CAIRE Liberator LIB20, LIB30, LIB37, LIB45, LIB60 Oxygen Equipment Service Manual

G4

Preface

I

SERVICE MANUAL

LIBERATOR SERIES—G4

LIB20, LIB30, LIB37, LIB45, LIB60

CAIRE, Inc.

1800 Sandy Plains Industrial Parkway

Suite 316

Marietta, GA 30066-6363 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:

Europe

Phone: +44 1344 403100 Fax:

888 932 2473

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

PRV Primary Relief Valve

QDV Quick Disconnect Valve

RMA Return Materials Authorization

RP Repair Procedure

RR Removal and Replacement

SRV Secondary Relief Valve

O2 Oxygen Gas

SF Side Fill

PTFE 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.

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Table of Contents

II

I. Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

II. Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . .3

III. Equipment Description . . . . . . . . . . . . . . . . . . . . . .4

IV. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

V. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

VI. Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . .7

VII. Unpacking and Setup . . . . . . . . . . . . . . . . . . . . . .10

VIII. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

IX. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . .13

X. Troubleshooting (Table of Contents) . . . . . . . . . . .15

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . .16

Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . .18

Service Tools/Equipment/Supplies . . . . . . . . . . . .31

XI. Parts Price List . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Ordering Information . . . . . . . . . . . . . . . . . . . . . . .33

XII. Restocking Policy . . . . . . . . . . . . . . . . . . . . . . . . .34

XIII. Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

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III

Equipment Description

FIGURE 1:

Liberator Components

The CAIRE Liberator® 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 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 -180°C (-300° F). The inner vessel is designed to safely hold liquid oxygen and is protected from over pressurization by the primary relief valve. Vacuum insulation between the inner and outer vessel keeps outside heat from causing the cold liquid inside to evaporate.

2. Breathing Circuit – This circuit consists of the manifold assembly, fixed orifice rotary flow control valve (FCV), breathing coil, and warming 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. Any water that condenses on the cold coils is routed into the condensate bottle. An economizer regulator is utilized to conserve LOX by drawing oxygen head gas into the breathing circuit.

3. Shroud Assembly – The shroud assembly houses and protects the breathing circuit and liquid level meter. Labels listing safety information and patient operating instructions 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 roller base can be provided to help move the

Liberator.

* For Top Fill or Dual Models Only

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Specifications

(Nominal Values)

IV

Capacity

kg (lbs) LOX

Liquid Liters

Gaseous Liters

Selectable Flow Rates

Liters Per Minute (LPM):

Flow Rate Accuracy

LIBERATOR 20 LIBERATOR 30 Liberator 37

24,6 (52)

21,6

17 780

34,0 (75)

31,2

25 650

41,7 (92)

38,3

31 460

LIBERATOR 45 LIBERATOR 60

50,8 (112)

46,6

38 300

65,3(144)

60,0

49 200

Off 0,25 0,50 0,75 1,0 1,5 2,0 2,5 3,0 4,0 5,0 6,0 8,0 10 12 15

± 0,1 liter per minute or ±10% of flow setting, whichever is greater

Hours of Operation

@ 2 LPM

Standard Fill Connections

148

Side

Top

213

Side

Top

262

Side

Top

319

Side

Top

410

Side

Top

Operating Pressure (Economizer Regulator)

Bar (PSIG) 1,4 (20)

Primary Relief Valve Setting

Bar (PSIG) 1,6 (23)

Secondary Relief Valve Setting

Bar (PSIG) 2,1 (30)

Normal Evaporation Rate

kg (lbs) per day 0,68 (1.5)

Filling Time (Fast Fill Technique)

Warm

minutes 2.5

Cold

minutes 1.5

Height

cm (in)

Diameter

cm (in)

Weight

Empty

kg (lbs)

Full

kg (lbs)

Fill Connector Types

62,2 (24.5)

35,6 (14)

17,6 (39)

41,3 (91)

1,4 (20)

1,6 (23)

2,1 (30)

0,68 (1.5)

3.0

2.0

74,9 (29.5)

35,6 (14)

20,4 (45)

54,4 (120)

Side Mounted Rotary Coupling

Top Mounted Rotary Coupling

Top Mounted Push Coupling

1,4 (20)

1,6 (23)

2,1 (30)

0,68 (1.5)

3.5

2.5

83,2 (32.75)

35,6 (14)

22,7 (50)

64,4 (142)

1,4 (20)

1,6 (23)

2,1 (30)

0,68 (1.5)

4.0

3.0

94,0 (37)

35,6 (14)

24,9 (55)

75,7 (167)

1,4 (20)

1,6 (23)

2,1 (30)

0,73 (1.6)

5.5

4.0

99,1 (39)

40,6 (16)

29,9 (66)

95,3 (210)

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V

Safety

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 1,4 bar (20 psig), the temperature of liquid oxygen is about -173°C (-280° F). Skin exposed to such a low temperature can become severely frostbitten.

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 noncombustible 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.

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.

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 (RP23). 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.

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.

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.

4. Always wear goggles, a face shield, and insulated gloves when working with or around liquid oxygen.

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.

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 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.

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 on its side.

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 oxygen-enriched atmosphere.

WARNING: 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.

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Theory of Operation

VI

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 terminates the fill process.

FIGURE 2:

Filling

FIGURE 3:

Temperature vs. Saturation Pressure

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).

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 saturation 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 saturation pressure, since it is easier to control than temperature. Treat saturation temperature as a dependent variable of saturation pressure.

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 that temperature corresponding to a pressure of 1,4 bar (20 psig), as shown in the graph. The temperature is lowered through boiling. All of the gas generated by this boiling is vented through the relief valve and/or primary relief valve and is lost.

If the saturation pressure of the liquid oxygen in the filling vessel 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.

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VI

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 1,6 bar (23 psig).

In the Liberator, as in all vacuum-insulated cryogenic containers, some liquid (oxygen in this case) is always evaporating into a gas. The rate of generation 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.

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 oxygen (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 flow rate, to the patient.

FIGURE 4:

Operation Above 1,4 Bar (20PSI)

FIGURE 5:

Operation Below 1,4 Bar (20PSI)

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Theory of Operation

VI

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 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 fill level. The higher the liquid level in the dewar, the more LEDs are activated, beginning 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 connected from the meter to a male spade terminal on the mounting 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 battery replacement. The meter battery is covered under a 2-year limited warranty. If battery failure occurs within 2 years of the

Liberator 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

(RP5). Replacement batteries can be found at most hardware stores or they can be ordered through CAIRE customer service.

The new level meter improves upon the previous meter by integrating all components within its casing, simplifying removal and replacement (RP4). Even more importantly, 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 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

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VII

Unpacking and Setup

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

FIGURE 7:

Flow Control Knob

1. Install condensation bottle bracket by squeezing bracket ends together and inserting into slot in handling ring directly below FCV outlet.

2. Install condensation bottle on bracket located below shroud.

Remove cap from bottle. Put condensation hose inside bottle.

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 disconnect 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. 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 corresponding 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.

FIGURE 8:

Lock Plate Layout

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.

CAUTION: Always ship, store, or transport a Liberator, empty or full, in an upright position, properly secured to prevent damage. DO NOT ROLL UNITS TO TRANSPORT

11. If desired, the flow control knob (Item 1) can be adjusted so it will not exceed maximum prescribed flow rate.

Transport

a. Remove FCV knob by firmly grasping the knob and pulling away from the base unit.

Specifically designed roller bases are available for moving

Liberators short distances on smooth surfaces. Hand trucks can also be utilized for Liberator transport.

b. Remove two phillips head screws (Item 4) from flow lock plate (Item 3) and remove plate.

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Operation

VIII

Liberator 20, 30, 37, 45 and 60 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).

i. Connect transfer hose fill adapter to a securely mounted mating QDV.

ii. Push adapter poppet against the side of a

Liberator unit or other unpainted stainless steel surface.

-ORg. 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.

b. Ensure the liquid oxygen in the fill source is saturated at

2,4-4,1 bar (35-60 psig). 3,4 bar (50 psig) is optimal.

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.

WARNING: Fill source must be in a well ventilated area to prevent developement of an oxygen enriched atmosphere.

l. While filling, throttle the vent valve with the vent valve wrench as needed to keep pressure at approximately 1,4 bar (20 psi).

WARNING: Wear insulated gloves and eye protection whenever working with liquid oxygen.

2. Fill Procedure

An alternate method is to attach a flow meter to the oxygen 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.

a. Required Equipment:

❏ Fill source as outlined above

❏ Liquid oxygen transfer line

❏ Male transfer line adapter for side fill Liberators

❏ Female transfer line adapter for top fill Liberators

❏ Liberator vent valve wrench

❏ Eye protection

❏ Pressure Gauge

❏ Insulated gloves m. When liquid spurts from vent outlet, disconnect transfer line.

n. Close Liberator vent valve immediately after removing transfer line.

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.

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: 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 transfer line adapter to transfer line.

e. Fully open liquid valve on fill source.

NOTE: The liquid level indicating system is accurate only after the vent valve is closed, and the oxygen has stabilized for five minutes.

f. Purge transfer line for a minimum of 5 seconds ensuring gas is safely piped away from operator:

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VIII

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 activation.

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.

TABLE 1:

Recommended Disinfectant Solutions

Name

Microbac

Forte

Wex-Cide

Producer

Bodie Chemie

Hamburg

Wexford Labs,

Inc.

Website

www.bode-chemie.com

www.wexfordlabs.com

Vesphene IIse Steris Corp.

www.steris.com

Note: The above solutions are recommendations only and there may be a number of other effective solutions.

Cleaning and Disinfection

To insure proper functioning and end-user safety, all Liberator units should be cleaned whenever dirt or grime is visually apparant. The unit should be disenfected according to any applicable local regulations or the home healthcare distributor’s own decontamination 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 respectively. If at any time either solution becomes visibly dirty or cloudy, it should be switched 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 accordance 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.

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TABLE 2:

Liberator Material Content

Part

Shroud

Breathing Coil

Vaporizer Coil

Dewar

Valves

Material

Polycarbonate

T3003 Aluminum

T3003 Aluminum

Stainless Steel

T6061 Aluminum

TABLE 3:

Common Disinfectant Chemicals

Disinfectant Agent

Compatible with Generation 4

Liberators

Yes Aldehyde

Quanternary Ammonium

Compound

Sauerstoffabspalter

Yes

Alcohol

Amine Derivatives

Phenol pH: Basic (alkaline) Cleaners

Ether/Ester based products

No

*Yes - Ethanol based cleaner

(only when all O2 has been purged)

Yes

Yes

Yes

No

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.

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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 equipment is operating properly.The healthcare distributor may follow 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. If a unit fails a given test, one of two things may be done: a. Refer to Troubleshooting section (Section X) of this manual.

-orb. Return the unit to CAIRE, Inc. for repair.

2. Schedule – 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 Troubleshooting section (Section X) of this manual.

1. Visual Inspection: a. Remove any LOX prior to maintenance (RP23).

b. Look for damaged or missing 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 to 1,7 bar (25 psig) (RP13) and check that

PRV opens.

c. Pressurize to 2,3 bar (34 psig) (RP13) and check that

SRV opens.

d. Recalibrate meter (RP7).

e. Test pressure retention (RP15).

f. Replace shroud (RP2).

TABLE 4:

FCV Setting

OFF

0,25

0,50

0,75

1,00

1,50

2,00

2,50

3,00

3,50

4,00

5,00

6,00

8,00

10,0

12,0

15,0

Flow Test Acceptable Ranges

LPM

0

0,15 to 0,35

0,40 to 0,60

0,65 to 0,85

0,90 to 1,10

1,35 to 1,65

1,80 to 2,20

2,25 to 2,75

2,70 to 3,30

3,15 to 3,85

3,60 to 4,40

4,50 to 5,50

5,40 to 6,60

7,20 to 8,80

9,00 to 11,0

10,8 to 13,2

13,5 to 16,5

3. 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).

4. 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 excessive venting from relief valve (some venting is normal).

c. If either condition is observed, conduct NER test (RP32).

5. Prepare for Use: a. Empty contents (RP23).

b. Allow unit to sit until warm (2-4 hours).

c. Clean and/or disinfect outside of unit following instruction set forth in the Operation section (Section VIII).

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IX

Maintenance

(Schedule B, Continuous)

Schedule B – Continuous

These inspections/tests should be done between patients

A. Introduction

1. Visually inspect for:

Continuous maintenance is a set of tests and inspections done periodically to ensure equipment is functioning properly. It can be performed by drivers or other personnel while the equipment is in service.

a. Broken shrouds/flow control knobs b. Cold sweaty bottle or excessive venting from relief valve

(vacuum problem). Some venting from relief valve is normal.

1. If a unit fails a given test, it should be taken out of service and sent to the Repair Center/Department for further inspection.

c. QDV deformation

2. Schedule – Checks should be made when the driver sees the patient and when moving equipment between patients.

d. Inspect under shroud (without removal) for any visible dirt or contaminants.

B. Procedure e. Inspect drain tube for visible dirt. Clean with a 6” cotton swab to remove dirt.

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:

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 approximately 7kg (15 lbs) of liquid oxygen and verify using the chart.

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. 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).

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.

Model

LED Min Max Min Max Min Max Min Max Min Max

1

2

3

4

5

TABLE 5:

20

Unit Weight (kg) vs. Meter Reading

30 37 45 60

17,6 20,6 20,4 24,7 22,7 27,9 24,9 31,3 29,9 38,1

20,6 23,5 24,7 28,9 27,9 33,1 31,3 37,6 38,1 46,3

23,5 26,5 28,9 33,2 33,1 38,3 37,6 44,0 46,3 54,4

26,5 29,5 33,2 37,4 38,3 43,6 44,0 50,3 54,4 62,6

29,5 32,4 37,4 41,7 43,6 48,8 50,3 56,7 62,6 70,8

TABLE 6:

Flow Test Ranges

FCV Setting

OFF

0,25

0,50

0,75

1,00

1,50

2,00

2,50

3,00

3,50

4,00

5,00

6,00

8,00

10,0

12,0

15,0

LPM

0

0,15 to 0,35

0,40 to 0,60

0,65 to 0,85

0,90 to 1,10

1,35 to 1,65

1,80 to 2,20

2,25 to 2,75

2,70 to 3,30

3,15 to 3,85

3,60 to 4,40

4,50 to 5,50

5,40 to 6,60

7,20 to 8,80

9,00 to 11,0

10,8 to 13,2

13,5 to 16,5

6

32,4 35,4 41,7 45,9 48,8 54,0 56,7 63,0 70,8 79,0

7

8

- 14 -

35,4 38,3 45,9 50,2 54,0 59,2 63,0 69,4 79,0 87,1

38,3 41,3 50,2 54,4 59,2 64,4 69,4 75,7 87,1 95,3

4. If the unit fails one of the above tests, return it to the Repair

Center or CAIRE. If unit passes all tests, clean outside of the unit with household glass cleaner and lint-free cloth, being careful not to get cleaner inside valves as this could lead to malfunction.

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Troubleshooting/Repair Procedures

X

Table of Contents

A.

B.

C.

D.

Introduction

RP18

RP19

RP20

RP21

RP22

RP23

RP24

RP25

RP10

RP11

RP12

RP13

RP14

RP15

RP16

RP17

RP26

RP27

RP28

RP29

Introduction ………………………………………………………………15

Troubleshooting Charts…………………………………………………16–17

Repair Procedures

RP1 General ………………………………………………………18

RP2

RP3

RP4

RP5

Shroud Assembly RR …………………………………………18

Condensation Bottle Bracket RR ……………………………18

Liquid Level Meter RR ………………………………………18

Liquid Level Meter Battery RR ………………………………19

RP6

RP7

RP8

RP9

Liquid Level Meter Calibration ………………………………19

G4 Meter Troubleshooting ……………………………………20

Manifold Capacitance Test ……………………………………20

Manifold Assembly RR ………………………………………20

Resolder Feed-thru Wire ……………………………………21

Manifold Harness Assembly RR ……………………………21

Clean/Dry Probe & Dewar ……………………………………21

Relief Valve Test………………………………………………22

Relief Valve RR ………………………………………………22

Pressure Retention Test ………………………………………23

Plumbing Leak Test …………………………………………23

Warming and Breathing Coil Assembly RR …………………24

Vent Valve RR ………………………………………………24

Twist Lock QDV Lip Seal RR ………………………………24

Twist Lock QDV Poppet Assembly RR ………………………25

Push-on QDV Assembly RR …………………………………25

Push-on Portable Pop-Off Assembly …………………………25

Empty Unit ……………………………………………………26

Warm Unit ……………………………………………………26

Flow Rate Test ………………………………………………27

Operating Pressure Test ………………………………………27

Flow Meter Verification ………………………………………27

Economizer Regulator RR ……………………………………28

Economizer Regualtor Adjustment …………………………28

RP30

RP31

Flow Control Valve (FCV) RR ………………………………28

Dewar RR ……………………………………………………29

RP32 Normal Evaporation Rate (NER) Test ………………………29

Service Tools / Fixtures / Equipment / Supplies …………………………30

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.

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XI

Troubleshooting Chart

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Troubleshooting Chart

XI

To use the Troubleshooting Chart:

• Start at the upper left corner.

• The top line shows the steps of routine maintenance.

• Unless otherwise noted by the arrows, the flow through the chart is down or to the right.

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XII

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.

RP2 – Shroud Assembly RR (Figure 9)

a. Remove humidifier adapter (Item 26) and FCV extension

(Item 25) from FCV (Item 24).

b. Remove shroud mounting screw (Item 13).

WARNING: Make sure the unit is empty and vent valve is open before replacing any component, except shroud assembly components or Lip Seals.

c. Remove shroud (Item 7) by lifting up and moving sideways to clear the QDV on side fill models, or by lifting straight up top fill models.

WARNING: The technician’s hands, tools, and clothing should be free of all oils and greases.

d. To replace shroud assembly, reverse above procedure.

Torque FCV Extension (Item 25) onto FCV to 45 N-m (4 in-lb).

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.

RP3 – Condensation Bottle Bracket RR

a. Remove condensate drain tube (Item 58) from bottle (Item

56) and remove bottle from bracket (Item 57).

b. Remove condensate bottle bracket (Item 57) squeezing legs together and pulling straight down.

WARNING: The manufacturer of fluorolubricant warns users not to allow fluorolubricant to contaminate tobacco products.

Wash fluorolubricant from hands before smoking.

c. To replace bracket, reverse above procedure.

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 installation.

CAUTION: Some components require a specific amount of torque when assembling. Follow torque requirements where specified.

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.

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: 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: Tampering with meter battery housing will void the battery’s 2-year warranty.

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.

If meter battery failure occures while the battery is under warranty, 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.

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.

- 18 -

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 the battery and carefully pry out the battery.

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Repair Procedures

XII

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 bration mode has been entered. If an error occurs, the calibration 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.)

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 calibrate, 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 capacitance part of the calibration, you can choose either of the two procedures.

FIGURE 10:

Liquid Level Meter

Calibrate Full Capacitance

There are two full capacitance procedures available. Procedure

1 is quite accurate and quicker to perform since it does not require 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.

NOTE: Please use only one of the following calibration methods.

TABLE 7:

Model

Liberator 20

Liberator 30

Liberator 37

Liberator 45

Liberator 60

Capacitance Span LED Settings

LED Setting

LED 2

LED 3

LED 3

LED 7

LED 5

Procedure 1: Capacitance Simulated Full Method a. Press the operate button 3 times within a 5 sec period of entering calibration mode. One of the LEDs will light continuously.

b. Press the calibrate button until the correct LED is continuously lit (See Table 7).

c. Press the operate button to save the calibration. If an error occurs, the calibration value will not be saved.

Enter Calibration Mode

a. Press and hold the hidden calibrate button. While still holding, continue to step B.

Procedure 2: Fill Method a. Enter calibration mode on a vent full unit with properly saturated LOX. If unit has just been filled, allow it to stabilize 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.

b. Within 3 sec, press and hold the operate button. LED 1 and

LED 8 will begin alternately flashing to signify that cali-

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XII

Repair Procedures

RP 7 – G4 Meter Error Codes (Figure 11)

The table below identifies the error codes that one is likely to come across.

FIGURE 11:

Calibration Errors

LEDs

2,3

6,7

1,4

Name

Low Cap

High Cap

Low Span

TABLE 8:

Calibration Errors

Notes Reason

Empty capacitance less than 100 PF

Empty capacitance greater than 300 PF

When calibrating empty

When calibrating empty

Span less than 30 PF When calibrating full

Solution

Check for loose connectinos and recalibrate

Remove moisture and debris from probe

Empty unit and recalibrate

5,8

1,3,5,7

LEDs

2,4,6

High Span

Range

Span greater than 80 PF

The new full cap value is less than empty cap value

Name

High Cap

When calibrating full

When calibrating full

TABLE 9:

Operation Errors

Reason Notes

Reading is 120 PF above calibrated full value

Moisture/

Debris on probe

Low Batt, 2,4,6 Bad Cal

Allow span cal setting to time out w/o pressing green button

New meter revision fixed

Empty unit and recalibrate

Empty unit and recalibrate

Solution

Remove moisture and debris from probe and recalibrate

Recalibrate

1,3,5,7 Low Cap

Cap reading is 5 PF or greater less than calibrated empty value

Moisture in harness; added with new meter rev (on all telemetry meters)

Completely dry harness assembly and recalibrate

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FIGURE 12:

Manifold Capacitance Test Setup

Repair Procedures

XII

b. Capacitance Test:

1. Remove shroud assembly (See RP2).

2. Disconnect the wires leading from the manifold harness assembly to the level meter by disconnecting the JST connector, 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.

NOTE: Make sure unit is empty and at room temperature before testing.

WARNING: Before removing manifold assembly, Liberator must be empty, warm and vent valve open.

RP8 – Manifold Capacitance Test (Figure 12)

a. Capacitance Meter Set-Up:

1. Connect capacitance meter adapter to capacitance meter according 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.

TABLE 10:

Manifold Capacitance Specifications

Model

Liberator 20

Liberator 30

Liberator 37

Liberator 45

Liberator 60

Low Limit (pF)

125

125

130

140

140

High Limit (pF)

160

170

170

180

180

RP 9 – Manifold Assembly RR (Figure 13 )

a. Remove shroud assembly (See RP 2).

b. Disconnect compression fitting (Item 34E) from top of economizer valve (Item 35). Also disconnect compression fittings on the sides of the economizer valve (Item 35).

c. Disconnect compression fitting from liquid withdrawal port

(Item D) being careful not to kink vaporizer coil or internal

PTFE tube.

d. Disconnect compression fitting (Item 34F) from FCV (Item

24).

e. If desired follow RP17 to remove coils from the top of the

Liberator in order to make manifold removal easier.

f. Remove the three bolts (Item 31) that run through the FCV bracket (Item 39) and through the manifold plate into the top of the dewar.

g. Remove two remaining manifold mounting bolts (Item 31, not visible in Figure 12), while holding manifold in place.

h. Lift manifold assembly straight up to remove.

i. Place dewar cap on dewar opening.

j. To replace manifold assembly, reverse above procedure.

Apply small amount of fluorolubricant to O-ring (Item 50) before assembly. Torque manifold mounting screws (Item 31) to

10–11 N-m (90-100 in-lbs) using cross-tightening method.

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XII

Repair Procedures

RP10 – Resolder Feed-thru Wire (Figure 14)

a Remove manifold assembly (See RP9).

b. Strip approximately 1/8” of insulation from feed-thru wire

(Item A) if necessary.

c. Remove strain relief material holding the signal wire against the capacitance probe.

d. Apply small amount of Stay-Clean flux to tinned area of probe

(Item B) using a cotton swab.

e. Resolder feed-thru wire (Item A) to tinned area of probe (Item

B). Add small amount of lead-free solid wire solder if necessary.

f. Clean flux residue with distilled water and cotton swab. Dry thoroughly.

g. Replace manifold following listed procedure (RP9).

RP11 – Manifold Harness Assembly RR (Figure 13)

a. Remove manifold assembly (See RP9).

b. Remove strain relief material holding signal wire against the capacitance probe.

c. Unsolder feed-thru wire (Item A) from probe (Item B).

d. Loosen feed-thru nut (Item C) and remove harness.

e. To replace manifold harness, reverse above procedure.

Tighten feed-thru nut (Item C) 1 to 2 flats past finger tight.

f. Solder feed-thru wire (Item A) following resolder procedure

(See RP10). Replace manifold assembly (See RP9).

RP12 – Clean/Dry Probe and Dewar

Procedure 1: a. Empty dewar per RP23.

b. Warm dewar per RP24.

c. If all moisture is not removed, continue with Procedure 2.

Procedure 2: a. Remove manifold assembly (See RP9).

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.

d. Replace manifold assembly (See RP9).

FIGURE 13:

Manifold Assembly

FIGURE 14:

Feed-thru Wire

CAUTION: Be careful not to bend or damage manifold assembly or dewar neck tube.

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FIGURE 15:

Relief Valve Test Set-up

FIGURE 16:

Primary Relief Valve

FIGURE 17:

Secondary Relief Valve

Repair Procedures

XII

RP13 – Relief Valve Test (Figure 15)

NOTE: Liberator should be empty and warm before testing.

a. Remove shroud (See RP2).

b. Assemble pressure gauge (Item A) and adapter (Item B) (use

PTFE tape).

c. Connect gauge assembly to humidifier adapter (Item 26) on

FCV outlet. Open FCV (Item 24) to 6 LPM setting.

d. Assemble oxygen regulator and pneumatic hose (Item C) with

DISS fittings and male pneumatic test adapter (Item D).

Connect assembly to oxygen gas source.

e. Connect male pneumatic test adapter (Item D) to Liberator

QDV (Item 15).

f. Increase pressure to 1,7 bar (25 psig). PRV (Item 62) should open (audible venting and/or bubbling of leak test solution).

g. Hold PRV (Item 62) closed and increase pressure to 2.3bar (34 psig). SRV (Item 28) should open (audible venting and/or bubbling of leak test solution).

h. 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).

RP14 –Relief Valve RR

WARNING: Liberator must be empty and vented before starting procedure.

Primary (Figure 16)

a. Remove shroud (See RP2).

b. Unscrew PRV (Item 62) from the economizer regulator (Item

35).

c. 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 (Figure 17)

a. Remove shroud (See RP2).

b. Unscrew SRV (Item 28) from FCV (Item 24). c. 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 finger tight.

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XII

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).

b. Connect gauge assembly to humidifier adapter (Item 26) on

FCV outlet. Open FCV (Item 24) to 6 LPM setting.

c. Assemble oxygen regulator, pneumatic hose (Item C) with

DISS fittings and male pneumatic test adapter (Item D).

Connect assembly to oxygen gas source.

d. Connect male pneumatic test adapter (Item D) to Liberator

QDV (Item 15).

e. Increase pressure to 1,4 bar (20 psig).

f. Disconnect male pneumatic test adapter (Item D) from QDV

(Item 15).

g. Turn FCV valve (Item 24) to Off setting.

h. Allow unit to sit undisturbed for 60 minutes.

i. Turn FCV valve (Item 24) to 6 LPM setting.

j. If pressure gauge (Item A) indicates less than 1,24 bar (18 psig), unit fails test.

h. Close FCV (Item 24) by turning to Off position. Remove pressure gauge assembly from humidifier adapter (Item 26).

i. Disconnect pneumatic adapter (Item D) from QDV

(Item 15).

j. Leak test QDV poppet and FCV outlet.

k. Repair all leaks by following appropriate repair procedures.

FIGURE 18:

Plumbing Tests Set-up

RP16 – Plumbing Leak Test (Figure 18)

NOTE: Liberator should be empty and warm before testing.

a. Remove shroud (See RP2).

b. Assemble pressure gauge (Item A) and adapter assembly (Item

B) (use PTFE tape).

c. Connect gauge assembly to humidifier adapter (Item 26) on

FCV outlet. Open FCV (Item 24) to 6 LPM setting.

d. Assemble oxygen regulator, pneumatic hose (Item C) with

DISS fittings and male pneumatic test adapter (Item D).

Connect assembly to oxygen gas source.

e. Connect male pneumatic test adapter (Item D) to Liberator

QDV (Item 15).

f. Increase pressure to 1,3 bar (19 psig).

g. Leak test all connections, joints, and valves with leak test solution.

NOTE: PRV and SRV may leak slowly. Repair all other leaks first and retest for pressure retention before changing relief valves.

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FIGURE 19:

Coil and Vent Assemblies

Repair Procedures

XII

RP18 – Vent Valve RR (Figure 19)

a Remove shroud (See RP2).

NOTE: Valve must be properly aligned to allow access to handle 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).

RP17 – Warming and Breathing Coil Assembly RR

(Figure 19)

WARNING: Liberator must be empty and vented before starting procedure.

a. Remove shroud (See RP2).

b. Disconnect breathing coil (Item 49) by unscrewing the tube nuts (Item 34) at the FCV (Item 24) and at the economizer

(Item 35).

c. Disconnect warming coil (Item 45) by unscrewing the tube nuts (Item 34) at the economizer (Item 35) and at the manifold.

d. Disconnect coils by snipping zip-ties (Item B) that hold them to the top of the Liberator.

e. Remove warming and breathing coil assemblies by slightly bending them outwards and pulling them up and over the top of the Liberator.

f. To replace coil assembly, reverse above procedure.

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 turning 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).

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XII

Repair Procedure

RP20 – Twist-Lock QDV Poppet Assembly RR (Figure

20)

WARNING: Liberator must be empty and vented before starting procedure.

a. Remove shroud (See RP2).

b. Loosen nut (Item C) by holding QDV body (Item 15) with a wrench and turning nut (Item C) clockwise.

c. Disassemble 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.

d. Apply thin film of fluorolubricant to O-ring (Item 16) and replace entire poppet assembly (Item 14).

e. Reassemble QDV, matching alignment marks on valve body and fill tube.

f. Torque nut (Item C) to 60–67 N-m (45-50 ft-lbs) while holding valve body (Item 15).

g. Replace shroud (See RP2).

FIGURE 20:

Side Fill (Twist Lock) QDV Assembly g. Replace poppet, retaining ring, and static seal.

h. 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.

i. Place pop-off sleeve over QDV.

j. Reassemble pop-off assembly to unit, ensuring spring-to-pin engagement into pop-off sleeve groove.

k. Replace shroud (See RP2).

RP22 – Push-on Portable Pop-Off Assembly RR

(Figure 21)

a. Remove shroud (See RP2).

b. Remove two screws (Item 37) and washers (Item 38) from pop-off assembly (Item 27) and remove pop-off assembly.

c. Detach spring from bracket (Item 39) and from pop-off assembly.

d. Disassemble as necessary to replace pop-off assembly parts.

e. Reattach pop-off assembly to unit being sure the pins at the bottom of the pop-off lever slide into the groove at the base of the pop-off sleeve.

f.

Reverse the remainder of the procedure to reinstall.

FIGURE 21:

Top Fill (Push-on) QDV Assembly

RP21 – Push-on QDV Assembly RR (Figure 21)

WARNING: Liberator must be empty and vented before starting this procedure.

a. Remove shroud (See RP2).

b. Remove pop-off assembly (See RP22).

c. Remove pop-off sleeve (Item 21) from QDV (Item 11).

d. Remove the top fill QDV by turning the QDV nut (Item

D) clockwise while holding the QDV (Item 11) with a wrench.

e. 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.

f. Remove the static seal (Item 67) and poppet retaining ring (Item

66) while holding poppet (Item 17) in place.

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FIGURE 22:

Emptying Unit

FIGURE 23:

Warming Unit

Repair Procedure

XII

RP23 – Empty Unit (Figure 22)

WARNING: 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.

a. Place one end of the transfer line (Item A) into a suitable cryogenic container such as an empty, clean Liberator dewar. 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.

b. Connect the adapter to the Liberator QDV (Item 15), keeping the vent valve (Item 41) closed.

c. Liquid oxygen will be discharged from the open end of the transfer line into the empty container. Continue process until Liberator is empty.

d. If Liberator has no pressure, pressurize with the following procedure.

1. Connect regulator (Item C) to oxygen gas source.

2. Connect pneumatic hose (Item D) to regulator and

Liberator DISS Fitting (Item E).

3. Adjust regulator (Item C) to supply up to 1,4 bar (20 psig).

4. Set Liberator FCV (Item 24) to 6 LPM setting.

5. Continue until Liberator is empty.

RP24 – Warm Unit (Figure 23)

a. Liberator may be allowed to sit (FCV off, vent closed) a minimum of 48 hours after emptying.

b. To warm a Liberator more quickly:

1. Connect regulator (Item C) to oxygen or nitrogen gas source.

2. Connect pneumatic hose (Item D) to regulator (Item C) and male pneumatic adapter (Item F).

3. Adjust regulator to 1,4 bar (20 psig). Open vent valve

(Item 41) to allow slow venting.

4. Allow Liberator to vent for 1-1/2 hours minimum after vent valve (Item 41) defrosts.

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XII

Repair Procedures

RP25 – 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.

FIGURE 24:

Flow and Pressure Tests

NOTE: Be careful to allow for accuracy tolerances of flow meter. Table 4 does not account for these tolerances.

a. Connect 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 positioned.

b. 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.

c. Flow rates must be nominal values within tolerances listed in Table 4 or unit fails flow rate test.

RP26 – 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).

b. Connect gauge assembly to DISS fitting on FCV outlet.

Open FCV (Item 24) to 6 LPM setting.

c. Read operating pressure on pressure gauge (Item H).

d. Operating pressure must be 1,2-1,5 bar (18-22 psig) or unit fails test.

RP27 – 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.

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TABLE 11:

Flow Test Acceptable Ranges

FCV Setting

OFF

0,25

0,50

0,75

1,00

1,50

2,00

2,50

3,00

3,50

4,00

5,00

6,00

8,00

10,0

12,0

15,0

LPM

0

0,15 to 0,35

0,40 to 0,60

0,65 to 0,85

0,90 to 1,10

1,35 to 1,65

1,80 to 2,20

2,25 to 2,75

2,70 to 3,30

3,15 to 3,85

3,60 to 4,40

4,50 to 5,50

5,40 to 6,60

7,20 to 8,80

9,00 to 11,0

10,8 to 13,2

13,5 to 16,5

FIGURE 25:

Economizer Regulator

FIGURE 26:

Economizer Test Setup

Repair Procedures

XII

RP28 – Economizer Regulator RR (Figure 25)

WARNING: Liberator must be empty and vented before starting 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 RP29 to ensure proper settings on the replacement regulator.

d. Reverse remainder of procedure to install new properly adjusted regulator.

RP29 – Economizer Regulator Adjustment (Figure 26)

a. Follow steps a and b of RP28 to remove economizer regulator.

WARNING: Liberator must be empty and vented before starting this procedure.

b. Connect the oxygen pressure source to the inlet of the economizer 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 1,48 bar (21.5 psig) and close at

1,41 bar (20.5 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 economizer regulator. The setting is modulated by turning the threaded rod inside the locking nut (Item C).

f. Loosen the locking nut allowing the threaded rod to be turned. g. Turn the threaded rod using an allen wrench to modulate the economizer setting. The economizer regulator should be set to open at 1,48 bar (21.5 psig) and close at 1,41 bar (20.5 psig).

h. Tighten lock nut to secure threaded rod into place.

i. Reverse steps a and b of RP28 to reinstall regulator.

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XII

Repair Procedures

RP30 – Flow Control Valve RR (Figure 27)

WARNING: Liberator must be empty and vented before starting this procedure.

NOTE: Special care should be taken in aligning the FCV in order to ensure that it lines up properly with the shroud.

a. Remove shroud (See RP2).

b. Loosen compression fitting nut (Item 34) at connection of breathing coil (Item 49) and FCV assembly. Disconnect

FCV assembly (Item 24) from coil.

c. Remove the FCV knob (Item 1) by grasping firmly and pulling upwards.

d. Unscrew the two screws (Item 4) holding the lock plate

(Item 3) and decal (Item 2) to the FCV (Item 24) and remove lock plate and decal.

e. Unscrew SRV (Item 28) from FCV (Item 24).

f. Replace the FCV (Item 24), by reversing the above procedure.

FIGURE 27:

Flow Control Valve d. Remove dewar cap from the new dewar and place the cap on old dewar.

e. Clean/dry both the probe and dewar following procedure in section VIII.

f. Connect the manifold assembly with coils to the new dewar; be sure to follow the manifold assembly replacement procedure (See RP9). Do not replace shroud.

g. Replace condensate bottle (Item 56), bracket (Item 57) and drain tube (Item 58).

h. Scribe part number and serial number on new dewar handle. Make part number and serial number on old dewar illegible.

i. Calibrate meter by following RP7.

RP32 – Normal Evaporation Rate Test

a. Fill the unit with correct amount of properly saturated liquid oxygen shown in Table 12. Values are approximate.

TABLE 12:

NER Filling Key

Model

Lib 20

Lib 30

Lib 37

Lib 45

Lib 60

Empty kg (lb)

17,6 (39)

20,4 (45)

22,7 (50)

24,9 (55)

29,9 (66)

Lox kg (1b)

12,3 (27)

18,2 (40)

21,3 (47)

25,0 (55)

24,5 (54)

Total kg (lb)

29,9 (66)

38,6 (85)

44,0 (97)

49,9 (110)

54,4 (120) 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).

RP31 – Dewar RR

WARNING: Liberator must be empty and vented before starting this procedure.

a. Remove shroud (See RP2).

b. Remove manifold assembly and coils (See RP9).

c. Remove condensate bottle (Item 56), drain tube (Item 55) and bracket (Item 54) following RP3.

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c. Weigh unit. Record weight and time.

d. Allow unit to sit undisturbed for a minimum of 24 hours.

e. Weigh unit. Record weight and time.

f. Calculate liquid loss rate (NER) using the following formula:

Weight lost (kg or lbs)

NER = ———————— x 24 hours/day

Elapsed time in hrs.

Example

0.63 kg

NER = ————— 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 reevacuation. 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/Equipment/Supplies

XIII

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

2. Soldering Iron

3. Oxygen Regulator

4. Pressure Gauge

5. Pressure Gauge Adapter

6. Flowmeter

7. 02 Gas Source (High Pressure bottle)

8. 02 Liquid Source

9. 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 lb) increments

Required Supplies

1. Stay-Clean Flux

2. Cotton Swabs

3. Lead-free Solder

4. Distilled Water

5. Household Glass Cleaner

6. Lint-Free Cloth

7. PTFE Tape

8. Fluorolubricant

9. Leak Detection Fluid

Cleaner

1. Simple Green available at www.simplegreen.com

Tools and Accessories available from Caire

Part No Description

10679862 Female Top Fill Pneumatic Test Adapter

10678157 Female Top Fill Transfer Line Adapter

CA200071 240 AC Fluorolubricant

CA200072 Leak Detection Fluid (gallon)

97200076

97212021

97212023

Erie "Liter Meter"

Male Side Fill Pneumatic Test Adapter

Male Side Fill Transfer Line Adapter w/Filter

CA005571 Transfer Line Adapter Cover

97217007 Pressure Gauge Adapter

CA400004 Replacement Filter/Male Transfer Line Adapter

97403016

97202005

97403015

Jeweler's Screwdriver

Vent Valve Wrench

Capacitance Meter

97403574

97403577

97404564

97405147

11847274

97405279

Dewar Cap

0-4.1 bar (0-60 psig) Pressure Gauge

Transfer Line Swivel Connector

0-3.1 bar (0-45 psig) Oxygen Regulator

Hand Truck w/Stair Climber

Pneumatic Hose with DISS Fittings

97405431

97405590

Liquid Oxygen Transfer Line – 2 m (6 ft)

Lip Seal Service Tool

CA406308 10.3 bar (150 psi) Relief Valve Assembly

CA406310 TEFLON Tape

CA406398 10.3 bar (150 psi) Relief Valve only

97406471

97406555

97406630

Tandem Tee Kit

Super Flex Liquid Oxygen Transfer Line – 6'

Dual Fill Head Tee

13350704

10661515

10660361

Service Manual

Conversion Kit TF to SF

Conversion Kit SF to Dual

10660344

10661523

13329091

Conversion Kit TF to Dual

Conversion Kit SF to TF

G4 Capacitance Meter Adaptor Kit

For a complete list of accessories, see catalog #401-038-901.

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XIV

Parts Price List

Contact Customer Service or visit www.cairemedical.com to obtain your parts price list.

- 32 -

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Ordering Information

XV

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.

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 CAIRE

(800 482 2473)

Toll Free Fax: 888 WE CAIRE

(To place an order): (888 932 2473)

Phone: 770 257 1299

Fax: 770 257 1300

Model

(0–15 LPM)

L20

L30

L37

L45

L60

Side Fill

13256435

13258449

13259695

13262085

13263782

Top Fill

13256654

13258641

13259919

13262253

13263811

Dual Fill

13256195

13256929

13259572

13261699

13263758

Asia, Australia, Pacific Rim

Phone:

Fax:

Europe

Phone:

Fax:

+61 297 494333

888 932 2473

+44(0) 1344 403100

+44(0) 1344 429224

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 infor-

mation:

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.

4. Mail or fax the completed purchase order for

confirmation to:

CAIRE, Inc.

1800 Sandy Plains Industrial Parkway

Suite 316

Marietta, GA 30066

CAIRE, Inc.

Unit 2, Maxdata Cantre

Downmill Rd.

Bracknell, Berkshire RG12 1Qs

United Kingdom

All new equipment 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 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. If a particular carrier or method of shipment is desired, specify when placing order.

For additional ordering and contact information, visit www.cairemedical.com

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XVI

Restocking Policy

When a Liberator 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 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 original shipping container, precisely as shipped.

3. Write 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

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. A 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:

CAIRE, Inc.

2000 Airport Drive

Ball Ground, GA 30107

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.

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 detailed listing of any maintenance performed.

Return of Unused Non-Defective Merchandise

CAIRE, Inc., at its discretion, charges a 15% restocking fee for unused non-defective merchandise that is returned. An

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.

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Notes

XVII

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XVII

Notes

- 36 -

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Chart Industries, Inc.

Caire, Inc., BioMedical Group

1800 Sandy Plains Industrial Parkway, Suite 316

Marietta, GA 30066

Ph 770-425-4470 • Toll Free 1-800-482-2473

Fax 770-425-4740

w w w . c a i r e m e d i c a l . c o m

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 © 2008 Ref 10662649 Rev L