Thermo Scientific CryoExtra CE8100 Series Operating And Maintenance Manual
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Thermo Scientific CryoExtra CE8100 Series Operating And Maintenance Manual

Liquid nitrogen storage systems
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CE8100 Series
RYO
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Liquid Nitrogen Storage Systems
Operating and Maintenance Manual 326636H01 Rev A

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Summary of Contents for Thermo Scientific CryoExtra CE8100 Series

  • Page 1 CE8100 Series XTRA Liquid Nitrogen Storage Systems Operating and Maintenance Manual 326636H01 Rev A...

  • Page 2: Preface

    TECHNICAL SUPPORT Phone: 1-800-438-4851 Thermo Scientific products are backed by a global technical support team ready to support your applications. Visit www.thermoscientific.com or call: North America (800) 438-4851 • India +91 22 6716 2200 • China +8621 68654588 • Japan +81 3 3816 3355 •...

  • Page 3: Table Of Contents

    Table of contents ..........................3 Safety and First Aid ..........................7 Certifications and Listings ......................... 9 Product Information .......................... 10 5.1. Freezer Models ..............10 Thermo Scientific CryoExtra 5.2. Plumbing Assembly ......................... 12 5.3. Controller Display ........................13 5.4. Controller Stand Alone Back Panel / Physical Connections ..........14 5.4.1.
  • Page 4 326636H01 Rev A 5.5. Specifications ..........................16 5.6. Operating Environment ......................17 Installation and Startup ........................18 Operation ............................22 7.1. Functions and Features ......................23 7.1.1. Liquid Nitrogen Level Measurement ................24 7.1.2. Automatic Liquid Nitrogen Level Control ..............25 7.1.3.
  • Page 5 326636H01 Rev A 7.5. Remote Alarm Tests ........................ 93 7.5.1. Global Remote ........................93 7.5.2. Discrete Contacts ......................... 93 Controller Menu Maps ........................94 8.1. Main Setup Menus ........................94 8.2. Temperature Setting Menus ....................95 8.3. Temperature Calibration Menus .................... 96 8.4.
  • Page 6 326636H01 Rev A Page intentionally blank 6 of 133...

  • Page 7: Safety And First Aid

    326636H01 Rev A 3. Safety and First Aid READ BEFORE OPERATING THIS EQUIPMENT General Liquid nitrogen (LN2) is used in CryoExtra Cryogenic Freezers as a refrigerant. Understanding and following certain safety precautions is extremely important when handling LN2 and cryogenic containers (Dewars).

  • Page 8: Recommended First Aid

    326636H01 Rev A Persons transferring LN2 should make every effort to protect the eyes and skin from accidental contact with liquid or cold vapor. ThermoFisher Scientific recommends the following protective clothing and accessories when transferring LN2 or handling hoses, valves, and plumbing components: Recommended protective clothing Cryogenic gloves (loose fitting) Full-face shield or chemical splash goggles...

  • Page 9: Certifications And Listings

    326636H01 Rev A 4. Certifications and Listings All fully automatic CryoExtra cryogenic freezer systems equipped with a controller are UL / CUL listed and CE marked to the Low Voltage Directive (LVD). Specially designated freezer models are also CE marked to the Medical Device Directive (MDD). The LVD is a European Union directive regulating the construction and operation of electrical equipment that is not considered a medical device.

  • Page 10: Thermo Scientific Cryoextra Tm Freezer Models

    Each freezer is a hand-made, double-walled, vacuum insulated stainless steel Dewar designed to maintain temperature with minimal LN2 evaporation. 5.1. Thermo Scientific CryoExtra Freezer Models Thermo Scientific CryoExtra cryogenic freezers offer specialized features and functionality. Below is the...
  • Page 11 326636H01 Rev A Figure 1: Top-view of HE Freezer showing offset neck and P and R turn-trays The CryoExtra High Efficiency / Vapor Series freezers will maintain a vapor storage temperature of - 190°C with minimal LN2 evaporation while accommodating a wide variety of inventory systems Minimu Minimum Turn-tray...

  • Page 12: Plumbing Assembly

    326636H01 Rev A 5.2. Plumbing Assembly The plumbing assembly carries and regulates the flow of LN2 from the liquid supply through the fill line, and into the freezer. It is comprised of three main circuits: fill circuit, purge circuit, and gas bypass circuit. Hot Gas Bypass Circuit Purge...

  • Page 13: Controller Display

    326636H01 Rev A 5.3. Controller Display The Controller front panel display is the primary user interface for the Controller. There are two display options: text or symbolic. LDC Display 20 x 4 LCD with backlight START FILL Key Used to manually initiate a fill Used to manually terminate a fill –...

  • Page 14: Controller Stand Alone Back Panel / Physical Connections

    326636H01 Rev A 5.4. Controller Stand Alone Back Panel / Physical Connections The Controller physical and electrical connections are located on the bottom of the stand-alone (non- cabinet) controller and on the back panel of the cabinet controller. Temp A Port Connection for Temp A probe Temp B Port Connection for Temp B probe...

  • Page 15: Controller 12-Pin Wiring Harness Connections

    326636H01 Rev A 5.4.1. Controller 12-Pin Wiring Harness Connections POSITION DESCRIPTION WIRE COLOR WIRE GAUGE LENGTH +24VDC BATTERY BACKUP DARK BLUE 50" -24VDC BATTERY BACKUP ORANGE 50" BLACK WHITE + LID SWITCH STRIPE 96" + FILL VALVE BROWN 82" - FILL VALVE PURPLE 82"...

  • Page 16: Specifications

    326636H01 Rev A 5.5. Specifications Controller Dimensions (stand-alone) Length 9.1 in. (232 mm) Width 3.5 in. (89 mm) Height 8.0 in. (203 mm) Weight 6.5 lbs. (2.95 kg) Display Type Liquid Crystal Display (LCD) with Size backlight Resolution 20 x 4 Character Keypad 8 x 5 Pixels per Character 8 keys, Multi function...

  • Page 17: Operating Environment

    326636H01 Rev A 5.6. Operating Environment Ambient Temperature and Relative Humidity CryoExtra cryogenic freezers are designed to be operated in environments near room temperature (65°F – 80°F, 18°C – 27°C) and relative humidity below 50%. Due to the large gradient between LN2 and ambient temperatures, an additional change of a few degrees will not have a significant impact on the freezer performance.

  • Page 18: Installation And Startup

    326636H01 Rev A 6. Installation and Startup This section will review the basic receiving, installation, and startup procedures for CryoExtra Freezers. Always inspect the bill of lading for accuracy and external crate/packaging for damage before accepting the shipment. Included with each full auto freezer: Literature Packet Controller Quick Start Reference Guide –...
  • Page 19 326636H01 Rev A Installation NOTE: Do not apply power to the controller or connect an LN2 supply until later in this procedure to avoid injury or damaging the equipment. Following the careful uncrating and unpacking of the freezer, install using these basic instructions. NOTE: Only install the freezer on a level surface.
  • Page 20 326636H01 Rev A NOTE: Do not connect the battery backup (if equipped) to the wire harness until later in the installation procedure. Connect the 12-pin wire harness to the Controller wire harness connection If the freezer is equipped with battery backup measure the voltage at the end connector for approximately 24VDC to 27VDC;...
  • Page 21 326636H01 Rev A Remove a caplug from the fill tee on the plumbing assembly in order to connect the LN2 supply. If using an LN2 cylinder as the liquid supply, securely connect and tighten the transfer hose to both the fill tee connection and the supply connection labeled “LIQUID”. If using a bulk LN2 supply system, securely connect and tighten the supply connection to the freezer fill tee connection.

  • Page 22: Operation

    326636H01 Rev A 7. Operation This section of the manual will detail the functions and features of the Controller and demonstrate how to access and adjust the various user settings and options. All CryoExtra Freezers utilize LN2 as the means of refrigeration. Under atmospheric conditions, the temperature of LN2 is -196°C (-320°F, 77 K).

  • Page 23: Functions And Features

    326636H01 Rev A 7.1. Functions and Features The Controller utilizes a variety of functions and features that enables it to closely monitor and control the environment inside a cryogenic freezer. This section will give an overview of the following features and their functionality: Liquid Nitrogen Level Measurement Automatic Liquid Nitrogen Level Control...

  • Page 24: Liquid Nitrogen Level Measurement

    326636H01 Rev A 7.1.1. Liquid Nitrogen Level Measurement The LN2 level in the tank is determined through the use of a differential pressure sensor. This sensor operates on the physical principle of hydrostatic head pressure. The pressure generated by a column of fluid is proportional to the height, or depth, of the fluid column.

  • Page 25: Automatic Liquid Nitrogen Level Control

    326636H01 Rev A 7.1.2. Automatic Liquid Nitrogen Level Control The Controller is equipped with a fully automated LN2 level control system. This level control system is based on user-defined parameters that can be adjusted to maintain a LN2 level in a freezer over a range of 3.0 inches (76 mm) up to 48.0 inches (1219 mm).

  • Page 26: Liquid Nitrogen Usage

    326636H01 Rev A 7.1.3. Liquid Nitrogen Usage The Controller is able to calculate and display an estimated rate of LN2 evaporation inside a freezer. This liquid usage is displayed in inches or millimeters per day. It takes time for the real-time data to accumulate in order for the liquid usage rate to be calculated.

  • Page 27: Temperature Measurement

    326636H01 Rev A 7.1.4. Temperature Measurement The Controller is equipped with two independent temperature measurement channels. They are designed to be used with 1000 ohm platinum RTD temperature probes, also referred to as Pt-1000 RTDs. The electrical resistance of the very fine platinum wires in these probes changes linearly with temperature. Platinum’s very linear relationship between resistance and temperature makes Pt-1000 RTDs ideal for temperature measurement in cryogenic environments.

  • Page 28: User Defined Alarms

    326636H01 Rev A 7.1.5. User Defined Alarms The Controller employs 18 different audible/visual alarms. These alarms are designed to alert the user to possible problems with the freezer temperature, LN2 level, controller power, and LN2 supply. In the event that a condition triggers an alarm, an audible buzzer will sound, that particular alarm will appear on the Controller LCD display, and the global remote alarm contacts will switch to alarm state.
  • Page 29 326636H01 Rev A Can be Enabled power for 30 minutes or Disabled Lid Open Freezer lid has been open longer than Lid Open Alarm Time setting Communication Controller has lost communication with the LCD display Loss If any alarms occur, contact your authorized CryoExtra Distributor or Technical Service.

  • Page 30: Remote Alarm Monitoring

    326636H01 Rev A 7.1.6. Remote Alarm Monitoring The Controller is equipped with a global remote alarm relay and four specific discrete dry contacts that allow remote monitoring of alarm conditions. Once activated, these latching contacts will retain their alarm state until the alarm condition is corrected and cleared. Although CryoExtra does not provide remote monitoring or programmable logic controller (PLC) systems, these devices can be easily connected to the Controller.

  • Page 31: Passwords / Security

    326636H01 Rev A 7.1.7. Passwords / Security The Controller has a multilevel security system that can be customized to meet your security needs. Four different levels of security can be assigned up to 10 passwords allowing users to control who has the ability to change specific settings as well as to what extent these settings may be altered.

  • Page 32: Communication / Networking Capabilities

    326636H01 Rev A 7.1.8. Communication / Networking Capabilities The Controller RS-485 Serial interface offers several advanced communication capabilities. The Controller is equipped with two, independent RJ-45 serial ports. These ports are intended for connection to another CryoExtra controller, PC, serial printer, or other RS-485 device. Up to 100 Controllers can be successfully networked.

  • Page 33: Event Log And Event Codes

    326636H01 Rev A 7.1.9. Event Log And Event Codes The Controller has a built-in data logging feature that automatically stores vital, time-stamped information including temperatures, LN2 level, liquid usage, and any alarms. Data is logged at a user-defined interval and anytime an event or alarm status changes. The default log interval is 4 hours. The Controller is able to store up to 30,000 events in its non-volatile memory.
  • Page 34 326636H01 Rev A Table 4: Controller Event Log Codes Event Code Description Alarm Mute Temp A High Alarm Temp A Low Alarm Running on battery power Temp B High Alarm Temp B Low Alarm Bypass Sensor Open Low Battery Voltage Alarm Hot Gas Bypassing Temp A Calibration Alarm Temp B Calibration Alarm...

  • Page 35: Lid Switch

    326636H01 Rev A 7.1.10. Lid Switch The Controller has the ability to support a lid switch. This additional feature allows the user to disable filling while the lid is open, utilize the Lid Open Alarm, or initiate an automatic fog clear. A lid switch comes standard on all CryoExtra Series.

  • Page 36: Hot Gas Bypass

    326636H01 Rev A 7.1.11. Hot Gas Bypass The Hot Gas Bypass is a feature on all CryoExtra freezer series equipped with a Controller. The Hot Gas Bypass is able to vent the warm nitrogen gas from the supply line before initiating a fill cycle. This prevents warm gas from entering the freezer space.

  • Page 37: Battery Backup (Optional)

    326636H01 Rev A 7.1.12. Battery Backup (Optional) The Battery Backup comes standard on all MDD freezers. The Controller is able to run seamlessly on power from this external battery system when the primary power source is interrupted. The Controller is able to run fully functional on the Battery Backup for approximately 72 hours in the event of a power failure.

  • Page 38: Adjusting Settings And Options

    326636H01 Rev A 7.2. Adjusting Settings and Options Password Entry This section describes how to access the Controller menus and adjust the various settings and options. With password entry enabled, the controller will prompt for a password anytime a user attempts to access the setup menus.

  • Page 39: Temperature Settings

    326636H01 Rev A 7.2.1. Temperature Settings This section describes how to access and adjust the various temperature settings on the Controller NOTE: Security Level 2 or higher is required to adjust the Temperature Settings. 7.2.1.1. Enable / Disable Sensors The default setting for both Temp A and Temp B sensors is enabled. 1.

  • Page 40: High Temperature Alarm Test

    326636H01 Rev A 7.2.1.2. High Temperature Alarm Test The high temperature alarm test allows a user to simulate a high temperature alarm without having to remove it from the freezer. Once initiated, the Controller will apply a small voltage to the sensor, which causes the sensor to heat up.

  • Page 41: Temperature Alarm Settings

    326636H01 Rev A 7.2.1.3. Temperature Alarm Settings This section describes how to navigate and adjust the temperature alarm settings. The high temperature alarm is used to alert the user when the temperature in the freezer space has risen above the set threshold.
  • Page 42 326636H01 Rev A 7. Press “SETUP” Temp A High Alarm The display will read “Temp A High Alarm”. Use the “▲/▼” keys to adjust setting and press ENABLED “ENTER” to save the change. Use ▲▼ to adjust 8. Press “SETUP” Temp A Low Alarm The display will read “Temp A Low Alarm”.

  • Page 43: Liquid Nitrogen Saturation Temperature

    326636H01 Rev A 7.2.1.4. Liquid Nitrogen Saturation Temperature This section shows how to adjust the LN2 saturation temperature. This temperature is altitude dependent. The default LN2 saturation temperature is -195.8°C (-320.4°F, 77.4 K). This value is accurate for altitudes ranging from sea level to 500 feet (152 m). For the appropriate saturation temperature, refer to Table 5: LN2 Saturation Temperatures.

  • Page 44: Liquid Level Settings

    326636H01 Rev A 7.2.2. Liquid Level Settings This section demonstrates how to adjust the LN2 level settings. 7.2.2.1. Level Setpoints and Alarms The auto fill settings can be adjusted in the Liquid Level Menus. With auto fill enabled, the Controller will initiate an auto fill when the level is at or below the Low Level Setpoint and terminate a fill when the level reaches the High Level Setpoint.

  • Page 45: Enable / Disable Auto Fill Control

    326636H01 Rev A 7.2.2.2. Enable / Disable Auto Fill Control Auto Fill Control can be enabled or disabled in the Advanced Level Menus. NOTE: Security Level 3 or higher is required to enable/disable Auto Fill. 1. Press “SETUP” Higher User Level Controller will prompt for a password.

  • Page 46: Level Offset

    326636H01 Rev A 7.2.2.3. Level Offset Since the annular line that carries the pressure level signal to the Controller is not located at the very bottom of the LN2 column, a Level Offset is needed. This value is determined and set at the factory and should not be adjusted to fix an inaccurate level reading unless setting up a freezer (see the First Fill Startup Procedure) or if instructed to do so by an authorized CryoExtra Distributor or Technical Service.

  • Page 47: Additional Feature Settings

    326636H01 Rev A 7.2.3. Additional Feature Settings This section details how to view and adjust the settings for the Battery Backup, Power Failure Alarm, Hot Gas Bypass, and Lid Switch. NOTE: Security Level 2 or higher is required to adjust the Hot Gas Bypass and Lid Switch settings.
  • Page 48 326636H01 Rev A 1. Press “SETUP” Higher User Level Controller will prompt for a password. A flashing cursor on the entry screen will make it clear which digit is being Required use ▲▼ to changed. Use the “▲/▼” keys to scroll to the appropriate number.

  • Page 49: Lid Switch Settings

    326636H01 Rev A 7.2.3.3. Lid Switch Settings 1. Press “SETUP” Higher User Level Controller will prompt for a password. A flashing cursor on the entry screen will make it clear which digit is being Required use ▲▼ to changed. Use the “▲/▼” keys to scroll to the appropriate number.

  • Page 50: Display And Output Settings

    326636H01 Rev A 7.2.4. Display and Output Settings This section demonstrates how to adjust the Display and Output Settings. 7.2.4.1. Temp and Level Display Units NOTE: Security Level 1 or higher is required to change the display units. 1. Press “SETUP” Higher User Level Controller will prompt for a password.

  • Page 51: Liquid Usage Display

    326636H01 Rev A Percentage Level Units Explanation The defined 0% and 100% values are independent of the automatic level control parameters. The percentage level units are just an alternative to displaying the measured level in inches or millimeters. The percentage parameters can be set to match the high and low fill setpoints or they can be set to any other value that makes interpreting the liquid level easier for the user.

  • Page 52: Alarm Buzzer

    326636H01 Rev A 7.2.4.3. Alarm Buzzer The audible alarm buzzer can be disabled. This will not disable the alarms, only the audible buzzer. Alarms will still be displayed visually on the screen if the alarm buzzer is inactive NOTE: Security Level 2 or higher is required to enable/disable the alarm buzzer. 1.
  • Page 53 326636H01 Rev A 7.2.4.4. Languages The Controller has five language options to choose from: English, Spanish, German, Italian, and French. NOTE: Security Level 2 or higher is required to change the language setting. 1. Press “SETUP” Higher User Level Controller will prompt for a password. A flashing cursor on the entry screen will make it clear which digit is being Required use ▲▼...
  • Page 54 326636H01 Rev A 7.2.4.5. Printer This section describes how to adjust the Printer settings. For instructions on how to connect a printer, see the Communication / Networking section. NOTE: Security Level 2 or higher is required to adjust the Printer settings. 1.

  • Page 55: Advanced Settings

    326636H01 Rev A 7.2.5. Advanced Settings This section describes how to change the various Advanced Settings. 7.2.5.1. Timed Filling The Controller has several advanced filling options including Timed Filling. Timed Filling allows the user to set a regular filling schedule based on a fill start time and a fill frequency. If a facility staff would like the peace of mind of knowing that all the freezers are full of LN2 before leaving for the weekend, then they could set up a timed fill for every Friday afternoon.
  • Page 56 326636H01 Rev A 4. Press “ENTER” Press ENTER for The display will read “Advanced Fill Menus”. Advanced Fill menus or press SETUP for 5. Press “ENTER” Timed Fill The display will read “Timed Fill”. Use the “▲/▼” keys to next menu adjust and press “ENTER”...

  • Page 57: Maximum Fill Time

    326636H01 Rev A 7.2.5.2. Maximum Fill Time The maximum fill time can be adjusted in the Advanced Fill Menus. If a freezer begins filling but does not reach its High Level Setpoint within the maximum fill time, then the Controller will terminate the fill and trigger a Fill Time Alarm.

  • Page 58: Time And Date

    326636H01 Rev A 7.2.5.3. Time and Date The time and date can be set in the Advanced Settings Menus. The user has the option of a 12 or 24 hour clock and a MM/DD/YY or DD/MM/YY date format. NOTE: Security Level 2 or higher is required to change the time and date. 1.
  • Page 59 326636H01 Rev A 12. Press “SETUP” Date Format The display will read “Date Format”. Use the “▲/▼” keys to adjust and press “ENTER” to save. MM/DD/YY Use ▲▼ to adjust Press ENTER to save 59 of 133...

  • Page 60: Communication Settings

    326636H01 Rev A 7.2.5.3.1. Communication Settings 7.2.5.3.2. COM Setup / Type The settings for the two serial ports can be adjusted in the COM 1 and COM 2 Setup Menus. Since they are independent serial ports, only one serial port can be set to a given COM Type. If COM 1 is set to ASCII, then COM 2 cannot also be set to ASCII.
  • Page 61 326636H01 Rev A 7.2.5.3.3. MODBUS ID The Controller MODBUS ID also serves as the ASCII Unit ID. This address can be adjusted in the MODBUS Menu and has a range of 1 to 200. NOTE: Security Level 2 or higher is required to change the MODBUS ID. 1.

  • Page 62: One Fill All Fill (Ofaf)

    326636H01 Rev A 7.2.5.4. One Fill All Fill (OFAF) This section describes how to adjust the various OFAF settings. For more information and instructions on how to setup an OFAF network, refer to the OFAF Network Setup section of this manual. NOTE: Security Level 3 or higher is required to adjust the OFAF settings.

  • Page 63: Restore Default Settings

    326636H01 Rev A 7.2.5.5. (Global Password) Restore Default Settings The Controller can be reset to the factory defaults in the Advanced Settings Menu. This will also reset post-factory calibrations and global password to 3 4 5 6. The accuracy of the level and temperature measurements should be confirmed after resetting.

  • Page 64: Controller Default Settings

    326636H01 Rev A Controller Default Settings Controller Default Settings Parameter Default Setting High Temp Alarm -110.0 °C / -166.0 °F / 163.2 K Low Temp Alarm -200.0 °C / -327.6 °F / 73.4 K High Level Alarm 8.0 in / 205 mm High Level Setpoint 7.0 in / 180 mm Low Level Setpoint...

  • Page 65: Restart Controller

    326636H01 Rev A 7.2.5.6. Restart Controller The Controller can be restarted in the Advanced Settings Menu. Restarting the controller and cycling the power are both safe ways to reboot the controller. NOTE: Security Level 3 or higher is required to restart the controller from the Advanced Settings Menu 1.

  • Page 66: Firmware Update

    326636H01 Rev A 7.2.5.7. Firmware Update NOTE: Controller firmware should only be updated by authorized CryoExtra Distributors or under the direction of Technical Service. Improper firmware updates can render the controller inoperable. The firmware, or controller software, can be updated in the event that a new revision is released. A personal computer, COM USB communications kit (PN 13376947), and the current firmware updater program are required to perform an upgrade.
  • Page 67 326636H01 Rev A NOTE: Security Level 3 or higher is required to update the firmware. 1. Press “SETUP” Higher User Level Controller will prompt for a password. A flashing cursor on the entry screen will make it clear which digit is being Required use ▲▼...

  • Page 68: Password / Security Setup

    326636H01 Rev A 7.2.6. Password / Security Setup This section details how to enable / disable password entry mode as well as how to change and setup multilevel security passwords. NOTE: Security Level 4 is required to setup or change passwords. 7.2.6.1.

  • Page 69: Global Password Change

    326636H01 Rev A 7.2.6.2. Global Password Change This section describes how to change the Global Password 3 4 5 6. The Global Password has Security Level 4 clearance. 1. Press “SETUP” Higher User Level Controller will prompt for a password. A flashing cursor on the entry screen will make it clear which digit is being Required use ▲▼...

  • Page 70: Multilevel Passwords

    326636H01 Rev A 7.2.6.3. Multilevel Passwords This section describes how to setup and change the 9 multilevel passwords. 1. Press “SETUP” Higher User Level Controller will prompt for a password. A flashing cursor on the entry screen will make it clear which digit is being Required use ▲▼...

  • Page 71: Calibration Procedures

    326636H01 Rev A 7.3. Calibration Procedures 7.3.1. Temperature Sensor Calibration This section describes how to calibrate the Controller temperature sensors. There are two calibration procedures: single point and two point calibration. For single point calibration, the reference point is LN2. For two point calibration, the reference points are LN2 and ice water.

  • Page 72: Single Point Calibration

    326636H01 Rev A 7.3.1.1. Single Point Calibration The single point calibration procedure requires a small volume of LN2; enough to completely submerge the end of the temperature sensor. It may be possible to use the LN2 in the freezer space if the probe length permits.
  • Page 73 326636H01 Rev A 7.3.1.2. Two Point Calibration The two point calibration procedure requires a small volume of LN2 and an ice water bath; enough to completely submerge the end of the sensor. Proper ice water bath preparation is imperative to ensure accuracy.
  • Page 74 326636H01 Rev A 10. Press “ENTER” Wait while probe The display will read “Wait while probe warms to room temperature”. Wait while the temperature sensor warms warms to room to room temperature and the controller counts down. temperature 180 seconds 11.

  • Page 75: Liquid Nitrogen Level Calibration

    326636H01 Rev A 7.3.2. Liquid Nitrogen Level Calibration This section describes the procedure to calibrate the LN2 level. This procedure requires the cryogenic meter dip stick supplied with each CryoExtra freezer. This calibration method provides level measurements with a ±0.5” (±13 mm) accuracy. All new freezers equipped with controllers have been calibrated at the factory.
  • Page 76 326636H01 Rev A Level dip stick inserted to measure the physical liquid nitrogen level Caution: Picture is for demonstration only (on an empty tank), Please use protective gear while working with liquid nitrogen. Please refer Section 3 for Safety while working with Liquid nitrogen. 76 of 133...
  • Page 77 326636H01 Rev A Liquid Level Calibration NOTE: Liquid level calibration cannot be performed while the Controller is filling. If Controller is filling, press “Stop Fill” and perform the calibration. Allow freezer plumbing to thaw 10 to 15 minutes before calibrating. NOTE: Liquid level calibration is most accurate when calibrated at 10.0 inches (254 mm).
  • Page 78 326636H01 Rev A 9. Wait 60 seconds Actual Level After the controller counts down, the display will read “Actual Level”. Use the “▲/▼” keys to input the meter 10.0 in dip stick measured level. Use ▲▼ to adjust 10. Press “ENTER” Level Calibration Press ENTER to save The display will read “Level Calibration Complete”.

  • Page 79: Hot Gas Bypass Sensor Calibration

    326636H01 Rev A 7.3.3. Hot Gas Bypass Sensor Calibration This section describes how to calibrate the Controller hot gas bypass sensor. There are two calibration procedures: single point and two point calibration. For single point calibration, the reference point is LN2. For two point calibration, the reference points are LN2 and ice water.
  • Page 80 326636H01 Rev A Hot Gas Bypass Sensor Removal CAUTION: Removing the hot gas bypass sensor while a LN2 supply is connected to the freezer will cause the user to be exposed to LN2. Before beginning procedure, shut off and disconnect all LN2 supply sources. Always wear protective gloves and face shield when handling LN2.
  • Page 81 326636H01 Rev A 7.3.3.1. Hot Gas Sensor Single Point Calibration 1. Press “SETUP” Higher User Level Controller will prompt for a password. A flashing cursor will make it clear which digit is being changed. Use the Required use ▲▼ to “▲/▼”...
  • Page 82 326636H01 Rev A 7.3.3.2. Hot Gas Sensor Two Point Calibration 1. Press “SETUP” Higher User Level Controller will prompt for a password. A flashing cursor Required use ▲▼ to will make it clear which digit is being changed. Use the “▲/▼”...
  • Page 83 326636H01 Rev A 15. Press “ENTER” Bypass Probe two The display will read “Bypass Probe two point calibration complete”. Point calibration complete 83 of 133...

  • Page 84: Communication / Networking

    326636H01 Rev A 7.4. Communication / Networking The Controller is equipped with two independent RJ-45 serial ports. These ports are intended for connection to another controller, PC, serial printer, or other RS-485 device. Up to 100 controllers can be successfully networked. NOTE: The Controller should never be connected directly to a LAN or public telecommunications network.

  • Page 85: Controller Connect (Computer Interface)

    326636H01 Rev A 7.4.1. Controller Connect (Computer Interface) Controller Connect is a free, downloadable software program that enables a user to download the event log and query and adjust controller parameters. Features include a user-friendly ASCII command window, automatic COM Port selection, real-time temperature, level monitoring, and the event log download button that allows a date range selection.
  • Page 86 326636H01 Rev A Installing Controller COM USB Kit 1. Insert the included USB to Serial Driver Disc into the PC CD-ROM 2. Plug the Controller COM USB Kit COM USB Kit into an open USB port 3. Follow the automatic installation prompts Downloading Controller Connect 1.
  • Page 87 326636H01 Rev A Downloading the Event Log 1. Connect to controller using Controller Connect 2. Select Event Download Range with Event 1 being the most recent logged event. The default download range includes all events 3. Designate a filename and save location. The default file name is the current date an time while the save location is the c:\ drive 4.
  • Page 88 326636H01 Rev A ASCII Command Interface American Standard Code for Information Interchange (ASCII) commands can be used to query and adjust all Controller settings and parameters. Commands must be entered in all capital letters just as they appear in the below tables. For a complete list of proper syntax and responses, refer to the Appendix CONTROL COMMANDS *IDN? ID Query...

  • Page 89: Ofaf Network Setup

    326636H01 Rev A 7.4.2. OFAF Network Setup OFAF networking allows multiple controllers to be linked together such that all of the freezers will fill whenever any networked controller calls for a fill. When multiple freezers are connected to a common supply source, it is advantageous to fill all freezers at the same time.
  • Page 90 326636H01 Rev A Figure 17: Diagram showing a typical OFAF network setup Table 7: Required items for OFAF network Description Quantity needed 11358251 OFAF Master Cable 10740053 Standard CAT 5e Cable # of controllers - 2 10856312 RJ-45 Splitter # of controllers - 2 1.
  • Page 91 326636H01 Rev A Cable Wiring OFAF Master Cable Figure 18: OFAF Master Cable wiring configuration. Numbering as viewed from side of RJ-45 connector opposite latch. Standard Cable Figure 19: Standard reverse RJ-45 network cable configuration. Numbering as viewed from side of connector opposite latch. Note: Pressing STOP FILL will delay the automatic fill circuit for 30 minutes.

  • Page 92: Printer Setup

    326636H01 Rev A 7.4.3. Printer Setup The Controller compatible printer kit allows users to print a hard copy of the freezer’s status at a set interval and as events occur. The Controller will print the current status of the freezer in the event log format.

  • Page 93: Remote Alarm Tests

    326636H01 Rev A 7.5. Remote Alarm Tests 7.5.1. Global Remote The Global Remote contacts can be checked for continuity using a digital multimeter or ohm meter. Normal State (No Alarms) There should be continuity between the COM and NC terminals The COM –...

  • Page 94: Controller Menu Maps

    326636H01 Rev A 8. Controller Menu Maps 8.1. Main Setup Menus 94 of 133...

  • Page 95: Temperature Setting Menus

    326636H01 Rev A 8.2. Temperature Setting Menus 95 of 133...

  • Page 96: Temperature Calibration Menus

    326636H01 Rev A 8.3. Temperature Calibration Menus 96 of 133...

  • Page 97: Add On Menus

    326636H01 Rev A 8.4. Add On Menus 97 of 133...

  • Page 98: Hot Gas Bypass Sensor Calibration Menus

    326636H01 Rev A 8.5. Hot Gas Bypass Sensor Calibration Menus 98 of 133...

  • Page 99: Display And Output Menus

    326636H01 Rev A 8.6. Display and Output Menus 99 of 133...

  • Page 100: Liquid Level Menus

    326636H01 Rev A 8.7. Liquid Level Menus 100 of 133...

  • Page 101: Liquid Level Calibration Menus

    326636H01 Rev A 8.8. Liquid Level Calibration Menus 101 of 133...

  • Page 102: Advanced Settings Menus

    326636H01 Rev A 8.9. Advanced Settings Menus 102 of 133...

  • Page 103: Password Menus

    326636H01 Rev A 8.10. Password Menus 103 of 133...

  • Page 104: Controller Display Screens

    326636H01 Rev A 8.11. Controller Display Screens 104 of 133...

  • Page 105: Preventative Maintenance

    326636H01 Rev A 9. Preventative Maintenance 9.1. Preventative Maintenance Schedule This section describes the preventative maintenance that should be performed on CryoExtra freezers to ensure optimum operation and performance, as well as maximum service life. As with any technical piece of laboratory equipment, preventative maintenance is key to equipment success.

  • Page 106: Preventative Maintenance Procedures

    326636H01 Rev A 9.2. Preventative Maintenance Procedures Level Verification The differential pressure measurement system used on CryoExtra freezers is nearly maintenance free. It provides a high level of accuracy and resolution to give the operator a precise indication of the exact amount of LN2 present in the freezer at all times.

  • Page 107: Plumbing Leak Check

    326636H01 Rev A Plumbing Leak Check Leaky plumbing connections can create a host of problems including but not limited to: Slow fill times Nuisance Alarms High LN2 Consumption Inaccurate level readings Inaccurate liquid usage readings Leaky plumbing connections are especially common on liquid cylinder supply systems, since the fittings are regularly loosened and tightened during liquid cylinder swap out.

  • Page 108: Level Alarm Test

    326636H01 Rev A Level Alarm Test The Controller can trigger a high level or low level alarm if the LN2 level in the freezer exceeds the user defined parameters. High Level Alarm Test 1. Observe and record the current LN2 level 2.

  • Page 109: Folding Step Inspection

    326636H01 Rev A Folding Step Inspection CryoExtra freezers equipped with folding steps assemblies should be inspected for integrity at least every 6 months. Verify that hinges and free of cracks and all connections are secure. Check that the anti- slip strips on the steps are in good condition and replace if necessary (PN 4810179). Ensure the step locking strap is able to securely hold the steps in their folded position.
  • Page 110 326636H01 Rev A SMC (black) Solenoid Valve Replacement CAUTION: Ensure that the LN2 supply valve is closed and the plumbing assembly is vented before removing the solenoid valves. 1.Remove plumbing shroud to gain access to plumbing system 2. Remove coil retaining clip by inserting a flathead screwdriver between the clip and the edge of the coil body.

  • Page 111: Relief Valve Replacement

    326636H01 Rev A NOTE: If the brass valve body requires replacing, the freezer plumbing will need to be disassembled and the entire valve replaced (PN 14224611S). It is typically easier to start disassembling the plumbing assembly beginning at the fill tee for fill valve replacement or the gas bypass muffler for gas bypass valve replacement.

  • Page 112: Complete Freezer Thaw And Moisture Removal

    326636H01 Rev A Complete Freezer Thaw and Moisture Removal 1. Remove freezer LN2 supply. 2. Unplug Controller main power and battery backup if equipped. 3. Open or remove lid from freezer. 4. Allow LN2 to completely evaporate and the freezer space to warm to room temperature. Placing a fan blowing into the freezer will accelerate this process.
  • Page 113 326636H01 Rev A 4. Purge annular line with nitrogen gas, maintaining a pressure below 50 PSI (3.4 bar), until the line in clear and completely free of any moisture. NOTE: If moisture is not completely removed for the freezer space and annular lines, ice will form when LN2 is reintroduced into the freezer.

  • Page 114: Replacement Parts And Accessories

    326636H01 Rev A 9.3. Replacement Parts and Accessories Replacement Parts Part Number Description Inline Filter – 40 micron mesh 11648945 Relief Valve – 50 PSI (3.4 bar) 1810032 SMC Solenoid Valve – Fill and Gas Bypass 14224611S 13284954S Purge/3-way Solenoid Valve Gas Bypass Temperature Sensor –...

  • Page 115: Troubleshooting Quick Reference

    326636H01 Rev A 10. Troubleshooting Quick Reference Symptom Possible Causes Fixes Instructions Equipment Usage Improperly connected LN2 supply Verify LN2 connections Page 8 Inadequate LN2 supply volume or Verify Adequate LN2 Supply Verify adequate supply pressure Page 106 Verify fill solenoid resistance Solenoid Valve Replacement Fill solenoid valves not opening...
  • Page 116 326636H01 Rev A Transition to generator power See "Incorrect LN2 level Inaccurate level readings readings" above. Increase lid gasket vent. Lid Gasket Replacement Insufficient freezer venting Replace gasket/lid if Page 111 necessary Short cycle fills Purge level sensing annular line and clear any Complete Freezer Thaw and debris in the bottom of Obstruction in level sensing line...

  • Page 117: Compliance Tables

    326636H01 Rev A 11. EN Compliance Tables Table 1: Guidance and manufacturer’s declaration – electromagnetic emissions for all Controllers (See 5.2.2.1 C). Guidance and Manufacturer’s Declaration - Electromagnetic Emissions The CONTROLLER is intended for use in the electromagnetic environment specified below. The customer or the user of the CONTROLLER should assure that it is used in such an environment.
  • Page 118 326636H01 Rev A Table 2: Guidance and manufacturer’s declaration – electromagnetic immunity – for all Controllers (See 5.2.2.1 F) Guidance and Manufacturer’s Declaration – Electromagnetic Immunity The CONTROLLER is intended for use in the electromagnetic environment specified below. The customer or the user of the CONTROLLER should assure that it is used in such an environment.
  • Page 119 326636H01 Rev A Table 4: Guidance and manufacturer’s declaration – electromagnetic immunity – for all Controllers (See 5.2.2.2) Guidance and Manufacturer’s Declaration – Electromagnetic Immunity The CONTROLLER is intended for use in the electromagnetic environment specified below. The customer or the user of the CONTROLLER should assure that it is used in such an environment.
  • Page 120 Local or national environmental laws and regulations may prohibit disposal of electrical and/or electronic equipment such as the controller. Contact the local city or town offices for instructions on proper disposal of electrical or electronic equipment. Alternately, Thermo Scientific may be contacted for disposal information.

  • Page 121: Appendix

    326636H01 Rev A 12. Appendix 12.1. Reference Tables 121 of 133...
  • Page 122 326636H01 Rev A 12.2. Table 10: LN2 Volume per Inch of Liquid in CryoExtra Freezers NOTE: The below values are accurate for the cylindrical portion of the freezer and do not take into account inventory components that will displace LN2. Freezer Model Inches Liters...
  • Page 123 326636H01 Rev A Table 11: Conversion of inches of LN2 to various pressure units NOTE: Conversion values do not take into account the Controller Level Offset 123 of 133...

  • Page 124: Controller Ascii Interface

    326636H01 Rev A 12.3. Controller ASCII Interface American Standard Code for Information Interchange (ASCII) is a standard code used in data transmission, in which 128 numerals, letters, symbols, and special control codes are represented by a 7- bit binary number. Below is a chart for these binary codes. Controller ASCII Command List Control Commands *IDN?
  • Page 125 326636H01 Rev A CALTB Calibrate Temp B in LN2 (Single Point) Input: CALTB Returned: No response Comments: Used to perform a single point calibration of Temp B. Temp B sensor must be submerged in LN2. See the Temperature Calibration Section of this manual. CALVL Set Level Offset Input: CALVL ±XXX.X...
  • Page 126 326636H01 Rev A HITA Set Temp A High Alarm Input: HITA ±XXX.X Returned: No response Comments: Used to set the Temp A High Alarm value. HITA? Temp A High Alarm Query Input: HITA? Returned: ±XXX.X Comments: Used to query the current Temp A High Alarm value HITAS? Temp A High Alarm Status Query Input: HITAS?
  • Page 127 326636H01 Rev A LOTA Set Temp A Low Alarm Input: LOTA ±XXX.X Returned: No response Comments: Used to set the Temp A Low Alarm value. LOTA? Temp A Low Alarm Query Input: LOTA? Returned: ±XXX.X Comments: Used to query the Temp A Low Alarm value. LOTAS? Temp A Low Alarm Status Query Input: LOTAS?
  • Page 128 326636H01 Rev A TEMPA? Temp A Current Data Query Input: TEMPA? Returned: ±XXX.X Comments: Used to query the current Temp A sensor reading. TEMPB? Temp B Current Data Query Input: TEMPB? Returned: ±XXX.X Comments: Used to query the current Temp B sensor reading. TUNI Set Temp Units Input: TUNI C, TUNI F, or TUNI K...
  • Page 129 326636H01 Rev A Returned: No response Comments: Used to set the maximum fill time in minutes from 30 to 240 minutes. FILT? Max Fill Time Query Input: FILT? Returned: XXX Comments: Used to query the maximum fill time. Value returned in minutes. FILTIM? Fill Duration Query Input: FILTIM?
  • Page 130 326636H01 Rev A HILM? High Level Alarm Mask Query Input: HILM? Returned: 0 or 1 Comments: Used to query the High Level Alarm Mask status where 0 = disabled and 1 = enabled. Default setting is 1 = enabled. LEVL? Current LN2 Level Query Input: LEVEL? Returned: XXX.X...
  • Page 131 326636H01 Rev A LOLM? Low Level Alarm Mask Query Input: LOLM? Returned: 0 or 1 Comments: Used to query the Low Level Alarm Mask status where 0 = disabled and 1 = enabled. Default setting is 1 = enabled. LUNI Set Level Units Input: LUNI E, LUNI M, or LUNI % Returned: No response...
  • Page 132 326636H01 Rev A Event Log Commands CLEVLG Clear the Event Log Input: CLEVLG Returned: No response Comments: Used to clear all data from the event log. Data will be permanently lost when the event log is cleared. DATE Set the Date Input: mm/dd/yy Returned: No response Comments: Used to set the current date in the format: mm/dd/yy...

  • Page 133: Decontaminating And Sanitizing

    326636H01 Rev A UNID Set Unit ID Input: UNID XXXXX Returned: No response Comments: Used to set the controller 5-digit Unit ID. CONTROLLER Unit ID should be between 1 and 200. UNID? Unit ID Query Input: UNID? Returned: XXXXX Comments: Used to query the controller Unit ID. 13.

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