CAIRE Companion C1000 Technical & Service Manual
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CAIRE Companion C1000 Technical & Service Manual

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Summary of Contents for CAIRE Companion C1000

  • Page 1 Companion Portables...

  • Page 2: Preface

    Customer & Technical Service: 1-800-482-2473 www.cairemedical.com NOTE: CAIRE Reservoir and Portable units are intended only for the delivery of medical grade oxygen as prescribed by a physi- cian. NOTE: SI pressure values expressed in manual are referenced to atmosphere. HELiOS™, Companion®, and Teleview™ are trademarks of CAIRE INC.
  • Page 3 Preface 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: Safety

    Certain items considered noncombus- tible in air may burn rapidly in such an environment. Keep all While CAIRE, Inc. equipment is designed and built to the most organic materials and other flammable substances away from rigid standards, no piece of mechanical equipment can ever be possible contact with oxygen;...
  • Page 6 Safety WARNING: When using concentrated oxygen, the risk of fire WARNING: Extreme high pressure can rupture container or is increased. plumbing components. Be sure specified pressure relief devices are present, in the proper location, and functioning properly. WARNING: The possibility of fire exists when the combina- WARNING: During transfer of liquid oxygen gas blow off tion of a fuel, source of ignition, and oxygen is present.
  • Page 7 Safety Table 2 Guidance and Manufacturer’s declaration—electromagnetic emissions The Companion 1000/T is intended for use in the electromagnetic environment specified below. The customer or the user of the Companion 1000/T should assure that it is used in such an environment. Emissions test Compliance Electromagnetic environment—guidance...
  • Page 8 Safety Table 3 Guidance and manufacturers declaration—electromagnetic immunity The Companion 1000/T is intended for use in the electromagnetic environment specified below. The customer or the user of the Companion 1000/T should assure that it is used in such an environment. Immunity test IEC 60601 test level Compliance level...
  • Page 9 Safety Table 4* Guidance and manufacturers declaration—electromagnetic immunity The Companion 1000/T is intended for use in the electromagnetic environment specified below. The customer or the user of the Companion 1000/T should assure that it is used in such an environment. Immunity test IEC 60601 test level Compliance level...
  • Page 10 Safety Table 5* Recommended separation distances between portable and mobile RF communications equipment and the Companion 1000/T The Companion 1000/T is intended for use in an electromagnetic environment in which radiated RF disturbances are controlled. The customer or the user of the Companion 1000/T can help prevent electromagnetic interference by maintaining a minimum distance between portable and mobile RF communications equipment (transmitters) and the Companion 1000/T as recommended below, ac- cording to the maximum output power of the communications equipment.

  • Page 11: Equipment Description

    NOTE: Throughout this manual the CAIRE Companion 1000 vacuum insulated Dewar for storing liquid oxygen (LOX) at and CAIRE Companion 1000 T will be referred to as the approximately -173°C/-280°F. The inner vessel is designed Companion 1000/T whenever information that is applicable to to safely hold liquid oxygen and is protected from over pres- both models is presented.

  • Page 12: Theory Of Operation

    (TF) reservoir with a compatible male QDV. The fol- evaporation rate (NER). When the flow control knob is in the off lowing CAIRE reservoirs are compatible with the C1000/T for position, this gas will build up pressure in the headspace above filling: the liquid oxygen.
  • Page 13 Portables Manufactured prior to January 1985 4 - 6 - 25 - 1 ever needed through CAIRE Customer or Technical Service. Prior to June 2010, the serial number for the C1000/T was etched on the vent valve mounting bracket. The vent valve is pulled...

  • Page 14: Specifications

    Specifications Table 6 Companion C1000 Companion C1000T 1.23 L / 0.04 ft 3 1.23 L / 0.04 ft 3 Volume of LOX (Typical) Weight of LOX (typical) 1.41 kg / 3.1 lb 1.41 kg / 3.1 lb 1058 L / 37.36 ft 3 1058 L / 37.36 ft 3...

  • Page 15: Saturation Principles

    Saturation Principles Oxygen, in its normal state, is a colorless, tasteless, and odorless gas that is non-flammable, although it greatly accelerates combustion in high concentrations. It constitutes about 21% of the Earth’s atmosphere by volume. Oxygen in higher concentrations is medically beneficial to patients suffering from certain respiratory diseases.
  • Page 16 Saturation Principles If the pressure in a container of saturated liquid decreases, the temperature required for saturation to occur will decrease. This leaves the liquid “super saturated” or too warm. When this occurs, rapid boiling and vaporizing of some of the liquid occurs. The rapid boil- ing and evaporation of the liquid dissipates the excessive heat until the remaining liquid cools down to the new saturation temperature associated with the decreased pressure (Figure 7).
  • Page 17 Saturation Principles If the saturation pressure of the liquid in the portable unit is greater than 1.93 bar (28 psi) the following symptoms may occur: • Increased product loss and evaporation rate • Decreased durations • High flow rates • Venting from relief valves • Relief valves frozen open If the saturation pressure of the liquid in the portable unit is lower than 1.2 bar (18 psi) the following symptoms may occur: • Decreased evaporation rates • Low flow rates • No oxygen flow...

  • Page 18: Unpacking And Setup

    VIII Unpacking and Setup Unpacking Transport 1. Inspect carton for shipping damage. Report any damage to The C1000/T are designed with carrying straps. Portable units the freight company before signing the bill of lading. may be moved about or transported in a vehicle while full 2.

  • Page 19: Operation

    Operation i. When you notice a change in the sound of the venting gas, Filling followed by the emission of a dense, white vapor around the 1. Fill Source Preparation reservoir shroud, close the vent valve to terminate the fill. j.
  • Page 20 Waste Electrical and Electronic Equipment Directive (WEEE), or other applicable codes and regulations. Alternatively, CAIRE may be contacted for disposal information. Companion Portable Technical Service Manual • PN 20562220 Rev B...

  • Page 21: Maintenance

    1. If a unit fails a given test, one of two things may be done: a. Refer to Troubleshooting section of this manual. -or- b. Return the unit to CAIRE, Inc. for repair. 2. Schedule – Maximum of two years between routine mainte- nance testing. Unit should be tested whenever a problem is suspected.
  • Page 22 Maintenance (Schedule A, Biennial) Schedule A (Biennial) Maintenance Checklist Step 10 Year Service Life Year 2 Year 4 Year 6 Year 8 Year 10 LOX Purged From Reservoir (Repair Procedure RP3) Performed or Verified By/Date Inpection for Damaged/Missing Parts Performed or Verified By/Date Contents Indicator Reads Empty and Spring Scale Performed or Verified By/Date Moves Freely...
  • Page 23 Maintenance (Schedule B, Continuous) Schedule B – Continuous Pre and Post Fill Inspection A. Introduction 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.
  • Page 24 Maintenance (Schedule B, Continuous) Schedule B (Continuous Pre and Post Fill Inspection) Maintenance Checklist Pre Fill Visual Inspection Cracks, warming or discoloration Verified By/Date QDV Deformation Verified By/Date Liquid Contents/Level Indicator Functionality Verified By/Date Cryogenic Reservoir Damage (Dents,Dings) Verified By/Date Visible Dirt or Contamination Verified By/Date Presence of All Required Labels...

  • Page 25: Troubleshooting & Repair Procedures

    Troubleshooting & Repair Procedures Table of Contents Introduction ----------------------------------------------------------------------------------------- 24 Troubleshooting Chart ----------------------------------------------------------------------------- 25 Repair Procedures General ---------------------------------------------------------------------------------- 30 RP2A Leak Test (Warm & Empty Unit) --------------------------------------------------- 30 RP2B Leak Test (Unit Containing Oxygen) ----------------------------------------------- 31 Emptying/Warming Portable RR ---------------------------------------------------- 31 Side Cover RR ------------------------------------------------------------------------- 31 Top Bezel RR -------------------------------------------------------------------------- 31 Carrying Strap RR --------------------------------------------------------------------- 32...

  • Page 26: Troubleshooting Chart

    Troubleshooting & Repair Procedures Table 5 below provides troubleshooting procedures for the Companion Portables. This guide is not all-inclusive but is intended to serve as a general outline for solving operational problems. The table describes symptoms, identifies probable causes, and suggests corrective actions.
  • Page 27 Allow the portable to warm and thaw. Attempt to re-fill the portable. Faulty relief valve Test the relief valve (RP9) and replace if necessary (RP10) Partial or complete loss of Conduct the NER test (RP23) and return the unit to CAIRE, Inc. if vacuum necessary. No Flow...
  • Page 28 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 Conduct the NER test (RP23) and return the unit to CAIRE, Inc. if neces- vacuum sary. 10) Excessive Frost...
  • Page 29 Troubleshooting & Repair Procedures Companion Portable Technical Service Manual • PN 20562220 Rev B...
  • Page 30 Troubleshooting & Repair Procedures (RP23) 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. Companion Portable Technical Service Manual •...

  • Page 31: Repair Procedures

    Troubleshooting & Repair Procedures RP1 – General RP2A - Leak Test (Warm & Empty Unit) 1) Remove the covers (RP4). The following procedures have been carefully prepared to allow 2) Set the flow control valve to 0 LPM (Off). proper removal and replacement of defective components and 3) Pressurize the C1000/T portable to approximately 1.52 bar should be used in conjunction with the Troubleshooting Chart and (22 psi) with gaseous oxygen using the portable pressurizing...

  • Page 32: Rp2B Leak Test (Unit Containing Oxygen)

    Troubleshooting & Repair Procedures RP3 – Emptying/Warming Portable RR 1) Turn the FCV knob to the highest flow setting. 2) Allow unit to sit for 24 hours before proceeding. RP4 – Side Cover RR 1) C1000T only: Remove the moisture cup by turning the quar- ter-turn fastener counter clockwise and pulling the cup away from the unit.

  • Page 33: Rp6 Carrying Strap Rr

    Troubleshooting & Repair Procedures 4) Remove the lever spacer, the spring, and the spring rod. RP6 – Carrying Strap RR 5) Use a medium-blade screwdriver to remove the four pan 1) Remove the covers (RP4) and top bezel (RP5). head screws from the indicator. Remove the four screws and 2) Use a small screwdriver to remove the outermost E-clip the four upper spacers from the indicator.

  • Page 34: Rp9 Prv Test

    Troubleshooting & Repair Procedures RP9 - PRV Test 1) Remove the covers (RP4). 2) Connect the pressurizing setup to the C1000/T as shown in Figure 9. 3) Place one drop of SNOOP on the PRV or PRV silencer. 4) Slowly pressurize the unit with gaseous oxygen by adjusting the oxygen regulator until tiny, foam-like bubbles begin to form to indicate that the PRV has opened.

  • Page 35: Rp11 Srv Test

    Troubleshooting & Repair Procedures RP11 – SRV Test RP13 – Pressure Retention Test 1) Remove the covers (RP4). 1) Empty the unit and remove the covers (RP4). 2) Connect the pressurizing setup as shown in Figure 9. NOTE: Perform RP13 only on warm, empty portable units. 3) Remove the silencer from the PRV.

  • Page 36: Rp14A Warming Coil Assembly Rr (C1000)

    Troubleshooting & Repair Procedures RP14A – Warming Coil Assembly RR (C1000) NOTE: Do not overtighten the tube nuts on the warming coil. 1) Remove the covers (RP4). Overtightening may result in a cracked fitting. Only a slight in- crease in torque is required to seal a compression fitting that has 2) Use side-cut pliers to cut the two wire ties from the warming already been made up.

  • Page 37: Rp16 Vent Valve Rr

    Troubleshooting & Repair Procedures RP16 - Vent Valve RR 1) Remove the covers (RP4). 2) Use a 9/16 inch open-end wrench to disconnect the 1/4inch tube nut that connects the vent extension tube to the vent valve (Figure 19). Figure 21: Vent Valve Removal 5) Slide the vent valve out of the mounting bracket.

  • Page 38: Rp17 Qdv Assembly Rr

    Troubleshooting & Repair Procedures RP17 – QDV Assembly RR RP18 – Lip Seal RR 1) Remove the covers (RP4). 1) Remove the QDV (RP17). 2) Use a 9/16inch open-end wrench to disconnect the tube nut 2) Hold the QDV body with an adjustable wrench placed on at the female adaptor (Figure 22).

  • Page 39: Rp19 Flow Rate Test Test

    Troubleshooting & Repair Procedures Table 10 C1000T FCV RP19 - FCV Test 1) Fill the C1000/T with liquid oxygen. Allow approximately Nominal Setting (LPM) Allowable Range (LPM) one hour for the system pressure to stabilize. Verify that the PRV is venting and that the system pressure is 1.28 – 1.62 0.50 0.33 - 0.67 bar (18.5 –...

  • Page 40: Rp20 Fcv Rr

    Troubleshooting & Repair Procedures RP21 – Back Flushing the FCV RP20 – FCV RR 1) Remove the FCV (RP20) and its filter screen. WARNING: Liquid oxygen discharge from the FCV can occur 2) Temporarily reinstall the oxygen outlet barbed fitting in the if a 0-15LPM C1000T FCV is installed on a C1000.

  • Page 41: Rp23 Ner Test

    Troubleshooting & Repair Procedures RP23 – NER Test RP24 – Manifold RR 1) Perform a leak test (RP2) and verify that the results are ac- 1) Remove the covers (RP4). ceptable. 2) Remove the top bezel (RP5). 2) Perform the PRV test (RP9) and verify that the PRV is func- 3) Loosen and remove the four socket head cap screws from tioning properly.

  • Page 42: Rp25 Cryogenic Container Rr

    Troubleshooting & Repair Procedures RP25 – Cryogenic Container RR 1) Remove the manifold (RP24). 2) Use a 5/8inch open-end wrench on the vent valve body hex flats to hold the body stationary. Use an 11/16inch open-end wrench to loosen the jam nut that holds the vent valve to the mounting bracket.

  • Page 43: Parts List

    Parts List Contact Customer Service or visit www.cairemedical.com to obtain your parts list. Companion Portable Technical Service Manual • PN 20562220 Rev B...

  • Page 44: Ordering Information

    Africa/Europe/Middle East fax to: +44 118 9799245 for each item ordered. 3. Telephone or fax CAIRE Inc. at one of the numbers listed All new equipment will be shipped either “prepaid”,, F.O.B. from below to begin immediate processing of the order: the factory, or collect via your specified carrier.

  • Page 45: Return & Restocking Policy

    Section VII, Unpacking and Setup Instructions. If it becomes necessary to cancel an order with CAIRE Inc. af- ter the shipment has been received, use the following “Restock If a problem with the unit should be encountered, reference Policy”...

  • Page 46: Service Tools/Equipment/Supplies

    Service Tools/Equipment/Supplies Tools and Accessories available from Caire Required Tools Hex Wrenches (various sizes) Description Item Number Flat Blade Screwdriver Backpack C1000/T 10018138 Needle Nose Pliers Adjustable Wrench—8 inch Erie Liter Meter (0-8 LPM) 97200076 Open End Wrenches (various sizes)
  • Page 47 . c a i r e m e d i c a l . c o m CAIRE Inc. reserves the right to discontinue its products, or change the prices, materials, equipment, quality, descriptions, specifications and/or processes to its products at any time without prior notice and with no further obligation or consequence.

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