338
Rev: 3a, 8/05
go to the previous screen. The > symbol allows the user to go to the next screen within
a selected option.
User Options
∧ User Options
Vacuum Control VLC

Temperature Units ºC
Vacuum Units Torr
Relay Test >
Vacuum Pump Maintenance >
Vac Ctrl depicts the currently set method used for vacuum level control. There are three
options, None, VLC or Power Save. A None value within the field disables the vacuum
level control and will not control vacuum independent of set point. The VLC option al-
lows gas to be bled within the system through a control valve to maintain vacuum set
point. The third option, Power save utilizes the VBS valve and vacuum pump to turn off
power to the vacuum pump and VBS valve thus isolating the system and maintaining
the pressure. As the system pressure goes up, the vacuum pump will be re-energized
and the system will be pulled back down.
Temp Units displays the current setting for indicating the temperature values. The tem-
peratures can be displayed in either f (Fahrenheit) or C (Celsius)
9
f = C + 32
5
5
C= ( f − 32 )
9
Vacuum Units display the current setting for indication of the system pressure. System
pressure can be displayed in mTorr, µbar and Pascal.
Relay Test allows for diagnosis of possible unit problems.
∧Solid State Relay Output Test

SSR1 SSR2
-Vacuum -Purge
-VBS -Bath
-Comp1 -Comp2
-Defrost -Alarm
∧-SSR1 ∨-SSR2 Menu-Exit
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Rev: 3a, 8/05
Relay positions that are preceded by a highlighted box indicate the output is active. To
test a relay bank, simply press the up or down button and each of the outputs on the re-
lay bank will fire sequentially.
Vacuum Pump Maintenance screen is used to adjust alarm parameters and current time
durations used to draw attention to necessary vacuum pump maintenance such as oil
changes.
∧ Vacuum pump Maintenance
Alarm Set Point: 0100

Current Hours: 0000 min: 007
The alarm set point is the number of hours of continuous operation the vacuum pump
can run before the vacuum pump maintenance alarm will be generated. The default fac-
tory value is 100 hours, but can be changed by pressing the MENU button while the
cursor flashes over alarm set point. The +/- buttons can then be used to change this
value.
The current hours can be reset at any time simply by pressing and holding the menu
button while the current hours are highlighted.
Alarms
By scrolling the cursor down to the alarms arrow and selecting it by pressing the MENU
button, the user can access the Alarm screen. The alarm screen displays all active
alarms and allows the user to acknowledge any active alarm.
∧ Alarms
_ Power Outage
_ Condenser Over Temperature
_ Vacuum Exceeded
_ Vacuum Pump Maintenance
Menu To Clear
Any alarm currently active will be depicted within the alarm screen with a solid box lo-
cated in front of the active alarm. To clear an alarm use the arrow buttons to scroll to the
desired alarm and press the MENU button. Before the alarm will clear, the condition
that caused the alarm, must be remedied.
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SP Industries
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In the following sections, values may be changed by using the arrow buttons (+/-) to
scroll to the desired field, and pressing and holding the MENU button. The selected
value can then be changed with the arrow buttons. Pressing the MENU button enters
the set point.
Set Points
∧ Set Points
Condenser Temperature -60

Vacuum OK 0500
Power save dead band 050
PRESS AND HOLD MENU BUTTON TO ADJUST
Condenser Temperature is the setpoint temperature at which during the auto mode, the
vacuum will start. The condenser over temperature alarm is also referenced from this
value. The alarm will generate when the condenser temperature is 10°C above the set
temperature.
Vacuum OK is the pressure set point at which the vacuum exceeded alarm will be gen-
erated. There is a 30 minute delay in activating the vacuum exceeded alarm to allow
flasks to be added to the system without generating this alarm.
Power save dead band, is the pressure rise that is acceptable within the system before
the vacuum pump is re-energized if the user is using the power save mode for vacuum
level control.
Vac Ctrl
The Vac Ctrl, displays the current vacuum level control set point. To change the set
point use the arrow buttons (+/-) to navigate down to the Vac Ctrl field.
Purge (option)
The Purge function controls a solenoid valve located between the vacuum pump and
the suction port within the unit. This allows a high vacuum to be pulled within the volume
between the pump and the valve without the entire unit being under vacuum. The gas
ballast within the pump can then be opened and the oil cleansed within the pump.
Note: This feature will only be displayed if your unit is equipped with a factory installed purge
valve.
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Rev: 3a, 8/05
Shell Freezing Bath (Option)

The bath function controls the refrigeration and roller mechanism is an option bath sys-
tem. If the system is set to ON the Bath refrigeration and rollers will be active when ever
the COND is active. If the unit is set to OFF the bath will not operate.
Note: This feature will only be displayed and depicted within your synoptic screen if your unit
is equipped with a factory installed shell bath.
The maintenance menus are used for system configuration, calibration and factory set
up. For this reason care should be used when changing factory settings.
Caution: Changing factory setting to enable features that were not

factory installed might result in improper operation not covered
under warranty.
Maintenance
To access the maintenance menu simultaneously press and hold the up and down ar-
row (+/-) buttons while in the main menu. The maintenance menu will be displayed.
∧ Maintenance
Factory Options >

Interstage Control >
Calibration >
Factory Options
∧ Factory options
Bath option YES

Purge Option YES
Hot Gas defrost YES
Purge and Bath options are activated when system is set to yes, this results in changes
to the main menu and synoptic screens to allow the user to operate these features.
Defrost is accomplished via two methods, electrical resistance heater and hot gas re-
frigeration loop. If Hot gas defrost is set to yes the system will energize both the defrost
output and the refrigeration system. If hot gas is configure to no then the system only
activates the defrost output to energize the resistance heaters.
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Interstage Control
Caution: Changing these settings can cause serious damage to your

refrigeration system!
∧ Interstage control
Interstage ON
ON –12 DIFF 025
Current Temp 11.3°C
Interstage control is used to control the operation of the second compressor if your unit
is equipped with a cascade system. This is safety device used to protect the refrigera-
tion system from overloading if the compressors were to start simultaneously.
If interstage control is active the high stage compressor is energized when COND or
AUTO is activated. The interstage temperature is monitored until the On temperature is
reached. The low stage compressor is then energized.
The DIFF temperature is used to prevent an overloading of the high stage such that if at
anytime during operation the interstage temperature rises to a value warmer than the
interstage on temperature plus the DIFF value, the low stage compressor will be de-
energized. It will re-energize when the interstage temperature recovers.
Calibration
∧ Calibration
Temperature Span 070

Temperature Zero 14.5°C 128
Vacuum 760 Torr 128
To calibrate the condenser temperature, connect a thermocouple simulator to the con-

denser temperature input. Set the simulator temperature to +25°C.
The current temperature is displayed in the calibration screen. Adjust the numerical
value of the temperature zero up to increase the temperature down to decrease. The
value will only be corrected after pressing the MENU button to enter the value.
Upon proper zero adjustment, change temperature simulator value to -60°C. Adjust the
Temperature span value such that the temperature displayed equals the calibrator set
value. Recheck the value at +25 and repeat adjustment if necessary. Check calibration
at desired temperature intervals for verification.
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To adjust the vacuum value, with the condenser door open adjust the trim pot located
on the main sentry module located within the electrical box. Set the value to 760Torr
then turn an additional 1/8 turn clockwise. Turning the pot clockwise increases the pres-
sure, counter-clockwise decreases.
Once the rough vacuum has been set, connect a reference tube. Adjust the vacuum
value located on the LCD screen up to increase the vacuum reading and down to de-
crease.
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OPERATION
IMPORTANT! Before going ahead, make sure you have completed the “installation”
section of the manual. Failure to pay attention to these suggestions could result in seri-
ous damage to your unit.
1. Make sure all valves, condenser drain, condenser door and/or chamber door are all
closed.
Make sure the condenser is clean and dry. Check the drain line for residual mois-
ture, which can be drawn up into the condenser when vacuum is applied, causing a
slow pumpdown.
Check vacuum pump oil level and clarity. Change or add as needed. On newly
supplied pumps, the sight glass oil is recirculated and is representative of what the
oil in the pump looks like. (Note: On older pumps, the oil in the sight glass on the front of the
pump indicates level only. Check clarity of the oil by draining approximately 20 mL, a little less than
an ounce, from the drain hose and examining closely.)
2. Switch on “COND”. Condenser refrigeration will begin. Wait until condenser status
lights indicates green before proceeding.
3. Switch on “VAC”. System evacuation will commence. Wait until vacuum status light
indicates “OK” before proceeding. The vacuum is factory-set at millitorr but can be
reset to microbar. See Sentry 2.0 Section for directions on charging units.
4. Drying – Knowing your product’s eutectic can conserve time and energy and leads
to a high quality freeze-dried product. If lacking the instrumentation for determining
eutectic, make sure that your product is well frozen, preferably below -40ºC.
(a) Manifold Drying – As soon as synoptic status indicates “OK”, connect a pre-
frozen sample to a Quickseal valve and turn valve to “Open” position. When
vacuum recovers to “OK” status, attach another sample.
Continue freeze drying until dryness is determined by one or more of the follow-
ing indicators:
Vacuum will approach a constant low reading.
Appearance of the product may indicate the extent of dryness: samples uniformly
powdery or fluffy, lack of frost on container, container at room temperature.
When samples are dry, close Quickseal valves and remove the containers.
Once all containers have been removed, break vacuum by opening Quickseal
valve to admit air.
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(b) Chamber Drying – These instructions were designed to be used in conjunction

with the instructions supplied with your drying chamber.
Freeze your samples according to instructions supplied with your chamber.
After the vacuum level reaches 100 microns or less, heat samples according to
instructions supplied with the chamber. Continue freeze drying until dryness is
determined by one or more of the following indicators:
Condenser temperature will approach its maximum low.
Vacuum will approach a constant low reading.
Product temperature will display steady temperatures close to shelf temperature.
Appearance of the product may indicate extent of dryness: uniformly powdery or

fluffy.
5. After vacuum is broken, IMMEDIATELY switch OFF “VAC”.
6. Switch OFF “COND”.
7. Defrosting – After the product has been removed, the Freezemobile is ready to be
defrosted.
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Insert drain line into the condenser drain and let drain into a large container.
Your freezemobile is equipped with the standard Quick Defrost Option, switch on
“DEF”. Hot gas from the refrigeration system will warm the condenser walls. The
cylinder of ice should break free from the condenser in about an hour. Then remove
the gasket and slide out the ice.
8. Shutdown – Turn off “DEFR”. Drain and clean condenser.
If you are drying corrosive materials, after each use, thoroughly clean and rinse all
parts of the unit which come in contact with product moisture. This prevents residual
buildup of corrosive and contaminating materials on interior surfaces, protecting both
the machine and the next product to be processed. Baking soda or another mild
buffering agent may be added to the rinse water to help neutralize acidic residue,
and a siphon-type squeeze bottle is useful to direct the rinse spray into corners.
9. Remove drain line. Dry Condenser.
OPTIONAL SHELL BATH

A product that is “stub frozen” on the bottom of a flask can damage the flask, prolong
freeze drying time, and create melt back. A thin, even coat of product helps to eliminate
these problems:
The VirTis shell-freezing bath comes with the following:
- Two flask lift devices

- Two lift device chains
- Two polypropylene plugs
- One clean PETG plastic shell bath cover
Check to be sure that all are included with your shell bath.
1. Fill flasks no more than halfway with product. Replace the cover and insert a poly-
propylene plug.
2. Fill shell bath with a sufficient amount of heat transfer fluid (such as methanol) with a
freezing point lower than your bath temperature to cover rollers, approximately 2-3 li-
ters, depending on desired depth. CAUTION: Be careful to handle and dispose of
toxic or flammable materials properly.
3. Press the “COND” switch on your freeze dryer. This will activate the condenser to
cool the system. The maximum low temperature for your shell bath will vary de-
pending on the refrigeration option. Your shell bath temperature is read on your
22
SP Industries
Phone 800-431-8232 • 845-255-5000 • Fax 845-255-5338
Rev: 3a, 8/05
temperature LCD display and is designated by “BATH”.
4. From the main menu set bath to on to activate the rollers and to allow the refrigera-
tion system to start cooling the bath. See Sentry 2.0 Section for details.
5. When the bath has become sufficiently cold, place flask lift device, with chain fully
extended, across the bath. The device may be placed in either of two positions for
high or low support. Select the one best suited for your flask. Put in polypropylene
plug.
6. Hold the flask at an angle so that the product just reaches the flask neck without
touching the filter inside the cap. Position the flask under the lift device, resting it
on the rollers. (See diagram #2)
7. Shorten the lift device chain (pull up through middle hole in device, to secure, slide it
to one side) until it rides in the groove of the polypropylene plug and supports the
flask at the correct angle. (See diagram #1)
8. Flasks should freely rotate on suspended chain. Continue until product is fully fro-
zen.
9. Frozen samples should be placed on manifold for freeze-drying or stored in freezer

immediately.
10. By using this procedure, bottles of various sizes can be shell frozen without chang-
ing the depth of fluid in the bath. The shell bath can handle the following flasks at
one time.
3 ea 150 mL flasks
2 ea 300 mL flasks
2 ea 600 mL flasks
1 ea 1200 mL flask
1 ea 2000 ml flask
11. To clean and maintain the VirTis shell bath, periodically drain bath liquid by removing
drain plug in hose located inside the cabinet. Flush with a mild detergent or a baking
soda solution with warm water to clean the stainless steel bath and rollers.
12. If a more thorough cleaning is required, the roller assembly may be removed by
loosening the two hex nuts holding it to the bath wall, lifting the opposite end of the
assembly and disengaging the chain drive from the sprocket. When reassembling,
be sure to replace and tighten the washers and nuts.
13. Drive chain tension is easily adjusted using the nylon cam on the end of the bath.
23
SP Industries
Phone 800-431-8232 • 845-255-5000 • Fax 845-255-5338
Rev: 3a, 8/05
Diagram 1
Diagram 2
OPTIONAL LIQUID NITROGEN TRAP

The LN2 Liquid Nitrogen Trap is a convenient way to protect your vacuum pump from
the corrosive action of acid and alkaline vapors as well as low temperature and organic
solvents that can be released during freeze-drying.
The LN2 Trap consists of the following:
24
SP Industries
Phone 800-431-8232 • 845-255-5000 • Fax 845-255-5338
Rev: 3a, 8/05
- Stainless steel vessel with inlet and outlet ports and drain line
- Center well and cover
- Vacuum by-pass assembly with three lever-activated ball values (see diagram
for each valve’s function)
1. Switch on ‘COND” and wait for condenser to reach its specified operating tempera-
ture.
2. Remove the plastic cover from the stainless steel vessel and add a small amount of
liquid nitrogen to the center well. If adding LN2 from a tank, provide adequate venti-
lation from gaseous vapors. Liquid Nitrogen expands and bubbles when it comes in
contact with the warm center well. Be sure to wear protective eyewear, and gloves.
Avoid skin contact.
3. Replace cover and wait one minute. Open well and slowly fill to capacity (2.8 liters
or 5 liters depending on center well size). Be sure to wear protective eyewear, and
gloves. Avoid skin contact.
4. Open valves 1 and 2 (see diagram 3) and close valve 3.
5. Switch on vacuum “VAC” until adequate pressure is reached. (Below 100 microns)
6. Trap is now in operation. Liquid Nitrogen evaporates rapidly over time and solvent is
condensed so occasionally check and refill center well.
7. Excessive accumulation of condensed vapors can result in loss of vacuum and is an

indication that the trap needs defrosting. Check this by isolating the trap (close
valves 1 and 2). Break vacuum to trap by removing drain plug from the drain hose
located under stainless steel vessel. Lift center well slightly. When the well cannot
be easily moved, defrost immediately!
8. To defrost your Liquid Nitrogen Trap, first remove any Liquid Nitrogen left in center
well. CAUTION: Be sure to handle and dispose of solvents properly.
9. Place an appropriate container under trap and remove drain hose plug.
10. If condensate permits, remove center well and rinse off any remaining condensate.
11. Putting hot water in center well can accelerate condensate melting.
25
SP Industries
Phone 800-431-8232 • 845-255-5000 • Fax 845-255-5338
Rev: 3a, 8/05
12. Rinse the interior of the trap. Be sure to insert ¾” diameter plugs in the vacuum
“inlet” and “outlet” ports before rinsing trap; water in the vacuum line can cause poor
vacuum and/or pump damage.
13. Wipe the trap dry and reassemble. Make sure that any plugs you have inserted in
the ports are removed and the plug in the drain line is replaced.
14. Be sure that all stainless steel parts exposed to acids are thoroughly rinsed with wa-
ter and baking soda or mild detergent after each defrosting. Under no circum-
stances should thawed condensate be allowed to remain in the trap.
Diagram 3
LIQUID NITROGEN AND FILTER TRAP ASSEMBLY IN SERIES

1. Prior to freeze-drying run, remove excess moisture is Soda Sorb using degassing
procedure (see page 28 for note). Valve 2 should be open, keep valves 1 and 3
closed.
2. Valves 1,2, and 3 closed allow for purging of the vacuum pump by opening gas bal-
last valve.
26
SP Industries
Phone 800-431-8232 • 845-255-5000 • Fax 845-255-5338
Rev: 3a, 8/05
3. Valves 1 and 2 open and 3 closed allows passage through both traps from the ice-
collecting condenser to the vacuum pump.
4. Valves 1 and 2 closed and 3 open bypasses both traps, allowing direct passage
from ice collecting condenser to vacuum.
5. Since both traps are in series, they may be used independently of each other by
simply leaving out the filter cartridge or LN2. All else remains the same.
FILTER TRAP INSTALLATION INSTRUCTIONS

1. The port marked “OUT” would be connected to the pump and the port marked “IN”
would be connected to the rest of the system.
2. On Position
Turning the handle fully counter-clockwise opens both inlet and outlet to allow vac-
uum to be obtained from vacuum pump, housing, and the rest of the system.
3. Off Position
Turning the handle fully clockwise both inlet and outlet and breaks vacuum inside the
housing only. The button is depressed in this position to vent the filter housing.
OPTIONAL FILTER TRAP

The VirTis Filter Trap protects your vacuum pump from damaging and corrosive vapors
released during freeze-drying. Your factory installed Filter Trap is located on the “vac-
uum pump” side of your freeze dryer. The Filter Trap assembly includes the following:
- Polypropylene clear housing
- Stainless steel mounting bracket
- White plastic top with inlet and outlet ports
- Choice of drop in disposable wire mesh cartridges must be ordered sepa-

rately.
- Soda Sorb Cartridge #250365

- Activated Charcoal Cartridge #250373
OPERATION:
1. Unscrew clear polypropylene housing from white plastic top.
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SP Industries
Phone 800-431-8232 • 845-255-5000 • Fax 845-255-5338
Rev: 3a, 8/05
2. Due to the highly absorbent nature of filter trap cartridges, it may be necessary to
subject them to vacuum (de-gassing) before beginning the freeze drying process.
Without degassing, vacuum pumpdown will be significantly longer than usual.
To start, turn on the “VAC” button. Make sure the gas ballast is slightly opened on
your vacuum pump, and all ports are closed. When the vacuum reaches 50 mi-
crons, (or less) close gas ballast valve. It may take between 12-24 hours for de-
gassing to be complete.
NOTE: De-gassing is necessary each time you change your filter trap cartridge.
Most filters need to be degassed overnight in order to allow for proper
vacuum to be established.
There are two reasons this may need to be done.

A. The filter may have picked up some moisture from the air.
B. There may be residual air or gasses trapped within the tiny pockets of
the cartridge.
3. Now you may add your product and begin freeze-drying.
4. Your cartridges are disposable. Their life depends on frequency of use and the vol-
ume of contaminants they readily absorb. The Soda Sorb cartridge contains a dye,
which indicates, need for replacement when a complete purple color change is evi-
dent. The activated charcoal cartridge contains no color indicating dye. Pump oil
must be routinely checked for clarity to assess the charcoal’s absorbing capacity.
CAUTION: Be careful to properly handle and dispose of used cartridges.
OPTIONAL ELECTRIC PURGE SYSTEM and

STANDARD VACUUM BRAKE SYSTEM INSTRUCTIONS
These are two (2) separate functions although both employ the vacuum pump as fol-
lows:
A. VACUUM - - - Press the “VAC” button and both the vacuum brake system (“VBS”)
and electric purge system (“EPS”) open for unrestricted air flow from the system
(freeze dryer) to and through the vacuum pump exhaust port. This is the normal
freeze drying flow path.
B. PURGE - - Press the “VAC” button to its off position. Set purge to on from the main
menu. The vacuum pump and VBS are energized. The EPS is in its closed posi-
tion. Airflow is blocked by the closed EPS. The vacuum display represents the
pump, hoses and fittings. This negligible volume in the hose and fittings for all prac-
tical purposes is called “Pump Vacuum”.
28
SP Industries
Phone 800-431-8232 • 845-255-5000 • Fax 845-255-5338
Rev: 3a, 8/05
Leaving the purge on and opening the vacuum pump gas ballast selector knob
(slightly or fully) will allow the vacuum pump oil to clarify trapped solvents or mois-
ture. As this clarifying continues, the vacuum improves to a level considered “SAFE”
as determined by the operator. After the purge “SAFE LEVEL” is reached. Set the
purge to off on the main menu. The freeze dryer is ready for another freeze drying
cycle.
The use of the optional purge feature should be based on the hours of freeze drying op-
eration and frequency of oil change. As a general rule, the purge feature should be
employed at least once between vacuum pump oil changes.
29
SP Industries
Phone 800-431-8232 • 845-255-5000 • Fax 845-255-5338
Rev: 3a, 8/05
General Maintenance
Provides instructions on how to care for and maintain the Freezemobile 25 and 35.
Proper periodic maintenance is the key to an efficiently operating unit with minimal
down time.
Vacuum Pump:
Clean oil is necessary for the best vacuum and overall efficiency of the entire system.
Checking and changing the oil on a consistent basis will greatly extend the life of the
vacuum pump. Vacuum pump oil should be changed on an “as-needed” basis by
checking the oil after each freeze-drying run. The following is a basic guideline to visu-
ally checking the oil. Drain a small amount (approximately 100ml) of oil by removing the
plug from the pump drain line. Use a clear container to capture the sample.
♦ Pale yellow or clear vacuum pump oil – indicates good condition.
♦ Dark vacuum pump oil – indicates acid contamination.
♦ Cloudy gray or white vacuum pump oil – indicates water contamination.
Use only VirTis vacuum pump oil or equivalent when changing the oil. This particular oil
is specially refined for vacuum pumps.
VirTis Part #185181 – One gallon can of vacuum pump oil.

VirTis Part #185207 – Two gallon can of vacuum pump oil.
VirTis Part #277228 – One-liter synthetic oil.
Changing the vacuum pump oil:
Change the oil right after shutting the freeze dryer off, while the oil is still hot.
1. Protect hands from the hot oil.
2. Drain the contaminated oil into a suitable container.
3. Add the new oil while visually checking the sight glass to insure proper level.
4. Operate pump for 10-15 minutes to flush any residual contaminated oil from inte-
rior components.
30
SP Industries
Phone 800-431-8232 • 845-255-5000 • Fax 845-255-5338
Rev: 3a, 8/05
If corrosive materials are frequently being freeze dried, the oil must be checked and
changed more frequently. In addition, a VirTis filter trap should be installed to protect
the vacuum pump.
VirTis Part #254185 – Filter trap for field installation.
VirTis Part #250365 – Soda sorb cartridge for acid.
VirTis Part #250373 – Activated charcoal cartridge for organic solvents.
VirTis Part #266783 – Molecular sieve cartridge for water vapor.
Please note cartridges must be ordered separately.
For further details on care and operation of the vacuum pump, consult the vacuum
pump manual.
Condenser:
The condenser is fabricated from stainless steel and under normal use can be rinsed
and kept clean with a mild detergent.
If corrosive materials are being freeze dried, thoroughly clean and rinse all parts of the
freeze dryer that come in contact with product moisture. This prevents residual build-up
of corrosive and contaminating materials on interior surfaces, protecting the freeze dryer
and the next product to be processed. Add baking soda or any mild buffering agent to
the rinse water to help neutralize acidic residue. Note: A siphon type squeeze bottle
can be used to direct the rinse spray into difficult to reach areas.
Failure to properly neutralize corrosive materials will damage your freeze dryer and void
the warranty.
31
SP Industries
Phone 800-431-8232 • 845-255-5000 • Fax 845-255-5338
Rev: 3a, 8/05
Trouble Shooting Guide

Gives a checklist to diagnose common problems
Vacuum Problems:
Remember maximum vacuum (5 millitorr) is only achievable with a clean dry system.
For efficient freeze drying, vacuum should be below 100 millitorr and this will need to be
coordinated with how the product is loaded on the manifold. See Super Sentry instruc-
tions page 12 for more information on using the Sentry 2.0 display to monitor freeze-
drying process.
The following is a checklist to eliminate possible causes.
♦ Was the condenser drained after the last run?
♦ Is the plug in the drain line? Is the drain line empty?
♦ Is the condenser gasket clean and properly greased?
♦ Are all the Quickseal valves in good condition? Is there a light coating of vacuum
grease on the valve plug and on the stainless steel valve port? Are they in the cor-
rect position?
♦ Is vacuum pump oil clean and at the proper level? (Check sight glass)
♦ Is the condenser maintaining the proper temperature? If the temperature rises due
to refrigeration problems, moisture may be leaving the condenser walls and migrat-
ing to the vacuum pump, causing poor vacuum.
If none of the above applies, try to isolate the problem by removing the manifold and
placing a stopper in the vacuum intake tube. This will seal the vacuum tube and when
the vacuum pump is operated a good check of the components between the pump and
the end of the tube will be obtained.
1. If you get a good vacuum reading (as shown on the Sentry 2.0 display) in about 1
minute, this check will eliminate any problem with the pump, vacuum probe and
vacuum tubing connections. At this point, recheck condenser gasket and mani-
fold for joint separations and dirty or rough surfaces.
32
SP Industries
Phone 800-431-8232 • 845-255-5000 • Fax 845-255-5338
Rev: 3a, 8/05
2. If you do not get a normal vacuum reading (as shown on the Sentry 2.0 display)
in about 1 minute, start checking components one by one.
a. Change and flush oil in vacuum pump (refer to page 25 or pump

manual.
b. Disassemble all vacuum tubing connections, clean with methanol, apply a

light coating of vacuum grease and reassemble.
c. Check all threaded and welded connections and seal with vacuum sealant.
d. If after re-testing, poor vacuum persists, the probable cause may be

the vacuum probe, which will have to be replaced.
33
SP Industries
Phone 800-431-8232 • 845-255-5000 • Fax 845-255-5338
Rev: 3a, 8/05
Freezemobile Spare Parts List
151423 Fan Motor 115V

151431 Fan Motor 230V
153650 Vacuum Probe Tube
428767 Caster
196253 Vacuum tubing 5/16" ID
196287 Vacuum tubing ¾" ID
198408 Gasket, 11" split ring
406215 Solenoid valve for vacuum control
275305 VBS valve diaphragm
275636 Plastic oil bottle
278663 Quad solid state relay
290353 Circuit breaker 15A
292573 Dual Thermocouple Probe, 6" long
296525 Oil separator
377614 Refrigerant, 89
314963 Compressor 1 HP 208/230V
337972 Refrigerant SUVA 95
354126 Door latch for 1” thick condenser doors
356808 90° rubber elbow
360628 Vent panel
428293 Manifold connector
368483 Side panel
446241 Condenser panel
428170 Top
445871 Sentry 2.0 Control
446072 Sentry 2.0 Membrane
399517 Lucite® Condenser door, 1" thick
368223 Fuse 500mA
368216 Fuse 115mA
290361 Circuit Breaker 20A
294538 Circuit Breaker 30A
426138 Refrigerant R807C
105197 Compressor ¾ HP 115V
255117 Compressor 1 ½ HP 208/230V
432917 Fan Motor/Blade/Guard Assembly 230V
Copyright, SP Industries 2005
34
SP Industries
Phone 800-431-8232 • 845-255-5000 • Fax 845-255-5338
Rev: 3a, 8/05

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Operators Manual

Inspection upon arrival 2

Operating Principles 5-7

Sentry 2.0 Control 11

Spare Parts List 34

a. If your shipment is F.O.B. destination, file your claim with SP

SP Industries sole responsibility under this warranty will be to repair or replace, at SP

The pumping unit (2 stage) is submerged in a high quality, specially com-

Heavily insulated with polyurethane foam, it is further enclosed by a metal

The refrigeration system automatically seeks the lowest possible tempera-

SET UP for all Freezemobile 25 and 35 Liter Freeze Dryers

1. The refrigeration system compressors may be mounted on shock absorbent

7. The Sentry displays condenser temperature, vacuum (microbar (µBar),

The following temperatures are represented by each LED on the

LED Temp. Color

LED Vacuum (MT) Color

Sentry 2.0 CONTROL

Up\Down (+/-) Buttons

LCD display functions

User Options >

Vacuum Control VLC

Relay Test allows for diagnosis of possible unit problems.

∧Solid State Relay Output Test

∧-SSR1 ∨-SSR2 Menu-Exit

∧ Vacuum pump Maintenance

Alarm Set Point: 0100

Condenser Temperature -60

PRESS AND HOLD MENU BUTTON TO ADJUST

Shell Freezing Bath (Option)

Caution: Changing factory setting to enable features that were not

Factory Options >

Bath option YES

Caution: Changing these settings can cause serious damage to your

Temperature Span 070

To calibrate the condenser temperature, connect a thermocouple simulator to the con-

Vacuum will approach a constant low reading.

(b) Chamber Drying – These instructions were designed to be used in conjunction

Freeze your samples according to instructions supplied with your chamber.

Condenser temperature will approach its maximum low.

Vacuum will approach a constant low reading.

Product temperature will display steady temperatures close to shelf temperature.

Appearance of the product may indicate extent of dryness: uniformly powdery or

5. After vacuum is broken, IMMEDIATELY switch OFF “VAC”.

6. Switch OFF “COND”.

8. Shutdown – Turn off “DEFR”. Drain and clean condenser.

9. Remove drain line. Dry Condenser.

OPTIONAL SHELL BATH

The VirTis shell-freezing bath comes with the following:

- Two flask lift devices

temperature LCD display and is designated by “BATH”.

9. Frozen samples should be placed on manifold for freeze-drying or stored in freezer

OPTIONAL LIQUID NITROGEN TRAP

The LN2 Trap consists of the following:

- Center well and cover

4. Open valves 1 and 2 (see diagram 3) and close valve 3.

7. Excessive accumulation of condensed vapors can result in loss of vacuum and is an

LIQUID NITROGEN AND FILTER TRAP ASSEMBLY IN SERIES

FILTER TRAP INSTALLATION INSTRUCTIONS

OPTIONAL FILTER TRAP

- Polypropylene clear housing

- Stainless steel mounting bracket

- White plastic top with inlet and outlet ports

- Choice of drop in disposable wire mesh cartridges must be ordered sepa-

- Soda Sorb Cartridge #250365