Worthington CS100 Instruction Manual

CS100 Control System
Operation & Maintenance Instructions
CAUTION - SAFETY FIRST!
• REVIEW AND UNDERSTAND ALL SAFETY PROCEDURES IN THE “HANDLE WITH CARE”
BOOKLET (P/N 367334) 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 K SERIES UNITS, YOU MUST READ THE SEPARATE OPERATING AND
SAFETY MANUAL PROVIDED WITH THAT WORTHINGTON INDUSTRIES UNIT.
K Series Cryostorage Systems
This manual covers the use and maintenance for the CS100 installed on the K SERIES Cryogenic
Storage System. Please read all documentation before using this equipment and all personnel
who use this equipment should be trained. In addition, all service and maintenance on this equipment
should be performed by an authorized distributor, service company or technician.
Failure to follow instructions in this manual may result in damage to equipment, poor or unexpected
performance or injury to personnel operating the equipment.
Material in this manual is for information purposes only. The contents and the product it describes are
subject to change without notice. Worthington Industries makes no representations or warranties with
respect to this manual. In no event shall Worthington Industries be held liable for any damages, direct
or incidental arising out of or related to the use of this manual.

CS100 Control System
TABLE of Contents
SAFETY PRECAUTIONS FOR LIQUID NITROGEN ...................................5
Extreme Cold - Cautionary Statement ...................................................................... 5
Keep Equipment Area Well Ventilated ..................................................................... 5
Liquid Nitrogen System ......................................................................................... 5
Electrical .............................................................................................................. 6
GENERAL INFORMATION ..................................................................6
DELIVERY & RETURNS .......................................................................7
Unpacking and Inspection ..................................................................................... 7
Freight Damage Procedures ................................................................................... 7
Repackaging for Shipment .................................................................................... 7
Getting Unit into Service ....................................................................................... 8
Electrical ............................................................................................................. 8
Electromagnetic Compatibility (EMC) ...................................................................... 8
Power Supply Connection ..................................................................................... 9
Validation ............................................................................................................ 9
OPERATION ...................................................................................... 9
Initial Fill ............................................................................................................. 9
Operating Environment ....................................................................................... 10
CS100 Components ............................................................................................ 10
General Equipment Description ............................................................................ 10
Features ............................................................................................................ 11
LN2Level Measurement and Control ..................................................................... 11
Temperature Monitoring ...................................................................................... 12
Harness Assembly .............................................................................................. 12
Alarm Conditions ............................................................................................... 12
Solenoid Valve ................................................................................................... 13
Thermocouples ................................................................................................... 13
Power Supply .................................................................................................... 14
Remote Alarm .................................................................................................... 14
Operating Parameters ......................................................................................... 14
Temperature Monitoring ...................................................................................... 14
Liquid Phase Storage .......................................................................................... 14
Introduction ....................................................................................................... 15
Normal Fill Cycle ............................................................................................... 15
Control Setting Adjustments ................................................................................. 16
Temperature ....................................................................................................... 18
Menu System ..................................................................................................... 18
Factory Defaults ................................................................................................. 18
Installation & Setup ............................................................................................. 19
Alarms and Error Conditions ................................................................................ 20
System Alarms ................................................................................................... 21
Logging ............................................................................................................. 21
Display Brightness .............................................................................................. 21
Making Adjustments to the CS100 SERIES Control System Sensor
Assembly .......................................................................................................... 21
Maintenance ..................................................................................................... 22

CS100 Control System
Troubleshooting .................................................................................................. 24
Product Information ............................................................................................ 24
Interconnection Block Diagram ............................................................................. 26
REPLACEMENT PARTS ......................................................................27
Controller Assembly Parts .................................................................................... 27
Plumbing Controller Assembly Parts ...................................................................... 28
TROUBLESHOOTING .......................................................................29
FREEZER SERVICE AND MAINTENANCE HISTORY LOG ......................................... 29
Appendix .......................................................................................30
Certifications & Listings ........................................................................................ 30
EN Compliance Tables......................................................................................... 30
EC Declaration of Conformity ............................................................................... 34
Warranty ........................................................................................................... 35
Labels ................................................................................................................ 35
TABLE of Contents

5
CS100 Control System
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.
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.
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.
WARNING:
Inlet pressure
should not exceed
22 psig (1.5
bar/152 kPa).
Higher pressures
could result
in damage to
equipment.
WARNING:
Maintain adequate
ventilation
to prevent
asphyxiation
hazard (see Safety
Precautions).

6
CS100 Control System
Safety Precautions
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.
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].
WARNING:
Electrical shock can
kill. Do not attempt
any service on these
units without first
disconnecting the
electrical power
cord.
The CS100 SERIES Control System can monitor and control the liquid nitrogen level range in the cryostorage
unit you have selected. CS100 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 CS100 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.
General Information

7
CS100 Control System
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 to 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 the
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 Returned Material Authorization
(RMA) 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 RMA:
1. System model and serial number, and controller model and serial number.
2. User’s name, company, address, and phone number
3. Malfunction symptoms

8
CS100 Control System
Delivery & Returns
If possible, the original packing material should be retained for reshipment. If not available, consult
Worthington Industries for shipping and packing instructions. It is your responsibility 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.
Getting Unit into Service
Your Cryostorage System comes with complete instructions for how you should remove the unit from the crate
and put it into service. Read both this manual and your Cryostorage System’s manual before beginning any
installation. Make sure to follow any required procedures and safety guidelines when you are connecting your
Liquid Nitrogen source.
The CS100 SERIES Control System is designed to be operated at normal room temperatures 15° C to 27° C
(60° F to 80° F) at a relative humidity level below 50%. The humidity level should be maintained such that the
electronics are not exposed to condensation.
The Worthington Industries Cryostorage freezer should be positioned such that all sides of the unit are easily
accessible and the user can easily connect/ disconnect the power cord from the wall socket.
Proper ventilation MUST BE adequate to sustain life for those working with or maintaining this equipment.
Electrical
The liquid level controllers used with these freezers operate at 12 VDC. The external power supply has a 120
VAC (50/60 Hz) primary. Disconnect the electrical power cord from the wall outlet before attempting any
service.
Electromagnetic Compatibility (EMC)
Although this equipment conforms to the intent of the 2004/108/EC EMC Directive, all medical equipment
may produce electromagnetic interference or be susceptible to electromagnetic interference. The following are
guidance and manufacturer’s declarations regarding EMC for the CS100 SERIES Control System.
The CS100 SERIES Control System needs special precautions regarding EMC and needs to be installed and
put into service according to the EMC information provided in the following pages.
Portable and Mobile RF communicati ons equipment can affect the performance of the CS100 SERIES Control
System. Please use the guidelines and recommendations specified in the EN Compliance tables found on
pages 30–33.
Other equipment or systems can produce electromagnetic emissions and therefore can interfere with the
functionality of the CS100 SERIES Control System. Care should be used when operating the CS100 SERIES
Control System adjacent to or stacked with other equipment. If adjacent or stacked use is necessary, the
CS100 SERIES Control System should initially be observed to verify normal operation in the configuration in
which it will be used.

9
CS100 Control System
The electrical cables, external power supplies and accessories listed or referenced in this manual have been
shown to comply with the test requirements listed in the EN Compliance tables found on pages 30–33. Care
should be taken to use only manufacturer-recommended cables, power supplies and electrical accessories with
the CS100 SERIES Control System. If a third-party supplier offers cables, external power supplies and electrical
accessories for use with the CS100 SERIES Control System and they are not listed or referenced in this manual,
it is the responsibility of that third-party supplier to determine compliance with the standards and tests in the EN
Compliance tables found on pages 30–33.
The use of electrical cables and accessories other than those specified in this manual or referenced documents
may result in increased electromagnetic emissions from the CS100 SERIES Control System or decreased
electromagnetic immunity of the CS100 SERIES Control System.
Power Supply Connection
Connect the power supply to your Cryostorage System and then plug the power supply into a surge-protected
wall outlet.
Validation
Some organizations require that equipment be validated periodically. If information is needed on the proper
techniques to validate this equipment, please contact your supplier.
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.
Delivery & Returns
Operation
Initial Fill
The Cryostorage System, using the CS100 SERIES Controller, comes preset from the factory. 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 22 psig (1.5
bar/152 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.

10
CS100 Control System
Operation
Operating Environment
The CS100 is designed to be operated at normal room temperatures (60°F to 80°F, 15°C to 27°C) and a
relative humidity level below 50%. The humidity level should be maintained such that the electronics are not
exposed to condensation.
The K SERIES Cryostorage system should be positioned such that all sides of the unit are easily accessible and
the user can easily connect/disconnect the power cord from the wall socket.
CS100 Components
The CS100 for the K SERIES Cryostorage system consists of the following components:
• Main Control and Display
• Harness Assembly
• Power Supply
• Thermocouple Assembly
• Sensor Assembly
• Cryogenic Solenoid Valve
• Remote Alarm Plug
The CS100 is assembled onto the freezer at the factory and completely tested. Start operation of the control
system by plugging the power cord into the wall outlet. The CS100 will go through a short startup routine
and then start operation. For information relating to assembly of the control components and connection
information, refer to Appendix A.
General Equipment Description
Main Control Front Panel