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.
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TW-357 REV E Table of Contents WARNING Safety Precautions for Liquid Nitrogen GENERAL INFORMATION Text Format Notation LABS Cryostorage Specifications INSTALLATION Unpacking and Inspection Liquid Nitrogen Supply Connection Power Supply Connection KRYOS Control Field Installation OPERATION Initial Fill Control Components Operating Parameters Adding an Inventory Control System Control Operation Control On Battery Backup Version Solenoid Valve INTERFACE SOFTWARE MAINTENANCE Strainer Cleaning Instructions Def
TW-357 REV E 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.
TW-357 REV E 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.
TW-357 REV E 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.
TW-357 REV E 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 (Top of Step to Lid opening) in mm 42.5 1080 42.5 1080 42.5 1080 Step Height in mm in.
TW-357 REV E 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.
TW-357 REV E 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.
TW-357 REV E 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. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Unplug power from old unit. Close liquid nitrogen supply at valve. Remove 4 Phillips head screws from rear of interface display box. Remove controller face from interface display box.
TW-357 REV E 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.
TW-357 REV E 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.
TW-357 REV E 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.
TW-357 REV E 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.
TW-357 REV E 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.
TW-357 REV E Inventory Control System Layouts (LABS Cryostorage System) Typical 13-2 Rack 100 Vial Polycarbonate 100 Vial Aluminum Boxes 81 Vial Polycarbonate, Cardboard, or Stainless Steel Boxes NOTE: RACKS ARE NOT SQUARE. ORIENTATION IS IMPORTANT.
TW-357 REV E Blood Bag Cassette Blood Bag Storage in Cassette LABS-20K LABS-80K LABS-40K Fenwal 4R9951 Blood Bags – ask about other Bag types PART NUMBER CAPACITY FRAMES CASSETTES LABS-80K 2100 300 2100 LABS-40K 1204 172 1204 LABS-20K 560 80 560 Figure 6.
TW-357 REV E Blood Bag Cassette Blood Bag Storage in Cassette LABS-20K LABS-80K LABS-40K Fenwal 4R9953 Blood Bags – ask about other Bag types PART NUMBER CAPACITY FRAMES CASSETTES LABS-80K 1505 301 1505 LABS-40K 820 164 820 LABS-20K 400 80 400 Figure 7.
TW-357 REV E Blood Bag Cassette Blood Bag Storage in Cassette LABS-20K LABS-80K LABS-40K Fenwal 4R5462 – 9955 Blood Bags – ask about other Bag types PART NUMBER CAPACITY FRAMES CASSETTES LABS-80K 1050 210 1050 LABS-40K 590 118 590 LABS-20K 290 58 290 Figure 8.
TW-357 REV E Control Operation This section of the operating manual is for Taylor-Wharton approved equipment that uses the KRYOS controller. Introduction The KRYOS temperature and LN2 level controller is designed for easy operation and uninterrupted, reliable service. This controller will maintain the selected temperature and liquid level range of LN2 in your refrigerator as well as provide audible and visual alarms for any alarm conditions that may occur.
TW-357 REV E Main Display Screen The main display screen consists of 4 lines of information. Line 1: Displays the current status of the control. It indicates if all systems are normal or if any errors have been detected. Error messages disappear when the error is corrected. Line 2: Displays the level sensing in the control. If the 7-thermistor or 8-thermistor assembly is being used, the control will indicate actual liquid level in the freezer.
TW-357 REV E Table 1.0 Menu System 1. Temperature 1.1 Thermocouple Select 1.2 Calibrate Temperature 1.3 Test Temperature System 2. Level Sensing 2.1 Test Level Sensors 2.2 Set Sensor Offset 2.3 Sensor Positions 2.3.1 Start Set Point 2.3.2 Stop Set Point 2.4 Sensor Type 2.5 Inch/Metric 3. Alarms 3.1 High-Temp Alarm #1 3.2 High-Temp Alarm #2 3.3 System Alarms 3.3.1 LN2 Supply Alarm 3.3.2 Sensor Error Alarm 3.3.3 Remote Alarm Timer 3.3.4 Lid Open Too Long 3.3.5 Thermocouple Alarm 3.4 Test Alarms 3.4.
TW-357 REV E Help Screens The Help button provides help to the user at any point in the menu system. The help message is displayed and the user is then prompted to press a button to return to the menu system. Temperature Thermocouple Select The chamber temperature is monitored with 1 or 2 Type T thermocouples. The thermocouple is placed in the chamber to monitor temperature level with the top rack.
TW-357 REV E Sensor Type The sensor type can be set through the menu system (MENU, 2, 4). The sensor type selection should match the sensor type that is being used in the system. This is a 4-sensor, a 7-sensor (Freeze-Guard) or an 8-sensor array. If the sensor assembly is unplugged and the main control is still on, the display will indicate that a sensor error has occurred.
TW-357 REV E System Alarms The Low LN2 Supply Alarm can be set through the menu system (MENU, 3, 3, 1). This alarm is activated if the solenoid valve is not closed within a designated time period after a fill starts. The solenoid valve can be closed either automatically (the LN2 level reaches the STOP FILL sensor) or manually (the stop fill button is pressed) to stop the timer which activates this alarm. The possible choices for this alarm are None, 15, 30, 45, 60 minutes, 2 or 3 hours.
TW-357 REV E The control consolidates the events in the internal log (combining “start event” / ”conclude event” information to provide one event with duration), however, when the data is sent out the serial port no consolidation of data occurs. As an example, a fill would provide one log entry in the internal log of the control, indicated as follows: Fill occurred on 9/28/98 @ 8:07 for 24 minutes.
TW-357 REV E OPEN THERMOCOUPLE LOGGING is accessible through the menu system of the control (MENU, 4, 2, 4). This menu choice turns on/off the logging of the thermocouple open alarm. The choices are ENABLE and DISABLE. Records data in the error log. HIGH TEMP #1 LOG is accessible through the menu system of the control (MENU, 4, 2, 5). This menu choice turns on/off the logging of the high temperature alarm for Thermocouple #1. The choices are ENABLE and DISABLE. Records data in the error log.
TW-357 REV E The MENU PASSWORD can be set through the menu system of the control (MENU, 5, 2). The menu password requires entry of a 4-digit password before allowing access to the menu system to change any control settings. Follow the directions on the display to set a new password or to disable a password. Codes 0000 & 9999 are invalid choices. A code of 9999 is used to access a procedure to clear passwords should they be forgotten.
TW-357 REV E Menu Password When the menu password is active, it is possible to review all of the control settings without having the password. When a password is activated and the user presses the menu key, two choices are available: 1) MENU (PASSWORD REQ) 2) CONTROL SETTINGS By selecting choice #2 the user can go through the menu system and see all of the settings in the control but in this mode, the user cannot change any settings.
TW-357 REV E Control Range CONTROL RANGE can be accessed through the menu system of the control (MENU, 6, 2, 3, 2, 2). KRYOS maintains a temperature range around the user-selected temperature. A tighter range maintains a temperature very close to the selected temperature at the cost of greater LN2 usage. A broad range provides more temperature variability but the LN2 usage is less. The range can be varied from +1º to +15ºC above and below the selected temperature.
TW-357 REV E Display Brightness DISPLAY BRIGHTNESS can be set through the menu system of the control (MENU, 6, 3). This option changes the intensity of the display. The possible choices are 25%, 50%, 75% and 100%. About this Control ABOUT THIS CONTROL can be accessed in the menu system (MENU, 6, 4). This option provides information about the control. In particular it tells the serial number of the control and the software version that the control is running.
TW-357 REV E The DC solenoid valve requires that the battery be connected for the system to work properly. If the battery is disconnected or completely discharged the valve operation and the control operation may be affected. In particular, if the control is calling for a fill, the solenoid will be called to open. Opening the solenoid takes a substantial inflow current, which the solenoid may “steal” from the control if it cannot get sufficient power from the battery.
TW-357 REV E MAINTENANCE Strainer Cleaning Instructions The container will not fill properly if the strainer is clogged with ice or dirt. To clean the strainer, first close the supply valve to the refrigerator. Vent the fill line of all pressure. Remove and warm the strainer to ambient temperature. Purge the strainer from both directions with dry nitrogen gas or dry oil-free air. Rinse the strainer with alcohol and purge it again with dry nitrogen gas or dry oil-free air to clear contaminants.
TW-357 REV E Cleaning Your Taylor-Wharton CryoStorage System The cryogenic vessel of all LABS CryoStorage Systems may need to be cleaned, and sterilized if the type of stored product is changed or the unit is taken out of service. The vessel must be defrosted, cleaned, and sterilized regardless of the type of stored product, prior to return to Taylor-Wharton for repair or maintenance. Prior to cleaning, the unit must be warmed and defrosted following the defrosting procedure described above.
TW-357 REV E WARNING: Never use chlorine-based disinfectants to clean a LABS CryoStorage System. Normal Evaporation Rate (NER) Test Nitrogen consumption is an accumulation of all system components and user introduced evaporation. The storage chamber is a double walled, vacuum insulated vessel and contributes to the daily consumption of liquid nitrogen. The liquid nitrogen supply vessel and transfer hose also contribute greatly to the daily consumption rate.
TW-357 REV E The Kryos Control installed on the Taylor-Wharton LABS80K refrigerator operates with software version 9.0 (regular operation) or 9.0B (battery backup). This control software has been specially designed to match the design characteristics of the LABS 80K refrigerator. The differences between the versions are in the table below Table: Software version differences Level Readings Default Start Fill / Stop Fill Default Auto Defog Offset Value Units of measure Kryos V4.0 Kryos V9.0 & Kryos V9.
TW-357 REV E • Move the sensor up or down so that the appropriate numbers of sensors are in liquid (read “L”). • Get back to the KRYOS main screen and the level indicated should match the physically measured reading. The Sensor Offset, the Start Fill and the Stop Fill can all be set through the KRYOS menu system (MENU, 2). Removing/Installing the Solenoid Valve Disconnect only the solenoid valve lead connection from the back of controller board.
TW-357 REV E Sensor Plug Schematic Figure 9.
TW-357 REV E LABS Plumbing Assembly Solenoid Valve Freeze-Guard Sensor Male Branch Tee 90 deg Elbow 90 deg Elbow Male Branch Tee Reducer Relief Valve Tube Strainer Female Connector Relief Valve Figure 10.
TW-357 REV E TROUBLESHOOTING Symptoms The key to troubleshooting your LABS CryoStorage system is to determine which component in the system is the source of the problem. Determine if the problem is occurring in any of the following subsystems: Supply Vessel, Transfer Line, Power Source, Temperature, Level Sensing, Security, Lid Switch, Solenoid Valve, Control Display, Alarm System, Communications.
TW-357 REV E • • Simulate an over fill by lowering the next thermistor into the LN2 . HIGH LEVEL alarm should sound with 10 seconds. Re-install sensor assembly and thermocouple into sensor tube as before. Open supply valve on LN2 supply. Indicates Low LN2 Supply When the START FILL thermistor is uncovered, the controller calls for the fill solenoid valve to open.
TW-357 REV E Fill Solenoid Cycles On and Off KRYOS features a Freeze-Guard function whereby the valve open duration is limited, allowed to shut for a short warm-up and then opened again. To confirm or change the valve open duration: • Select MENU, USER OPTIONS, CONTROL OPTIONS, FREEZE-GUARD OPTIONS, VALVE OPEN DURATION. If the controller detects that the valve is stuck in the open position (i.e.
TW-357 REV E Defog Feature Will Not Operate See LID OPEN ALARM. To activate or adjust times: Select MENU, USER OPTIONS, CONTROL OPTIONS, LID/DEFOG SETTINGS, AUTO DE-FOG. Push Buttons Will Not Respond 1. Check all ribbon cable connectors on back of display panel. 2. Moisture may have migrated into the sealed faceplate. Call Taylor-Wharton for a Return Authorization. Liquid Level Readout is Incorrect Liquid level is determined by a seven-thermistor assembly inside a protective sensor tube.
TW-357 REV E Factory Settings To restore factory settings at any time KRYOS can be re-initialized. Please note that a re-initialization clears all logs and passwords and resets settings to those listed in the table below. To reset factory settings in the control, go to the menu choice ABOUT THIS CONTROL. (MENU, 6, 4) and while looking at this screen type in 1973. The control will lead you through the process required to reset the factory settings.
REPLACEMENT PARTS Refrigerator Parts (LABS) 80K/40K/20K Lid Assembly……………………………………………………………LA80-9C85/LA40-9C85/LA20-9C85 Caster, ……………….. …………………………………………………………… 7300-8040 Decal, Warning……………………………………………………………………. R23K-9C42 Decal, Warning………………………………………………………………… R10K-9C42 Inventory Rack 25 Vials [13 shelves tall for 2 in (51mm.) boxes] (ea.)…………… R10K-9C44 Inventory Rack 100 Vials [13 shelves tall for 2 in (51mm.) boxes] (ea.) R23K-8C35 Level Controller Electrical/Mechanical Parts Controller KRYOS ……...
Fill in top section at installation. Copy this form each time service is required. Fill bottom section with service notes to keep a complete log of each freezer service and maintenance history.
4075 Hamilton Blvd. Theodore, Alabama 36582 U.S.A. Telephone (251) 443-8680 Fax (251) 443-2250 In U.S.