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SERVICE MANUAL G4 SERVICE MANUAL

1. 34 RP26 Flow Meter Verification 34 RP27 Economizer Regulator RR 35 RP28 Economizer Regualtor Test 35 RP29 Flow Control Valve FCV RR 36 RP30 Dewar RR 36 RP31 Normal Evaporation Rate NER Test 36 Service Tools Fixtures Equipment Supplies 37 1 These procedures are designed to be performed only by qualified personnel with proper equipment 2 Any failure during routine maintenance checks will refer you to this section See troubleshooting chart for appropriate procedure PN 13350704 Rev D 19 Troubleshooting Charts Symptom Unable to start fill or excessively long fill Liquid leaks from the coupled QDVs during the fill Unable to disconnect the transfer line from the reservoir after a fill Liquid leaks from the QDV poppet after filling Excessive venting from relief valves hissing sound No flow at oxygen outlet Low flow at oxygen outlet on all LPM settings Probable Cause Corrective Action a Transfer line not engaged fully on Make sure the QDV on the transfer line and reservoir are properly aligned and ensure that Reservoir QDV a downward force is being applied to the transfer l
2. 25 RP6 Liquid Level Meter Calibration 25 RP7 G4 Meter Troubleshooting 26 RP8 Manifold Capacitance Test 27 RP9 Manifold Assembly RR 27 RP10 Resolder Feed thru Wire 28 RP11 Manifold Harness Assembly RR 28 RP12 Clean Dry Probe amp Dewar 28 RP13 Relief Valve Test 29 RP14 Relief Valve RR 29 RP15 Pressure Retention Test 30 RP16 Plumbing Leak Test 30 RP17 Warming and Breathing Coil Assembly RR 31 RP18 Vent Valve RR 31 RP19 Twist Lock QDV Lip Seal RR 31 RP20 Twist Lock QDV RR 32 RP21 Push on QDV RR 32 RP22 Empty Unit ooo nn 33 RP23 Warm Unit 33 RP24 Flow Rate Test 34 RP25 Operating Pressure Test
3. Safet WARNING Medical electrical Equipment needs special pre WARNING The use of Accessories transducers and cables cautions regarding EMC and needs to be installed and put into other than those specified by the manufacturer may result in service according to the EMC information provided in this increased Emissions or decreased immunity of the Liberator manual WARNING The Liberator should not be used adjacent to or WARNING Portable and mobile RF communications equip stacked with other equipment and that if adjacent or stacked ment can affect Medical Electrical Equipment use is necessary the Liberator should be observed to verify nor mal operation in the configuration in which it will be used Table 1 Guidance and Manufacturer s declaration electromagnetic emissions The Liberator is intended for use in the electromagnetic environment specified below The customer or the user of the Liberator should assure that it is used in such an environment Emissions test Compliance Electromagnetic environment guidance RF emissions Group 1 The Liberator uses RF energy only for internal function CISPR 11 Therefore its RF emissions are very low and are not likely to cause any interference in nearby electronic equipment RF emissions CISPR 11 Class B Harmonic emissions The Liberator is suitable for use in all establishments including IEC 61000 3 2 Not applicable domestic establishments and those directly connected to the public
4. Peers sure unit is empty and at room temperature be d Lift manifold assembly straight up to remove ore testing e Place cover on top of dewar WARNING Before removing manifold assembly Liberator must a il procedure be empty warm and vent valve open Apply small amount of Krytox to O ring Item 50 before assembly Torque manifold mounting screws RP8 Manifold Capacitance Test Figure 12 a fO SONUN iail a Capacitance Meter Set Up 1 Connect capacitance meter adapter to capacitance meter ac cording to Figure 12 2 Turn on capacitance meter and select 200 pF range 3 Move zero adjustment on the front of the meter until the display reads zero PN 13350704 Rev D Repair Procedures RP 10 Resolder Feed thru Wire Figure 14 g Remove manifold assembly See RP9 Strip approximately 1 8 of insulation from feed thru wire Item A if necessary Remove strain relief material holding the signal wire against the capacitance probe Apply small amount of Stay Clean flux to tinned area of probe Item B using a cotton swab Resolder feed thru wire Item A to tinned area of probe Item B Add small amount of lead free solid wire solder if neces sary Clean flux residue with distilled water and cotton swab Dry thoroughly Replace manifold following listed procedure RP9 RP11 Manifold Harness Assembly RR Figure 13 a b Remove manifold assembly See RP9 Remove strain
5. Not Applicable DC powered device Not Applicable Not Applicable Power frequency magnetic fields should be at levels characteristic of a typical location in a typical commercial or hospital environment Note UT is the a c mains voltage prior to application of the test level This statement indicates that the required testing was performed in a controlled environment and the Liberators are found to be compliant with regulations E Liberator 10 Service Manual Safet Guidance and manufacturers declaration electromagnetic immunity The Liberator is intended for use in the electromagnetic environment specified below The customer or the user of the Liberator should assure that it is used in such an environment Immunity test IEC 60601 test level Compliance level Electromagnetic environment guidance Conducted RF 3Vrms Not Applicable Portable and mobile RF communications equipment should IEC 61000 4 6 150kHz to 80 MHz Battery powered be used no closer to any part of the Liberator including device cables than the recommended separation distance calculated from the equation applicable to the frequency of the transmitter Recommended separation distance d 1 2 VP d 1 2 VP 80 MHz to 800 MHz d 2 3VP 800 MHz to 2 5 GHz where P is the maximum output power rating of the Radiated RF 3 V m transmitter in watts W according to the transmitter IEC 61000 4 3 80 MHz to 2 5 GHz manufacturer and d is the recommended separation dis
6. Voltage fluctuations low voltage power supply network that supplies buildings used for flicker emissions Not applicable domestic purposes IEC 61000 3 3 PN 13350704 Rev D Safet Table 2 Guidance and manufacturers declaration electromagnetic immunity The Liberator is intended for use in the electromagnetic environment specified below The customer or the user of the Liberator should assure that it is used in such an environment Immunity test IEC 60601 test level Compliance level Electromagnetic environment guidance Electrostatic discharge ESD 6 kV contact 8 kV air 6 kV contact 8 kV air Floors should be wood concrete or ceramic tile If floors are covered with synthetic material the relative IEC 61000 4 2 humidity should be at least 30 Electrical fast transient burst IEC 610004 4 2 kV for power supply lines 1 kV for Not applicable DC powered device Not applicable Not applicable input output lines No data input output lines Surge IEC 61000 4 5 Voltage dips short interruptions and voltage variations on power supply input lines IEC 61000 4 11 Power frequency 50 60 Hz magnetic field IEC 61000 4 8 1 kV line s to line s 2 kV line s to earth lt 5 UT gt 95 dip in UT for 0 5 cycle 40 UT 60 dip in UT for 5 cycles 70 UT 30 dip in UT for 25 cycles lt 5 UT gt 95 dip in UT for 5 sec 3 A m Not Applicable DC powered device
7. tance in meters m Field strengths from fixed RF transmitters as determined by an electromagnetic site survery should be less than the compliance level in each frequency range Interference may occur in the vicinity of equipment marked with the following symbol NOTE 1 At 80 MHz and 800 MHz the higher frequency range applies NOTE 2 These guidelines may not apply in all situations Electromagnetic propagation is affected by absorption and reflection from structures objects and people Field strengths from fixed transmitters such as base stations for radio cellular cordless telephones and land mobile radios amateur radio AM and FM radio broadcast and TV broadcast cannot be predicted theoretically with accuracy To asses the elec tromagnetic environment due to fixed RF transmitters an electromagnetic site survey should be considered If the measured field strength in the location in which the Liberator is used exceeds the applicable RF compliance level above the Liberator should be observed to verify normal operation If abnormal performance is observed additional measures may be necessary such as reori enting or relocating the Liberator gt Over the frequency range 150 kHz to 80 MHz field strengths should be less than 3 V m This table is included as a standard requirement for equipment which has been tested to specific test levels and over specific frquency ranges and been found compliant with regulati
8. If an error occurs the calibra tion value will not be saved c Proceed to next step within 45 seconds Calibrate Empty Capacitance a Press and hold calibrate button for 3 sec to record empty capacitance reading LED 1 will flash for 3 sec b LED 1 will flash to signify successful calibration If an error occurs certain LEDs will flash signifying a specific error code and the calibration value will not be saved See Table 8 for a list of error codes Calibrate Full Capacitance There are two full capacitance procedures available Procedure 1 is quite accurate and quicker to perform since it does not re quire you to fill the dewar Procedure 2 is even more accurate but requires the dewar be vent full with LOX To start either procedure calibration mode must first be entered There is no need to perform both procedures for any given calibration PN 13350704 Rev D 25 Repair Procedures Procedure 1 Capacitance Simulated Full Method RP 7 G4 Meter Error Codes Figure 11 NOTE Please use only one of the following calibration meth ods The table below identifies the error codes that one is likely to TABLE 7 Capacitance Span LED Settings ene LED Setting FIGURE 11 Calibration Errors a Press the operate button 3 times within a 5 sec period of entering calibration mode One of the LEDs will light con ti LED 1 inuously b Press the calibrate button until the correct LED is continu ously lit See Table
9. 1 7 bar 18 24 2 psig or unit fails test RP26 Flow Meter Verification Flow meter accuracy is best verified by a calibration labora tory Equipment should indicate liter per minute oxygen gas at atmospheric pressure and 21 C 70 F Flow meter accuracy may also be tested by comparison to one or more new unused calibrated flow meters This method will increase confidence in accuracy of readings but not necessarily verify accuracy ES Liberator 10 Service Manual FIGURE 24 Flow and Pressure Tests TABLE 11 Flow Test Acceptable Ranges o EE pp w sx40to6s0 Repair Procedures FIGURE 25 Economizer Regulator FIGURE 26 Economizer Test Setup Pressure Source Valve Set Above Desired Regulator Setting S ZAS RP27 Economizer Regulator RR Figure 25 WARNING Liberator must be empty and vented before start ing this procedure a Remove shroud See RP2 b Loosen the three compression fitting nuts Item 34 at the economizer regulator Item 35 Move coils on the sides and economizer tube Item D away from the economizer regulator Item 35 c Follow RP28 to ensure proper settings on the replace ment regulator d Reverse remainder of procedure to install new properly adjusted regulator RP28 Economizer Regulator Test Figure 26 a Follow steps a and b of RP27 to remove economizer regulator WARNING Liberator must be empty and vented before start ing this proced
10. See RP2 Repair Procedure FIGURE 22 Emptying Unit RP2 WA b G d 1 2 FIGURE 23 Warming Unit 3 4 5 a l 2 Empty Unit Figure 22 RNING Make sure open end of transfer line remains inside cryogenic container Wear insulated gloves and eye protection when using this procedure DO NOT reuse liquid oxygen Place one end of the transfer line Item A into a suitable cryogenic container such as an empty clean Liberator de war Connect a male transfer line adapter Item B to the other end of the line NOTE Female transfer line adapter should be substituted for item B in top fill version Connect the adapter to the Liberator QDV Item 15 keep ing the vent valve Item 41 closed Liquid oxygen will be discharged from the open end of the transfer line into the empty container Continue process until Liberator is empty If Liberator has no pressure pressurize with the following procedure Connect regulator Item C to oxygen gas source Connect pneumatic hose Item D to regulator and Liberator DISS Fitting Item E Adjust regulator Item C to supply up to 1 4 bar 20 psig Set Liberator FCV Item 24 to 6 LPM setting Continue until Liberator is empty RP23 Warm Unit Figure 23 Liberator may be allowed to sit FCV off vent closed a minimum of 48 hours after emptying b To warm a Liberator more quickly Connect regulator Item C to oxygen or nit
11. and the oxygen has stabilized for five minutes PN 13350704 Rev D 15 Operation Liquid Level Measurement As noted in the Theory of Operation Section 6 Generation 4 Liberators are equipped with new liquid level meters In order to obtain a liquid level reading the technician or end user should depress the green operate button on the face of the meter note that the button has been moved onto the meter from its previous position This will cause the LEDs to quickly flash from right to left around the meter s perimeter to indicate button activa tion The LEDs will then light from the left to the right signifying the liquid level in the cylinder 1 LED for empty 8 for full If you feel the meter is giving incorrect measurements reference RP7 to calibrate the meter Cleaning and Disinfection To insure proper functioning and end user safety all Liberator units should be cleaned whenever dirt or grime is visually appa rant The unit should be disenfected according to any applicable local regulations or the home healthcare distributor s own decon tamination schedule Preparation Prior to cleaning or disinfection the unit should be completely purged of LOX The technician should wear appropriate safety gear and prepare mild solutions of glass cleaner or Simple Green available at www simplegreen com and disinfectant respec tively If at any time either solution becomes visibly dirty or cloudy it should be switch
12. from the meter to the point where the pinched or otherwise damaged sensor wire enters the reservoir manifold Replace as necessary Contents indicator not calibrated Calibrate the meter as needed following RP6 properly Ice crystal in reservoir causing incor Empty and warm the reservoir following RP23 RP24 to melt and evaporate moisture rect or empty level reading from inside the reservoir Meter malfunctioning damaged Inspect for physical damage Replace meter as necessary then recalibrate the meter following RP6 PN 13350704 Rev D Troubleshooting Charts 4 Low Battery Meter Calibration Replace Defective Part Replace Relief Valve Replace Battery Calibrate Meter Calibrate Meter Replace Battery Meter ves 1 LED on Remove Manifold Clean Dry Probe amp Dewar Calibrate Meter Replace Meter Replace Probe Reassemble Manifold 22 Liberator 10 Service Manual Troubleshooting Charts Empty Dewar Clean File Records Return Unit to Service Replace Lip Seal Replace Dewar Replace off Let Sit 24 Hrs Empty Dewar Replace Economizer Regulator e Unless otherwise noted by the arrows the flow through the chart is down or to the right To use the Troubleshooting Chart e Start at the upper left corner e The top line
13. is too high Inspect the saturation pressure of the reservoir Allow at least 30 minutes at no flow for the reservoir to saturate properly b Leak in the system Perform a leak check on the plumbing RP16 Repair leaks as necessary Relief valve open Ensure that there is no venting from the relief valves If there is refer to the corrective actions for Excessive venting from relief valves hissing sound El Partial or complete loss of vacuum Conduct the NER test RP32 and return the unit to CAIRE Inc if necessary Excessive Frost Frost is acceptable Some frost on the shroud and on the plumbing is acceptable especially at high flow NOTE Minimal frost on rates during continuous use This is due to the evaporation of LOX to gas and the the shroud and on the temperature difference between the LOX and room temperature ee is ets High humidity level High humidity levels can increase frost accumulation is symptom applies to i pa is Kai Saturation pressure is too high Inspect the saturation pressure of the reservoir Allow at least 30 minutes at no flow greater than what is for the reservoir to saturate properly normally observed d Leaki in the system Perform a leak check on the plumbing RP16 Repair leaks as necessary Relief valve open Ensure that there is no venting from the relief valves If there is refer to the corrective actions for Excessive venting from relief valves hissing sound n Partial or complete loss of vacuum Con
14. over or un reasonably abused immediately but cautiously raise the con tainer to its normal vertical position If substantial container damage has occurred remove the liquid oxygen from the ves sel in a safe manner RP22 Purge the unit with an inert gas nitrogen and promptly return it to CAIRE for inspection The container should be prominently marked CONTAINER DROPPED INSPECT FOR DAMAGE Failure to comply with these procedures may result in personal injury and can seriously damage the container WARNING Personnel must remove liquid oxygen and depres surize the unit before removing parts or loosening fittings from a unit Failure to do so may result in personal injury from the extreme cold of liquid oxygen and or the pressure in the vessel WARNING During transfer of liquid oxygen components will become extremely cold Care should be used to avoid any con tact with these components as serious frostbite may result WARNING During transfer of liquid oxygen gas blowoff from the vent valve creates a loud horn like noise Ear protection is recommended WARNING Keep filled unit upright at all times Tip over of filled unit may result in liquid oxygen leakage and or an oxy gen enriched atmosphere WARNING Only use replacement equipment which is compat ible with liquid oxygen and has been cleaned for oxygen use Do not use regulators fittings hoses etc which have been pre viously used in non oxygen service
15. ration pressure since it is easier to control than temperature Treat saturation temperature as a dependent variable of satura tion pressure FIGURE 3 Temperature vs Saturation Pressure 6 9 157 4 1 4 173 8 kK 4 5 SATURATION PRESSURE BAR There are two conditions which can seriously affect the overall efficiency and operation of the system 1 Saturation pressure of the liquid oxygen in the fill source is substantially higher than the Liberator operating pressure oversaturated 2 Saturation pressure of the liquid oxygen in the fill source is substantially lower than the Liberator operating pressure undersaturated For example when a Liberator is filled from a liquid source saturated at 6 9 bar 100 psig larger transfer losses will occur This is because the Liberator is designed to operate at 1 4 bar 20 psig and the liquid it is filled with is saturated at a much higher pressure and at its correspondingly higher temperature It is necessary for this liquid to reach equilibrium at a lower pressure and temperature before the relief valve will close and the Liberator will operate properly In order to become saturated at 1 4 bar 20 psig the liquid oxygen must release enough heat for its temperature to be lowered to the temperature corresponding to a pressure of 1 4 bar 20 psig as shown in the graph The temperature is low ered through boiling All of the gas generated by this boiling is vented thr
16. shows the steps of routine maintenance PN 13350704 Rev D 23 Repair Procedures RP1 General The following procedures have been carefully prepared to allow proper removal and replacement of defective components and should be used in conjunction with the Troubleshooting Chart and the tests in this section WARNING Make sure the unit is empty and vent valve is open before replacing any component except shroud assembly com ponents or Lip Seals WARNING The technician s hands tools and clothing should be free of all oils and greases WARNING Parts that are welded in place must not be replaced in the field Should these parts fail return complete assembly or sub assembly to factory for repair DO NOT use solder or silver solder to repair broken welds WARNING The manufacturer of fluorolubricant warns users not to allow fluorolubricant to contaminate tobacco products Wash fluorolubricant from hands before smoking WARNING Do not use glue type thread locking compounds or unapproved sealants on any repairs CAUTION When replacing components make sure the new part is oriented exactly the same as the original part prior to in stallation CAUTION Some components require a specific amount o torque when assembling Follow torque requirements where specified NOTE All replacement parts must be factory approved cleaned for oxygen service and stored in sealed plastic bags The repair area must be clea
17. the bat tery and carefully pry out the battery d Insert new battery with the positive terminal facing up e Apply a thin coating of fluorolubricant to the o ring f Replace battery cover by pushing it into the back of the level meter s case ensuring the o ring seals evenly and without kinks to restore the air tight seal FIGURE 9 Shroud Assembly RP6 Liquid Level Meter Calibration Figure 10 WARNING You must first calibrate the empty side and then calibrate the full side Calibration is required to ensure accurate meter readings and should be done whenever an error in level readings is suspected or when the meter has been replaced If a calibration procedure is unsuccessful the calibration value will not be saved and an error code will be displayed on the LEDs See Table 7 To cali brate first enter calibration mode before performing either full or empty calibration NOTE In order to obtain an accurate calibration you must calibrate both empty and full capacitance For the full capaci tance part of the calibration you can choose either of the two FIGURE 10 Liquid Level Meter LED 8 Calibrate Button Hidden Operate Button Enter Calibration Mode a Press and hold the hidden calibrate button While still holding continue to step B b Within 3 sec press and hold the operate button LED 1 and LED 8 will begin alternately flashing to signify that calibra tion mode has been entered
18. 0107 CAIRE Inc Unit 2 Maxdata Centre Downmill Rd Bracknell Berkshire RG12 1QS United Kingdom 4 Finally a Credit Memo minus a 15 restocking fee will be issued to the distributor when all equipment has been received inspected and restocked by CAIRE Inc Return of Unused Non Defective Merchandise CAIRE Inc atits discretion charges a 15 restocking fee for unused non defective merchandise that is returned An RMA number must be obtained from CATRE Inc Customer Service prior to return of any goods Merchandise cannot be returned for credit after sixty 60 days Customer to pay all freight charges Tracking capability and insurance on all returned goods is advised CATRE Inc will not be responsible for misdi rected shipments Chart Industries Inc Caire Inc BioMedical Group 2200 Airport Industrial Dr Ste 500 Ball Ground GA 30107 Ph 770 721 7700 Toll Free 1 800 482 2473 Fax 770 721 7701 ZF CAIRE A Chart Industries Company www cairemedical com Chart BioMedical Ltd Unit 2 Maxdata Centre Downmill Road Bracknell Berks RG12 1QS United Kingdom Ph 44 0 1344 403100 Fax 44 0 1344 429224 Copyright 2012 Ref 13350704 Rev D
19. 7 c Press the operate button to save the calibration If an error occurs the calibration value will not be saved Calibrate Button Procedure 2 Fill Method Cia a Enter calibration mode on a vent full unit with properly saturated LOX If unit has just been filled allow it to stabi Operate Button lize before continuing b Press and hold operate button for 3 sec LED 8 will flash as the meter stores calibration value If successful LED 8 will flash again and calibration mode will exit If an error occurs the calibration value will not be saved TABLE 8 Calibration Errors LEDs Reason Empty capacitance less E Check A loose connectinos as Low Cap Ply S 00 PF When calibrating empty cadera Empty capacitance greater Remove moisture and debris SE High Cap 300 PF When calibrating empty ion Low Low Span Span less than 30 PE less than 30 PF When When calibrating full full Empty unit and recalibrate unit and recalibrate High Span Span greater than 80 PF When calibrating full Empty unit and recalibrate 1 3 5 7 Range The new cap valu is When calibrating full Empty unit and recalibrate less than empty cap value TABLE 9 Operation Errors ace ey Pa a High Ca Reading is 120 PF above cali me Remove moisture debris 8 ap brated full value Debris on probe from probe and recalibrate Low Batt 2 4 6 Bad Cal dia tame New meter revision fixed Recalibrate out w o pres
20. G4 LIBERATOR 10 SERVICE MANUAL SERVICE MANUAL LIBERATOR 10 G4 CAIRE Inc 2200 Airport Industrial Dr Ste 500 Ball Ground GA 30107 www cairemedical com Customer Technical Service United States Phone 800 482 2473 Fax 888 932 2473 Asia Australia Pacific Rim Phone 61 297 494333 Fax 888 932 2473 Europe Phone 44 1344 403100 Fax 888 932 2473 Abbreviations FCV Flow Control Valve LED Light Emitting Diode LOX Liquid Oxygen LPM Liters Per Minute NER Normal Evaporation Rate POI Patient Operating Instructions N2 Nitrogen Gas TF Top Fill DF Dual Fill Definition of Terms PRV QDV RMA RP SRV 02 SF PTFE Preface Primary Relief Valve Quick Disconnect Valve Return Materials Authorization Repair Procedure Removal and Replacement Secondary Relief Valve Oxygen Gas Side Fill Polytetrafluoroethylene Teflon WARNING Description of a condition that can result in personal injury or death CAUTION Description of a condition that can result in equipment or component damage NOTE A statement containing information important enough to emphasize or repeat ITEM Item numbers used throughout this manual are shown on the illustrations beginning on page 34 Disclaimer This manual is intended for use by experienced personnel only No attempt should be made to fill or maintain this equip ment until both this manual and the Patient Operating Instruction booklet have been read and fully
21. QDV RR Figure 20 ing procedure RP21 Push on QDV Assembly RR Figure 21 WARNING Liberator must be empty and vented before start WARNING Liberator must be empty and vented before start ing this procedure a b Remove shroud See RP2 Loosen nut Item C by holding QDV body Item 15 with a wrench and turning nut Item C clockwise Remove QDV by pulling QDV body Item 15 off and then pulling the hex coupler Item 89 and O ring Item 16 out of the fill tube NOTE All Internal Components of the QDV Must Remain Assembled During this Process d e Apply thin film of fluorolubricant to O ring Item 16 Reattach QDV by matching alignment marks on valve body and fill tube Torque nut Item C to 60 67 N m 45 50 ft lbs while holding valve body Item 15 Replace shroud See RP2 FIGURE 20 Side Fill Twist Lock QDV Assembly 32 Liberator 10 Service Manual a b p Remove shroud See RP2 Remove the top fill QDV by turning the QDV nut Item D clockwise while holding the QDV Item 11 with a wrench Pull the QDV straight up and off of the fill tube Item D Use rubber mallet to lightly knock upward if required If replacing entire QDV recommended skip to step h Remove and replace the static seal Item 67 if needed Push QDV back on to fill tube Item D and torque nut to 60 67 N m 45 50 ft lbs while holding valve body to fasten QDV in place Replace shroud
22. V outlet 2 Install condensation bottle on bracket located below shroud Remove cap from bottle Put condensation hose inside bot tle 3 Install FCV extension by screwing it into the side of the FCV to 45 N cm 4 in lb 4 Install humidifier elbow if applicable by screwing it into the side of the FCV extension 5 Visually inspect the Liberator for damage from improper handling Note any dents in the container cracks in the shroud missing or loose hardware and bent quick discon nect valves or humidifier adapters 6 Check for smooth operation of the flow control selector making sure that a positive detent is felt at all settings The flow control knob should be secure and properly aligned 7 Check the vent valve for smooth operation 8 If possible connect a portable unit to the Liberator to check for smooth coupling and to make sure the portable unit is in proper alignment with the Liberator when mated 9 Verify operation of the level meter by depressing the operate button LEDs will light displaying the level of liquid oxygen If the unit is empty only the leftmost LED should light If it does not or if other erroneous indications are given refer to the Troubleshooting Section Section X 10 Check all labels for damage and wipe away any dust on unit with a clean dry lint free cloth 11 If desired the flow control knob Item 1 can be adjusted so it will not exceed maximum prescribed flow rate a Rem
23. a standard requirement for equipment which has been tested to specific test levels and over specific frquency ranges and been found compliant with regulations 10 Liberator 10 Service Manual Theory of Operation Filling The Liberator is filled by connecting a pre purged transfer line with a fill adapter from a larger liquid oxygen source to the Liberator side fill or top fill QDV The Liberator vent valve is then opened The pressure differential between the Liberator and source tank forces liquid oxygen through the transfer line and into the Liberator inner vessel There will be some oxygen vaporized during filling This gas is discharged through the vent valve When the Liberator is full liquid oxygen is expelled Disconnecting the fill adapter from the Liberator QDV and closing the Liberator vent valve termi nates the fill process FIGURE 2 Filling Saturation Pressure The saturation point of a liquid is a steady state condition where the liquid has absorbed the maximum amount of heat possible A liquid can be at its saturation point at a number of different pressures and temperatures but each specific satura tion pressure has a corresponding saturation temperature and vice versa see Figure 3 This means that the final temperature of your liquid oxygen is dependent upon the pressure at which it is transferred from the storage system to the Liberator For the purposes of this manual we will speak in terms of satu
24. ct CAIRE Inc customer service for a replacement meter If the meter battery is no longer under warranty the CR2032 coin cell battery can be replaced RP5 Replacement batteries can be found at most hardware stores or they can be ordered through CATRE customer service The new level meter improves upon the previous meter by in tegrating all components within its casing simplifying removal and replacement RP4 Even more importantly there is a much improved calibration procedure that requires no addi tional tools and a range of error reporting codes which can be read directly from the LEDs to report calibration errors These can be found in the calibration procedure RP7 NOTE Tampering with meter battery housing will void the battery s 2 year warranty FIGURE 6 Liquid Level Meter Circuit Level Meter Signal JST Connector _ Liquid Fill Tube Probe Inner Cylinder PN 13350704 Rev D FE Unpacking and Setu Unpacking 1 Inspect carton for shipping damage Report any damage to freight company before signing bill of lading 2 Check description on carton against your order 3 Unpack unit including condensation bottle and bracket POI FCV extension and humidifier elbow kit 4 Set aside packing materials in case unit must be returned to the factory Setup 1 Install condensation bottle bracket by squeezing bracket ends together and inserting into slot in handling ring di rectly below FC
25. d oxygen in the fill source is saturated at 2 4 4 1 bar 35 60 psig 3 4 bar 50 psig is optimal WARNING Fill source must be in a well ventilated area to pre vent developement of an oxygen enriched atmosphere WARNING Wear insulated gloves and eye protection when ever working with liquid oxygen 2 Fill Procedure a Required Equipment I Fill source as outlined above I Liquid oxygen transfer line 1 Male transfer line adapter for side fill Liberators L Female transfer line adapter for top fill Liberators J Liberator vent valve wrench L Eye protection I Pressure gauge I Insulated gloves b If refilling a partially filled Liberator verify flow rates are within tolerance specifications before filling c Verify that liquid level meter is operating properly The LED display should indicate approximate level in unit The low battery LED should not be lit NOTE If flow rates are out of specifications or liquid level meter operates improperly refer to Troubleshooting section Section X d Connect transfer line to fill source Connect proper trans fer line adapter to transfer line e Fully open liquid valve on fill source f Purge transfer line for a minimum of 5 seconds ensuring gas is safely piped away from operator i Connect transfer hose fill adapter to a securely mounted mating QDV OR Operation ii Push adapter poppet against the side of a Liberator unit or other unpainted stainle
26. duct the NER test RP32 and return the unit to CAIRE Inc if necessary Unit will not maintain Saturation pressure is unacceptable Inspect the saturation pressure of the reservoir used for filling Allow at least 30 acceptable system minutes at no flow for the portable to saturate properly pressure b Vent valve not completely closed Close vent valve Leak check vent valve outlet and stem Replace or repair as needed Leak in the system Perform a leak check on the plumbing RP16 Repair leaks as necessary a Economizer valve faulty Test the economizer RP28 and replace RP29 if necessary o Primary releif valve faulty Test the primary relief valve RP13 and replace RP14 if necessary High Pressure at Reser Saturation pressure is too high Inspect the saturation pressure of the reservoir Allow at least 30 minutes at no flow voir oxygen outlet for the reservoir to saturate properly Primary releif valve set too high or Perform relief valve test Replace as needed relief valve operating improperly Economizer valve stuck in closed Perform Economizer test Replace as needed state a Partial or complete loss of vacuum Conduct the NER test RP32 and return the unit to CAIRE Inc if necessary Contents indicator Battery voltage too low to operate Replace battery as needed RP5 then calibrate the meter following RP6 reads incorrectly contents indicator Sensor wires not connected properly Visually inspect the meter harness assembly
27. e or visit www cairemedical com to obtain your parts price list 38 Liberator 10 Service Manual Orderin Information Ordering Information The following steps should be used when ordering a new Liberator or replacement parts for an existing unit 1 Compile a list of all equipment and replacement parts to be ordered NOTE Use the following numbers to order a complete unit Model 0 15 LPM Side Fill Top Fill For European Part Numbers please call 44 0 1344 40310 For Asia Part Numbers please call 61 297 494333 2 Fill out a purchase order containing the following informa tion a Purchase order number b Name and address of billing location c Name and address of shipping location d Quantity part number description and unit cost for each item ordered 3 Telephone or fax CAIRE Inc at one of the numbers listed below to begin immediate processing of the order USA Toll Free Phone 800 48 CATRE 800 482 2473 Toll Free Fax 888 WE CAIRE To place an order 888 932 2473 Phone 770 257 1299 Fax 770 257 1300 Asia Australia Pacific Rim Phone 61 297 494333 Fax 888 932 2473 Europe Phone 44 0 1344 403100 Fax 44 0 1344 429224 4 Mail or fax the completed purchase order for confirmation to CAIRE Inc 2200 Airport Industrial Dr Ste 500 Ball Ground GA 30115 USA Unit 2 Maxdata Cantre Downmill Rd Bracknell Berkshire RG12 1Qs United Kingdom All new equi
28. ed out for fresh solution Cleaning 1 Inspect through air holes in shroud to see if any debris has accumulated beneath shroud If it has remove debris using long tongs or tweezers 2 Wipe off the exterior of the unit with the cleaning solution using a lint free cloth The cloth should be damp but not dripping Be as thorough as possible 3 Discard the cleaning cloth 4 Wipe off excess cleaning solution and dry thoroughly with a lint free cloth Discard the cloth Disinfection Disinfection should be performed in accordance with the home healthcare provider s own validated procedures and or in accord ance with local regulations Table 1 shows disinfectants which have proven to be compatible with materials used in the construction of the Liberator base unit Table 2 shows actual material content of the Liberator base unit to assist the home healthcare distributor in establishing its own disinfection protocol Table 3 lists a selection of common disinfectant chemicals and their compatibility with Liberator base units 16 Liberator 10 Service Manual TABLE 1 Recommended Disinfectant Solutions Microbac Bodie Chemie www bode chemie com Forte Hamburg i Wexford Labs Note The above solutions are recommendations only and there ay be a number of other effective solutions TABLE 2 Liberator Material Content TABLE 3 Common Disinfectant Chemicals Disinfectant Agent Compatible with Generation 4 Libera
29. g parts c Verify the meter reads empty one LED the low battery LED is not lit and no error codes appear on the meter 2 Component Test a Remove shroud RP2 b Pressurize the unit between 1 5 bar 21 8 psig and 1 7 bar 24 2 psig and check that PRV opens c While sealing off the PRV pressurize the unit to between 1 9 bar 27 0 psig and 2 3 bar 33 0 psig pressurize the unit to between 27 0 33 0 RP13 and check that SRV opens d Recalibrate meter RP7 Test pressure retention RP15 f Replace shroud RP2 o TABLE 4 Flow Test Acceptable Ranges FCV Setting w 54Wtv s0 Flow Test a Fill with approximately 7kg 15 lbs of properly saturated LOX b Set FCV to maximum setting and run for one hour minimum c Check all flow settings according to Table 4 and verify pressure stays above 1 24 bar 18 psig Check Efficiency of Unit a Set FCV to zero and allow unit to warm up 10 15 min b Inspect unit for cold or sweaty condition and for ex cessive venting from relief valve some venting is normal c If either condition is observed conduct NER test RP31 Prepare for Use a Empty contents RP22 b Allow unit to sit until warm 2 4 hours c Clean and or disinfect outside of unit following instruc tion set forth in the Operation section Section VIII PN 13350704 Rev D Maintenance Schedule B Continuous Schedule B Continuous A Introductio
30. ine assembly Verify that pressure from the source is within the 35 50 psi range to fill the reservoir Vent valve not open or is blocked Ensure that the vent valve is able to be turned to the fully open position d Source tank is either under or Allow LOX to saturate to proper pressure oversaturated e Fill connector not opening properly Check fill connector and cartridge assembly for damage make sure fill connectors fully engage f Vent valve is obstructed Inspect the valve for blockages and verify that flow passes through during a fill Clean by blowing out with compressed gas or replace parts if necessary Leak in the system Check the reservoir for leaks RP16 and repair if needed Leave the units el with the vent valve closed and let them sit until they warm up enough to disconnect Always ensure that male and female QDV s are cleaned and dried prior to each fill Ice crystal preventing the QDV from Engage and disengage the transfer line onto the reservoir several times to dislodge the closing properly ice crystal Always be sure that the male and female QDVs are wiped clean and dry before filling Dirty or damaged QDV poppet Replace the QDV cartridge RP20 or the entire QDV assembly RP21 at no flow for the portable to saturate properly Test the relief valve RP13 and replace if necessary RP14 Conduct the NER test RP32 and return the unit to CAIRE Inc if necessary Ensure the flow control knob is not in the
31. istributors emphasize safety and safe han dling practices to their employees and customers While safety features have been designed into the unit and safe operations are anticipated it is necessary that all distributor personnel care fully read and fully understand WARNINGS CAUTIONS and NOTES throughout the manual Periodic review of this infor mation is recommended CAUTION The Liberator should be moved by utilizing the roller base or hand truck Do not roll units on their side or edge as insulation damage can occur The Liberator must be used stored and transported in a vertical position Do not lay store or ship the unit on its side 6 Liberator 10 Service Manual WARNING Excess accumulation of oxygen creates an oxy gen enriched atmosphere defined by the Compressed Gas Association as an oxygen concentration above 23 In an ox ygen enriched atmosphere flammable items may burn vigor ously and may explode Certain items considered non combus tible in air may burn rapidly in such an environment Keep all organic materials and other flammable substances away from possible contact with oxygen particularly oil grease kerosene cloth wood paint tar coal dust and dirt which may contain oil or grease DO NOT permit smoking or open flame in any area where oxygen is stored handled or used Failure to com ply with this warning may result in serious personal injury WARNING In the event a unit is dropped tipped
32. ler base can be provided to help move the Liberator Specifications Nominal Values Capacity kg Ibs LOX Liquid Liters Gaseous Liters Selectable Flow Rates Liters Per Minute LPM Flow Rate Accuracy LIBERATOR 10 11 8 26 10 7 8881 Off 25 5 75 1 1 5 2 2 5 3 4 5 6 0 1 liter per minute or 10 of flow setting whichever is greater Hours of Operation Refer to the Liquid Oxygen Duration Time Chart located at www cairemedical com Standard Fill Connections Operating Pressure Economizer Regulator Bar PSIG Primary Relief Valve Setting Bar PSIG Secondary Relief Valve Setting Bar PSIG Normal Evaporation Rate kg lbs per day Height cm in Diameter cm in Weight Empty kg lbs Full kg 1bs Fill Connector Types Side Top 1 4 20 2 1 5 1 7 21 8 24 2 1 9 2 3 27 0 33 0 0 54 1 2 495 19 5 35 6 12 11 8 26 23 5 52 Side Mounted Rotary Coupling Top Fill Push On PN 13350704 Rev D ES Safet Oxygen as it exists at standard atmospheric pressure and tem perature is a colorless odorless and tasteless gas Oxygen constitutes 21 of the atmosphere by volume Aside from its well documented ability to sustain life oxygen also supports combustion even though it is nonflammable Many substances which will burn in air burn at a faster rate and at a higher tem perature in an oxygen enriched atmosphere Other materials that do not burn in air will bu
33. low rate to the patient FIGURE 5 Operation Below 1 4 Bar 20PSI Breathing Coils Warming Coils Theory of Operation Liquid Level Measurement Liberators are equipped with a unique liquid level measurement system This system measures the level of liquid oxygen inside the unit with a capacitance probe and displays that liquid level on the level meter s LEDs The liquid level probe consists of two concentric stainless steel cylinders extending inside the inner vessel As the liquid oxy gen level rises the capacitance of this assembly goes up The level meter then displays the liquid level in the cylinder based on a calibration relating capacitance to fill level The higher the liquid level in the dewar the more LEDs are activated begin ning at the leftmost LED Electrical connection between the level meter and the probe is made via a single conductor JST connector This male plug is attached to its female counterpart extending from the probe creating a watertight connection A single ground wire is con nected from the meter to a male spade terminal on the mount ing bracket The meter is powered by an internal battery offering battery life of 5 years or more at 30 cycles per day The meter has a low battery LOW BATT indicator which signals the need for bat tery replacement The meter battery is covered under a 2 year limited warranty If battery failure occurs within 2 years of the Liberator shipment date conta
34. ly Item B use PTFE tape Connect gauge assembly to humidifier adapter Item 26 on FCV outlet Open FCV Item 24 to 6 LPM setting Assemble oxygen regulator pneumatic hose Item C with DISS fittings and male pneumatic test adapter Item D Connect assembly to oxygen gas source Connect male pneumatic test adapter Item D to Liberator QDV Item 15 Increase pressure to 1 3 bar 19 psig Leak test all connections joints and valves with leak test solu tion NOTE PRV and SRV may leak slowly Repair all other leaks first and retest for pressure retention before changing relief valves EN Liberator 10 Service Manual Close FCV Item 24 by turning to Off position Remove pres sure gauge assembly from humidifier adapter Item 26 Disconnect pneumatic adapter Item D from QDV Item 15 Leak test QDV poppet and FCV outlet Repair all leaks by following appropriate repair procedures FIGURE 18 Plumbing Tests Set up Repair Procedures FIGURE 19 Coil and Vent Assemblies RP17 Warming and Breathing Coil Assembly RR Figure 19 WARNING Liberator must be empty and vented before start ing procedure a Remove shroud See RP2 b Remove manifold assembly without coils RP9 c Remove three screws Item 48 retaining coil brackets d Remove warming and breathing coil assemblies e To replace coil assembly reverse above procedure RP18 Vent Valve RR Figure 19 a Remove shro
35. me in hrs Example R 2 x 24 hours day 25 5 hrs NER 0 59 kg day g If NER is more than 0 9 kg day 2 lbs day for a Liberator the dealer may want to send the unit to CAIRE Inc for re evacuation If NER is more than 2 3 kg day 5 lbs day the dealer should remove the unit from service and have the unit re vacuumed Service Tools Equi Required Tools 1 Hex Wrenches various sizes 2 Flat Blade Screwdriver 3 5 16 Nut Driver 4 Open End Wrenches 1 2 to 1 1 8 5 Side Cutters 6 Pliers 7 Torque Driver Wrenches 12 17 N cm 10 15 in lbs 23 29 N cm 20 25 in lbs 69 92 N cm 60 80 in lbs 104 115 N cm 90 100 in lbs 6 2 6 9 N m 45 50 ft lbs 8 Jeweler s Screwdriver Required Fixtures Equipment 1 Capacitance Meter Soldering Iron Oxygen Regulator Pressure Gauge Pressure Gauge Adapter Flowmeter 02 Gas Source High Pressure bottle 02 Liquid Source N DAN DW U A A WY N N2 Gas or Clean Dry Compressed Air Source 10 Tubing 02 compatible 11 Lip Seal Service Tool 12 Male Pneumatic Test Adapter 13 LO2 Transfer Line 14 Transfer Line Adapter with Filter 15 Dewar Cap 16 Vent Valve Wrench 17 Scale 0 70 kg 0 150 lbs 0 02 kg 0 05 Ib increments Required Supplies 1 Stay Clean Flux Cotton Swabs Lead free Solder Distilled Water Household Glass Cleaner Lint Free Cloth PTFE Tape Fluorolubricant Leak Detectio
36. n Continuous maintenance is a set of tests and inspections done pe riodically to ensure equipment is functioning properly It can be performed by drivers or other personnel while the equipment is in service 1 Ifa unit fails a given test it should be taken out of service and sent to the Repair Center Department for further inspection 2 Schedule Checks should be made when the driver sees the patient and when moving equipment between patients B Procedure These inspections tests should be done by the driver as part of the Standard Fill Procedure every time the reservoir is filled 1 Visually inspect for a Broken shrouds b Cold sweaty bottles vacuum problem c QDV deformation 2 Check prescription flow rate s using an Erie liter meter 0 25 LPM 3 Check the liquid level meter Push operate button before fill and verify that the battery is not low there are no error codes and the meter reading is within one LED of the values shown in Table 5 After filling verify that the meter reads full TABLE 5 Unit Weight kg vs Meter Reading Liberator 10 Service Manual These inspections tests should be done between patients 1 Visually inspect for a Broken shrouds flow control knobs b Cold sweaty bottle or excessive venting from relief valve vacuum problem Some venting from relief valve is nor mal c QDV deformation d Inspect under shroud without removal for any visible dirt or con
37. n Fluid Oo AN HD HT A WwW N Cleaner ment Supplies 1 Simple Green available at www simplegreen com Tools and Part No 10679862 10678157 CA200071 CA200072 97200076 97212021 97212023 150753478 97217007 CA400004 97403016 97202005 3910486 97403577 97404564 97405147 97405279 97405431 97405590 CA406308 CA406310 CA406398 97406471 97406555 97406630 13350704 10661515 10660361 10660344 10661523 13329091 Accessories available from Caire Description Female Top Fill Pneumatic Test Adapter Female Top Fill Transfer Line Adapter 240 AC Fluorolubricant Leak Detection Fluid gallon Erie Liter Meter Male Side Fill Pneumatic Test Adapter Male Side Fill Transfer Line Adapter w Filter Transfer Line Adapter Cover Pressure Gauge Adapter Replacement Filter Male Transfer Line Adapter Jeweler s Screwdriver Vent Valve Wrench Dewar Cap 0 4 1 bar 0 60 psig Pressure Gauge Transfer Line Swivel Connector 0 3 1 bar 0 45 psig Oxygen Regulator Pneumatic Hose with DISS Fittings Liquid Oxygen Transfer Line 2 m 6 ft Lip Seal Service Tool 10 3 bar 150 psi Relief Valve Assembly TEFLON Tape 10 3 bar 150 psi Relief Valve Only Tandem Tee Kit Super Flex Liquid Oxygen Transfer Line 6 Dual Fill Head Tee Service Manual Conversion Kit TF to SF Conversion Kit SF to Dual Conversion Kit TF to Dual Conversion Kit SF to TF G4 Capacitance Meter Adaptor Kit PN 13350704 Rev D XIV Parts Price List Contact Customer Servic
38. n and separate from other areas Room air should be filtered and free from dust soot and other contaminants NOTE When replacing components with pipe threads use PTFE tape thread sealant Apply two rounds of PTFE tape to threads near end of component avoiding first thread NOTE When assembling new compression fittings tighten 1 8 1 4 and 1 2 nuts eight flats past finger tight and 3 16 nuts five flats past finger tight When reassembling previously used compression fittings tighten nuts one to two flats past fin ger tight 24 Liberator 10 Service Manual RP2 Shroud Assembly RR Figure 9 a Remove humidifier adapter Item 26 from FCV Item 24 b Loosen set screw s in FCV knob Item 1 Remove knob c Remove number disc Item 2 d Remove two screws Item 4 retaining locking plate Item 3 then remove plate e Remove three shroud mounting screws Item 39 f pp For side fill units a Remove shroud Item 7 by pressing on shroud at 90 each side of QDV Item 11 and rotating shroud Item 7 up and off QDV OR f2 For top fill units a Lift shroud straight up g Disconnect manifold harness assembly Item 22 located un der shroud Item 7 h To replace shroud assembly reverse above procedure Torque humidifier adapter Item 25 to 60 80 in lbs on FCV Item 24 RP3 Condensation Bottle Bracket RR a Remove three shroud mounting screws Item 39 b Remove c
39. neration of this gas with the flow control valve closed is called the normal evaporation rate NER This gas is lost through the primary relief valve FIGURE 4 Operation Above 1 4 Bar 20PSI Gas to Patient Breathing Coils 12 Liberator 10 Service Manual When the flow control valve is at any setting other than off and the economizer valve is open presure over 1 4 bar 20 psig see Figure 4 gaseous oxygen is forced from the head space in the inner vessel through the economizer valve to the breathing coil This process conserves or economizes liquid oxygen by withdrawing the head gas first instead of allowing it to escape through the relief valve While flowing through the breathing coil the cold gaseous oxygen is warmed to near ambient temperature before being metered and dispensed by the flow control valve Whenever gas is removed from the space above the liquid oxy gen head space the inner vessel internal pressure begins to drop slightly When the pressure drops to 1 4 bar 20 psig the economizer valve closes see Figure 5 forcing liquid oxygen up the withdrawal tube and through the warming coil where it becomes gas The gas then flows through the bypass tee to the breathing coil the flow control valve and then the patient As the pressure in the container increases over 1 4 bar 20 psig the economizer valve opens and the cycle repeats maintaining constant oxygen flow at the selected f
40. off 0 position Perform a leak check on the plumbing RP16 Repair leaks as necessary Ensure that there is no venting from the relief valves If there is refer to the corrective actions for Excessive venting from relief valves hissing sound m enaner serena lychee Fi FcVinletfilteris obstructed Clean or replace RP30 the filter screen g Blockage in the liquid withdrawal Check the warming coils and withdrawal tubes for blockages Replace if necessary circuit lo FCV Faulty Replace the FCV RP30 Nasal cannula kinked or leaking Inspect the functionality of the nasal cannula b Saturation pressure is too low Inspect the saturation pressure of the reservoir Allow at least 30 minutes at no flow for the reservoir to saturate properly Leak in the system Perform a leak check on the plumbing RP16 Repair leaks as necessary Liberator 10 Service Manual Troubleshooting Charts Symptom Probable Cause Corrective Action Low flow at oxygen d Flow control valve inlet filter screen Clean or replace RPxx the filter screen outlet on all LMP set dirty tings cont a Economizer valve faulty Test the economizer RP28 and replace RP29 if necessary Blockage in the liquid withdrawal Check the warming coils and withdrawal tubes as well as the flow restrictor for block circuit or the flow restrictor ages Replace if necessary g FCV faulty Replace the FCV RP30 Increased NER a Saturation Pressure
41. ondensate drain tube Item 58 from bottle and remove bottle Item 56 from bracket Item 57 c Lift shroud Item 7 approximately 1 2 DO NOT force shroud d Squeeze ends of wireform bracket together Lift bottom of bracket up and away from the tank sidewall Twist the bracket to the side and remove hooks from under conden sation ring e To replace bracket reverse above procedure RP4 Liquid Level Meter RR a Remove shroud See RP2 b Remove two screws attaching liquid level meter to the bracket being careful not to pull on the meter wires Repair Procedures c Detach JST connector red signal wire and spade connector black ground wire d To replace meter screw new meter into place using the top set of holes on the meter and reattach wires e Calibrate meter per RP6 RP5 Liquid Level Meter Battery RR NOTE Tampering with meter battery housing will void the battery s 2 year warranty If meter battery failure occures while the battery is under war ranty contact customer service to obtain a replacement meter If meter battery is no longer under warranty the CR2032 coin cell battery may be replaced following the steps below a Remove liquid level meter See RP4 b Using a pair of pliers grasp the battery cover on the back of the meter Twist counter clockwise and pull the cover away from the meter removing the battery cover c Slide the tip of a flathead jeweler s screwdriver beside
42. ons PN 13350704 Rev D EM Safet Recommended separation distances between portable and mobile RF communications equipment and the Liberator The Liberator is intended for use in an electromagnetic environment in which radiated RF disturbances are controlled The cus tomer or the user of the Liberator can help prevent electromagnetic interference by maintaining a minimum distance between portable and mobile RF communications equipment transmitters and the Liberator as recommended below according to the maximum output power of the communications equipment Rated maximum output Separation distance according to frequency of transmitter power of transmitter m W 150 kHz to 80 MHz 80 MHz and 800 MHz 800 MHz to 2 5 GHz d 1 2VP d 1 2 VP d 2 3 VP 0 12 m 0 12 m 0 23 m 0 1 0 38 m 0 38 m 0 73 m 1 1 2m 1 2m 2 3m 10 3 8 m 3 8 m 7 3 m 100 12m 12m 23m For transmitters rated at a maximum output power not listed above the recommended separation distance d in meters m can be estimated using the equation applicable to the frequency of the transmitter where P is the maximum output power rating of the transmitter in watts W according to the transmitter manufacturer NOTE 1 at 80 MHz and 800 MHz the separation distance for the higher frequency range applies NOTE 2 These guidelines may not apply in all situations Electromagnetic propagation is affected by absorption and reflection from structures objects and people This table is included as
43. ough the relief valve and or primary relief valve and is lost If the saturation pressure of the liquid oxygen in the filling ves sel is lower than the normal operating pressure of the Liberator oxygen vaporization within the dewar works to raise the system pressure to the required 1 4 bar 20 psig This may require as long as a day The time required for saturation to 1 4 bar 20 psig depends on the initial liquid saturation pressure PN 13350704 Rev D EM Theory of Operation WARNING Low oxygen flow rates to the patient may result if the Liberator is filled with under saturated liquid oxygen WARNING The vent valve orifice does not guarantee properly saturated LOX The filling source tank must have a minimum 1 6 bar 23 psi to transfill into the Liberator or low saturation will occur in the Liberator To minimize the effect of undersaturated liquid in the Liberator a fixed orifice has been installed in the outlet of the vent valve This orifice regulates the back pressure in the unit during the fill process resulting in improved saturation pressures in the Liberator Operation If the flow control valve and vent valve are closed with LOX in the unit then the pressure in the inner vessel will remain near the primary relief valve setting of 1 5 1 7 bar 21 8 24 2 psig In the Liberator as in all vacuum insulated cryogenic contain ers some liquid oxygen in this case is always evaporating into a gas The rate of ge
44. ove FCV knob by firmly grasping the knob and pull ing away from the base unit b Remove two phillips head screws Item 4 from flow lock plate Item 3 and remove plate E Liberator 10 Service Manual FIGURE 7 Flow Control Knob c Remove flow rate decal number disc Item 2 d Remove locking pin Item 65 from its storage position on flow lock plate Item 3 and place in underside of hole cor responding to maximum allowable flow rate e Replace flow lock plate Item 3 number disc Item 2 and knob Tighten screws Item 4 to 45 65 N cm 4 6 in lbs Verify flow lock is at correct position Transport Specifically designed roller bases are available for moving Liberators short distances on smooth surfaces Hand trucks can also be utilized for Liberator transport CAUTION Always ship store or transport a Liberator empty or full in an upright position properly secured to prevent dam age DO NOT ROLL UNITS TO TRANSPORT Liberator 10 units may be moved about or transported in a vehicle while full without damage however they should not be dropped or handled roughly in order to prevent necktube damage Filling NOTE The fill source should have the correct fitting 5 8 x 45 male flare to connect to transfer line 1 Fill Source Preparation a Ensure the source contains a sufficient amount of liquid oxygen to completely fill the Liberator approximately 120 of Liberator volume b Ensure the liqui
45. pment will be shipped either prepaid F O B Canton Georgia or collect via your specified carrier All replacement parts will be sent by UPS prepaid and the shipping charges for equip ment and parts will be added to the final invoice Payment for re placement parts are located on CAIRE Inc s invoice with payment date indicated All shipments will originate from Canton Georgia Ifa particular carrier or method of shipment is desired specify when placing order For additional ordering and contact information visit www cairemedical com PN 13350704 Rev D 39 Return amp Restockin Polic When a Liberator is received it should be inspected im mediately as outlined in Section VII Unpacking and Setup Instructions If a problem with the unit should be encountered reference should be made to the Troubleshooting Chart in Section X page 12 13 If these procedures do not provide a solution for the problem the following steps should be taken 1 Call CAIRE Inc Customer Service State the problem with the unit If it is determined that the problem cannot be solved by the distributor a Return Material Authorization RMA number will be assigned to the unit or part s If a Purchase Order Number is to be referenced please give this number to the Customer Service Representative at that time 2 Carefully package the parts or repack the unit in its origi nal shipping container precisely as shipped 3 Wri
46. pneumatic hose Item C with DISS fittings and male pneumatic test adapter Item D Connect assembly to oxygen gas source Connect male pneumatic test adapter Item D to Liberator QDV Item 15 Slowly begin increasing pressure to between 1 5 1 7 bar 21 8 24 2 psig PRV Item 62 should begin venting audible noise will be heard or bubbling will be seen if leak testing Slowly begin decreasing the pressure until the PRV Item 62 closes meaning the audible noise is no longer heard or the bubbling is no longer seen if leak testing The pressure at which the PRV closes should be greater than 1 4 bar 20 5 psig Hold PRV Item 62 closed and increase pressure to 1 9 2 3 bar 27 33 psig SRV Item 28 should open audible venting and or bubbling of leak test solution Decrease pressure to 1 3 bar 19 psig Test relief valve with leak test solution A minimal amount of leakage bubbling is acceptable If leakage is questionable run pressure retention test before changing relief valve RP15 RP 14 Relief Valve RR WARNING Liberator must be empty and vented before starting procedure Primary Figure 16 a b Remove shroud See RP2 Unscrew PRV Item 62 from the economizer regulator Item 35 To replace PRV Item 62 reverse above procedure Tighten the PRV approximately 10 20 degrees clockwise after the PRV body contacts the economizer regulator minimum of 230 350 N cm 20 30 in lbs Secondary Figu
47. rator must be empty and vented before start ing this procedure e Remove condensate bottle Item 56 drain tube Item 55 and bracket Item 54 following RP3 Remove dewar cap from the new dewar and place the cap on old dewar Clean dry both the probe and dewar following procedure EN Liberator 10 Service Manual in section VIII Connect the manifold assembly with coils to the new de war be sure to follow the manifold assembly replacement procedure See RP9 Do not replace shroud Replace condensate bottle Item 56 bracket Item 57 and drain tube Item 58 Scribe part number and serial number on new dewar han dle Make part number and serial number on old dewar il legible Calibrate meter by following RP7 RP31 Normal Evaporation Rate Test a Fill the unit with correct amount of properly saturated liq uid oxygen shown in Table 12 Values are approximate TABLE 12 NER Filling Key Empty kg Ib Lox kg 1b Total kg Ib b Allow unit to sit undisturbed for a minimum of 12 hours with the FCV in Off position and the vent closed NOTE Scale must be accurate to 0 02 kg 0 05 lbs C d Weigh unit Record weight and time Allow unit to sit undisturbed for a minimum of 24 hours e Weigh unit Record weight and time Fh Calculate liquid loss rate NER using the following for mula Weight lost kg or lbs NER x 24 hours day Elapsed ti
48. re 17 Remove shroud See RP2 Remove SRV Item 28 from elbow Item 47 on FCV Item 24 Hold elbow Item 47 to eliminate stress on coil tubing To replace SRV Item 28 apply Teflon tape to the threads staying back one thread from the end of the RV d Tighten SRV to be leak free approximately one turn from fin ger tight PN 13350704 Rev D EN Repair Procedures RP15 Pressure Retention Test Figure 18 WARNING Liberator must be empty and vented before starting procedure a Assemble pressure gauge Item A and adapter assembly Item B use PTFE tape Connect gauge assembly to humidifier adapter Item 26 on FCV outlet Open FCV Item 24 to 6 LPM setting Assemble oxygen regulator pneumatic hose Item C with DISS fittings and male pneumatic test adapter Item D Connect assembly to oxygen gas source Connect male pneumatic test adapter Item D to Liberator QDV Item 15 Increase pressure to 1 4 bar 20 psig Disconnect male pneumatic test adapter Item D from QDV Item 15 Turn FCV valve Item 24 to Off setting Allow unit to sit undisturbed for 60 minutes Turn FCV valve Item 24 to 6 LPM setting If pressure gauge Item A indicates less than 1 24 bar 18 psig unit fails test RP16 Plumbing Leak Test Figure 18 NOTE Liberator should be empty and warm before testing a b Remove shroud See RP2 Assemble pressure gauge Item A and adapter assemb
49. relief material holding signal wire against the capacitance probe Unsolder feed thru wire Item A from probe Item B Loosen feed thru nut Item C and remove harness To replace manifold harness reverse above procedure Tighten feed thru nut Item C 1 to 2 flats past finger tight Solder feed thru wire Item A following resolder procedure See RP10 Replace manifold assembly See RP9 RP 12 Clean Dry Probe and Dewar Procedure 1 a b Qi Empty dewar per RP22 Warm dewar per RP23 Ifall moisture is not removed continue with Procedure 2 Procedure 2 Remove manifold assembly See RP9 Blow off probe assembly with clean dry nitrogen gas Blow out inside of dewar with clean dry nitrogen gas until inside is clean and dry Replace manifold assembly See RP9 28 Liberator 10 Service Manual FIGURE 13 Manifold Assembly FIGURE 14 Feed thru Wire CAUTION Be careful not to bend or damage manifold assembly or dewar neck tube Repair Procedures FIGURE 15 Relief Valve Test Set up FIGURE 16 Primary Relief Valve RP 13 Relief Valve Test Figure 15 NOTE Liberator should be empty and warm before testing a b Remove shroud See RP2 Assemble pressure gauge Item A and adapter Item B use PTFE tape Connect gauge assembly to humidifier adapter Item 26 on FCV outlet Open FCV Item 24 to 6 LPM setting Assemble oxygen regulator and
50. rn as oxygen concentration in creases Additionally many greases and liquid solvents become extremely hazardous materials when placed in an oxygen en riched environment In its liquid form oxygen is still odorless and tasteless but is pale blue in color At an operating pressure of 1 5 1 7 bar 21 8 24 2 psig the temperature of liquid oxygen is about 173 C 280 F Skin exposed to such a low tempera ture can become severely frostbitten These hazards require certain safety precautions to be taken when working with or around gaseous and or liquid oxygen 1 Never permit combustible substances such as greases oils solvents or other compounds not oxygen compatible to contact any component of the unit exposed to higher than atmospheric concentrations of gaseous or liquid oxygen This especially applies to tubing fittings and valves 2 Keep oxygen equipment away from open flames or electri cal appliances such as heaters stoves toasters and other devices with heating elements 3 Never permit smoking in an area where oxygen equipment is repaired filled or used 4 Always wear goggles a face shield and insulated gloves when working with or around liquid oxygen While CAIRE Inc equipment is designed and built to the most rigid standards no piece of mechanical equipment can ever be made 100 foolproof Strict compliance with proper safety practices is necessary when using any Liberator unit We rec ommend that our d
51. rogen gas source Connect pneumatic hose Item D to regulator Item C and male pneumatic adapter Item F Adjust regulator to 1 4 bar 20 psig Open vent valve Item 41 to allow slow venting Allow Liberator to vent for 1 1 2 hours minimum after vent valve Item 41 defrosts PN 13350704 Rev D 33 Repair Procedures RP24 Flow Rate Test Figure 24 NOTE For flow rate test Liberator needs to be at least 1 4 to 1 2 full of properly saturated liquid oxygen NOTE Be careful to allow for accuracy tolerances of flow me ter Table 11 does not account for these tolerances a Conneztz FCV Item 24 outlet to flow meter Item G inlet with respiratory tubing Make sure flow meter outlet is open and unobstructed and flow meter Item G is properly posi tioned Unit should operate for 1 1 2 hours minimum overnight is optimum Test flow rate at each FCV Item 24 position Record all flow rates Flow rates must be nominal values within tolerances listed in Table 11 or unit fails flow rate test RP25 Operating Pressure Test Figure 24 NOTE If testing operating pressure because of improper flow rates test pressure immediately after flow rate test a Assemble pressure gauge Item H and adapter Item J use PTFE tape Connect gauge assembly to DISS fitting on FCV outlet Open FCV Item 24 to 6 LPM setting Read operating pressure on pressure gauge Item H Operating pressure must be 1 2
52. sing green button Cap reading is 5 PF or greater Moisture in harness added with a Completely dry harness 1 3 5 7 Low Cap less than calibrated empty new meter rev on all assembly and recalibrate value telemetry meters EJ HE 10 Service Manual Repair Procedures FIGURE 12 Manifold Capacitance Test Setup b Capacitance Test 1 Remove shroud assembly See RP2 2 Disconnect the wires leading from the manifold harness as sembly to the level meter by disconnecting the JST connec tor which is zip tied to the bracket 3 Connect JST connector on capacitance meter adapter to manifold harness assembly Item 29 4 Connect alligator clip to manifold bracket 5 Read manifold capacitance and compare to the acceptable ranges found in Table 10 If it does not meet specifications call Technical Support TABLE 10 Manifold Capacitance Specifications Low Limit pF High Limit pF RP9 Manifold Assembly RR Figure 13 a a Remove shroud assembly See RP 2 b1 If removing with coils 1 Remove three screws Item 48 retaining breathing and warming coils OR b2 Ifremoving manifold without coils 1 Disconnect compression fittings Item 34 from econo mizer valve tee Item 35 2 Disconnect compression fitting from liquid withdrawal port Item D When disconnecting tube be careful not to kink vaporizer tube or internal teflon tube c Remove five manifold mounting screws Item 31
53. ss steel surface g Wipe reservoir fill connector with lint free rag if moist NOTE Purge the transfer line any time fill source valve has been closed h Weigh unit as required by local and federal standards i Fully open Liberator vent valve j Connect transfer line to Liberator to begin fill k Connect a pressure gauge to oxygen outlet and open the flow control valve to 2 LPM or greater l While filling throttle the vent valve with the vent valve wrench as needed to keep pressure at approximately 1 4 bar 20 psi An alternate method is to attach a flow meter to the oxy gen outlet set the flow control valve to 2 LPM and then throttle the vent valve to maintain a flow of 2 LPM This is equivalent to using a pressure gauge m When liquid spurts from vent outlet terminate the fill by disconnecting transfer line n Close Liberator vent valve immediately after removing transfer line p Disconnect pressure gauge or flow meter from oxygen outlet and turn off FCV CAUTION Do not allow excessive venting of liquid oxygen through the vent valve Prolonged exposure may freeze the valve in the open position q Replace protective cover on QDV adapter and hang adapter and transfer line using hook provided r Verify that all flow rates are within tolerance specification and that the liquid level meter indicates full NOTE The liquid level indicating system is accurate only after the vent valve is closed
54. taminants e Inspect drain tube for visible dirt Clean with a 6 cotton swab to remove dirt 2 Verify that the meter battery is not low there are no error codes and the meter is within one LED of the table If the unit is empty verify the meter reads empty then fill with ap proximately 7kg 15 lbs of liquid oxygen and verify using the chart 3 Set FCV to maximum flow rate for one hour Check all flow settings according to Table 4 and verify pressure remains above 1 24 bar 18 psig TABLE 6 Flow Test Ranges o po S 6w 540to660 4 Ifthe unit fails one of the above tests return it to the Repair Center or CAIRE Inc If unit passes all tests clean outside of the unit with household glass cleaner and lint free cloth be ing careful not to get cleaner inside valves as this could lead to malfunction Troubleshootin Table of Contents Introduction Introduction 19 Troubleshooting Charts 20 23 Repair Procedures RP1 General 24 RP2 Shroud Assembly RR 24 RP3 Condensation Bottle Bracket RR 24 RP4 Liquid Level Meter RR 24 RP5 Liquid Level Meter Battery RR
55. te the Return Authorization Number on the top of the shipping container 4 Return the unit or parts by professional carrier to CAIRE Inc 2000 Airport Drive Ball Ground GA 30107 CAIRE Inc Unit 2 Maxdata Centre Downmill Rd Bracknell Berkshire RG12 1QS United Kingdom All equipment returned to CAIRE Inc must be shipped prepaid When the defective item s is received at CAIRE Inc it will be serviced and returned to the distributor as soon as possible A copy of the Repair Cost Sheet will be enclosed giving a de tailed listing of any maintenance performed Ma Liberator 10 Service Manual Restocking Policy If it becomes necessary to cancel an order with CATRE Inc af ter the shipment has been received use the following Restock Policy procedure 1 Notify the Customer Service Department at CAIRE Inc using the toll free number When contacting Customer Service personnel it will be necessary to relay the follow ing information a State the quantity and description of equipment to be re turned b Give the Serial Number of each unit to be returned c State the equipment purchase date 2 ARMA number will be issued in the name of the distribu tor by CAIRE Inc for the equipment to be returned When the equipment is shipped to the factory the RMA number must appear on the packing slip 3 All equipment must be returned prepaid to CAIRE Inc 2000 Airport Drive Ball Ground GA 3
56. to deliver gaseous oxygen to the patient at near ambient temperature The Liberator is comprised of four major assemblies grouped according to function 1 Cryogenic Container This assembly is a double walled vacuum insulated dewar for storing liquid oxygen LOX at approximately 173 C 280 F The inner vessel is de signed to safely hold liquid oxygen and is protected from over pressurization by the primary relief valve Vacuum in sulation between the inner and outer vessel keeps outside heat from causing the cold liquid inside to evaporate N Breathing Circuit This circuit consists of the manifold assembly fixed orifice rotary flow control valve FCV breathing coil and warming coil It withdraws liquid oxy gen from the cryogenic container warms it to near ambi ent temperature and regulates the flow of oxygen gas to the patient Any water that condenses on the cold coils is routed into the condensate bottle An economizer regula tor is utilized to conserve LOX by drawing oxygen head gas into the breathing circuit 3 Shroud Assembly The shroud assembly houses and pro tects the breathing circuit and liquid level meter Labels listing safety information and patient operating instruc tions are affixed to the side of the shroud 4 Liquid Level Meter This system uses a capacitance probe and an electronic LED readout to measure and display the LOX level by pressing the onboard operate button An optional rol
57. tors Matye ve Yes Compound Sauerstoffabspalter Yes Ethanol based cleaner only when all O2 has been purged pH Basic alkaline Cleaners TEE End of Life At the end of the unit s service life all Liberator units must be returned to a recycling facility in compliance with the Waste Electrical and Electronic Equipment Directive WEEE or other applicable codes and regulations Maintenance schedule A Biennial There are two schedules for routine maintenance which the home health care distributor may follow These schedules allow the distributor maximum flexibility while assuring that equip ment is operating properly The healthcare distributor may fol low either Schedule A or Schedule B or a combination of the two schedules Schedule A Biennial A Introduction Routine maintenance is a series of steps used to assure that equipment is functioning properly 1 Ifa unit fails a given test one of two things may be done a Refer to Troubleshooting section Section X of this manual Or b Return the unit to CAIRE Inc for repair 2 Schedule Maximum of two years between routine mainte nance testing Unit should be tested whenever a problem is suspected B Procedure Follow the steps in order listed If the unit fails any step refer to Troubleshooting section Section X of this manual 1 Visual Inspection a Remove any LOX prior to maintenance RP22 b Look for damaged or missin
58. ud See RP2 NOTE Valve must be properly aligned to allow access to han dle through hole in shroud b Remove vent valve Item 41 by unthreading valve nut while supporting the valve to prevent it from turning NOTE Ensure static seal Item 67 is not damaged and is in its proper place c Replace vent valve Item 41 Tighten vent valve nut to 60 67 N m 45 50 ft lbs Support the valve to prevent it from turning when tightening valve d Replace shroud See RP2 RP19 Twist Lock QDV Lip Seal RR Figure 20 NOTE Lip seal may be changed on a full Liberator Side Fill Only a Insert lip seal tool into Liberator female QDV Item 15 Engage tabs on tool with slots in retaining ring Item 87 b Use wrench on hex end of tool Push in on tool while turn ing to engage tabs on tool with slots in retaining ring Item 87 Turn tool clockwise to loosen retaining ring Item 87 Remove the ring c Remove lip seal Item 88 from QDV Item 15 Jeweler s screwdriver may be used if necessary but seating surfaces must not be damaged d Apply thin film of fluorolubricant to new lip seal Item 88 e Place retaining ring Item 87 and new lip seal Item 88 on tool f Install retaining ring Item 87 in QDV body Item15 by turning tool counter clockwise while pushing in on tool Torque retaining ring Item 87 to 225 280 N cm 20 25 in lbs PN 13350704 Rev D E Repair Procedure RP20 Twist Lock
59. understood PN 13350704 Rev D 1 Table of Contents am A A A E A 1 I Table of Contents conasssssociitar andara 3 Il Equipment Description coiosororrrarararis erre 4 IV Specifications rr rro aces 5 Ve oa 0 AE EEEE EEA EE 6 VI Theory of Operation eones 11 VII Unpacking and Setup ccc cece eee eens 14 MI OPEO e aatcanetns tae meee la data tas out ass 15 ss A Beoteedeeageseaapeeeass 17 X Troubleshooting ricos soso arte era RE 19 XI Troubleshooting Charts 4 uss acerca casar ws 20 23 XII Repair Procedures rra canoe 24 XIII Service Tools Equipment Supplies 37 ANV Parts Prce Lita crucetas rasos Baca 38 XV Ordering Information evicosntisiosda daras 39 XVI Return amp Restocking Policy 40 PN 13350704 Rev D ES Portable Release Button Shroud Liquid Level Meter Operate Button Liquid Level Meter Primary Relief Valve y TES z 2 i a gt Economizer Regulator WOLD SR SS A N NY Warming Coil NGS j REN N hs Za INIA Flow Control Valve al Side Fill Fitting Cryogenic Container Dewar Condensate Bottle For Top Fill or Dual Models Only 4 Liberator 10 Service Manual The CAIRE Liberator 10 is the stationary component of the Liberator Portable supplementary oxygen system The Liberator incorporates a stainless steel cryogenic container with the valves plumbing and associated hardware required
60. ure b Connect the oxygen pressure source to the inlet of the econo mizer regulator Item 35 as shown in Figure 25 The inlet is the side attached to the economizer tube Item D Figure 25 c Open the pressure source valve Adjust the pressure source regulator to 1 6 bar 23 psig The economizer regulator should be set to open at 1 47 bar 21 3 psig and close at 1 34 bar 19 5 psig d Slowly open valve Item B just enough to allow some gas to escape e Pressure gauge Item A will indicate the setting of the econo mizer regulator f Reverse steps a and b of RP27 to reinstall regulator Note If the economizer is suspected to be malfunctioning please contact Technical Service PN 13350704 Rev D ENS Repair Procedures RP29 Flow Control Valve RR Figure 27 WARNING Liberator must be empty and vented before start ing this procedure NOTE Special care should be taken in aligning the FCV in or der to ensure that it lines up properly with the shroud Remove shroud See RP2 Loosen compression fitting nut Item 34 at connection of breathing coil Item 49 and FCV assembly Disconnect FCV assembly Item 24 from coil Remove elbow Item 47 and SRV Item 28 from FCV Item 24 Replace the FCV Item 24 by reversing the above proce dure FIGURE 27 Flow Control Valve RP30 Dewar RR a Remove shroud See RP2 b Remove manifold assembly and coils See RP9 WARNING Libe

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