Taylor TW-357 User Manual

TW-357 REV E

LABS

(Laboratory Archival Biological Storage)

CRYOSTORAGE SYSTEM

OPERATING AND MAINTENANCE INSTRUCTION

REVIEW AND UNDERSTAND ALL SAFETY PROCEDURES IN FORM # TW-10 P/N 7950-8052 BEFORE ATTEMPTING TO INSTALL, OPERATE OR PERFORM MAINTENANCE ON THIS CRYOSTORAGE SYSTEM.

DO NOT ATTEMPT TO USE OR MAINTAIN THIS UNIT UNTIL YOU READ AND UNDERSTAND THESE INSTRUCTIONS. DO NOT PERMIT UNTRAINED PERSONS TO USE OR MAINTAIN THIS UNIT. IF YOU DO NOT FULLY UNDERSTAND THESE INSTRUCTIONS, CONTACT YOUR SUPPLIER FOR FURTHER INFORMATION.

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Table of Contents

WARNING 4

Safety Precautions for Liquid Nitrogen 4

GENERAL INFORMATION 6

Text Format Notation 6 LABS Cryostorage Specifications 7

INSTALLATION 9

Unpacking and Inspection 9 Liquid Nitrogen Supply Connection 9 Power Supply Connection 10 KRYOS Control Field Installation 10

OPERATION 11

Initial Fill 11 Control Components 12 Operating Parameters 14 Adding an Inventory Control System 15 Control Operation 20

Control On Battery Backup Version 31 Solenoid Valve 31 INTERFACE SOFTWARE 32 MAINTENANCE 33

Strainer Cleaning Instructions 33

Defrosting Your LAB-Series CryoStorage System 33

Cleaning Your Taylor-Wharton CryoStorage System 34

Making Adjustments to the LABS KRYOS Sensor Assembly 35

Removing/Installing the Solenoid Valve 37

Sensor Plug Schematic 38

LABS Plumbing Assembly 39 TROUBLESHOOTING 40

Symptoms 40

Factory Settings 44 Replacement Parts 45

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WARNING

The following safety precautions are for your protection. Before installing, operating, or maintaining this unit read and follow all safety precautions in this section and in reference publications. Failure to observe all safety precautions can result in property damage, personal injury, or possibly death.

Safety Precautions for Liquid Nitrogen

Nitrogen is an inert, colorless, odorless, and tasteless gas making up four-fifths of the air you breathe. Liquid nitrogen is obtained by cooling air until it becomes a liquid and then removing the oxygen. Air is roughly one-fifth oxygen. Liquid nitrogen is at a temperature of -320°F (-196°C) under normal atmospheric pressure.

Extreme Cold - Cover Eyes and Exposed Skin Accidental contact of liquid nitrogen or cold issuing gas with the skin or eyes may cause a freezing injury similar to frostbite. Handle the liquid so that it won't splash or spill. Protect your eyes and cover the skin where the possibility of contact with the liquid, cold pipes and cold equipment, or cold gas exists. Safety goggles or a face shield should be worn when operating this equipment. Insulated gloves that can be easily removed and long sleeves are recommended for arm protection. Trousers without cuffs should be worn outside boots or over the shoes to shed spilled liquid.

Keep Equipment Area Well Ventilated Although nitrogen is non-toxic and non-flammable, it can cause asphyxiation in a confined area without adequate ventilation. Any atmosphere not containing enough oxygen for breathing can cause dizziness, unconsciousness, or even death. Nitrogen, a colorless, odorless, and tasteless gas, cannot be detected by the human senses and will be inhaled normally as if it were air. Without adequate ventilation, the expanding nitrogen will displace the normal air resulting in a non-life-supporting atmosphere.

Liquid Nitrogen System

The liquid nitrogen supply pressure at the inlet to the refrigerator should be in the range of 10 psig (0.7bar/69 kPa) to 20 psig (1l4bar/138 kPa) for optimum performance. Higher operating pressures will increase transfer losses and create excessive turbulence of the liquid in the refrigerator which can generate false signals to the liquid level controller causing the refrigerator to under-fill. In “liquid phase” storage applications, excessive turbulence can cause splashing which could result in personal injury and/or damage to the refrigerator. When installing piping or fill hose assemblies, make certain a suitable safety relief valve is installed in each section of plumbing between shut-off valves. Trapped liquefied gas will expand greatly as it warms and may burst hoses or piping causing damage or personal injury. A relief valve is installed in the refrigerator plumbing to protect the line between the customer supplied shut-off valve and the refrigerator solenoid valve.

CAUTION: When installing field fabricated piping, make certain a suitable safety valve is installed in each section of piping between shut-off valves.

For more detailed information concerning safety precautions and safe practices to be observed when handling cryogenic liquids consult CGA pamphlet P-12 "Handling Cryogenic Liquids" available from the Compressed Gas Association, 1235 Jefferson Davis Highway, Arlington, VA 22202.

Warning: Inlet pressure should not exceed 22 psig (1.5bar/152 kPa). Higher pressures could result in damage to equipment.

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Dispose of Waste Liquid Nitrogen Safely Dispose of waste liquid nitrogen out-of-doors where its cold temperature cannot damage floors or driveways and where it will evaporate rapidly. An outdoor pit filled with clean sand or gravel will evaporate liquid nitrogen safely and quickly.

Electrical

Electrical Shock Can Kill – the liquid level controllers used with these refrigerators operate from 16.5VAC. However, the external transformer does have an 110/220VAC primary.

Do not attempt any service on these

units without disconnecting the electrical power cord.

Note: Units are supplied with Taylor-Wharton approved controllers. If other liquid level controllers are used, please contact Taylor-Wharton before putting the refrigerator into service.

Freight Damage Precautions

Any Freight damage claims are your responsibility. Cryostorage systems are delivered to your carrier from Taylor-Wharton’s dock in new condition. When you receive our product you may expect it to be in that same condition. For your own protection, take time to visually inspect each shipment in the presence of the carrier’s agent before you accept delivery. If any damage is observed, make an appropriate notation on the freight bill. Then, ask the driver to sign the notation before you receive the equipment. You should decline to accept containers that show damage, which might affect serviceability.

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GENERAL INFORMATION

Thank you for purchasing this product. This state of the art CRYOSTORAGE SYSTEM can control either the liquid level and/or the vapor temperature range. The features are designed to provide a safe environment for samples while at the same time tracking all relevant information associated with the freezer. This control provides a complete historical record of the environment in your freezer and therefore, the environment in which your samples have been stored.

Text Format Notation

In this owner’s manual we use some special text formats to denote certain portions of the system. These are listed below:

• Menu is indicated in ALL CAPS BOLD.

• Actual Menu Choices are indicated in ALL CAPS.

• Start Fill and Stop Fill sensor are indicated in ALL CAPS ITALICS.

• Specific Menu Descriptions under a main category are listed in Italics.

Taylor-Wharton LABS CryoStorage Systems are designed for applications where extremely low temperature storage of biological products is required. They are also appropriate for industrial or other applications where liquid nitrogen temperatures and high capacity are needed.

The LABS style refrigerator covered by this publication is designed for, but not limited to, the laboratory environment. Each model is supplied with casters to enable limited mobility for cleaning and positioning purposes.

The standard model is also equipped with the KRYOS electronic liquid level controller that will monitor and control the supply of liquid nitrogen to the unit. The controller features a vacuum fluorescent display. The addition of a liquid nitrogen supply and inventory control racks for systematic retrieval of stored product completes the total cryostorage system.

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LABS Cryostorage Specifications

Liquid nitrogen at atmospheric pressure weighs 1.78 lb./liter (0.8 kg/liter). All Taylor-Wharton Gas Equipment cryostorage systems are designed to support the full weight of liquid nitrogen and a complete stainless steel or aluminum inventory control system with boxes and specimens.

Dimensions 80K 40K 20K

External Operating Height in 42.5 42.5 42.5 (Top of Step to Lid opening) mm 1080 1080 1080

Step Height in 11 11 11 mm 279 279 279 Overall Height in. 60 60 60 (Top of Control Interface) mm 1524 1524 1524

Usable Height, Internal in. 30.0 30.0 30.0 mm 762.0 762.0 762.0 Outside Diameter in 59.5 45.0 34.0 mm 1511 1143 863.6 Internal Working Diameter in 55.0 40.5 29.5 mm 1397 1029 750 Neck Opening in 24.5 18.0 13.0 mm 622 457 330

Capacity

LN2 Capacity L 1350 606 407

Power Supply

Evaporation Rate1 L/day 15.0 9.0 8 Weight, Empty lb 1550 920 650

kg 703 417 295

Maximum Gross Weight2 lb. 3956 2000 1375

kg 1794 907 624

Inventory Control System Specifications

No 5.0 x 5.0 Racks No. Shelves/Rack 13 13 13 No. 3.0 x 3.0 Racks No. Shelves/Rack 13 13 13 Vial Capacity, 2 ml Blood Bag (Fenwall 4R9951) 2100 1204 560 Blood Bag (Fenwall 4R9953) 1505 820 400 Blood Bag (Fenwall 4R9955) 1050 590 290

Footnotes:

This is the power supply for the standard battery backup version. The Kryos version (No Battery) uses a 24 VAC power supply.

For power outlets other than North American 110 VAC contact Taylor-Wharton Customer Service.

Evaporation rate is nominal. Actual rate may be affected by the nature of the contents, atmospheric

conditions, container history, and manufacturing tolerances.

Includes the empty weight and total LN2 capacity weight.

5.0 in. x 5.0 in. (127 mm x 127 mm) 100 cell box.

3.0 in. x 3.0 in. (76 mm x 76 mm) 25 cell box.

2 ml vial size; 12.5 mm O.D. internal thread.

VAC 16.5 16.5 16.5

58 30 14

12 8 4

79300 41600 19500

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KRYOS Specifications

Configurations: Designed exclusively for all Taylor-Wharton LABS CryoStorage

Systems

Power Supply: 16.5 VAC, 40 Voltamps – Standard Battery Backup Version

24 VAC, 40 Voltamps (No Battery) (For power outlets other than North American 110 VAC contact Taylor-Wharton Customer Service.)

Sensor Assembly: Freeze-Guard Assembly – Standard

8-Thermistor Assembly– Optional 4-Thermistor Assembly – Optional

Thermocouples: Operates with none, 1 or 2 Type T

Thermocouples (1 piece standard) Solenoid Valve: 12 VDC cryogenic solenoid valve – Standard Control Type: Liquid Level Control or Liquid Level Control with Temperature

Control Security: User Access via 2-digit password

Power On/Off Password

Menu access Password Alarms: Audible

Visual red LED

Alarm description

Remote alarm relay Diagnostics: Circuit diagnostics at start-up

Sensor diagnostics from front panel

Thermocouple diagnostics from front panel

Manual Test for audible, visual and remote alarms Temp. Calibration: Automated calibration from the front panel Communications: RS-232 Serial Port for 2-way communications capable Logging Capacity: System Logs (4096 events)

Alarm Logs (4096 events)

Temperature Logs (32,768 events) Battery: A CR2032 coin cell battery is used to back up time/date

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INSTALLATION

Unpacking and Inspection

Inspect shipping containers for external damage. All claims for damage (apparent or concealed) or partial loss of shipment must be made in writing within five (5) days from receipt of goods. If damage or loss is apparent, please notify the shipping agent immediately.

Open the shipping containers; a packing list is included with the system to simplify checking that all components, cables, accessories, and manuals were received. Please use the packing list to check off each item as the system is unpacked. Inspect for damage. Be sure to inventory all components supplied before discarding any shipping materials. If there is damage to the system during transit, be sure to file proper claims promptly with the carrier and insurance company. Please advise Taylor-Wharton of such filings. In case of parts or accessory shortages, advise Taylor-Wharton immediately. Taylor-Wharton cannot be responsible for any missing parts unless notified within 60 days of shipment.

Repackaging for Shipment

If it is necessary to return any part of the system for repair or replacement, a Material Return Authorization (MRA) number must be obtained from an authorized factory representative before returning the instrument to our service department. Contact your distributor for return authorization. When returning an instrument for service, the following information must be provided before obtaining an MRA:

A. System model and serial number, and controller serial number B. User’s name, company, address, and phone number C. Malfunction symptoms D. Description of System

If possible, the original packing material should be retained for reshipment. If not available, consult TaylorWharton for shipping and packing instructions. It is the responsibility of the shipper to assure that the goods are adequately packaged for return to the factory.

Liquid Nitrogen Supply Connection

The package included with the refrigerator includes a strainer. The liquid fill hose from a low pressure source of liquid nitrogen must be connected to the inlet through this fitting. This liquid nitrogen source must have a shut-off valve, and may be any portable liquid cylinder or a bulk supply. The liquid nitrogen supply pressure at the inlet to the refrigerator should be in the range of 10 psig (0.7 bar/69 kPa) to 20 psig (1.4 bar/38 kPa) for optimum performance. Higher operating pressures will increase transfer losses and create excessive turbulence of the liquid in the refrigerator which can generate false signals to the liquid level controller causing the refrigerator to under-fill. In “liquid phase” storage applications, excessive turbulence can cause splashing which could result in personal injury and/or damage to the refrigerator. If the liquid nitrogen supply pressure at the inlet to the refrigerator rises above the opening pressure of the relief valve on the refrigerator, liquid nitrogen will be discharged into the surrounding area which can cause a rapid and very dangerous depletion of oxygen in the atmosphere. Once this pressure relief device has opened and cooled to liquid nitrogen temperature, it will not reseat until it has warmed to near ambient temperature. ENTIRE CONTENTS OF THE LIQUID NITROGEN SUPPLY SYSTEM TO BE DISCHARGED INTO THE IMMEDIATE AREA OF THE REFRIGERATOR(S) .

WARNING: In order to prevent the relief device on the nitrogen refrigerator(s) from opening when the system is in operation, the liquid nitrogen supply system must be protected by a pressure relief device that will open when the pressure at the inlet to the refrigerator(s) is approximately 22 psig (1.5 bar/152 kPa). Never install the supply system pressure relief device onto a liquid service line.

THIS COULD PERMIT THE

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Power Supply Connection

Connect the 16.5 Volt AC power supply to the control of the LABS cryostorage system; then plug the power supply into a surge protected 110/120 VAC outlet.

KRYOS Control Field Installation

1. Unplug power from old unit.

2. Close liquid nitrogen supply at valve.

3. Remove 4 Phillips head screws from rear of interface display box.

4. Remove controller face from interface display box.

5. Finish face removal by disconnecting plug and ground wire.

6. Remove 2 Phillips head screws from the old control located underneath the tabletop.

7. Withdraw old controller from underneath table top, noting how the controller body has been

resting on outer upper head.

8. Unplug all connectors and wires and set panel aside.

9. Disconnect supply hose from solenoid valve.

10. Remove old solenoid.

11. Remove spiral wire wrap.

12. Mark old sensor locations with electrical tape

13. Measure and make note of the “Start Fill”, “Stop Fill” and temperature sensors from the bottom

of the appropriate sensor tube. You will need this information to set up the new controller.

14. Remove old sensor wires.

15. Calibrate new KRYOS control to new temperature sensor.

16. Reverse procedure to install KRYOS control.

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OPERATION

These instructions are for operators experienced with cryogenic equipment. Before operating the system, become familiar with the safety precautions in this manual and in reference publications. Make certain all applicable provisions set forth in the Installation Section have been followed before placing a system in operation. Study this manual thoroughly. Know the location and function of all system components.

Initial Fill

The LABS cryostorage system using the KRYOS controller, comes preset from the factory. The liquid nitrogen supply pressure at the inlet to the refrigerator should be in the range of 10 psig (0.7 bar/69 kPa) to 20 psig (1.4 bar/138 kPa) for optimum performance. Higher operating pressures will increase transfer losses and create excessive turbulence of the liquid in the refrigerator which can generate false signals to the liquid level controller causing the refrigerator to under fill. In “liquid phase” storage applications, excessive turbulence can cause splashing which could result in personal injury.

WARNING: Maintain adequate ventilation to prevent asphyxiation hazard (see Safety Precautions).

WARNING: If the fill fails to stop for any reason, quickly close the liquid supply valve to prevent overfilling until the cause of the problem can be determined.

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Control Components

Interface Panel

The KRYOS Interface panel, which the user will interact with, contains the vacuum fluorescent display as well as the number keypad, power button, help button and the soft-key control buttons. (See figure 1.0 below.)

Figure 1.0 KRYOS Interface Panel

Main Control

The “brain” for the control system “talks” to the interface unit and makes all decisions regarding liquid levels, temperatures, valve opening/closing, etc. It is located away from the Interface Panel on the upper outer head. (See figure 2.0 below.)

Main Control

Figure 2.0 KRYOS Main Control

Sensor Assembly

A standard 7+1 thermistor assembly, includes the Freeze-Guard over-fill sensor. Optional 4-thermistor, or 8thermistor sensor assemblies can be ordered. The 4-thermistor assembly maintains the liquid level between 2 middle sensors. The 8-thermistor assembly maintains the liquid level between the high sensor and the low sensor assigned by the user. The standard 7-thermistor assembly is similar to an 8 sensor assembly in that the user can select the START FILL and STOP FILL positions. The eighth position on this assembly is tied into an inline plumbing thermistor, which detects if the solenoid valve fails to close.

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Lid Switch

Is attached to the hinge and determines whether or not the lid is open on the freezer. This also allows the control to determine whether to activate the Quickchill, Auto Defog or Lid Alarm features.

Lid Switch

Figure 3.0 Lid Switch

Solenoid Valve

Designed to work with 12 VDC solenoid valves manufactured by Valcor, Parker-Hannifin, ASCO or Alcon. (See plumbing assembly Figure 10.0 on page 37 of this manual.)

Thermocouples

Type T thermocouples determine the temperature in the freezer. The user may choose to use NONE, 1 or 2 thermocouples with this control at any time. (The unit comes complete with one Thermocouple)

Wall Transformer

A 16.5 VAC, 40 VA wall transformer is a standard option on the LABS cryostorage system with battery backup. A 24 VAC, 40 VA wall transformer is supplied for the Kryos version (No Battery). The system is supplied with a transformer compatible with common household (North American) 110VAC. (For other power outlets contact Taylor-Wharton Customer Service.) These wall transformers have UL approval. UL approval for the system as a whole is not required since the control operates on low voltage. If your power source differs, or is subject to disruption or line surges due to other equipment on line, consult your TaylorWharton representative.

Battery Backup

The LABS cryostorage system with the battery backup option has a 12VDC battery installed underneath the unit's tabletop.

Remote Alarm

If an error condition occurs after a user defined period of time a remote alarm circuit can be initiated. This is accomplished by connecting a remote device to the remote alarm jack on the rear electrical panel. The 3-pin jack on the back of the unit provides continuity between pin #2 (common) and pin #3 in the normal condition. Continuity between pin #1 and pin #2 is provided in an error condition. (See Figure 4.0 below.)

Figure 4.0 Remote Alarm Plug Connection

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Operating Parameters

When materials are immersed in liquid nitrogen, they will assume the temperature of the liquid -196ºC (320ºF). When material is stored in the vapor phase over the liquid, the liquid nitrogen is still a very cold refrigerant, but the refrigerator’s interior temperature increases somewhat as product is stored higher over the liquid. This temperature differential is not significant in many biological storage applications, and is affected by the amount of product stored in the refrigerator, the type and size of inventory control system, and the liquid level in the unit.

The liquid level in the refrigerator is determined by the position of the sensor probes in the tube located to the right of the refrigerator. These probes are set at installation to maintain a specific liquid level. The controller operates a fill cycle that adds liquid at a low level, fills to a predetermined high level, then stops the fill. The cycle repeats when the liquid level drops to the low level sensor over time. Sensor probe assignments may be changed on the controller keypad to define new high and low levels, and these levels may be set independently to vary the liquid level differential between fills. Prior to the initial fill of the refrigerator, a determination should be made whether vapor phase or liquid phase storage will be utilized.

The sensor probe contains seven thermistors that can be preprogrammed for any liquid level application. The separate sensor in the sensor tube is the temperature thermocouple. The thermocouple is normally positioned at the top of the storage rack. The factory sensor positions will maintain a liquid level within a distance of 2 in. (50.8 mm) from the bottom of the operating tray.

Liquid Phase Storage Liquid phase storage is normally utilized when liquid nitrogen temperatures are required to maintain stored product viability and the storage medium is adequate for storage in liquid nitrogen.

In a typical liquid phase storage system, the liquid level sensors are positioned to maintain the liquid level at or below the top level of the inventory control system. During operation, the upper levels of the inventory control system will at times become exposed as the liquid level fluctuates.

Care must be taken to ensure that the liquid level remains below the bottom of the refrigerator lid. Exposure to liquid nitrogen may result in physical damage to the lid. Additionally, operating the refrigerator with high liquid levels characteristic of liquid phase storage may result in turbulence during fill cycles. Caution must be exercised if the refrigerator lid is opened during a fill, and appropriate safety equipment should always be worn.

The LABS cryostorage system is set at the factory for vapor phase storage. To reconfigure the system's settings for liquid phase, the following steps should be used.

1. Power up the unit.

2. Remove the “Start Fill”, “Stop Fill” (Thermistor) sensors.

3. Allow the unit to fill to your desired “Stop Fill” elevation.

4. Stop the fill by closing the supply line valve.

5. On the interface panel, push (MENU, 2, 1).

6. Insert the “Start Fill”, “Stop Fill” (Thermistor) sensors until the #6 sensor changes on the display

from G (gas) to L (liquid).

7. Return to the main (MENU).

8. Dress wires and seal with stopper.

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Thermocouple Positioning

The thermocouple is a separate sensor used to monitor and control the temperature within the refrigerator. The factory-supplied thermocouple in the LABS cryostorage system is positioned to monitor the temperature 30” above the tray.

Adding an Inventory Control System

The purpose of the inventory control system is to bring order to the storage of many small samples, and to allow direct retrieval of the particular sample you need at any time. It is important to be aware that when you lift an ICS rack from the refrigerator it is in a warmer environment. Learn to locate your sample quickly to avoid unnecessary warming of your stored product. Keep ICS inserts (drawers or boxes) and dividers in good repair. Replacement inserts and dividers are available from your Taylor-Wharton distributor to keep your system as efficient as possible.

Always wear gloves when handling ICS racks or stored product, as they are very cold – read the precautions in the Safety section of these instructions, and in Taylor-Wharton publication TW-10 “Handle With Care”, for more detail on handling product stored in liquid nitrogen.

When removing ICS racks to retrieve product, protect the labels, plastic, and electronic areas of the refrigerator from liquid nitrogen that may spill from the rack inserts. These parts of the refrigerator are subject to damage from the extreme low temperature of the refrigerant.

Do not let ice or debris collect in the bottom of the freezer. Schedule periodic clean out if racks no longer stand upright.

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