CAIRE SAROS 4000 Service Manual
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CAIRE SAROS 4000 Service Manual

Oxygen system
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SERVICE MANUAL
CAIRE Inc.
2200 Airport Industrial Dr., Ste 500
Ball Ground, GA 30107
www.caireinc.com
Copyright © 2020 CAIRE Inc.. 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. All rights not expressly stated herein are reserved by us, as applicable.
MN260 B
Oxygen System
MODEL 4000

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Summary of Contents for CAIRE SAROS 4000

  • Page 1 Ball Ground, GA 30107 www.caireinc.com Copyright © 2020 CAIRE Inc.. 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.
  • Page 2 Service Manual WARNING: DO NOT OPERATE THIS EQUIPMENT WITHOUT FIRST READING AND UNDERSTANDING THIS MANUAL. IF YOU ARE UNABLE TO UNDERSTAND THE WARNINGS AND INSTRUCTIONS, CONTACT YOUR EQUIPMENT PROVIDER BEFORE ATTEMPTING TO USE THIS EQUIPMENT; OTHERWISE, INJURY OR DAMAGE MAY RESULT. DEFINITION OF SYMBOLS PAGE / WARNING PAGE WARNING: INDICATES A HAZARDOUS SITUATION THAT, IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY.
  • Page 3 Service Manual INTERNAL SYMBOLS COUNCIL DIRECTIVE 2012/19/EU: WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT (WEEE) Keep away from flammable materials, oil and grease. WEEE Oxygen Output; The port from which the Oxygen flows and where the tubing or interface(standard nasal cannula) is connected. IEC 60601-1: MEDICAL ELECTRICAL EQUIPMENT - Amperes (Current) PART 1: GENERAL REQUIREMENTS FOR BASIC SAFETY...

  • Page 4: Table Of Contents

    Service Manual TABLE OF CONTENTS INDICATIONS FOR USE ..............................7 INDICATIONS ................................7 CONTRAINDICATIONS ..............................8 SAFETY GUIDELINES ............................... 8 BATTERY SAFETY ..............................9 1.0 THEORY OF OPERATION ............................. 11 2.0 OPERATOR MAINTENANCE & SERVICE ......................16 2.1 CLEANING THE SAROS ..........................16 2.2 ROUTINE MAINTENANCE ..........................
  • Page 5 Service Manual ILLUSTRATIONS Figure 1-1. System Board Diagram ........................ 12 Figure 2-1. SAROS Components ........................17 Figure 7-1. Inside SAROS ..........................24 Figure 7-2. Removal of the three BIP screws ....................27 Figure 7-3. Removal of the three Rain Guard Screws ................... 27 Figure 7-4.
  • Page 6 Service Manual Figure 7-60. Secure ............................44 Figure 7-61. Screws ............................44 Figure 7-62. Secure Wires ..........................45 Figure 7-63. Secure Ferrites ..........................45 Figure 7-64. Connect ............................45 Figure 7-65. Fan Connector ..........................45 Figure 7-66. Flow Tube ........................... 46 Figure 7-67.

  • Page 7: Indications For Use

    Service Manual INDICATIONS FOR USE SAROS oxygen system is indicated for the administration of supplemental oxygen. The device is not intended for life support nor does it provide any patient monitoring capabilities. The SAROS can be used in the Military Medical Service that is operation- ally used for medical assemblages, such as the Expeditionary Medical Support (EMEDS) and En-Route Patient Staging System (ERPSS), in deployed scenarios, including wartime operations, deterrence and humanitarian and contingency operations.

  • Page 8: Contraindications

    Service Manual CONTRAINDICATIONS SAFETY GUIDELINES These are Warnings and Cautions that apply to hazards or unsafe practices that could result in serious injury or property damage. WARNING: FEDERAL U.S. LAW RESTRICTS THIS DEVICE TO SALE BY OR ON THE ORDER OF A PHYSICIAN. WARNING: DO NOT USE SAROS IF IT HAS A DAMAGED POWER CORD OR PLUG.

  • Page 9: Battery Safety

    OCCUR. NOTE: ONLY USE THE CAIRE INC. SUPPLIED AC POWER ADAPTER AND 24 VDC CABLE WITH THE SAROS. USE OF ANY OTHER AC POWER ADAPTER OR DC CABLE MAY BE HAZARDOUS, CAUSE SERIOUS DAMAGE TO THE SAROS AND WILL VOID THE WARRANTY.
  • Page 10 CAUTION: IT IS NOT RECOMMENDED THAT THE BATTERY IS CHARGED BELOW 41° F (5° C) OR ABOVE 104° F (40° C). CAUTION: ONLY USE THE BATTERY FOR ITS INTENDED PURPOSE. CAUTION: PUSH LOCKING/UNLOCKING BUTTON BEFORE BATTERY INSTALLATION. Reference SAROS 4000 User Manual for additional information, warnings, and specifications. 10 | MN260 B...

  • Page 11: Theory Of Operation

    Service Manual 1.0 THEORY OF OPERATION BASIC THEORY OF OPERATION SAROS Oxygen System uses a variable speed compressor to provide both positive and negative air pressure and is driven by a Brushless DC Motor (BLDC) and drive system. The ATF Concentrator Module accepts positively and negatively pressurized air and extracts oxygen from this air using the Pres- ®...

  • Page 12: Figure 1-1. System Board Diagram

    Service Manual POWER BOARD The Power Board takes external power that comes into the SAROS from the AC Power Adapter, 24 VDC Cable or Battery and monitors and controls power distribution to the rest of the SAROS system. The Power Board also drives the cooling fan. SYSTEM BOARD The System Board is the center of nearly all the SAROS functions.
  • Page 13 • Nasal Cannula with 7 feet (2.1 m) of tubing: PN 5408-SEQ • CAIRE offers the OxySafe™ as an optional accessory. This is intended to be used in conjunction with the SAROS concentrator. For customers in regions requiring compliance to EN ISO 8359:1996-Amendment 1:2012, this accessory will meet this need.

  • Page 14: Table 1-1. Battery Pack

    Exposure to excessive heat may shorten the Battery’s service life. Other than excessive heat, other factors influence Battery life, such as the number of Charges/Discharges that the battery has been undergone. CAIRE Inc. advises that a typical service life of a battery is 80% Nominal Capacity after 200 Charge/Discharge cycles.
  • Page 15 (nominally 30%). Do not store the SAROS with the battery installed in the unit. Remove the battery from the unit when storing to prevent damage to the battery and the unit. CAIRE Inc. recommends a first in, first out rotation of Battery inventory for maximum service life.

  • Page 16: Operator Maintenance & Service

    TO AVOID THE RISK OF FIRE AND BURNS. Cleaning the SAROS Battery The Battery in the SAROS requires special care to assure a longer life and the highest level of performance. The CAIRE Inc. Bat- tery is the only approved Battery recommended for use with the SAROS.

  • Page 17: Figure 2-1. Saros Components

    Service Manual Inlet Cover Screws x4 Air Inlet Filter (9291-SEQ) (9798-SEQ) 9V Battery (9257-SEQ) Inlet Cover (9758-SEQ) Oxygen Outlet Port (9764-SEQ) HEPA Filter (4770-SEQ) Simplified User Instructions Label (behind) Battery Figure 2-1. SAROS Components See User Manual for the following procedures: Cleaning or Replacing Air Inlet Filter, Replacing the HEPA Filter, Run Device and Fully Drain SAROS Battery, Replacing the 9V Battery.

  • Page 18: Saros Performance Verification Test

    Service Manual 2.3 SAROS PERFORMANCE VERIFICATION TEST NOTE: The entire verification procedure is recommended to be completed after repairs to verify overall functionality of the unit. Verify functionality of the SAROS using the following procedures. The performance verification test shall be performed upon initial receipt of the SAROS, any time a problem is suspected, and at regular 6 month intervals.
  • Page 19 Service Manual 10) Verify the functionality of the pulse dose mode button. Press the button and verify the device toggles between a continuous flow setting (C) and pulse dose setting (P). The C & P are displayed on the far left side of the screen.

  • Page 20: Alerts, Alarms, And Troubleshooting Table

    Service Manual c) Complete this step using one of the methods below: i) If using test equipment that automatically triggers a breath follow the manufacturer’s instructions for operation of the test equipment. Record the average bolus reading. ii) If manually triggering breaths, note and record the bolus size in mL of each breath. Repeat 5 times. Average the five bolus measurements and record the average reading.

  • Page 21: System Troubleshooting Guide

    Service Manual 3.1 SYSTEM TROUBLESHOOTING GUIDE SYMPTOM PROBABLE CAUSE REMEDY No Battery installed Install Battery or plug into external power SAROS does not power on Battery is discharged or no external when ON/OFF button is pressed Plug into external power power is present (constant tone) Other...

  • Page 22: Reprogramming/Calibration

    4.0 REPROGRAMMING/CALIBRATION All reprogramming of the circuit boards shall be performed by CAIRE, Inc or by a factory authorized service center. Flow calibra- tion is required whenever replacing an ATF, control board, compressor, or proportional valve. Flow calibration can be done at a CAIRE authorized service center or in the field using item T-10560.

  • Page 23: Overhaul & Repair

    Service Manual 7.0 OVERHAUL & REPAIR 7.1 TOOLS AND TEST EQUIPMENT • #1 Phillips Screwdriver • #1 Flathead Screwdriver • Needle nose pliers • Wire cutting pliers • 3/8” open end wrench • Oxygen analyzer that includes the capability to measure both flow rate (LPM and mL) and Oxygen concentration/purity %. •...

  • Page 24: Reprogramming After Overhaul And Repair Procedures

    Product Tank, PCB Circuit Board, Proportional Valve. If any of these components are replaced, flow calibration is required. Flow calibration can be done at a CAIRE authorized service center or in the field using item T-10560. See manual MN053 for details on performing flow calibration and firmware updates in the field using item T-10560.

  • Page 25: Comprehensive Troubleshooting Guide

    Service Manual 7.5 COMPREHENSIVE TROUBLESHOOTING GUIDE Indications Code Possible Cause Remedy During start up or stabilization period 5 minutes before alert conditions will Alert condition will be silent until the warm up pe- when a control panel sound or code riod or stabilization period is over, 5 minutes.

  • Page 26: Table 7-2. Troubleshooting Guide (Continued)

    Service Manual Indications Code Possible Cause Remedy Breath rate malfunc- A200 While in Pulse mode, the breath rate 1) Press Mode button to re-establish Pulse Mode, if tion (Pulse Mode was not sensed for more than 60 sec. SAROS switched to Continuous; only) 2) Ensure patient is breathing through their nose, not their mouth;...

  • Page 27: Removal Procedures

    Service Manual 7.6 REMOVAL PROCEDURES 7.6.1 BATTERY INTERFACE PLATE, RAIN GUARD, AND SLEEVE Battery Interface 7.6.1.1 Remove the three screws (Part# 9914-11-SEQ) and re- Plate Part move the Battery Interface Plate (Part# SP9939-1-SEQ ). # SP9939-1-SEQ Screws Part# 9914-11-SEQ Figure 7-2. Removal of the three BIP screws 7.6.1.2 Removing the two screws (Part# 9960-15-SEQ) from the Screws Rain Guard (Part# 21494877)

  • Page 28: Inlet Cap Removal

    Service Manual 7.6.1.5 Remove Fiberglass Sleeve (Part# 21341894) from the rails Sleeve: 21341894 Figure 7-6. Fiberglass Sleeve 7.7.2 INLET CAP REMOVAL NOTE: Use ESD Controls when removing the Inlet Cap. 7.7.2.1 Loosen the four CAPTIVE screws (Part# 9291-SEQ) and remove the Air Inlet Cover (Part# 9758). Captive Screws Figure 7-7.

  • Page 29: Figure 7-10. Oxygen Outlet Tube Disconnect

    Service Manual 7.7.2.4 Move sleeve ring aside and cut green cable tie and dis- connect the Oxygen Outlet Tube from the Flow Valve. oxygen outlet tube Figure 7-10. Oxygen Outlet Tube Disconnect. 7.7.2.5 Remove tape (Part# 2696-SEQ) from Front Panel Flex Cable and Top Mounting Struts (Part# 9778-SEQ).

  • Page 30: Remove Pcb Assembly

    Service Manual 7.7.2.8 Disconnect the Breath Detect Tube. disconnect Figure 7-14. Tube Disconnect 7.7.2.9 Remove the Extended Top Cap (Part# SP9756V2-SEQ) Guide and guide AC Power Cable under the frame of the PCB Assem- Wires bly. Remove and set aside speaker foam. Figure 7-15.

  • Page 31: Figure 7-17. Battery Power Wires For Battery Interface

    Service Manual 7.7.3.5 Loosen the Compressor Power screws and remove the wires. 5-Loosen 5-Loosen 4-Remove 3-Disconnect 1-Remove 2-Loosen Figure 7-17. Battery Power Wires for Battery Interface 7.7.3.6 Disconnect Battery Communication Connector. Fan Connector ATF Thermistor Battery communications 7.7.3.7 Disconnect the ATF Stepper Motor Connector from the (red and black (blue wires) connector (5 pin)

  • Page 32: Proportional Valve Removal (5293-Seq)

    Service Manual 7.7.3.12 Slide the PCB Assembly away from the struts. (Place in ESD bag.) NOTE: Always use ESD Control when handling the PCB Assembly. igure 7-20. PCB Assembly 7.7.3.13 Place PCB Set in ESD Protective Bag. 7.7.4 PROPORTIONAL VALVE REMOVAL (5293-SEQ) 7.7.4.1 Remove Proportional Valve wire from PCB Assembly (if not done so already).

  • Page 33: Compressor Fan Removal (9767-Seq)

    Service Manual 7.7.5 COMPRESSOR FAN REMOVAL (9767-SEQ) 7.7.5.1 Remove Compressor Fan wire from PCB Assembly (if not done so already). Figure 7-24. Remove Compressor Fan wire 7.7.5.2 Lift the Proportional Valve out of the way (See Propor- tional Valve Removal Step.) Figure 7-25.

  • Page 34: Battery Cable Removal (21494875)

    Service Manual 7.7.6 BATTERY CABLE REMOVAL (21494875) 7.7.6.1 Pull out the wires from the grommets on the bulkhead of the Compressor as shown in figure below. Hall Effect Sensor Hall Effect Sensor Figure 7-27. Hall Effect Sensor 7.7.6.2 Remove the two large wires (Battery Connector Cable) thru the middle Bulkhead as shown in figure below.

  • Page 35: Rail Removal

    Service Manual 7.7.6.5 Cut and remove all four Cable Ties between the STRUT (9779-SEQ) and the ATF Assembly. CAUTION: Do not cut wires or damage insulation. Figure 7-30. Cable Ties and Struts 7.7.7 RAIL REMOVAL 7.7.7.1 Remove five screws (part# 9912-1-SEQ) from left strut (9779-SEQ). Side Strut Figure 7-31.

  • Page 36: Atf & Compressor / Tank Assembly Removal

    Service Manual 7.7.8 ATF & COMPRESSOR / TANK ASSEMBLY REMOVAL 7.7.8.1 Remove Kapton Tape (2696) from the Muffler Assembly and left strut (9779-SEQ), as shown in figure. Muffler Assy 2x3” tape Cut cable tie here Figure 7-33. Kapton Tape 7.7.8.2 Remove exhaust tube and ATF to product tank tubing. Cap the connection port on the ATF that is exposed when the tub- ing is removed.

  • Page 37: Installation Procedures

    Service Manual 7.7.8.5 Cap both ATF ports (Feed and Vacuum ports). Cap 2X Figure 7-37. ATF ports 7.7.8.6 Remove the ATF Bulkhead FROM the bottom of the ATF Module Assembly as shown in figure below. ATF module assy (SP9729-SEQ) NOTE: Mark the position for installation. ATF bulkhead assy (9922-SEQ) Figure 7-38.

  • Page 38: Atf & Compressor/Product Tank Installation

    NOTE: A flow calibration procedure is required after replacing the ATF or Compressor, the PCB Circuit Board, the Proportional Valve. If any of these components are replaced, flow calibration is required. Flow calibration can be done at a CAIRE authorized service center or in the field using item T-10560.

  • Page 39: Figure 7-45. Cap

    Service Manual 7.8.2.4 Apply cap (1137-SEQ) to Product Tank outlet fitting to prevent ATF desaturation! cap off fitting Figure 7-45. Cap 7.8.2.5 Apply 2 Cable Ties as shown on figure. NOTE: Pre Loop Zip Ties. Figure 7-46. Cable Ties 7.8.2.6 Attach the Exhaust Filter, Tube, Muffler Assembly and Tube, Muffler as shown in figure below. NOTE: Ensure Arrow on Filter points in the correct direction.

  • Page 40: Rail Installation

    Service Manual 7.8.2.7 Install the ATF Product Pipe onto the Product Tank with Silicone tubing and secure with Cable ties. Install the other end onto the ATF with the Product Tube and Clamp as shown in figure below. 0.5” silicone tube cable tie ATF product clamp x2...

  • Page 41: Battery Cable Installation

    Service Manual 7.8.4 BATTERY CABLE INSTALLATION 7.8.4.1 Secure two Cable Ties through the holes in LEFT STRUT (9779-SEQ) and round all wires. Secure two Cable Ties around all wires (battery cables & ATF Bundle). Apply one Cable Tie around all battery cables, close to the battery board, as in Figure below. NOTE: Leave the Cable Ties loose in case slack is needed at the PCBA assembly.

  • Page 42: Figure 7-54. Secure Battery Wires

    Service Manual 7.8.4.3 Secure the Battery Power wires on the LEFT STRUT (9779-SEQ) with Cable Tie. NOTE: Leave the Cable Ties loose in case slack is needed at the PCBA assembly. NOTE: Ensure slack to wires where indicated. cable ties v slack 6968-SEQ Figure 7-54.

  • Page 43: Compressor Fan Replacement

    Service Manual 7.8.5 COMPRESSOR FAN REPLACEMENT 7.8.5.1 Attach the Fan subassembly (9767-SEQ) with the flow arrows towards the Bulkhead as shown on figure. Apply Loctite note wire 222MS (1405-SEQ) on the screws and torque to 2.0 in-lbs. location screws 9913-10-SEQ Figure 7-57.

  • Page 44: Proportional Valve Replacement (5293-Seq)

    NOTE: A flow calibration procedure is required after replacing the ATF or Compressor, the PCB Circuit Board, the Proportional Valve. If any of these components are replaced, flow calibration is required. Flow calibration can be done at a CAIRE authorized service center or in the field using item T-10560.

  • Page 45: Figure 7-62. Secure Wires

    Service Manual 7.8.7.2 Insert and secure the Battery Power and Compressor compressor Power Wires where shown. Use a flat blade screwdriver to power wires tighten and torque the screws to 4.4 in-lbs. NOTE: Battery wire polarity indicated on the PCBA. Red is (+) and Black is (-).

  • Page 46: Figure 7-66. Flow Tube

    Service Manual 7.8.7.7 Attach the Flow Tube into the Product Tank. Secure the Flow Tube with Cable tie. Figure 7-66. Flow Tube 7.8.7.8 Tighten and secure all wires with Cable Ties. NOTE: Orient ALL Cable Tie knots towards the Compressor. SLACK cable ties (6968-SEQ)

  • Page 47: Power Connector Replacement (9766-Seq)

    Service Manual 7.8.7.9 Add Cable Tie to hold wires away from the coil. Hand- tighten loose as in Figure below. cable tie (6968-SEQ) Figure 7-69. Cable Ties 7.8.7.10 Attach Top STRUT (9778-SEQ) with 5 screws as shown on figure below. Torque the screws to 6.0 in-lbs. STRUT (9978-SEQ) screws...

  • Page 48: Membrane Panel Replacement (9731-1-Seq)

    Service Manual 7.8.9 MEMBRANE PANEL REPLACEMENT (9731-1-SEQ) 7.8.9.1 After performing steps 7.7.1.1 thru 7.7.1.8 from “INLET CAP REMOVAL”. 7.8.9.2 Peel off the User Panel (9731-1-SEQ) as shown in the figure below. Figure 7-73. Peel 7.8.9.3. Clean the surface shown in the figure with isopropyl clean alcohol before re-applying the new User Panel.

  • Page 49: Inlet Cap Installation (Sp9756V2-Seq)

    Service Manual 7.8.10 INLET CAP INSTALLATION (SP9756V2-SEQ) 7.8.10.1 Place O-Ring in the Ring Sleeve. O-Ring (9374-SEQ) Ring Sleeve (9928-SEQ) Figure 7-77. O-ring attached 7.8.10.2 Align and slide the three O-Rings in the Ring Sleeve over the three struts. NOTE: Verify arrow points towards the inlet cap. Figure 7-78.

  • Page 50: Figure 7-81. Power Harness Wires

    Service Manual 7.8.10.5 Insert Power Harness wires from the Extended Top Cap and tighten the screws to 4.4 in-lbs. Route AC power wires through ferrite attached to board. NOTE: Battery wire polarity indicated on the PCBA. Red is (+) and Black is (-).

  • Page 51: Installation Of The Sleeve & Battery Interface Plate

    Service Manual 7.8.10.9 Secure the three Inlet Cap Mounting screws (9914-11- SEQ) to each STRUT. inlet cap mounting screws 9914-11-SEQ Figure 7-85. Inlet Cap mounting screws 7.8.10.10 Insert and connect the 9V Battery (9257-SEQ) and the Filter (9798-SEQ). filter Figure 7-86. 9V battery 7.8.10.11.

  • Page 52: Figure 7-89. Second Sleeve

    Service Manual 7.8.11.2 Align second Sleeve (9928-SEQ) AND O-RING (9928- SEQ) over the STRUTS, to the Sleeve leaving the Battery board alignment exposed. ring Figure 7-89. Second sleeve 7.8.11.3 Attach the Battery Interface Assembly (21494877) to the Rain Guard by attaching the two screws (9960-15-SEQ). Torque to 3.5 in-lb.

  • Page 53: Classification

    Service Manual 8.0 CLASSIFICATION Type of protection against electric shock: Protection against potential electromagnetic or other interfer- Class II Protection from electric shock is achieved by double ence between the equipment and other devices. insulation. • Tested to be in compliance with EN 60601-1-2/IEC 60601-1-2: 4th Edition.

  • Page 54: Service And Maintenance Record

    Service Manual 9.2 SERVICE AND MAINTENANCE RECORD Whenever maintenance or service is performed on an SAROS unit, an entry should be made in the service log for that concentra- tor or recorded in accordance with your company’s standard procedure. Whenever the sleeve of the SAROS is removed, the flow rate, purity, and alarm status should be verified per the Test Procedures in this manual.
  • Page 55 Service Manual APPENDIX A A.1 SAROS PERFORMANCE VERIFICATION CHECKLIST SAROS Serial Number: Hours of Operation: Date of Testing: A. General Operation Test Pass Fail 1) Battery installs properly 2) External power cord (AC or DC) connects securely 3) Unit powers on after holding ON/OFF button for 3 seconds 4) Audible alarm sounds upon start-up 5) 5-minute warm up period complete with...
  • Page 56 Service Manual NOTES 56 | MN260 B...
  • Page 57 Service Manual NOTES MN260 B | 57...
  • Page 58 Borngasse 20 35619 Braunfels, Germany Tel: +49 (0) 6442-962073 Email: info@mps-gmbh.eu CAIRE and CAIRE Inc. are registered trademarks of CAIRE Inc. Please visit our website below for a full listing of trademarks. Trademarks: www.caireinc.com/corporate/trademarks/. Salter Labs is a registered mark of Salter Labs, Arvin, CA 92303.

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Saros 3000

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