Worthington CS200 Instruction Manual

CAUTION - SAFETY FIRST!
• REVIEW AND UNDERSTAND ALL SAFETY PROCEDURES IN THE “HANDLE WITH CARE”
BOOKLET BEFORE ATTEMPTING TO INSTALL, OPERATE OR PERFORM MAINTENANCE
ON THIS LN2CONTROLLER.
• DO NOT ATTEMPT TO USE OR MAINTAIN ANY LIQUID NITROGEN FREEZER 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.
• BEFORE ATTEMPTING TO OPERATE THIS CONTROLLER WITH ANY WORTHINGTON
INDUSTRIES LABS OR K SERIES UNITS, YOU MUST READ THE SEPARATE OPERATING
AND SAFETY MANUAL PROVIDED WITH THAT UNIT.
CS200 Control Systems
LABS and K Series Cryostorage Systems
Operation & Maintenance Instructions

CS200 Control Systems
Table of Contents
SAFETY PRECAUTIONS .......................................................................5
Liquid Nitrogen (LN2)............................................................................................. 5
Extreme Cold - Cautionary Statement....................................................................... 5
Keep Equipment Area Well Ventilated ..................................................................... 5
Liquid Nitrogen System ......................................................................................... 5
Electrical .............................................................................................................. 5
GENERAL INFORMATION ................................................................... 6
CS200 Series Control System Specifications ............................................................ 7
DELIVERY AND RETURNS..................................................................10
Unpacking and Inspection.................................................................................... 10
Freight Damage Procedures ................................................................................. 10
Repackaging for Shipment .................................................................................. 10
INSTALLATION .................................................................................11
Getting Unit into Service ..................................................................................... 11
Electrical ........................................................................................................... 11
Electromagnetic Compatibility (EMC) .................................................................... 11
Power Supply Connection ................................................................................... 12
Validation .......................................................................................................... 12
OPERATION .................................................................................... 13
Initial Fill ........................................................................................................... 13
Control Components ........................................................................................... 13
CS200 Controller Display Guide........................................................................... 14
Operational Theory ............................................................................................. 14
Alarm Conditions ............................................................................................... 15
Lid Switch .......................................................................................................... 16
Solenoid Valve ................................................................................................... 17
Thermocouples ................................................................................................... 17
Power Supply .................................................................................................... 17
Remote Alarm .................................................................................................... 17
Operating Parameters ......................................................................................... 17
Temperature Monitoring ....................................................................................... 18
Liquid Phase Storage ........................................................................................... 18
Maintenance ...................................................................................................... 18
CONTROLLER OPERATION ................................................................ 20
Introduction ....................................................................................................... 20
Operation Data .................................................................................................. 20
Communications ................................................................................................. 20
Normal Fill Cycle ............................................................................................... 20
Control Setting Adjustments .................................................................................. 20
Temperature ....................................................................................................... 26
Battery Operation .............................................................................................. 26
LED Status Wheel ............................................................................................... 26
Lid Switch........................................................................................................... 26
Menu System ..................................................................................................... 27
Factory Defaults ................................................................................................. 29
Troubleshooting .................................................................................................. 30
Interconnection Block Diagram.............................................................................. 30

CS200 Control Systems
Table of Contents
Wiring Diagram.................................................................................................. 31
Installation & Setup.............................................................................................. 32
External Connector Ratings................................................................................... 34
LED Status Wheel Flash Patterns............................................................................ 35
Temperature Thermocouple Select ......................................................................... 35
Temperature Calibration ...................................................................................... 35
Test Temperature System....................................................................................... 36
Test Level Sensors ................................................................................................ 36
Alarms and Error Conditions ................................................................................ 37
System Alarms .................................................................................................... 37
Test Alarms ........................................................................................................ 37
Logging ............................................................................................................. 37
Display Brightness ............................................................................................... 38
Making Adjustments to the CS200 Series Control System Sensor Assembly ............... 38
Removing/Installing the Solenoid Valve ................................................................. 39
Removing/Installing the Controller 10K/24K Units ................................................. 39
Removing/Installing the Thermocouple .................................................................. 40
Removing/Installing the Sensor Probes .................................................................. 40
Making Adjustments to the Level Settings ............................................................... 40
Removing/Installing the Solenoid Valve ................................................................. 41
REPLACEMENT PARTS ......................................................................42
Plumbing Assembly ............................................................................................. 42
Controller Assembly ............................................................................................ 43
TROUBLESHOOTING ........................................................................45
Symptoms ......................................................................................................... 45
Controller Will Not Turn ON ............................................................................... 45
High Liquid Level ................................................................................................ 45
Indicates Low LN2Supply ..................................................................................... 46
Indicates Open Sensor......................................................................................... 46
Temperature Reading 10° to 20° Warm................................................................. 46
Fill Solenoid Cycles On and Off............................................................................ 47
Solenoid Makes Excessive Humming Noise ............................................................ 47
Lid Open Alarm .................................................................................................. 47
QCF (Quick Chill Feature) Will Not Operate ......................................................... 47
Auto Defog Feature Will Not Operate .................................................................. 47
Push Buttons Will Not Respond ............................................................................ 48
Liquid Level Readout is Incorrect ........................................................................... 48
Power Failure Alarm ........................................................................................... 48
SERVICE AND MAINTENANCE HISTORY LOG ....................................49
APPENDIX.......................................................................................50
EN Compliance Tables......................................................................................... 50
EC Declaration of Conformity ............................................................................... 54
Warranty ........................................................................................................... 55
Labels ................................................................................................................ 55

5
CS200 Control Systems
Safety Precautions
Liquid Nitrogen
Nitrogen is an inert, colorless, odorless, and tasteless gas making up four-fifths of the
air you breathe – and can be very dangerous. Air is roughly one-fifth oxygen. Liquid
nitrogen is at a temperature of -196°C (-320°F) under normal atmospheric pressure.
Cryogenic freezers are used in LN2service only.
Extreme Cold - Cautionary Statement
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 it won’t splash or
spill. Protect your eyes and cover the skin where the possibility of contact with the
liquid, cold pipes and 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 that cannot be detected by the
human senses, will be inhaled normally as if it were air. One (1) liter of liquid
nitrogen is equivalent to 24.6 scf of nitrogen gas. Without adequate ventilation, the
expanding nitrogen will displace the normal air resulting in death.
Liquid Nitrogen System
The liquid nitrogen supply pressure at the inlet to the freezer 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 freezer, which can generate false signals
to the liquid level controller causing the freezer to under-fill. In “liquid phase”
storage applications, excessive turbulence can cause splashing which could result
in personal injury and/or damage to the freezer. When installing piping or fill hose
assemblies, make certain a suitable safety relief valve is installed in each section
of plumbing between any two isolation points. 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 freezer plumbing to protect the line between
the customer-supplied shut-off valve and the freezer solenoid valve. Relief valves can
be piped to the outside of the building.
Electrical
• This product is not intended for a life support function.
• This product is intended to be used in hospitals and clinics.
• This product has no Radio Transmitter (Intentional Radiator) functions.
• This product is not intended for electromagnetic shielded rooms only.
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.
WARNING:
Maintain adequate
ventilation to prevent
asphyxiation hazard
(see Safety Precautions).
WARNING:
Inlet pressure should not
exceed 22 psig
(1.5 bar/152 kPa).
Higher pressures could
result in damage to
equipment.
WARNING:
Electrical shock can
kill. Do not attempt
any service on these
units without first
disconnecting the
electrical power cord.
Caution:
When installing field
fabricated piping, make
certain a suitable safety
relief valve is installed
in each section of piping
between any two
isolation points.

66
CS200 Control Systems
General Information
• This product does not intentionally apply RF energy for its function.
• This product does not intentionally receive RF energy for its function.
The liquid level controllers used with these freezers operate from 12 VDC. Disconnect the electrical power cord
from the outlet before attempting any service.
For more detailed information concerning safety precautions and safe practices to be observed when handling
cryogenic liquids consult CGA publication P-12 “Safe Handling of Cryogenic Liquids” available from the
Compressed Gas Association: CGA website: www.cganet.com; CGA customer service +1.703.788.2700; or
email [e-mail].
General Information
The CS200 SERIES Control System can monitor and control both the liquid nitrogen level and the vapor
temperature range in the cryostorage unit you have selected. CS200 SERIES Control Systems are designed
to work with Worthington Industries Cryostorage Systems. 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 unit and therefore, the environment
in which your samples have been stored in this system. This 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.
Worthington Industries 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.
Before beginning installation or operation of this CS200 SERIES Control System, make sure that you read and
understand this manual as well as the operating and safety instructions for the cryostorage unit you will be
using with this controller.

7
CS200 Control Systems
General Information
CS200 SERIES Control System Specifications
Specifications
Control Type LN2Level Control & Temperature Control
Level Measurement
Sensor Type 8-Thermistor Fixed (standard)
Range 8 inch range (8-Thermistor)
Redundancy Multiple discrete points
Temperature Measurement Sensor Type Type T Thermocouple
Accuracy 1oor 1.5% of reading
Resolution .1oC
Number of channels 2
Temperature Display Units oC, F, K, R
Electrical
Input Voltage 100-240 VAC
Input Current (max) 1.75 A
Input Current (continuous) .5 A
Power Consumption (max) 21 W
Power Consumption (continuous) 6 W
Input Frequency 50/60 Hz
Output 12 VDC
Control Input Voltage 12 VDC
Power cord Available for all countries
Battery
Rating 12 Volt, 18Ah
Type AGM Sealed Non-Spillable
Short Protection Installed PCB with thermal fuse
Battery Cover Vinyl
Solenoid Valve
Input Voltage 12 VDC
Input Current .96 amps
Communications
Protocol CryoWire Secure™
Number of Communication Ports 3

CS200 Control Systems
8
General Information
User Interface
Display Type Vacuum Fluorescent Display (VFD)
Buttons 11
Level, Temperature and Alarm Information VFD
“At a Glance” status LED status wheel
Filling 1 LED
Menu Access 1 LED
Language English and German
Control Tests
Power Up Self-Test Control system check
Thermistor Status Yes
Battery voltage Yes
Control voltages Yes
Temperature circuit Yes
Alarms
Low Level Alarm Always enabled
High Level Alarm Always enabled
Sensor Error Alarm Always enabled
High Temperature Alarm (T/C #1, T/C #2) Programmable
Low Temperature Alarm (T/C#1, T/C#2 ) Programmable
Thermocouple Calibration Alarm Always enabled
Thermocouple Open Alarm Always enabled
Power Failure (Remote only) Always enabled
Low LN2Supply Alarm Programmable
Battery Mode Warning Always enabled
Lid Open Too Long Alarm Programmable
Valve Stuck Open Alarm Programmable
Unauthorized Access Warning Programmable
LN2Use Warning Programmable
Low Battery Voltage Always enabled
Audible Alarm Always enabled
Audible Alarm Re-trigger Programmable
Visual Alarm Indicator Always enabled
Remote Alarm Delay Programmable
CS200 SERIES Control System Specifications (cont’d)

9
CS200 Control Systems
Buttons
Power Turns power on/off
Fill/Defog Open Valve
Stop Close Valve
Menu Access Menu
Mute Silence audible
Enter Save a setting or select a menu choice
Back/Exit Leave a setting unchanged or back out of menu.
Up arrow Scroll the menu system or increase a value
Down arrow Scroll the menu system or decrease a value
Left arrow Scroll horizontal menu
Right arrow Scroll horizontal menu
Data Collection
Temperature Yes
Level Yes
Alarms Yes
Memory 4 Mb
Dimensions
Display Width 9.5” (241 mm)
Display Height 2.0” (50.8 mm)
Display Depth 1.31” (33.3 mm)
Display Weight .625 lbs (.28 kg)
Main Control Width 8.875” (225.4 mm)
Main Control Height 6.688” (169.9 mm)
Main Control Depth 1” (25.4 mm)
Main Control Weight 1.0 lbs (.45 kg)
Battery Width 7.25” (184.2 mm)
Battery Height 6.375” (161.9 mm)
Battery Depth 3.25” (82.6 mm)
Battery Weight 12.4 lbs (5.6 kg)
General Information
CS200 SERIES Control System Specifications (cont’d)
NOTE: Above measurements are for LABS; CS200 controllers are integrated into all K Series models.

CS200 Control Systems
10
Delivery & Returns
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 ten (10) days from receipt of goods. If damage or loss is apparent,
please notify the appropriate parties as indicated below:
Domestic LTL Shipments – The customer should notify and file the appropriate damage claims with the
carrier. All products are shipped Ex Works.
Domestic UPS Shipments – Any damage should be noted and reported to shipper upon delivery, and
Worthington Industries must also be notified. Confirm with Worthington Industries Customer Service the filing
procedures for any UPS damage claims.
International Shipments – Any damage and/or claims are to be filed with the carrier. Insurance agent(s)
and Customs should also be notified.
In all cases, Worthington Industries should be notified so we can assist if needed in filing
damage claims.
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. Please advise Worthington Industries of such filings. In case of parts or accessory shortages, advise
Worthington Industries immediately. Worthington Industries cannot be responsible for any missing parts unless
notified within 10 days of shipment.
Freight Damage Procedures
Any freight damage claims are your responsibility. Cryostorage Systems are delivered to your
carrier from Worthington Industries’ 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.
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 equipment
to our service department. Contact your distributor for return authorization. When returning equipment for
service, the following information must be provided before obtaining an MRA:
1. System model and serial number, and controller model and serial number.
2. User’s name, company, address, and phone number
3. Malfunction symptoms
If possible, the original packing material should be retained for reshipment. If not available, consult
Worthington Industries for shipping and packing instructions. It is the responsibility of the customer to assure
that the goods are adequately packaged for return to the factory. All freezers returned to Worthington Industries
must be clean and decontaminated before return.