Forma Scientific 8172 User manual

Forma Scientific, Inc.
P.O. Box 649
Marietta, Ohio 45750
U.S.A.
Telephone: [phone]
Telefax: [phone]
________________________________________
Models:
8140 thru 8167,
8149 thru 8157 and
8172 thru 8180
Cryoplus II, III and IV
Storage Container
Manual No. 8008150 Rev. 0
Read this instruction manual
Failure to read, understand and follow the instructions in this manual may result in
damage to the unit, injury to operating personnel and poor equipment performance.
Caution: All internal adjustments and
maintenance must be performed by
qualified service personnel.
Refer to the serial tag on the
rear cover of this manual

The material in this manual is for information purposes only. The contents and the product
it describes are subject to change without notice. Forma Scientific, Inc. makes no
representations or warranties with respect to this manual. In no event shall Forma Scientific,
Inc. be held liable for any damages, direct or incidental, arising out of or related to the use of
this manual.
MANUAL NO. 8008150
0 7-93 Standard Manual
REV ECN DATE DESCRIPTION

ii
GENERAL SAFETY NOTES
The Occupational Safety and Health Administration (O.S.H.A.) has revised Section
1910-147, The Control Of Hazardous Energy (Lockout/Tagout).
Hazardous energy may be: electric, air, hydraulic, water, steam, gravity, spring & all other
equally hazardous energy.
This revised regulation, states that you will de-energize all potential sources of
energy (may be more than one energy source) prior to performing service or maintenance on
any equipment. It also states that a lock shall be placed on the de-energized control, along
with a verified test (use of a voltmeter or other equipment) to insure no accidental starts. If
you are not familiar with this regulation, review the O.S.H.A. Regulation, Section 1910-147.
In field service, full compliance with this regulation is difficult at best.
Troubleshooting must often be performed with hazardous energy applied; therefore extreme
caution must be followed during these troubleshooting steps. Only Qualified Personnel
Must Perform This Work. This phase of the repair work must be coordinated through the
customer's facilities maintenance department or designated person.
When performing service or maintenance as an outside contractor/worker, follow
the Outside Work Force's Lockout/Tagout system. Be alert for new types of
lockout/tagout devices.
√Always use the proper protective equipment (clothing, gloves, goggles etc.).
√Always dissipate extreme cold or heat, or wear protective clothing.
√Always follow good hygiene practices.
√Each individual is responsible for his/her own safety.
For your safety adhere to all DANGER and CAUTION statements.
Danger: This word is used to call attention to immediate hazards of
equipment or conditions which, if not avoided, could result in personal
injury, loss of life or property damage.
Caution: This word is used to call attention to potential hazards of
equipment or conditions which, if not avoided, could
result in personal injury, loss of life or property damage.

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TABLE OF CONTENTS
SECTION 1 - RECEIVING
1.1 Preliminary Inspection
1.2 Visible Loss or Damage
1.3 Responsibility for Shipping Damage
SECTION 2 - INTRODUCTION
2.1 Cryoplus Series - General Description
2.2 Power Switch/Resettable Circuit Breaker
2.3 Controller Overview
2.4 Control Panel
SECTION 3 - INSTALLATION AND START-UP
3.1 Unpacking List
3.2 Location
3.3 Connecting the Liquid Nitrogen Transfer Hose
3.4 Start-Up
3.5 Setting the Clock
SECTION 4 - OPERATION
4.1 Programming the Controller
4.2 Alarms and Printer Functions
SECTION 5 - MAINTENANCE
5.1 Solenoid Valve Maintenance

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SECTION 6 - CALIBRATION
6.1 LN2Level Control Calibration Procedure
SECTION 7 - SPECIFICATIONS
7.1 Model Listing According to Series
7.2 Specifications - Cryoplus Series
SECTION 8 - PARTS LIST
SECTION 9 - SUPPLEMENTS AND DRAWINGS

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SECTION 1 - RECEIVING
1.1 Preliminary Inspection
This item was thoroughly inspected and carefully packed prior to shipment
and all reasonable precautions were taken to ensure safe arrival of the
merchandise at its destination. Immediately upon receipt, before the unit is
moved from the receiving area, carefully examine the shipment for loss or
damage. Unpack the shipment and inspect both interior and exterior, for any in-
transit damage.
1.2 Visible Loss or Damage
If any loss or damage is discovered, note any discrepancies on the delivery
receipt. Failure to adequately describe such evidence of loss or damage may
result in the carrier refusing to honor a damage claim. Immediately call the
delivering carrier and request that their representative perform an inspection. Do
not discard any of the packing material, and under no circumstances move the
shipment from the receiving area.
1.3 Responsibility for Shipping Damage
For products shipped F.O.B. Marietta, Ohio, the responsibility of Forma
Scientific, Inc. ends when the merchandise is loaded onto the carrier's vehicle. On
F.O.B. Destination shipments, Forma Scientific's , and the carrier's responsibility,
ends when your Receiving Department personnel sign a free and clear delivery
receipt.
Whenever possible, Forma Scientific, Inc. will assist in settling claims for
loss or in-transit damage.

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SECTION 2 - INTRODUCTION
2.1 CryoPlus Series - General Description
The Cryoplus series of liquid Nitrogen storage system combines the well
insulated storage tank with a microprocessor based controller.
The exterior is constructed of fiberglass with a stainless steel interior. The
unit features counterbalanced, lockable lids and heavy-duty casters.
The microprocessor controller features a control/alarm system which
continuously monitors the level of the liquid LN2. All system functions and
components are monitored by an extensive, self-diagnostic program.
The operating and alarm setpoints are easily programmed using the touch pad
control panel. The non-volatile memory stores operational functions and alarm
sequences. Once programmed, the control panel may be locked to prevent
unauthorized entry or inadvertent program erasure.
Double fill solenoid valves assure positive liquid Nitrogen transfer. If the
microcomputer detects a fill valve or liquid Nitrogen supply problem, visual and
audible alarms are activated and remote alarms contacts change state.
An RS-232 port permits computer interface or connection of an optional
thermal data printer.
2.2 Power Switch/Resettable Circuit Breaker
The main power switch is located on the rear of the unit adjacent to the
power cord. OFF Position= (o) and ON= (|).
In order for the system to be operational, the power switch must be ON and
the key switch must be set to the ON (LOCK) position.
The power switch is also a resettable circuit breaker. If an overload condition
occurs, the built-in circuit breaker trips and the power switch will turn OFF.
Turning the power switch ON resets the circuit breaker.

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Note: If the circuit breaker trips again within a short time period, the unit should
be checked by a qualified electrician.
2.4 Control Panel
a. Bar Graph: The twenty four tri-color LED displays the Nitrogen level, start
fill (Low Level Set Point) and stop fill (High Level Set Point), alarm level
setpoints and scale selection.
•Orange: Remaining space above, stop fill flashing indicator.
•Flashing Orange: The upper LED is the stop fill indicator and the High
Level Alarm setpoint. The lower LED is the start fill and the Low Level
Alarm setpoint.
Note: The High Level Alarm indicates that the liquid Nitrogen level is over the
stop fill indicator by one inch for a two minute time period.
The Low Level Alarm indicates that the liquid Nitrogen level is below
the start fill indicator.
•Green: Indicates the liquid Nitrogen level.
•Red: Indicates the liquid Nitrogen alarm levels.
b. Scale Selection: The LED's at the top of the bar graph indicates which scale
is in use.
•Green light, located on the left side of bar graph, indicates that the 2 to 24
inch (liquid) scale is in use. Scale is in one inch increments.
•Green light, located on the right side of bar graph, indicates that the 2 to 7
inch (vapor) scale is in use. Scale is in 1/4 inch increments.
c. Solenoid Valve: The single green LED indicates that the solenoid valve is
open and the container is filling.
d. System Status: The six bar LED's are visual warnings of:
•Level Sensor: Indicates that the level sensor has malfunctioned and
sounds the audible alarm.

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•Fill Coil: Indicates a solenoid valve malfunction and sounds the audible
alarm.
•LN2Source: Indicates an empty liquid Nitrogen source and sounds the
audible alarm.
•Bypass Sensor: Indicates that the bypass sensor has malfunctioned or has
been disconnected and sounds an audible alarm.
Note: This indicator is for the gas bypass option only.
•Vent Coil: Indicates a malfunction of the vent solenoid valve and sounds
the audible alarm.
Note: This indicator is for the gas bypass option only.
•Stuck Valve: Indicates solenoid valve is stuck "open", and sounds
audible alarm.
•Stuck Valve Bypass Sensor: Indicates bypass valve is stuck open and
sounds audible alarm.
e. Digital Temperature Display: The seven segment display indicates actual
under the lid temperature, and high temperature alarm setpoint.
•Actual Temperature Display: Key switch must be in the "LOCK"
position.
•High Temperature Alarm Setpoint Display: Key switch must be in the
FULL ACCESS position.
f. Keypad: Used for selection, or operation, of all control functions (functional
only when key switch is in the FULL ACCESS position.)
•Up Arrow: Raises stop fill indicator to a higher setpoint. Raises the start
fill indicator to a higher setpoint. Raises the high temperature alarm to a
warmer setpoint.
•Down Arrow: Lowers stop fill indicator to a lower setpoint. Lowers
start fill indicator to a lower setpoint. Lowers high temperature alarm to a
colder setpoint.

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•High Level: Used in conjunction with UP and DOWN arrows, when
changing stop fill indicator setpoint.
•Low Level: Used in conjunction with UP and DOWN arrows, when start
fill indicator setpoint.
•High Temperature Alarm: Used in conjunction with UP and DOWN
arrows, when changing high temperature alarm setpoint.
•Scale Select: Used to select vapor scale 2 to 7 inches, or liquid scale 2 to
24 inches.
•Set: Locks selected setpoints into the controller memory.
•Alarm Mute: Used to silence audible alarm.
•Manual Fill: Used to manually start, or stop, a liquid Nitrogen filling
cycle.
Note: Level must be greater than one inch below high level
setpoint to start a manual fill.
g. Key Switch: Two position power switch.
•Full Access: Allows access to all controller functions.
Note: FULL ACCESS is a timed position. If a keypad is not
depressed within four minutes, access is denied, and the
controller functions are locked. To regain access, turn the
key switch to ON (Lock) and then return to FULL
ACCESS.
•On (LOCK): Locked automatic operation.
Note: Electrical power is controlled by an On-Off switch on the
back of the unit.

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SECTION 3 - INSTALLATION AND START-UP
3.1 Unpacking List
A four foot long Nitrogen transfer hose with swivel end and fittings is
supplied with the unit.
Note: A 6' long hose, with swivel, is available as an option; however the use
of a transfer hose longer than six feet is not recommended, and may
degrade system performance. Contact Forma Scientific Service Dept. if
extended transfer hose length is required.
The freezing system requires a user supplied low pressure regulated (22
PSIG) liquid Nitrogen supply. An optional temperature recorder is available
from Forma Scientific, Inc.
3.2 Location
Locate the Cryoplus Series freezing storage container in a well ventilated
area of the laboratory, with adequate work space available for loading and
unloading specimens. Allow for adequate lid swing clearance since such
precautions are essential to safe specimen handling.
The container should also be located near the liquid Nitrogen supply
(allowing enough space for tank replacement) and near a suitable electric outlet.
Arrangements should be made to collect the condensate, which will form on the
transfer hose.
3.3 Connecting the Liquid Nitrogen Transfer Hose
Liquid Nitrogen is the only consumable material that is required for
operation of the equipment. Some facilities use portable cryogenic liquid
Nitrogen supply tanks, or the Nitrogen supply may come from an in-house
storage system.
Caution: Some Nitrogen storage systems contain a pressure capable of
supplying liquid, and gaseous, Nitrogen at up to 235 PSIG. Under
such conditions, the supply tank must be changed to one with a 22
PSIG setting, to provide compatibility with Cryomed equipment.

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Connect the transfer hose (packed in the Cryoplus unit) between a low
pressure liquid Nitrogen supply tank (22 PSIG) and the storage container.
Connect the transfer hose to the liquid outlet of the supply tank.
Note: The liquid inlet fitting is located at the hinged side of the
container. After the transfer hose has been connected, open the
supply tank valve and check the connections for leaks.
3.4 Start-Up
With the power switch Off, connect the controller to an adequate grounded
power source.
Note: Refer to the electrical schematic, or the serial tag on the rear of
the controller, for specific electrical requirements.
Before start-up set the clock to the current date and time. The factory default
setting is Eastern Standard Time (USA). Refer to Section 3.5.
Turn the main power switch on. Turn the key switch to the ON (LOCK)
position. The freezer will fill until the liquid Nitrogen reaches the stop fill
indicator and the 5" "Flashing Orange" LED changes to "Flashing Red" LED. The
freezer is now in full automatic operation.
Caution: On initial power-up do not depress any control key pads, during the
two second lamp test.
The maximum depth of LN2must not exceed 25 inches
from the bottom of the tank.
To set the controller for maximum fill, turn the key to
“Full Access” and press the High Level key. Press the up or
down arrows until the amber light at level 24 flashes and press
“Set.” The controller will automatically fill the tank and shut
off when the lamp at 24 turns red. The tank’s liquid level will
be between 24 and 25 inches.

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Upon power-up the controller operates automatically, using the factory
settings listed below. (These settings are typical vapor phase settings.)
The Lower Scale (vapor) on the right side of the bar graph, numbered 2
through 7 will be used.
Start Fill Setpoint (Low Level)............................. 3" (Flashing Orange LED)
Stop Fill Setpoint (High Level) ............................5" (Flashing Orange LED)
High Temperature Alarm (optional) .....................+30°C*
*The high temperature alarm range is +50°C to -199°C.
Note: The freezing chamber lid should remain open during the initial fill
which will take approximately 45 minutes.
Before loading, operate the freezer 48 to 72 hours to allow complete
container cool down and system check operation.
Note: When start-up is complete remove the lid key and the control key to
insure system security.
3.5 Setting the Clock
The "real time clock" feature of the Cryoplus Series enables alarms, program
changes, and the current system status to be printed relative to the actual time and
date of occurrence.
To set the clock:
Turn the key switch to FULL ACCESS. Press the High Level button on the
key pad while turning on the power switch.
Starting from the bottom, the first LED on the bar graph lights and the display
shows the current hundredths of seconds.
Press the up arrow (to increase) or down arrow (to decrease) the setting.
Press the SET key to lock in the value and advance to the next setting. The
chart below shows the settings in their sequence.

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LED lights* Clock Setting
1 hundredths of seconds
2 seconds
3 minutes
4 hours (in military time)
5 day of the week
6 day of the month
7 month
8 year
*LED on the Bar Graph, starting at the bottom of the graph and
counting upward.

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SECTION 4 - OPERATION
4.1 Programming the Controller
To program the controller:
Turn the key switch to the FULL ACCESS position.
Note: Full Access is a timed position. If a key pad is not depressed within four
minutes, access is denied and controller functions are locked out. To
regain access, turn the key switch to On (lock) and then return to Full
Access.
If the green solenoid valve indicator is on, indicating that the controller is in
fill mode, depress the MAN FILL touch switch to stop filling operation.
Select the scale by depressing the SCALE SELECT touch switch. The green
indicator above bar graph alternates between low scale 2" to 7" range (vapor
scale right side), and full scale 2" to 24" range (liquid left side).
High Level Adjust: (Stop fill indicator)
Depress the high level touch switch.
Depress UP ARROW to raise setpoint (flashing orange LED) or DOWN
ARROW to lower setpoint.
Depress SET touch switch, after flashing orange LED reaches the
desired level on the bar graph.
Low Level Adjust: (Start fill indicator)
Depress low level touch switch.
Depress UP ARROW to raise setpoint (flashing orange LED) or
DOWN ARROW to lower setpoint.
Depress SET touch switch, after flashing orange LED reaches desired
level on bar graph.

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High Temperature Alarm Adjust:
Depress the high temperature alarm touch switch. Three decimal points
in the digital display will flash On and Off.
Depress the Up Arrow to raise temperature setpoint or the Down
Arrow to lower the temperature setpoint in digital display.
Depress the SET touch switch, after desired temperature is displayed.
When programming is complete, turn the key switch to the On (lock)
position. The controller will store in memory and automatically operate at the
new setpoints.

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4.2 Alarms and Printer Functions
FRONT PANEL DISPLAY DISPLAY DESCRIPTION CONTROL
ACTIONS*
PRINTER
LOG #
Flashing Top
3 System Lamps
AC Input Error (2) (3) (6) ERROR 1
Flashing Bottom
3 System Lamps
A/D Converter Error (2) (3) (6) ERROR 2
Fill Coil Lamp Liquid Valve Coil/Electrically Open (1) (2) (6) ERROR 3
LN2Source Lamp Liquid Valve On, LN2Rise Rate
Seems to Be Zero
(1) (2) (5) (7) ERROR 4
Flashing Valve Stuck Component Failure In Valve Circuit (1) (2) (6) ERROR 5
Stuck Valve Valve Is Off, but Level Is Still Rising (2) (3) (6) ERROR 5
LN2Source and Solid Red Bar
Graph LED's Below Setpoint
Level Below Setpoint too Long (1) (2) (5) (7) ERROR 6
Vent Coil Vent Valve Electrically Open (1) (6) (8) ERROR 7
LN2Source Vent Valve On, No LN2Sensed By
Bypass Probe
(1) (2) (5) (7) ERROR 8
Flashing Bypass Sensor and
Flashing Stuck Valve
Component Failure In Bypass (Vent)
Valve Circuit
(1) (2) (6) ERROR 9
Bypass Sensor Lamp and
Stuck Valve Lamp
Bypass (Vent) Valve Stuck Open (2) (3) (6) ERROR 9
Flash Level Sensor Lamp Pressure Transducer Voltage
Reading too Low or too High
(1) (2) (6) ERROR 10
Level Sensor Lamp Pressure Transducer
Malfunction
(1) (2) (6) ERROR 10
Flashing Temp Display High Temperature Alarm (1) (4) (6) ERROR 11
Temperature Display Flashes
+199
Bad or Disconnected Temperature
Probe
(1) (4) (6) ERROR 12
Bypass Sensor Lamp Bad or Disconnected Bypass (Vent)
Probe
(1) (4) (6) (8) ERROR 13
Flashes All 6 System Lamps EPROM Check Sum Wrong on
Power Up
(1) (6)
Set to Default
Limits
ERROR 14
LED's Above High Setpoint Level Is One Inch or Greater Above
the High Setpoint
(1) (4) (6) ERROR 15
All Lamps Flash Stack Overflow (Resets System) No Action
Required
(Self
Correcting)
STACK
OVERFLOW
*Refer to key on the following page.

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CONTROL ACTIONS - KEY
Set the remote alarm relay contacts to come ON in 30 minutes.
Disable run cycle decision making (both valves turned OFF).
Set remote relay contacts to come ON immediately.
Self correcting alarm.
Low Nitrogen error can be cleared in full access mode by operator action.
Audio alarm will sound, but can be cleared for this occurrence permanently.
Audio alarm will sound and can be cleared but will resound if condition is not
corrected in 30 minutes.
Disable bypass valve until power is restored.
CONTROL PRINTER FUNCTIONS
The printer provides the following information:
Power up
All error numbers and hour/date as they occur
Auto fill starts and hour/date as they occur
Manual fill start and hour/date
Manual fill stop and hour/date
Changes in program settings and hour/date
Current level, current temperature, and hour, every 2 hours (programmable to
24); or on demand in full access after the alarm mute key is pressed
Add 2,047 Hours; The Unit Will Count Up To 2,047 Hours Before It Will
Wrap Around To Hour Number One

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SECTION 5 - MAINTENANCE
5.1 Solenoid Valve Maintenance
OPERATION
Normally closed: Valve is closed when
solenoid is de-energized, valve is open when
solenoid is energized.
POSITIONING/MOUNTING
This valve is designed to perform properly
when mounted in any position. However, for
optimum life and performance, the solenoid
should be mounted upright, to reduce the
possibility of foreign matter accumulating in the
core tube area.
MAINTENANCE
WARNING: Turn OFF electrical power
supply and de-pressurize valve before making
repairs. It is not necessary to remove valve from
pipe line for repairs.
CLEANING
A periodic cleaning of all solenoid valve(s)
is desirable. The time between cleanings will vary,
depending upon media and service conditions.
Generally, if the voltage to the coil is correct,
sluggish valve operation, excessive noise, or
leakage will indicate that cleaning is required.
VALVE DISASSEMBLY AND
REASSEMBLY (REF. FIGURE)
De pressurize valve and turn OFF electrical
power supply. Proceed in the following manner:
1. Remove retaining clip and slip entire solenoid
enclosure off solenoid base sub-assembly.
Caution: When metal retaining clip
disengages, it will spring upward.
2. Unscrew solenoid base sub-assembly and
remove body gasket, core assembly with rider
ring and core spring attached.
3. Clean and reassemble in reverse order of
disassembly, paying careful attention to
exploded view provided for identification and
placement of parts.
After maintenance, operate the valve a few
times to ensure proper opening and closing.