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Please read your operating manual and create a preventative maintenance schedule for the vacuum pump.  

• oil change
• oil filter change
• exhaust  filter change
• additional PM tips
• Maintaining the see the maintenance manual and establish a preventative maintanece schedule that tracks the oil level, changing the oil, and filter.  The parts number are located in the manual.  Please contact your OEM for parts.  
• make sure the water cooling system isnt getting build up 
• use clean water to cool system

Make sure to always keep an eye on the oil level in the site glass and the resivior on top in addition to the condition of the oil. 

Change oil any time it looks contaminated or after recommended intervals per Leybold.

1. Please become familiar with the refrigeration compressors operating manual .The screw compressor  needs the air chiller to cool the oil which lubricates the compressor.  make sure that the oil resivoir has the amount of oil required.  
2. the compressor has a high temp limit of 100C.  make sure not to exceed this temp. and if it continues to have alarms for over heating check to make sure that the water chiller is functioning properly, and if so, check to see if it has the correct amount of oil.   
3. Check the oil filter and change according to usage specs of Bitzer for this model.
4. Because of the brazing of the copper pipes from the out door condenser to the freeze dryer, it is common for the lines to have contaminant in it from dirty pipes, or other contaminants during the brazing process.  because of this we recommend changing the oil filters between 200 and 500 hours of use.  

1. The Freeze Dryer uses Dow Silicone oil.  Make sure to check the oil level and that there arent any leaks in the piping.  
2. make sure that the valves are operating and open.
3. make sure there are not any leaks from the manifold to the shelves, at both the inlet and the outlet connections.

Every opening or passthrough on a freeze dryer can be a leaking point.  If you have a serious leak, there are leak detectors that are nitrogen sniffers that can help you locate leaks.  A good way to determine if you have a leak is to look at the trending and if you see that the vacuum pressure is not able to be pulled as low as normal, check first to see if the vacuum pumps are operating efficiently, and that the oil levels are correct, the oil filter is clean.  Afther this do the following 

1. Make sure the piping to the vacuum pumps are properly connected.  
2. Check to make sure that the door gasket is not cut or damaged.  
3. make sure any passthrough into the chamber are properly sealed, and are properly seated with the orings and the clamps.
4. make sure that the site glasses that you view inside the chamber are not damaged, cracked, and that they are sealed properly, and that any sensor passing though has not been bumped or damaged.  

It's important to understand how ice crystal size effects drying. This is important to expedite freeze drying, in addition to making sure that all the product is frozen below the -45 C melting point before starting the freeze drying process.

Freezing the product

Before runningthe machine, make sure that all the valves are in thier proper configuations, and that the temps on the dryer for the compressor oil and the oil cooler and air chiller are within range.  make sure the vacuum pump oil is clean and clear of debris, follow a proper preventative maintanace program for changing the oil filters for the vacuum system and the refrigeration system.  

make sure there is no water or ice in the condenser and that your silicone oil site glass shows you have enough oil. 

Verify items after installation are wired correctly and all hoses are set in the direction of the liquid or air flow.  Make sure all fittings and clamps are tightened and sit properly.

Check whether the wiring is loose and whether the equipment is grounded correctly;

Check whether the rotation direction of the compressor motor meets the normal working requirements.

Check whether the rotation direction of the vacuum pump motor meets the normal working requirements.

Check whether the rotation direction of the circulating pump motor meets the requirements of normal operation.

Check whether the motor rotation direction of the Roots pump meets the requirements of normal operation

If you need to move the machine, or reconnect piping for the refrigeration, the drain, or removing the guages, this video shows how to set up the machine to its original setup.

1. Read all equipment operation manuals and equipment maintenance and cleaning protocols . 
2. Carefully check whether there are any abnormalities. Do this by becoming familiar with the main sceen on the computer interface That shows the temperatures, the compressor, and vacuum pumps.  Make sure all valves are working properly.
3.  If there are any abnormalities, they must be dealt with prior to starting up.
4.  Familiarize yourself with the structure, principle, performance, operation essentials and operational precautions of the equipment, and know well. 
5. Look to see if there are any alarms. 
6. Make sure there is no water in the condenser.
7.  Hoses are hooked up properly.
8. The water chiller is on and has had enough time to get the water cool enough to control the  DV 650 VAcuum pump .
9. Check whether the product temperature sensor, cold trap temperature and compressor oil temperature display in the drying screen are normal.
10. Check whether the vacuum sensor on the drying chamber and the vacuum pump pipe display is normal.
11. Check the lubricating oil of the compressor, it should be clear, meet the requirements of the instructions, and whether the oil level is visible in the oil glass.
12. Check the vacuum oil of the vacuum pump. It should be clear and meet the requirements of the instructions. Whether the oil level is in the upper position in the oil glass.
13. Check the vacuum oil in the oil cup of the Roots pump. It should be clear and meet the requirements of the instruction. Whether the oil level is in the upper position in the oil cup.
14. Check the silicone oil in the silicone oil storage tank. It should be clear and whether the liquid level is in the middle of the liquid level pipe
15. Check whether all valves in the refrigeration system are in the open position.
16. Check whether the valve position in the vacuum system meets the normal working requirements. All valves leading to the atmosphere should be closed
17. Check whether the defrosting water in the condenser has been drained clean.
18. Check whether the power supply voltage  is normal and whether the switches on the control cabinet are in the open position.

Alarms are critical in maintaining the equipment.  Pay attention to them and make sure that if you see continued alarms, you correct the reason that the system is throwing the alarm. The below listed are the system alarms. 

YOU MUST RESET THE FOLLOWING ALARMS THAT ARE DENOTED BEFORE THE SYSTEM WILL FUNCTION.  

BEFORE JUST RESETTING THE ALARMS.  MAKE SURE TO TROUBLE SHOOT AND ASSESS THE REASON FOR THE ALARMS.

1. Compressor high pressure alarm（need reset）

• causes can be low oil
• stuck valves

2. Compressor low oil level alarm（need reset）

• low oil. check the refrigeration compressor oil and that it has the correct amount.

3. Compressor oil temperature low alarm（need reset）

4. Compressor oil flow alarm（need reset）

• check to make sure that there is enough oil and that there is no obstruction or valves that are not functioning.  Check to see if the oil needs to be changed.  

5. Compressor oil filter monitoring alarm（Reminder with oil change filter）

• check to see that the oil filter allows oil to flow unrestrictive and is not excessivley dirty.  ONLY USE the manufacturer recommended oil filters.

6. Compressor oil stop valve monitoring alarm（need reset）

7. Compressor motor high temperature alarm（Requires module power-down reset）

• this can be due to continuous reset, electric low voltage 

8. Compressor Power fault

9. Compressor thermal relay 1 trip（need reset）

10. Compressor thermal relay 2 trip（need reset）

11. Cooling water low pressure fault（need reset）

12. Phase-monitoring-alarm

• check to make sure that there isn't a leg down on the 3 phase. Make sure that the voltage regulator is properly running and set correctly, and that there is enough electric to power the system.

13. Circulation pressure was low alarm（After confirming the alarm, click the circulation pump

to turn off, then click the circulation pump to turn on.）

14. Electric heating over temperature alarm

15. Electric heating 1 power alarm

16. Electric heating 2 power alarm

17. Electric heating 3 power alarm

18. Electric heating 4 power alarm

19. Vacuum over pressure alarm

20. Vacuum leakage alarm

21. Vacuum pump power fault

22. Roots pump power fault

23. Circulation pump power fault

If you are seeing the alarms and are not sure of the problem, contact the OEM.

1. If there is a power failure, first make sure the system is stable. 
2. Check to make sure the product did not raise in temp.  if so refreeze before continuing freeze drying.
3. Restart the profile only after confirming the system is stable. If the failure was a short duration just continue from the setpoint you were at.  If there was a long delay and your product could have gone liquid, refreeze to below the critical temp of the product ( -40C) then skip steps to get back to the step you were at before the failure. Being careful not to ramp more then 1 degree a minute.
4. make sure the water chiller for the vacuum pump is cycled on first and has cooledthe water to the required temp.
5. make sure that the compressor has enough compressed air flow to properly actuate the valves, and the vacuum pump has a constant flow of air to the purge valves needed.

Overheating compressor most likely is due to:

1. The compressor is overheating, the fans are  not cooling the refrigerant
2. Excessive starting and stopping the compressor.
3. Low oil.
4. Low freon.
5. Stuck valves.
6. excessively hot working enviornment
7. Contact a refrigeration tech and call the OEM if you are not confident of the issue.

Typically there is an easy fix.  

1. Make sure of the simple things first. Check to see if the vacuum pumps are operating correctly.
2. Check the door. is there debris or is the seal damaged?
3. Make sure the vacuum pumps have the proper amount of oil ( follow regular scheduled PM to make sure the vacuum pumps are effectivy maintained.)
4. Did you drain the water out of the condenser? 
5. Did the condeser get properly defrosted and drained duriing the last cycle?
6. If you can still not determine why, it may be a faulty wire connecting the vacuum gauge.
7. Lastly contact the OEM to troubleshoot.  

1. Check the refrigeration valves and make sure they are properly functioning.
2. Check to make sure that the machine is not low on freon.
3. Make  sure there are not any leaks in the refrigeration lines.
4. IF these don't correct the issue, contact your OEM. 

1. Determine if the heating exchanger is working properly.
2. check to see if the circulation pump is functioning properly
3. Check to make sure that the valves are operating properly.
4. Make sure that there is enough silicone oil.
5. Check to make sure it meets all the interlocks that are set ( vacuum depth) 

1. Check to make sure that the compressor is running.
2. Check to make sure valves are open and not stuck.
3. Check to make sure that the silicone oil level is adequate.
4. Check for leaks in the lines for refrigeration. 
5. Check freon level in the compressor.

The red light on the refrigeration compressor indicates that the compressor is not running.  When in a cycle and the compressor is running, the indicator light will turn off.  *****CAUTION*****   If when the compressor is running and the redi indicator light is on, this indicates an error.  Check to see if there are any alarms, if the trending screen shows high compressor temp, The compressor will fail and should shut off if the temp exceeds 100C.  check to see if the oil level is low, check to make sure the freon is at the correct level( contact a qualified refrigeration engineer capable to service the screw compressor).

Use the proper sized allen wrench to make sure that the bolts are all tightened fully.  use the same technique used when tighening lug nuts on a wheel.   If there is still a leak this needs to be corrected, as ionized oil in the chamber will not condense, and will contaminate your product rendering it unusable.  Locate the silicone oil draining nut and follow instructions on emptying the oil.  be prepaired to have a container(s) capable of holding all of the oil.  make sure that the container is contaminant and dirt free, prior to use. 

Make sure to read all manuals.  Follow these guides from the manufacturer before starting the machine.

1. Turn on the breakers and power switches.  
2. turn on the air compressor
3. turn on the key switch of the control cabinet
4. turn on the computer power and monitor powering on the computer will automatically enter the freeze dryer operating system after power on.
5. Enter "User Admin", click "Log on", enter the user name (admin) in Login and enter (admin123456)   In the Password feild before operation.
6. Enter "Freeze-Drying Set.": Set "Product", set the operating parameters to be run see videos, select the product to be run, and click "Write Tags".
7. Load frozen product.  Click "Manually"-"Circulation Pump"-"compressor"-"Shelf cooling"-when the plate layer temperature reaches the feed temperature, open the freeze dryer door, and push the prepared material tray into the freeze dryer onto the shelves.
8. Insert product temperature probes into different layers of materials, and place the plate with product temperature closest to the door.
9. Close the freeze dryer door  after all trays, which are evenly loaded with product are place.

1.  Enter "Freeze-Drying", set pre-freezing steps and drying steps, and set vacuum parameters. (SEE VIDEOS) 
2. Click "Apply" and then "Start". The system starts to run automatically. When the screen displays: "CV Step 1" close "Manually", click "Vacuum Control"
3. The normal automatic operation process of the drying program is as follows: 

• turn on the circulating pump, 
• turn on the compressor, 
• turn on the plate refrigeration valve, and start the pre-freezing step. 
• When the pre-cooling step is completed, close the plate refrigeration valve and open the cold trap refrigeration valve 
•  When the temperature of the cold trap is lower than -40℃, turn on the main vacuum pump and the condenser chamber begins to enter a state of vacuum.  The valve between the condenser chamber and the main drying chamber opens, and once the   vacuum of the freeze dryer reaches below 50,000 mTorr, the  Roots pump cycles on. 
• When the vacuum of the main drying chamber reaches the set value of the initial vacuum level  of drying To start the drying step.
• When the running time of the drying program is reached, it prompts that the freeze-drying is over. At this time, click "stop" to stop the drying program.

1. Enter "Break vacuum", set the venting time for the amount of time needed to completely come to atmosphere.  
2. click "Start" to start. The system will automatically start to pressurize. 
3. Take out the finished product trays as soon as possible after the repressurization is completed. Then start to defrost the condenser. NEVER DEFROST THE MACHINE WITH PRODUCT IN IT OR IF IT IS IN A STATE OF VACUUM.

1. After each freeze-drying cycle, it must be defrosted. Automatic defrosting or manual defrosting can be used.

2. Precautions before defrosting:

• Make sure the compressor is not charging and running freon through the Condenser. Check to make sure compressor has been shut off.
•  Whether the vacuum pump has stopped working.
•  Whether the cabinet has been vented back to atmosphere.
• Make sure the  cold trap drain valve is closed
•  Confirm whether the product has been taken out.
• Make sure  the air compressor has been pressurized to handle the valves opening.

3. During automatic defrosting, the defrosting time, soaking time, and drainage time should be set according to the actual situation. Then turn on the defrost function.

4. After the defrosting function is running, please check whether there is ice in the cold trap that has not melted, and whether the water at the bottom of the cold trap has been drained. Make sure that there is no ice or water in the cold trap before closing the door and the valves.

Manual defrosting:

1. Enter "Manually", click "Defrost", click "Overflow Valve", observe the defrosting water level, when it rises to the upper part of the condenser mirror window, turn off "Defrost". 
2. Wait for the ice inside the condenser to melt.
3. Turn on "Drainage valve", when the condenser water is completely drained, close the "Overflow Valve" and "Drainage valve".

Checkling the end pressure and making sure the product temp and the shelf temp are the same.  Also keep an eye every run on the vacuum pump  oil.  Always take a couple oz to determine need for ballast opening, dont just look at the tube for condensate.