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12.
MAINTENANCE PLAN
This manual is a guide to the serviceable components of the freeze-dryer that require maintenance. It must be an
active document that can be modified according to user requirements.
The maintenance plan consists of inspections and operations that must be performed from every day through to a
period of once a year. The information will have to be compiled and detailed in order to be useful in the following
maintenance operations.
CAUTION
•
Before the maintenance operations begin, the freeze-dryer must be disconnected from the power supply.
•
In general, a periodic inspection of the correct operation of all the unit components should be performed once
a year.
12.1. VACUUM UNIT MAINTENANCE
The revision and maintenance operations that must be performed in the vacuum unit are as follows:
OIL CONDITION CONTROL
The oil condition can be observed via the sight glass. To carry out this operation, when the pump is at working
temperature, switch off the unit.
In normal conditions the oil is clear and transparent. Oil draining and changing is recommended when it has a cloudy
appearance (contaminated by water).
The vacuum unit has a Gas-Ballast function in order to prevent the non-condensable vapors of the product of
contaminating the oil. The Ulvac 136 GLD-136C vacuum pump has external Gas-Ballast (see Fig. 32), and it is
recommended to leave the Gas-Ballast opened (¼ setting) during the first step of the freeze dryer cycle. The Ilmvac
P6Z-101 vacuum pump has a bubbler (gas purging apparatus) instead of a gas ballast system.
OIL LEVEL CONTROL
The correct oil level will cover half of the sight glass. If the oil level is below this level, the necessary oil quantity must
be added through the filling opening in order to reach the correct level. Before filling, the pump must be stopped.
VISUAL CONTROL OF OIL LOSS
Verify the absence of oil around the vacuum pump. The presence of oil around the pump indicates a possible leak in
the joints, incorrect tightness of the caps, the oil level sight glass, or the saturation of the filter. The unit must be
cleaned in order to be able to locate the origin of the leak.
OIL CHANGE
Oil changes can only be performed when the unit has run and is at working temperature. This change must be
performed after the pump has worked for a minimum of 20 minutes, this to obtain more oil fluidity.
The steps to change the vacuum pump oil are the following ones:
1.
Unscrew the drain cap to drain off old oil.
2.
To completely drain the unit, it may be necessary to run the pump (3-5 secs) and stop.
3.
Screw the drain cap.
4.
Remove the filling cap.
5.
Add the new oil through the filling hole until halfway the sight glass.
6.
Screw the filling cap.
It is advisable to change the oil before any long periods of non-usage; it is harmful for the pump to contain dirty oil
during long periods of non-usage.
PUMP BODY CLEANLINESS
The steps to clean the body of the pump are as follows:
1. Empty the used oil from the pump.
2. Refill the oil in the pump up to ¼ of the capacity.
3. Run the pump for approximately 30 seconds.
4. Empty the pump.
5. Repeat the steps 1, 2 and 3.
6. Fill the pump with oil, (up to halfway the sight glass).
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