CAIRE G4 Hi Flow Stroller SERVICE MANUAL

HI FLOW STROLLER
G4
SERVICE MANUAL
PN 14314465 Rev C
Preface
I
SERVICE MANUAL
Hi Flow STROLLER®
CAIRE, Inc.TM
2200 Airport Industrial Drive
Suite 500
Ball Ground, GA 30107
www.cairemedical.com
Customer/Technical Service:
United States
Phone:
800 482 2473
Fax :
Asia, Australia, Pacific Rim
Phone:
+61 297 494333
Fax:
888 932 2473
Europe
Phone:
Fax:
+44(0) 1344 429224
+44 (0) 1344 403100
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
PRV
QDV
RMA
RP
R/R
SRV
O2
SF
PTFE
888 932 2473
Primary Relief Valve
Quick Disconnect Valve
Return Materials Authorization
Repair Procedure
Removal and Replacement
Secondary Relief Valve
Oxygen Gas
Side Fill
Polytetrafluoroethylene (Teflon®)
Definition of Terms
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 equipment
until both this manual and the Patient Operating Instruction booklet have been read and fully understood.
PN 14314465 Rev C
-1-
II Table of Contents
I. Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
II. Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
III. Equipment Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
IV. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
V. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
VI. Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
VII. Unpacking and Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
VIII. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
IX. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
X. Troubleshooting/Repair Procedures (Table of Contents) . . . . . . 15
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Service Tools/Equipment/Supplies . . . . . . . . . . . . . . . . . . . . . 33
XI. Parts Price List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Ordering Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
XII. Restocking Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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Hi Flow Stroller Technical Service Manual
Equipment Description III
FIGURE 1: Hi Flow Stroller Components
CAIRE, Inc.’s Hi Flow Stroller is the portable component of the
Liberator/Portable supplementary oxygen system. Enclosed in
a durable simulated leather case, Hi Flow Strollers incoporate
a stainless steel cryogenic container with the valves, plumbing,
and associated hardware required to deliver gaseous oxygen to
the patient at near ambient temperature.
The Hi Flow Stroller is comprised of five major assemblies,
grouped according to function.
1. Cryogenic Container – This assembly is a double walled,
vacuum insulated dewar for storing liquid oxygen at approximately -180°C (-300° F).
2. Breathing Circuit – This circuit consists of the manifold
assembly, fixed orifice rotary flow control valve (FCV) and
vaporizing coil. It withdraws liquid oxygen from the cryogenic container, warms it to near ambient temperature,
and regulates the flow of oxygen gas to the patient. Water
that condenses on the cold coils is collected and absorbed
by the condensate pad.
3. Case Assembly – The case houses and protects the cryogenic container, the breathing circuit, and the liquid level
meter.
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.
5. Filling Circuit – This manual covers both the side fill Hi
Flow with the rotary quick disconnect valve and the top fill
Hi Flow with the push quick disconnect valve for filling.
PN 14314465 Rev C
-3-
IV Specifications (Nominal Values)
HI FLOW STROLLER
Capacity
LOX lbs. (kg)
Liquid Liters
Gaseous Liters
Hi Flow Selectable Flow Rates
Flow Rate Accuracy
Normal Evaporation Rate lbs./day (kg/day)
Operating Pressure PSIG (Bar)
Primary Relief Valve Setting PSIG (Bar)
Secondary Relief Valve Setting PSIG (Bar)
Filling Time
Warm minutes:seconds
Cold minutes:seconds
3.0 (1,36)
1,25
1026
Off 0,5 1,0
2,0 2,5 3,0
4,0 6,0 8,0
10,0 12,0 15,0
± 0.1 liter per minute
or ±10% of flow
setting, whichever
is greater
1.2 (0,54)
20 (1,4)
19.7 - 20.6 (1,35 - 1,42)
60 - 71 (4,13 - 4,89)
2:00
1:00
Height in (cm)
13.5 (34,3)
Width in (cm)
7.25 (18.4)
Weight
Empty lbs. (kg)
Full lbs. (kg)
Fill Connector Types
-4-
Hi Flow Stroller Technical Service Manual
5.1 (2,3)
8 (3,6)
Male side mounted rotary coupling, female bottom mounted push-on coupling,
or female bottom mounted rotary coupling.
Safety V
Oxygen, as it exists at standard atmospheric pressure and temperature, 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 temperature in an oxygen enriched atmosphere. Other materials
that do not burn in air will burn as oxygen concentration increases. Additionally, many greases and liquid solvents become
extremely hazardous materials when placed in an oxygen-enriched environment. In its liquid form, oxygen is still odorless
and tasteless, but is pale blue in color. At an operating pressure
of 20 psig (1,4 bar), the temperature of liquid oxygen is about
-173°C (-280° F). Skin exposed to such a low temperature 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-thanatmospheric concentrations of gaseous or liquid oxygen.
This especially applies to tubing, fittings, and valves.
2. Keep oxygen equipment away from open flames or electrical 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 Hi Flow unit. We recommend that our distributors emphasize safety and safe handling
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 carefully read and fully understand WARNINGS, CAUTIONS, and
NOTES throughout the manual. Periodic review of this information is recommended.
WARNING: Excess accumulation of oxygen creates an oxygen-enriched atmosphere (defined by the Compressed Gas
Association as an oxygen concentration above 23%). In an oxygen-enriched atmosphere, flammable items may burn vigorously and may explode. Certain items considered non-combustible 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 comply
with this warning may result in serious personal injury.
WARNING: In the event a unit is dropped, tipped over, or unreasonably abused; immediately, but cautiously, raise the container to its normal vertical position. If substantial container
damage has occurred, remove the liquid oxygen from the vessel
in a safe manner (RP14). Purge the unit with an inert gas (nitrogen) and promptly return it to CAIRE, Inc. 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 depressurize 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 contact with these components, as serious frostbite may result.
WARNING: Keep filled unit upright at all times. Tip over of
filled unit may result in liquid oxygen leakage and/or an oxygen-enriched atmosphere.
CAUTION: Only use replacement equipment which is compatible with liquid oxygen and has been cleaned for oxygen use. Do
not use regulators, fittings, hoses, etc. which have been previously
used in non-oxygen service.
PN 14314465 Rev C
-5-
V
1 Title
Safety
WARNING: Medical electrical Equipment needs special precautions regarding EMC and needs to be installed and put into
service according to the EMC information provided in this
manual.
WARNING: Portable and mobile RF communications equipment can affect Medical Electrical Equipment.
WARNING: The use of Accessories, transducers, and cables
other than those specified by the manufacturer may result in
increased Emissions or decreased immunity of the Hi Flow.
WARNING: The Hi Flow should not be used adjacent to or
stacked with other equipment, and that if adjacent or stacked
use is necessary, the Hi Flow should be observed to verify normal operation in the configuration in which it will be used.
Table 1
Guidance and Manufacturer’s declaration—electromagnetic emissions
The Hi Flow is intended for use in the electromagnetic environment specified below. The customer or the user of the Hi Flow
should assure that it is used in such an environment.
Emissions test
RF emissions
Compliance
Group 1
CISPR 11
Electromagnetic environment—guidance
The Hi Flow uses RF energy only for internal function.
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
IEC 61000-3-2
The Hi Flow is suitable for use in all establishments,
Not applicable
Voltage fluctuations/
flicker emissions
the public low-voltage power supply network that supplies
Not applicable
IEC 61000-3-3
-6-
including domestic establishments and those directly connected to
Hi Flow Stroller Technical Service Manual
buildings used fordomestic purposes.
Safety V
Table 2
Guidance and manufacturers declaration—electromagnetic immunity
The Hi Flow is intended for use in the electromagnetic environment specified below. The customer or the user of the Hi Flow
should assure that it is used in such an environment.
Immunity test
Electrostatic
discharge (ESD)
IEC 60601 test level
Compliance level
±6 kV contact
±6 kV contact
±8 kV air
±8 kV air
IEC 61000-4-2
Electrical fast
Electromagnetic environment—guidance
Floors should be wood, concrete or ceramic tile. If floors
are covered with synthetic material, the relative
humidity should be at least 30%.*
±2 kV for power
Not applicable
transient/burst
supply lines
DC powered device
IEC 610004-4
±1 kV for
Not applicable
Not applicable
input/output lines No data input/output lines
±1 kV line(s)
Surge
IEC 61000-4-5
to line(s)
Not Applicable
±2 kV line(s)
DC powered device
Not Applicable
to earth
Voltage dips,
short interruptions
<5% UT (>95% dip
in UT) for 0,5 cycle
and voltage
40% UT (60% dip
variations on
in UT) for 5 cycles
Not Applicable
power supply
70% UT (30% dip
DC powered device
input lines
in UT) for 25 cycles
IEC 61000-4-11
<5% UT (>95% dip
Not Applicable
in UT) for 5 sec
Power frequency
3 A/m
3 A/m
Power frequency magnetic fields should be at levels
(50/60 Hz)
characteristic of a typical location in a typical
magnetic field
commercial or hospital environment.
IEC 61000-4-8
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 Hi Flows are found to be
compliant with regulations.
PN 14314465 Rev C
-7-
V Safety
Table 4*
Guidance and manufacturers declaration—electromagnetic immunity
The Hi Flow is intended for use in the electromagnetic environment specified below. The customer or the user of the Hi Flow
should assure that it is used in such an environment.
Immunity test
Conducted RF
IEC 61000-4-6
IEC 60601 test level
3Vrms
150kHz to 80 MHz
Compliance level
Not Applicable
Battery powered
device
Radiated RF
IEC 61000-4-3
3 V/m
80 MHz to 2,5 GHz
3 V/m
Electromagnetic environment—guidance
Portable and mobile RF communications equipment should
be used no closer to any part of the Hi Flow,
including cables, than the recommended separation
distance calculated from the equation applicable to the
frequency of the transmitter.
Recommended separation distance
d = 1.2 √P
d = 1.2 √P 80 MHz to 800 MHz
d = 2.3 √P 800 MHz to 2,5 GHz
where P is the maximum output power rating of the
transmitter in watts (W) according to the transmitter
manufacturer and d is the recommended separation
distance in meters (m).
Field strengths from fixed RF transmitters, as determined
by an electromagnetic site surverya, should be less than
the compliance level in each frequency rangeb.
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
electromagnetic environment due to fixed RF transmitters, an electromagnetic site survey should be considered. If the measured
field strength in the location in which the Hi Flow is used exceeds the applicable RF compliance level above, the Hi Flow should
be observed to verify normal operation. If abnormal performance is observed, additional measures may be necessary, such as
reorienting or relocating the Hi Flow.
b
Over the frequency range 150 kHz to 80 MHz, field strengths should be less than 3 V/m.
a
* 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 regulations.
-8-
Hi Flow Stroller Technical Service Manual
Safety V
Table 6*
Recommended separation distances between portable and mobile
RF communications equipment and the Hi Flow
The Hi Flow is intended for use in an electromagnetic environment in which radiated RF disturbances are controlled. The customer or the user of the Hi Flow can help prevent electromagnetic interference by maintaining a minimum distance between
portable and mobile RF communications equipment (transmitters) and the Hi Flow 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=1.2√P
d=1.2 √P
d=2.3 √P
0,01
0.12 m
0.12 m
0.23 m
0,1
0.38 m
0.38 m
0.73 m
1
1.2 m
1.2 m
2.3 m
10
3.8 m
3.8 m
7.3 m
100
12 m
12 m
23 m
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 a standard requirement for equipment which has been tested to specific test levels and over specific
frquency ranges and been found compliant with regulations.
PN 14314465 Rev C
-9-
VI Theory of Operation
Filling
Oxygen Withdrawl
1. Method
With oxygen in the unit, and the vent valve closed, the pressure in the inner vessel will remain at or near the primary relief
valve pressure of 19.7 - 20.6 (1,35 - 1,42).
The Hi Flow Stroller is a portable unit designed to be filled by
the patient from a Liberator, Low Loss Reservoir, or other compatible unit.
The unit is filled by coupling the quick disconnect valve of
the Hi Flow Stroller with the quick disconnect valve on the
Reservoir and opening the vent valve on the portable. Liquid
oxygen is forced up the Reservoir fill tube, through the coupled quick connectors, and into the inner vessel of the Hi Flow
Stroller.
There will be some oxygen vaporized during filling. This gas is
discharged through the vent valve. When the unit is full, liquid
oxygen is expelled through the vent valve. Closing the vent
valve and separating the units terminates the fill process.
At operating pressure and with the flow control valve at any
setting other than Off, pressure forces liquid oxygen up the liquid withdrawl tube and into the breathing coil. In the breathing coil, liquid oxygen absorbs heat and vaporizes, warming to
almost ambient temperature by the time gas is dispensed by the
flow control valve to the patient.
FIGURE 3: Oxygen Withdrawl
2. Saturation Pressure
PRV
The liquid oxygen saturation pressure can seriously affect the
overall efficiency and operation of the Hi Flow Stroller.
Gas to Patient
a. If the saturation pressure of the liquid in the fill source
is greater than 30 psig (2,1 bar), high filling losses and/or
frozen open relief devices may result.
SRV
b. If the saturation pressure of the liquid in the fill source
is below 18 psig (1,2 bar), below tolerance flow rates may
result.
FIGURE 2: Filling
PRV
Gas
FCV
SRV
Gas
Vent Valve
Liquid
Fill Connection
(QDV)
- 10 -
Hi Flow Stroller Technical Service Manual
FCV
Theory of Operation VI
Liquid Level Measurement
1. LED
Hi Flow Strollers 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 oxygen 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 level. The higher the
liquid level in the dewar, the more LEDs are activated, beginning at the leftmost LED.
Electrical connection between the G4 meter and the probe is
made via a single conductor JST connector. The male plug is
attached to its female counterpart extending from the probe,
creating a watertight connection. A single ground wire is connected from the meter to a male spade terminal on the mounting bracket.
The meter is powered by an internal battery, offering an estimated battery life of 5 years or more at 30 actuations per
day. The meter has a low battery (LOW BATT) indicator
which signals the need for battery replacement. The meter
battery is covered under a 2-year limited warranty. If battery
failure occurs within 2 years of the Hi Flow Stroller shipment
date, contact 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 (RP2). The battery
can be found at most hardware stores, or they can be ordered
through CAIRE, Inc. customer service.
The new level meter improves upon the previous meter by
integrating all components within its casing, simplifying removal and replacement (RP8). Even more importantly from a
technical service point of view, there is a much improved calibration procedure requiring no additional tools and a range
of error reporting codes which can be read directly from the
LEDs to report calibration errors. These calibration codes can
be found in the calibration procedure (RP5).
FIGURE 4: Liquid Level Meter
Meter Package
Plug Connector
Male Quick
Connect Valve
Probe Outer
Cylinder
Liquid Fill Tube
(Probe Inner Cylinder)
PN 14314465 Rev C
- 11 -
VII Unpacking and Setup
Unpacking
1. Inspect the carton for shipping damage. Report any damage
to the freight company before signing the bill of lading.
2. Check the description on the carton against your order.
3. Unpack the unit, including the Patient Operating
Instructions (POI).
4. Set aside the packing material in case the unit must be returned to the factory.
Setup
If desired, the flow control knob (Item 20) can be adjusted so it
will not exceed the maximum prescribed flow rate.
1. To remove the flow control knob, firmly grip and pull
straight up away from the portable.
2. Remove the flow rate decal number disc (Item 21).
3. Remove the 2 Phillips head screws (Item 22) from the flow
lock plate (Item 26) and remove the plate.
4. Remove the locking pin (Item 23) from its storage position
on the flow lock plate and place in the underside of the hole
corresponding to the maximum allowable flow rate.
5. Replace the flow lock plate (Item 26) and tighten screws
(Item 22). Replace number disk (Item 21) and push-on
knob (Item 20). Verify the flow lock is at the correct position.
VIII Operation
Refer to Patient Operating Instrucions (POI) Manual.
- 12 -
Hi Flow Stroller Technical Service Manual
FIGURE 5: Flow Control Knob
Maintenance (Schedule A, Biennial) IX
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 the
equipment is operating properly.
Schedule A – Biennial
A. Introduction
Routine maintenance is a series of steps used to assure that
equipment is functioning properly.
1. If a unit fails a given test, one of two things may be done:
a. Refer to Troubleshooting section (Pages 17-21) of this
manual.
b. Return the unit to CAIRE, Inc. for repair.
2. Schedule A – Maximum of two years between routine maintenance 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 the Troubleshooting section (Pages 17-21) of this manual.
1. Visual Inspection:
TABLE 1: Flow Test Acceptable Ranges
Unit Type
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
FCV Setting
OFF
0,50
1,00
2,00
2,50
3,00
4,00
6,00
8,00
10,00
12,00
15,00
LPM
0
0,40 to 0,60
0,90 to 1,10
1,80 to 2,20
2,25 to 2,75
2,70 to 3,30
3,60 to 4,40
5,40 to 6,60
7,20 to 8,80
9,00 to 11,00
10,8 to 13,20
13,50 to 16,50
b. Check all flow settings to chart above and check pressure
to be at least 18 psig (1,2 bar).
5. Prepare for Use:
a. Empty contents by setting FCV at the highest flow setting
and running unit until dry and warm to room temperature (approximately one hour).
b. Verify that meter reads empty (1 LED) and that the low
battery LED is not lit.
c. Clean case with household glass cleaner and lint free cloth
(do not get in any valves).
a. Look for damaged or missing parts.
b. Dry condensation pad. Replace if soiled.
2. Full Unit:
a. Fill, vent full, of LOX.
b. Check for audible or visual leaks in QDV and vent valve.
c. Verify that the meter reads full (8 LED).
3. Check Efficiency of Unit:
a. Allow the unit to stabilize after filling (10–15 minutes).
b. Inspect the bottle for cold sweaty condition, and for excessive venting from relief valve (some venting is normal).
c. If either condition is observed, conduct NER test (see
RP28 in this manual).
4. Flow Test (Table 1):
a. Set FCV to the highest flow setting, run for at least 20
minutes.
PN 14314465 Rev C
- 13 -
IX Maintenance (Schedule B, Continuous)
Schedule B – Continuous
A. Introduction
Continuous maintenance is a set of tests and inspections performed periodically to ensure the equipment is functioning
properly. It can be done with equipment in service by drivers or
other personnel.
1. If a unit fails a given test, it should be taken out of service.
Refer to the Troubleshooting section (Pages 17-21) or contact Technical Service.
2. Schedule B – Checks are made when the driver visits patients and when equipment is transferred between patients.
B. Procedure
These inspections are to be performed at least once per year by
the driver or other personnel when the Hi Flow is in use by the
patient (LOX in the unit).
1. Visual Inspection:
a. Case not damaged or dirty. Flow control knob turns
easily with firm detent feel.
b. Condensation pad is not soaking wet or excessively
dirty.
c. QDV pin not bent (side fill only).
2. Verify that the meter reads the correct liquid level.
3. Check flow rate, Erie liter meter (± 0.25 LPM) can be used.
These inspections/tests are to be done between patients.
1. Visual Inspection:
a.
b.
c.
d.
Damaged case.
Condensation pad (replace if soiled).
QDV pin not bent (side fill only).
Inspect interior of unit for dirt or contaminants.
2. Verify that liquid level meter reads empty.
3. Fill Unit:
a. Verify that liquid level gauge reads full.
b. Check for audible/visual leaks in QDV and vent valves.
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Hi Flow Stroller Technical Service Manual
4. Flow Test (Table 1):
a. Set flow control knob to highest flow setting, run for at
least 20 minutes.
b. Check all flow settings with chart below and check pressure to at least 18 psig (1,2 bar).
5. Prepare for Use:
a. Empty contents by turning flow selection knob to highest flow setting and running unit until dry and warm to
room temperature (approximately one hour).
b. Verify that the meter reads empty.
c. Clean case per RP27.
Troubleshooting/Repair Procedures X
Table of Contents
Introduction
---------------------------------------------------------------------------- 16
Troubleshooting Charts ----------------------------------------------------------------------- 17-21
Repair Procedures
RP1
General ---------------------------------------------------------------------------- 22
RP2
Battery RR ------------------------------------------------------------------------ 22
RP3
Condensate Pad RR -------------------------------------------------------------- 23
RP4
Soft Case RR ---------------------------------------------------------------------- 23
RP5
G4 Empty Capacitance Meter Calibration -------------------------------------- 24
RP6
G4 Meter Span Setting Adjustment --------------------------------------------- 25
RP7
Manifold Capacitance Test ------------------------------------------------------ 25
RP8
G4 Meter RR ---------------------------------------------------------------------- 26
RP9
Manifold Assembly RR----------------------------------------------------------- 26
RP10
Resolder Feed-Thru Wire -------------------------------------------------------- 26
RP11
Clean/Dry Probe Dewar --------------------------------------------------------- 27
RP12
LOX Fill --------------------------------------------------------------------------- 27
RP13
Liberator Lip Seal RR (Side Fill) ------------------------------------------------- 27
RP14
Empty and Warm ---------------------------------------------------------------- 27
RP15
QDV RR (Side Fill) --------------------------------------------------------------- 27
RP16
QDV RR (Top Fill) --------------------------------------------------------------- 27
RP17
Pressure Retention Test --------------------------------------------------------- 28
RP18
Plumbing Leak Test -------------------------------------------------------------- 28
RP19
Vent Valve RR ------------------------------------------------------------------- 29
RP20
FCV RR --------------------------------------------------------------------------- 29
RP21
SRV RR---------------------------------------------------------------------------- 29
RP22
PRV RR --------------------------------------------------------------------------- 29
RP23A Breathing Coil RR (Side Fill)----------------------------------------------------- 30
RP23B Breathing Coil RR (Top Fill) ----------------------------------------------------- 30
RP24
Flow Rate Testing ---------------------------------------------------------------- 31
RP25
Operating Pressure Test---------------------------------------------------------- 31
RP26
Flow Meter Verification ---------------------------------------------------------- 31
RP27
Case Cleaning --------------------------------------------------------------------- 32
RP28
Normal Evaporation Rate Test -------------------------------------------------- 32
Service Tools/Equipment/Supplies --------------------------------------------------------------- 33
PN 14314465 Rev C
- 15 -
X Troubleshooting Chart
Introduction
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.
- 16 -
Hi Flow Stroller Technical Service Manual
Troubleshooting Chart X
Symptom
1)
Probable Cause
Unable to start fill or
a) QDV not properly engaged on
excessivly long fill times
the reservoir
Corrective Action
Make sure the QDV on the portable and reservoir are
properly aligned. Ensure that a downward force is being
applied to the portable for top fill. Ensure the portable is
completely engaged for side fill.
b) Reservoir is empty
Swap or re-fill the reservoir
c) Vent valve not open
Ensure that the vent valve lever is fully in the open position.
The lever must be open to begin a fill.
d) FCV is open
Be sure that the FCV knob is in the off (“0”) position. If the
valve is open, fill times can increase.
e) Reservoir saturation pressure is
too low
Swap reservoirs or allow the reservoir time to stabilize and
build pressure
f) Vent valve is obstructed
Inspect the vent tubes for blockages. Clean by blowing out
with compressed gas or replace parts if necessary.
g) Leak in the system
Check the portable for leaks (RP18) and repair if needed.
h) QDV damaged or faulty
Inspect the QDV and be sure the poppet opens properly
and smoothly. If necessary, replace the QDV (RP15 or
RP16)
i) Faulty vent valve
Replace the vent valve (RP19)
2)
Liquid leaks from the
coupled QDVs during
the fill
a) Worn or damaged lip seal
Replace the QDV lip seal if top fill (RP16). See reservoir
technical manual for replacement of side fill lip seal on reservoir.
3)
Unable to disconnect
the portable from the
reservoir
a) Pop-off assembly not being utilized (Top fill only)
Ensure that the pop-off assembly on the reservoir is being
used (top fill only). Do not use force to separate the QDVs
on top fill or side fill.
b) QDVs are frozen together
Leave the units coupled 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.
a) Ice crystal preveting the QDV
from closing properly.
Engage and disengage the portable onto the reservoir several times to dislodge the ice crystal. Always be sure that
the male and female QDVs are wiped clean and dry before
filling.
b) Dirty or damaged QDV poppet
Replace the QDV (RP15 or RP16)
a) Vent valve is not fully closed
Ensure that the vent valve lever is fully in the closed position.
b) The portable has been transported or laid in an improper
operating position
Return the portable to an upright or acceptable operating
position and allow several minutes for stabilization.
c) Vent valve is frozen open
Allow the portable to warm until the vent valve can close.
After the warm up, allow up to 60 minutes for the portable
to stabilize and build pressure before operating.
d) Faulty vent valve
Replace the vent valve (RP19)
4)
5)
Liquid leaks from the
QDV poppet after filling
Liquid leaks from the
vent valve tube/outlet
PN 14314465 Rev C
- 17 -
X Troubleshooting Chart
Symptom
6)
7)
Excessive venting from
relief valves (hissing
sound)
No Flow
Probable Cause
Corrective Action
a) The portable has been transported or laid in an improper
operating position
Return the portable to an upright or acceptable operating
position and allow several minutes for stabilization.
b) Saturation pressure too high.
Inspect the saturation pressure of the reservoir used for filling. Allow at least 30 minutes at no flow for the portable to
saturate properly.
c) Relief valve frozen open
Allow the portable to warm and thaw. Attempt to re-fill the
portable.
d) Faulty relief valve
Test the operating pressure (RP25) and replace the relief
valve if necessary (RP22)
e) Partial or complete loss of vacuum
Conduct the NER test (RP28) and return the unit to CAIRE,
Inc. if necessary.
a) Portable is empty
Check the contents indicator/level gauge and fill the portable if needed.
b) Flow control valve turned off
Ensure the flow control knob is not in the off (“0”) position.
c) Nasal cannula kinked or disconnected
Ensure proper nasal cannula functionality and positioning
d) Saturation pressure is too low
Inspect the saturation pressure of the reservoir used for filling. Allow at least 30 minutes at no flow for the portable to
saturate properly.
e) Leak in the system
Preform a leak check on the plumbing (RP18). Repair leaks
as necessary.
f) Relief valve is 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)”
g) Vent valve is open
Ensure that there is no venting from the vent valve outlet/
tube. If there is refer to the corrective actions for “Liquid
leaks from the vent valve tube/outlet”
h) Blockage in the liquid withdrawal Check the warming coils and withdrawal tubes for blockcircuit
ages. Replace if necessary.
i) FCV Faulty
8)
Low flow at all LPM set- a) Nasal cannula kinked or leaking
tings
b) Saturation pressure is too low
Replace the FCV (RP20)
Inspect the functionality of the nasal cannula.
Inspect the saturation pressure of the reservoir used for filling. Allow at least 30 minutes at no flow for the portable to
saturate properly.
c) Leak in the system
Preform a leak check on the plumbing (RP18). Repair leaks
as necessary.
d) PRV faulty
Test the operating pressure (RP25) and replace the relief
valve if necessary (RP22).
e) Blockage in the liquid withdrawal Check the warming coils and withdrawal tubes for blockcircuit
ages. Replace if necessary.
f) FCV faulty
- 18 -
Hi Flow Stroller Technical Service Manual
Replace the FCV (RP20)
Troubleshooting Chart X
Symptom
9)
Increased NER
Probable Cause
a) Saturation Pressure is too high
Inspect the saturation pressure of the reservoir used for filling. Allow at least 30 minutes at no flow for the portable to
saturate properly.
b) Leak in the system
Preform a leak check on the plumbing (RP18). Repair leaks
as necessary.
c) 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)”
d) Partial or complete loss of
vacuum
Conduct the NER test (RP28) and return the unit to
CAIRE, Inc. if necessary.
10) Excessive Frost
a) Frost is acceptable
NOTE: Minimal frost
on the case and on the
plubming is normal,
especially at higher flow b) High humidity level
rates. This symptom
c) Saturation pressure is too high
applies to frost that is
much greater than what
is normally observed.
d) Leak in the system
11) Unit will not maintain
acceptable pressure
when in use
Corrective Action
Some frost on the outer case and on the plumbing is acceptable, especially at high flow rates. This is due to the
evaporation of LOX to gas and the temperature difference
between the LOX and room temperature.
High humidity levels can increase frost accumulation.
Inspect the saturation pressure of the reservoir used for filling. Allow at least 30 minutes at no flow for the portable to
saturate properly.
Preform a leak check on the plumbing (RP18). Repair leaks
as necessary.
e) 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)”
f) Partial or complete loss of
vacuum
Conduct the NER test (RP28) and return the unit to
CAIRE, Inc. if necessary.
a) Saturation pressure is unacceptable
Inspect the saturation pressure of the reservoir used for filling. Allow at least 30 minutes at no flow for the portable to
saturate properly.
b) Leak in the system
Preform a leak check on the plumbing (RP18). Repair leaks
as necessary.
c) PRV faulty
Test the operating pressure (RP25) and replace the relief
valve if necessary (RP22).
PN 14314465 Rev C
- 19 -
X Troubleshooting Chart
Good
Case
Visual
Low
Battery
LED
Off/
Spring Scale
OK
QDV Pin
Bad
On
Bad
Replace
Defective Part
Replace*
Battery (RP 2)
Replace QDV
(RP 15, 16)
Fill
QDV
Leaks
During Fill
No
QDV
Leaks
After Fill
No
No
Vent
Leaks
Yes
Yes
Yes
Replace Lip
Seal (RP 16)
Empty &
Warm Dewar
(RP 14)
Empty &
Warm Dewar
(RP 14)
Fill
Replace Vent
Valve (RP 19)
No
OK
Meter 1
LED on
No
(0 LED)
Yes
No
(2–8 LED)
No
QDV
Leaks
After Fill
Replace*
Battery (RP 2)
Calibrate
Meter
Meter
Indicates
8 LEDs
Yes
Empty &
Warm Dewar
(RP 14)
Meter 1
LED On
Yes
No
(0 LED)
No
Replace QDV
(RP 15, 16)
Capacitance
Test (RP 7)
High
Empty &
Warm Dewar
(RP 14)
Good
Low
Remove
Manifold
(RP 9)
Clean/Dry
Probe &
Dewar (RP 11)
Calibrate
Meter
(RP 5, 6)
No
(1–7 LED)
Good
Wire
Broken
No
Replace FeedThru (RP 10)
Yes
Resolder Wire
(RP 10)
Capacitance
Test (RP 7)
Meter 1
LED On
Bad
No
Replace
Manifold (RP
9)
Replace Meter
(RP 8)
Bad
Capacitance
Test (RP 7)
Good
Reinstall
Manifold
(RP 9)
*see NOTE in RP 2
- 20 -
Hi Flow Stroller Technical Service Manual
Yes
Empty &
Warm Dewar
(RP 14)
Calibrate
Meter
(RP 5, 6)
Troubleshooting Chart X
Yes
Suspected
Poor NER
No
Yes
Let Sit 16–18
Hours
Test Flows
(RP 24)
Fail
Test
Operating
Pressure (RP
25)
Pass
Meter
Indicates
4–8 LEDs
Pass
Yes
Empty &
Warm Dewar
(RP 14)
Fail Low
Fail High
No
Empty &
Warm Dewar
(RP 14)
Empty &
Warm Dewar
(RP 14)
Clean Case
(RP 27)
Test
Flowmeter
(RP 26)
Empty &
Warm Dewar
(RP 14)
Pass
Plumbing
Leak Test
(RP 18)
Calibrate
Meter (RP 5,
6)
Replace PRV
(RP 22)
Empty &
Warm Dewar
(RP 14)
Empty &
Warm Dewar
(RP 14)
Replace PRV
(RP 22)
Replace FCV
(RP 20)
Replace
Flowmeter (RP
26)
File Records
Fail
Refill
Repair Leak
Return Unit to
Service
Pass
Fail
Let Sit 16–18
Hours
Meter
Indicates
4–8 LEDs
Fail
Pressure
Retention
Test (RP 17)
Pass
Yes
No
Refill
Replace Dewar
Wait 4 Hours
Pressure
Retention Test
(RP 17)
Pass
Fail
Plumbing Leak
Test (RP 18)
Pass
Fail
Repair Leak
To use the Troubleshooting Chart:
% Start at the upper left corner.
% Unless otherwise noted by the arrows, the flow through the
chart is down or to the right.
PN 14314465 Rev C
- 21 -
X Repair Procedures
RP1 – General
RP2 – Liquid Level Meter Battery RR
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 listed in this section.
NOTE: Tampering with meter battery housing will void the
meter’s 2-year warranty. If meter battery failure occurs while
under warranty, contact customer service to obtain a replacement meter. If the meter battery is no longer under warranty,
the CR2032 coin cell battery may be replaced following the
steps below.
WARNING: Make sure the unit is empty and vent valve is open
before replacing any component, except case assembly components or lip seals.
WARNING: The technician’s hands, tools, and clothing should
be free of all oils and greases.
a. Expose Gen 4 meter by removing shoulder strap, unzipping
the two top zippers then easing back the top cover.
b. Remove 2 Phillips head screws and turn meter over.
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.
c. Using a pair of pliers, grasp the battery cover on the back of
the meter. Twist and pull the cover away from the meter.
WARNING: The manufacturer of fluorolubricant warns users
not to allow fluorolubricant to contaminate tobacco products.
Wash fluorolubricant from hands before smoking.
e. Insert new battery with the positive terminal facing up.
WARNING: Do not use glue type thread locking compounds or
unapproved sealants on any repairs.
g. Replace battery cover by pushing it into the back of the meter’s case, ensuring the o-ring seals evenly to restore the airtight seal. Replace meter on bracket.
d. Slide the tip of a flat head jeweler’s screwdriver beside the battery and carefully pry out the battery.
f. Apply a thin coating of fluorlubricant to the o-ring.
CAUTION: When replacing components, make sure the new
part is oriented exactly the same as the original part prior to installation.
CAUTION: Some components require a specific amount of
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 clean 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 finger tight.
- 22 -
Hi Flow Stroller Technical Service Manual
FIGURE 6: Liquid Level Meter Battery
Repair Procedures X
RP3 – Condensate Pad R/R
FIGURE 7: Top Cover Assembly
a. Unzip bottom case zipper.
b. Remove condensate pad and wring out any absorbed moisture. Allow pad to dry completely or dispose (if pad will not
be reused).
c. Replace condensate pad and rezip condensate cup.
RP4 – Soft Case R/R
a. Remove strap from the top of the unit.
b. Unzip the top and side zippers.
c Carefully remove the unit from case.
d. To replace, reverse the above steps
CAUTION: Be careful not to pinch wires!
FIGURE 8: Bottom and Side Cover
PN 14314465 Rev C
- 23 -
X Repair Procedures
FIGURE 9: G4 Meter
RP5 – G4 Meter Empty Capacitance Calibration (Figure 9)
a. Completely empty dewar.
NOTE: The meter must first be calibrated empty and then the
span must be set for your particular model. The unit must be
empty, warm, and dry for calibration.
LED 8
LED 1
b. Allow dewar to warm to room temperature.
c. Enter Calibration Mode
Calibrate Button
(Hidden)
1. Press and hold the hidden calibrate button located on
the center of the meter face.
Operate Button
2. While holding the calibrate button, press and hold the
green operate button.
3. Continue holding both buttons until LED 1 and LED 8
alternately flash. The meter is now in calibration mode.
TABLE 2: Calibration Error Codes
4. Release both buttons.
Error Code
Reason for Fault
Solution
LED 1 & LED 4
Empty to full span
is too low.
Ensure tank is empty.
Recalibrate.
e. If successful, LED 1 will flash again for 3 seconds and exit
calibration mode storing the new empty value.
LED 2 & LED 3
Open Circuit
Check meter connections
and wire integrity.
f. If calibration is unsuccessful, multiple LEDs will flash. The
LEDs indicate what error has occurred (see Table 2).
LED 6 & LED 7
Empty capacitance
is too high.
Remove moisture
from inner vessel.
Decontaminate probe.
LED 5 & LED 8
Empty to full span
is too high.
Ensure tank is empty.
Recalibrate.
LED 2, LED 4 &
High Capacitance
LED 6
Remove moisture
from inner vessel.
Decontaminate probe.
d. Press and hold the hidden calibrate button for 3 seconds.
LED 1 will flash for 3 seconds followed by a short pause.
NOTE: Step d must be performed within 45 seconds or calibration mode will exit.
RP6 – G4 Meter Span Setting Adjustment (Figure 9)
a. Enter Calibration Mode
LED 1, LED 3,
LED 5 & LED 7
- 24 -
Hi Flow Stroller Technical Service Manual
Calibrated full
value less than
empty value.
Dry harrness assembly.
Decontaminate.
Repair Procedures X
1. Press and hold the hidden calibrate button located on the
center of the meter face.
FIGURE 10: Manifold Capacitance Test Setup
Ground
2. While holding the calibrate button, press and hold the
green operate button.
3. Continue holding both buttons until LED 1 and LED 8
alternately flash. The meter is now in calibration mode.
4. Release both buttons.
b. Press the green operate button 3 times within a 5 second
period.
NOTE: Step d must be performed within 45 seconds or calibration mode will exit and the meter will NOT be calibrated properly. The calibration procedure will then need to be repeated
from the beginning.
c. One of the meter LED’s will light continuously.
d. Press the hidden calibrate button until the LED which
matches the Hi Flow Stroller being calibrated is continuously lit. See Table 3 below for the correct LED setting for
your unit.
e. Once the correct LED for your unit is lit, press the green operate button to store the setting and exit calibration mode.
RP7 – Manifold Capacitance Test (Figure 10)
a. Capacitance Meter Setup:
1. Connect wire adapter with jumper wire (Item D) to capacitance meter, following color code.
2. Turn on capacitance meter and select 200 pF range.
TABLE 3: Preset Capacitance Span LED Setting
Model
High Flow Stroller
LED Setting
LED 8
3. Move zero adjustment on front of meter until display reads
zero.
b. Capacitance Test:
WARNING: Make sure the unit is empty, dry, and at room temperature before testing.
1. Remove shoulder strap, unzip the top case zipper, and fold
the top flap back in order to access manifold harness connection.
2. Connect wire adapter (Item D) to manifold harness connection (Item A).
3. Connect alligator clip to bracket or any other properly
grounded surface.
4. Read manifold capacitance and verify that it is 145–180 pF.
If it does not meet specifications, call Technical Support.
PN 14314465 Rev C
- 25 -
X Repair Procedures
RP8 – G4 Meter RR
a. Remove shoulder strap, unzip top case zipper, and fold back
top flap.
b. Remove 2 meter mounting screws.
c. Remove meter assembly.
d. Unplug the wiring connection.
e. Disconnect ground wire spade terminals.
f. To replace G4 meter, reverse above procedures.
CAUTION: Be careful not to pinch wires!
RP10 – Resolder Feed-thru Wire (Figure 11)
a Remove manifold assembly (See RP 9).
b. Strip approximately 1/8” (0,3 cm) of insulation from feed-thru
wire if necessary.
c. Apply small amount of Stay-Clean flux to tinned area of probe
using a cotton swab.
d. Resolder feed-thru wire to tinned area of probe. Add small
amount of lead-free solid wire solder if necessary.
e. Clean flux residue with distilled water and cotton swab. Dry
thoroughly.
f. Replace manifold following listed procedure (RP9).
RP9 – Manifold Assembly RR (Figure 11)
FIGURE 11: Feed-thru Wire
WARNING: The unit must be empty, warm and vented before
starting procedure.
a. Remove soft case and Gen 4 meter. (RP 4,8).
b. Remove (3) bracket screws (Item 29) and lift bracket (Item 28)
from manifold.
c. Loosen and disconnect breathing coil nut (Item 38) from withdrawl fitting and FCV (Item 24). Be careful not to bend or
kink Teflon® tubing.
d. Loosen and disconnect primary relief valve tube (Item 46) and
vent outlet tube from manifold fitting.
e. For top fill units, loosen and remove QDV tube from manifold
fitting.
f. Use a hex wrench to loosen and remove the (4) manifold retaining screws (Item 31).
g. Remove manifold assembly (Item 41) by lifting straight up.
i. To replace manifold, reverse above procedure.
NOTE: If substantial force is required, closely examine wire and
probe for damage.
NOTE: Ensure proper seating of O-ring in dewar. Apply small
amount of fluorolubricant to O-ring before assembly. Torque
manifold mounting screws (Item 31) to 24–26 in-lbs (270–290
N-cm) using cross-tightening method.
- 26 -
Hi Flow Stroller Technical Service Manual
Repair Procedures X
RP11 – Clean/Dry Probe and Dewar
RP16 – QDV and Lip Seal RR (Top Fill) (Figure 13)
Procedure 1:
a. Empty and warm dewar per RP 14).
b. Open vent valve.
c. Loosen feed-thru nut and remove harness.
d. After vent valve (Item 50) is thawed, if all moisture is not removed, continue with procedure #2.
Procedure 2:
a. Remove manifold assembly (See RP 9).
b. Blow off probe assembly with clean, dry nitrogen gas.
c. Blow out inside of dewar with clean, dry nitrogen gas
until inside is clean and dry.
WARNING: The unit must be empty and vented before starting
procedure.
a. Remove soft case (RP 4).
b. Remove two retaining nuts and lift bottom fill tube out of coil.
c. Replace QDV by substituting old QDV (Item 62) with the
new one, tightening Item 57 to 140–150 inch-lbs (1550–1700
N-cm) and Item 58 to 300 inch-lbs (3000 N-cm).
d. Replace lipseal by removing Item 65 and Item 64. Apply a
thin film of fluorolubricant to new Item 64 and insert into
QDV. Tighten Item 65 to 140–150 inch-lbs (1550–1700
N-cm).
d. Replace manifold assembly (See RP 9).
RP12 – LOX Fill
Refer to POI for proper fill procedure.
FIGURE 12: Side Fill QDV
NOTE: Filling source must contain a minimum of 5 liters of
properly saturated LOX.
RP13 – Liberator Lip Seal RR (Side Fill)
Refer to Liberator Service Manual.
RP14 – Empty and Warm
a. Turn FCV knob to highest flow setting.
b. Allow unit to sit for 24 hours before proceeding.
RP15 – QDV RR (Side Fill) (Figure 12)
FIGURE 13: Top Fill QDV
WARNING: The unit must be empty and vented before starting
procedure.
a. Remove soft case (RP 4).
b. Loosen QDV retaining nut (Item A).
c. To replace QDV, reverse above procedure, aligning pin in the
upright position. Apply thin film of fluorolubricant to O-ring
(Item 36). Torque retaining nut to 140–150 inch-lbs (1550–
1700 N-cm).
d . Replace soft case (RP 4).
PN 14314465 Rev C
- 27 -
X Repair Procedures
RP17 – Pressure Retention Test (Figure 14)
a. Assemble oxygen regulator, pneumatic adapter and hose.
Connect assembly to oxygen gas source.
FIGURE 14: Plumbing Tests Set-up
b. Assemble pressure gauge (Item J) and adapter assembly.
Thread hose barb onto pressure gauge (use Teflon ® tape).
Push tubing onto hose bard and attach with clamp.
c. Connect gauge assembly (Item J) to hose barb on FCV outlet.
Open FCV (Item 24) to highest flow setting.
d. Connect the proper pneumatic adapter to QDV (Item 37) for
side fill units or (Item 62) for top fill.
e. Increase pressure to 19 psig (1,3 bar).
f. Turn FCV valve (Item 24) to Off setting.
g. Allow unit to sit undisturbed for 60 minutes.
h. Turn FCV valve (Item 24) to highest flow setting.
i. If pressure gauge (Item J) is at or above 10 psig (0,7 bar), unit
passes test.
RP18 – Plumbing Leak Test (Figure 14)
WARNING: The unit must be empty and vented before starting
procedure.
a. Remove soft case (RP 4)
b. Assemble oxygen regulator, pneumatic adapter and hose.
Connect assembly to oxygen gas source.
c. Assemble pressure gauge (Item J) and adapter assembly.
Thread hose barb onto pressure gauge (use Teflon ® tape).
Push tubing onto hose bard and attach with clamp.
d. Connect gauge assembly (Item J) to hose barb on FCV outlet.
Open FCV (Item 24) to highest flow setting.
e. Connect the proper pneumatic adapter to QDV (Item 37) for
side fill units or (Item 62) for top fill.
f. Increase pressure to 19 psig (1,3 bar).
g. Leak test all connections, joints, and valves with leak test solution.
NOTE: PRV (Item 49) and SRV (Item 43) may leak slowly. Repair
all other leaks first and retest for pressure retention before changing relief valves.
h. Close FCV (Item 24) by turning to Off position. Remove pressure gauge assembly
i. Disconnect pneumatic adapter from QDV.
j. Leak test QDV poppet and FCV outlet.
k. Repair all leaks by following appropriate repair procedures.
- 28 -
Hi Flow Stroller Technical Service Manual
FIGURE 15: Vent Valve Assembly
Repair Procedures X
FIGURE 16: Breathing Coil and Top Fill QDV Assembly
RP19 – Vent Valve RR (Figure 15)
WARNING: The unit must be empty and vented before starting
procedure.
a. Remove soft case (RP 4).
b. Open the vent valve.
b. Remove vent valve (Item 16) by turning counterclockwise.
c. To replace vent valve, reverse above procedure. Torque nut
to 90-100 inch-lbs (1000–1100 N-cm).
RP20 – FCV RR
WARNING: The unit must be empty and vented before starting
procedure.
a. Remove soft case (RP 4).
b. Disconnect coils from FCV inlet by loosening compression
fitting (Item 44), and removing coils.
c. Remove FCV knob and flow decal.
d. Disconnect and remove the FCV from bracket by removing
two screws.
FIGURE 17: Breathing Coil and Top Fill QDV Assembly
e. Remove SRV from FCV.
f. To replace FCV, reverse above procedure. Tighten screws to
4–6 inch-lbs. (45–70 N-cm). Record FCV serial number.
RP21 – SRV RR
a. Remove soft case (RP 4).
b. Disconnect SRV from FCV (Item 24).
c. Replace SRV in reverse order. When reassembling SRV,
tighten approximately 10 to 20 degrees after the SRV contacts the FCV body (20-30 inch-lbs, 225-350 N-cm minimum).
RP22 – PRV RR (Figure 18)
a. Remove soft case (RP 4).
b. Remove PRV (Item 49) while holding adapter (Item 48).
c. Replace the PRV using two rounds of Teflon® tape on the
threads and tighten 6-7 flats past snug.
d. Reassemble in the reverse order.
PN 14314465 Rev C
- 29 -
X Repair Procedures
RP23A – Breathing Coil RR (Side Fill) (Figure 18)
FIGURE 18: PRV, Breathing Coil and QDV Assembly
WARNING: The unit must be empty and vented before starting
procedure.
a. Remove soft case (RP 4).
b. Loosen the two compression fitting nuts (Items 38 and 44)
from liquid withdrawl fitting (Item 41) and FCV (Item 24).
Disconnect breathing coil (Item 67), being careful not to
kink breathing coil or internal Teflon® tube.
c. Carefully remove breathing coil outlet from around top of
dewar.
d. To replace breathing coil, reverse above procedure.
CAUTION: The vaporizer coil is fragile. Do not drop coil. Do
not hit or mar coil with wrenches.
RP23B – Breathing Coil RR (Top Fill) (FIgure 19)
WARNING: The unit must be empty and vented before starting
procedure.
a. Remove soft case (RP 4).
b. Loosen the two compression fitting nuts (Items 38 and 44)
from liquid withdrawl fitting (Item 41) and FCV (Item 24).
Disconnect breathing coil (Item 67), being careful not to
kink breathing coil or internal Teflon® tube.
c. Loosen QDV tube (Item 56) nut.
d. Loosen QDV jam nut (Item 58). Remove QDV (Item 62)
from fill tube.
e. Cut two cable ties holding coil in place. Remove breathing coil by sliding straight down from fill line. Be careful to
properly remove breathing coil outlet from around top of
dewar.
f. To replace coil, reverse above procedure. Tighten QDV jam
nuts to 140–150 inch-lbs. (1550–1700 N-cm).
- 30 -
Hi Flow Stroller Technical Service Manual
FIGURE 19: Breathing Coil and Top Fill QDV Assembly
Repair Procedures X
FIGURE 20: Flow Rate and Pressure Test
RP24– Flow Rate Testing (Figure 20)
M
a. Unit must be at least 1/2 full with correctly saturated LOX.
24
b. Set FCV to 2 LPM setting and allow unit to operate for 20–
60 minutes.
J
c. Connect FCV outlet (Item N) to flowmeter inlet (Item M)
with respiratory tubing. Make sure flowmeter outlet is open,
unobstructed, and properly positioned.
N
d. Test flow rate at each FCV position. Record all flow rates.
e. Flow rates must be nominal valus within tolerances listed
in specification section of this manual or unit fails flow rate
test.
NOTE: Be careful to allow for accuracy tolerances of flowmeter.
RP25 – Operating Pressure Test (Figure 20)
a. Assemble pressure gauge and adapter assembly (Item J).
Thread hose barb onto pressure gauge (use Teflon® tape).
Push tubing onto hose barb and attach with clamp.
b. Connect gauge assembly (Item J) to hose barb on FCV outlet. Open FCV (Item 24) to highest flow setting.
c. Read operating pressure on pressure gauge (Item J).
NOTE: If testing operating pressure because of improper flow
rates, test immediately after flow rate test.
d. Operating pressure must be 18-22 psig (1.2-1.5 bar) or unit
fails test.
RP26 – Flow Meter Verification
a. Flow meter accuracy is best verified by a calibration laboratory. Equipment should indicate liter per minute oxygen gas
at atmospheric pressure and 21°C (70° F).
b. 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.
PN 14314465 Rev C
- 31 -
X Repair Procedures
RP27 – Case Cleaning
NOTE: Clean case only after unit is empty and warm. Do not
clean in oxygen enriched atmosphere.
a. Clean using household glass cleaner or Simple Green D and
lint-free cloth. Do not get glass cleaner inside case or onto
any plumbing components. Simple Green D is available at
www.simplegreend.com
b. If necessary, a soft bristle brush can be used to help remove
dirt and debris. If desired, Caire, Inc. Technical Service can
supply a specific list of additionale reccommended cleaning tools.
b. Allow unit to dry thoroughly before filling.
RP28 – Normal Evaporation Rate Test
a. Fill unit following procedure found in the Patient Operating
Instructions (POI).
b. Push button and check that all 8 LEDs are on, or verify that
the spring scale reads full.
c. Check for leaks in QDV and vent valve.
d. Let unit sit 16–18 hours.
e. Make sure FCV and vent valves are closed.
f. Do not move unit during this time.
g. If the Hi Flow is at least half full (4 LEDs), the unit passes.
Maximum loss rate prior to dewar servicing is 1.75 lbs./day
(0,8 kg/day).
- 32 -
Hi Flow Stroller Technical Service Manual
Service Tools / Equipment / Supplies X
Required Tools
Tools and Accessories available from CAIRE, Inc.
1. Hex Wrenches (various sizes)
2. Flat Blade Screwdriver
Part No
Description
3. 5/16” Nut Driver
CA200071
240 AC Fluorolubricant
4. Open End Wrenches (1/2” to 1-1/8”)
CA200072
”Snoop” Leak Detection Fluid
5. Side Cutters
CA400004
Replacement Filter/Male Transfer Line Adapter
6. Phillips Screwdriver
CA406308
7. Pliers
CA406310
10.3 bar (150 psi) Relief Valve Assembly
Teflon® Tape
8. Torque Driver/Wrenches:
CA406398
10.3 bar (150 psi) Relief Valve only
12-17 N-cm (10-15 in-lbs)
14314465
Service Manual
23-29 N-cm (20-25 in-lbs)
13214825
AirLift Backpack
10018138
C1000 Backpack
97112026
Female Side Fill Pneumatic Test Adapter
97200076
Erie “Liter Meter”
97217007
Pressure Gauge Adapter
97212021
Male Side Fill Pneumatic Test Adapter
97403015
Capacitance Meter
97403016
Jeweler’s Screwdriver
4. Pressure Gauge
97405279
Pneumatic Hose with DISS Fittings
5. Pressure Gauge Adapter
97403574
Dewar Cap
6. Flowmeter
97403577
0-4.1 bar (0-60 psig) Pressure Gauge
7. 02 Gas Source (High Pressure bottle)
12917730
Stroller Cart
8. 02 Liquid Source
97405147
0–45 psig Oxygen Regulator
9. N2 Gas or Clean, Dry Compressed Air Source
97405431
Liquid Oxygen Transfer Line – 2 m (6 ft)
10. Tubing (02 compatible)
97404564
Transfer Line Swivel Connector
97405590
Lip Seal Service Tool
1. Stay-Clean Flux
97406471
Tandem Tee Kit
2. Cotton Swabs
97406555
Super Flex Liquid Oxygen Transfer Line – 6’
3. Lead-free Solder
97406630
Dual Fill Head Tee
4. Distilled Water
13329091
G4 Capacitance Meter Adaptor Kit
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)
9. Jeweler’s Screwdriver
Required Fixtures/Equipment
1. Capacitance Meter
2. Soldering Iron
3. Oxygen Regulator/Hose Kit
Required Supplies
5. Household Glass Cleaner
6. Lint-Free Cloth
7. Teflon® Tape
8. Fluorolubricant
9. Leak Detection Fluid
PN 14314465 Rev C
- 33 -
XI Parts Price List
Contact Customer Service or visit
www.cairemedical.com
to obtain your parts list.
- 34 -
Hi Flow Stroller Technical Service Manual
Ordering Information XI
Ordering Information
3. Telephone or fax CAIRE, Inc. at one of the numbers listed
below to begin immediate processing of the order:
The following steps should be used when ordering a new Hi
Flow, or replacement parts for an existing unit:
1. Compile a list of all equipment and replacement parts to be
ordered. An exploded view of assemblies for easy parts identification, along with parts/price lists can be found on www.
cairemedical.com.
For US/Canada Part Numbers, please call 770 721 7759.
For European Part Numbers, please call +44(0) 1344 403100.
For Asian, Australia, New Zealand Part Numbers, please call
+61 297 494333.
2. Fill out a purchase order containing the following information:
a.
b.
c.
d.
Purchase order number.
Name and address of billing location.
Name and address of shipping location.
Quantity, part number, description, and unit cost
for each item ordered.
USA
Toll Free Phone:
Toll Free Fax:
(To place an order):
Phone:
Fax:
800 48 CAIRE
(800 482 2473)
888 WE CAIRE
(888 932 2473)
770 721 7758
770 721 7759
Asia, Australia, Pacific Rim
Phone:
+61 297 494333
Fax:
888-932-2473
Europe
Phone:
Fax:
+44(0) 1344 403100
+44(0) 1344 429224
4. Mail or fax the completed purchase order for
confirmation to:
CAIRE, Inc.
2200 Airport Industrial Drive
Suite 500
Ball Ground, GA 30107
Chart BioMedical Ltd.
Unit 6, Ashville Way
Wokingham, Berkshire, RG41 2PL
United Kingdom
All new equipment will be shipped either “prepaid”, F.O.B. Canton,
Georgia, F.O.B. Bracknell, UK, or collect via your specified carrier.
All replacement parts will be sent by UPS “prepaid”, and the shipping charges for equipment and parts will be added to the final invoice. Payment for replacement parts are located on CAIRE, Inc.’s
invoice with payment date indicated. All shipments will originate
from Canton, Georgia or Bracknell, UK. If a particular carrier or
method of shipment is desired, specify when placing order.
For additional ordering and contact information, visit www.cairemedical.com
PN 14314465 Rev C
- 35 -
XII Restocking Policy
When a Hi Flow Stroller is received, it should be inspected immediately, 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 Charts on pages 17-21.
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 original shipping container, precisely as shipped.
3. Write the Return Material Authorization Number on the
top of the shipping container.
4. Return the unit or parts by professional carrier to:
CAIRE, Inc.
2205 Airport Drive
Ball Ground, GA 30107
Chart BioMedical Ltd.
Unit 6, Ashville Way
Wokingham, Berkshire, RG41 2PL
United Kingdom
All equipment returned to CAIRE, Inc. must be shipped
“prepaid”.
When the defective item(s) is received at CAIRE, 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 detailed listing of any maintenance performed.
Restocking Policy
If it becomes necessary to cancel an order with CAIRE, Inc. after 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 following
information:
a. State the quantity and description of equipment to be
returned.
b. Give the Serial Number of each unit to be returned.
c. State the equipment purchase date.
2. An RMA number will be issued in the name of the distributor 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 the original
shipping location:
CAIRE, Inc.
2205 Airport Drive
Ball Ground, GA 30107
Chart BioMedical Ltd.
Unit 6, Ashville Way
Wokingham, Berkshire, RG41 2PL
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., at its discretion, charges a 15% restocking fee for
unused non-defective merchandise that is returned. A RMA
number must be obtained from CAIRE, 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. CAIRE, Inc. will not be responsible for misdirected shipments.
- 36 -
Hi Flow Stroller Technical Service Manual
Caire, Inc.
2200 Airport Industrial Drive, Suite 500
Ball Ground, GA 30107
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Chart BioMedical Ltd.
Unit 6, Ashville Way
Wokingham,
Berkshire, RG41 2PL
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www.cairemedical.com
Copyright © 2012 Ref 14314465 Rev C
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