CAIRE Liberator G4 Series Technical & Service Manual
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CAIRE Liberator G4 Series Technical & Service Manual

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Liberators —G4

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Summary of Contents for CAIRE Liberator G4 Series

  • Page 1 Liberators —G4...

  • Page 2: Preface

    Preface SERVICE MANUAL LIBERATOR SERIES—G4 LIB20, LIB30, LIB37, LIB45, LIB60 CAIRE, Inc. 2200 Airport Industrial Dr., Ste. 500 Ball Ground, GA 30107 www.cairemedical.com Customer/Technical Service: North and South America Phone (US Only): 800-482-2473 Fax: 888-932-2473 770-721-7759 Fax: 770-721-7758 Asia, Australia, Pacific Rim...
  • Page 3 Abbreviations FCV Flow Control Valve Primary Relief Valve LED Light Emitting Diode Quick Disconnect Valve LOX Liquid Oxygen Return Materials Authorization LPM Liters Per Minute Repair Procedure NER Normal Evaporation Rate Removal and Replacement POI Patient Operating Instructions Secondary Relief Valve N2 Nitrogen Gas Oxygen Gas TF Top Fill...

  • Page 4: Table Of Contents

    Table of Contents I. Preface ..........1 II.

  • Page 5: Equipment Description

    Liberator. Serial Number Information For Liberators manufactured before 2006, the serial number was ten digits. The first three digits represented CAIRE specific information, followed by two digits signifying the year of manufacture, followed by a two digit number to digit...

  • Page 6: Specifications

    Specifications (Nominal Values) LIBERATOR SPECIFICATIONS MODEL LIBERATOR 20 LIBERATOR 30 LIBERATOR 37 LIBERATOR 45 LIBERATOR 60 Volume of LOX 21.0 liters / .021 m3 31.0 liters / .031 m3 37.3 liters / .0373 m3 45.7 liters / .0457 m3 60.2 liters / .0602 m3 (typical) Weight of LOX at 24 23kg (50.7 lbs)

  • Page 7: Safety

    WARNING: During transfer of liquid oxygen, components will become extremely cold. Care should be used to avoid any contact While CAIRE, Inc. equipment is designed and built to the most with these components, as serious frostbite may result. rigid standards, no piece of mechanical equipment can ever be made 100% foolproof.
  • Page 8 Safety WARNING: Medical electrical Equipment needs special precau- WARNING: The use of Accessories, transducers, and cables other tions regarding EMC and needs to be installed and put into service than those specified by the manufacturer may result in increased according to the EMC information provided in this manual. Emissions or decreased immunity of the Liberator.
  • Page 9 Safety Table 2 Guidance and manufacturers declaration—electromagnetic immunity The Liberator is intended for use in the electromagnetic environment specified below. The customer or the user of the Liberator should assure that it is used in such an environment. Immunity test IEC 60601 t Compliance level Electromagnetic environment—guidance...
  • Page 10 Safety Table 4* Guidance and manufacturers declaration—electromagnetic immunity The Liberator is intended for use in the electromagnetic environment specified below. The customer or the user of the Liberator should assure that it is used in such an environment. Immunity test IEC 60601 test level Compliance level Electromagnetic environment—guidance...
  • Page 11 Safety Table 6* Recommended separation distances between portable and mobile RF communications equipment and the Liberator The Liberator is intended for use in an electromagnetic environment in which radiated RF disturbances are controlled. The customer or the user of the Liberator can help prevent electromagnetic interference by maintaining a minimum distance between portable and mobile RF communications equipment (transmitters) and the Liberator as recommended below, according to the maximum output power of the communications equipment.

  • Page 12: Theory Of Operation

    Theory of Operation FIGURE 3: Temperature vs. Saturation Pressure Filling The Liberator is filled by connecting a pre-purged transfer line -155 with a fill adapter from a larger liquid oxygen source to the 6.9, -157.4 Liberator side fill or top fill QDV. The Liberator vent valve is -160 then opened.
  • Page 13 LOX. The filling source must be correctly saturated or drawing the head gas first, instead of allowing it to escape through low/high saturation will occur in CAIRE reservoirs. the relief valve. While flowing through the breathing coil, the cold gaseous oxy-...
  • Page 14 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).

  • Page 15: Unpacking And Setup

    Unpacking and Setup FIGURE 7: Flow Control Knob 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.

  • Page 16: Operation

    2,4-3,4 bar (35-50 psig). open the FCV to 2LPM or greater. NOTE: Proper saturation is critical when filling a CAIRE reservoir. If filling pressure is not monitored, it must be ensured that If the fill source is not properly saturated, the unit will not func-...
  • Page 17 NOTE: Only use disinfectants or cleaning agents approved for use with this equipment by CAIRE such as Sporicidin, Hydroklean, or others as specified by CAIRE. Liberators Technical Service Manual • PN 13350704 Rev K...

  • Page 18: Maintenance

    If the dewar bottle is cold and sweating, and/or there is excessive venting from the relief valve, an NER test should be b. Return the unit to CAIRE, Inc. for repair. performed (RP32). 2. Schedule – Maximum of two years between routine 4.
  • Page 19 Maintenance (Schedule B, Continuous) Schedule B – Continuous Cryogenic reservoir damage (dents, dings) A. Introduction If LOX is still present in the unit, inspect for heavy frost or condensation on the exterior of the unit, which would in- Continuous maintenance is a set of tests and inspections done pe- dicate poor vacuum.

  • Page 20: Troubleshooting

    Troubleshooting Table of Contents Introduction ------------------------------------------------------------------------- 19 Troubleshooting Charts -------------------------------------------------------- 20–23 Repair Procedures General ---------------------------------------------------------------- 24 Shroud Assembly RR ------------------------------------------------- 24 Condensation Bottle Bracket RR ------------------------------------- 24 Liquid Level Meter RR ------------------------------------------------ 24 Liquid Level Meter Battery RR --------------------------------------- 24 Liquid Level Meter Calibration -------------------------------------- 25 G4 Meter Troubleshooting ------------------------------------------- 26 Manifold Capacitance Test ------------------------------------------- 27...

  • Page 21: Troubleshooting Charts

    Faulty relief valve Test the relief valve (RP13) and replace if necessary (RP14) Partial or complete loss of vacuum Conduct the NER test (RP32) and return the unit to CAIRE, Inc. if necessary. No flow at Reservoir is empty Check the contents indicator/level gauge and fill the reservoir if needed.
  • Page 22 “Excessive venting from relief valves (hissing sound)”. Partial or complete loss of vacuum Conduct the NER test (RP32) and return the unit to CAIRE, Inc., if necessary. Frost is acceptable Some frost on the shroud and on the plumbing is acceptable, especially at high flow...
  • Page 23 Troubleshooting Charts Liberators Technical Service Manual • PN 13350704 Rev K...
  • Page 24 Troubleshooting Charts 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. Liberators Technical Service Manual •...

  • Page 25: Repair Procedures

    Repair Procedures RP2 – Shroud Assembly RR (Figure 9) RP1 – General The following procedures have been carefully prepared to allow a. Remove humidifier adapter (Item 26) and FCV extension (Item proper removal and replacement of defective components and 25) from FCV (Item 24). should be used in conjunction with the Troubleshooting Chart and the tests in this section.

  • Page 26: Rp6 Liquid Level Meter Calibration

    d. Insert new battery with the positive terminal facing up. b. Within 3 sec, press and hold the operate button. LED 1 and LED 8 will begin alternately flashing to signify that calibra- e. Apply a thin coating of fluorolubricant to the o-ring. tion mode has been entered.
  • Page 27 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. See Table 5 for typical LED meter reading versus unit weight.
  • Page 28 Repair Procedures RP 7 – G4 Meter Error Codes (Figure 11) FIGURE 11: Calibration Errors The table below identifies the error codes that one is likely to come across. TABLE 6: Calibration Errors LEDs Name Reason Notes Solution Empty capacitance less than Check for loose connections Low Cap When calibrating empty...

  • Page 29: Rp8 Manifold Capacitance Test

    Repair Procedures FIGURE 12: Manifold Capacitance Test Setup b. Capacitance Test: 1. Remove shroud assembly (See RP2). Ground 2. Disconnect the wires leading from the manifold harness as- sembly to the level meter by disconnecting the JST connec- tor, which is zip-tied to the bracket. 3.

  • Page 30: Rp10 Resolder Feed-Thru Wire

    Repair Procedures FIGURE 13: Manifold Assembly 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.

  • Page 31: Rp13 Relief Valve Test

    Repair Procedures FIGURE 15: Relief Valve Test Set-up 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).

  • Page 32: Rp15 Pressure Retention Test

    Repair Procedures g. Leak test all connections, joints, and valves with leak test solu- tion. WARNING: Liberator must be empty and vented before starting h. Close FCV (Item 24) by turning to Off position. Remove pressure procedure. gauge assembly from humidifier adapter (Item 26). i.

  • Page 33: Rp17 Warming And Breathing Coil Assembly Rr

    Repair Procedures FIGURE 19: Coil and Vent Assemblies 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.

  • Page 34: Rp20 Twist Lock Qdv Rr

    Repair Procedures g. Push QDV back on to fill tube (Item D) and torque nut to 60–67 RP20 – Twist-Lock QDV RR (Figure 20) N-m (45-50 ft-lbs) while holding valve body to fasten QDV in place. WARNING: Liberator must be empty and vented before starting h.

  • Page 35: Rp23 Empty Unit

    Repair Procedures FIGURE 22: Emptying Unit 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.

  • Page 36: Rp25 Flow Rate Test

    Repair Procedures RP25 – Flow Rate Test (Figure 24) NOTE: Factory flow rate specifications are within the +/- 10% RP26 – Operating Pressure Test (Figure 24) tolerance required by ISO 18777 for environmental conditions NOTE: If testing operating pressure because of improper of temperature between 10 C –...
  • Page 37 This table reflects tolerance requirements of ISO 10524. This does not affect CAIRE's factory compliance with the +/-10% tolerance requirement of ISO 18777. Liberators Technical Service Manual • PN 13350704 Rev K...

  • Page 38: Rp28 Economizer Regulator Rr

    Repair Procedures RP30 – Flow Control Valve RR (Figure 26) RP28 – Economizer Regulator RR (Figure 25) WARNING: Liberator must be empty and vented before starting this procedure. 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.

  • Page 39: Rp32 Normal Evaporation Rate (Ner) Test

    3. Full weight of LIB 45 Reservoir: 74.99 kg (165.32 lbs) g. If NER is more than 0,9 kg/day (2 lbs/day) for a Liberator, the dealer may want to send the unit to CAIRE, Inc. for re- evacuation. If NER is more than 2,3 kg/day (5 lbs/day) the 4.

  • Page 40: Service Tools/Equipment/Supplies

    Cleaner 1. Hex Wrenches (various sizes) 1. Simple Green available at www.simplegreen.com 2. Flat Blade Screwdriver 3. 5/16” Nut Driver Tools and Accessories available from Caire 4. Open End Wrenches (1/2” to 1-1/8”) Part No Description 5. Side Cutters 10679862 Female Top Fill Pneumatic Test Adapter 6.

  • Page 41: Parts Price List

    Parts Price List Contact Customer Service or visit www.cairemedical.com to obtain your parts list. Liberators Technical Service Manual • PN 13350704 Rev K...

  • Page 42: Ordering Information

    Ordering Information Ordering Information 3. Telephone or fax CAIRE Inc. at one of the numbers listed be- low to begin immediate processing of the order: The following steps should be used when ordering a new Liberator or replacement parts for an existing unit:...

  • Page 43: Return & Restocking Policy

    Restocking Policy as outlined in Section VII, Unpacking and Setup Instructions. If it becomes necessary to cancel an order with CAIRE Inc. af- If a problem with the unit should be encountered, reference ter the shipment has been received, use the following “Restock should be made to the Troubleshooting Chart in Section X, page Policy”...
  • Page 44 . c a i r e m e d i c a l . c o m Copyright © CAIRE, Inc. 2019. CAIRE Inc. reserves the right to discontinue its products, or change the prices, Copyright © 2019, Ref 13350704 Rev K materials, equipment, quality, descriptions, specifications and/or processes to its products at any time without prior notice and with no further obligation or consequence.

This manual is also suitable for:

Liberator 30Liberator 20Liberator 37Liberator 45Lib37Liberator 60 ... Show all

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