CAIRE COMPANION 1000 Technical Manual
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CAIRE COMPANION 1000 Technical Manual

Liquid oxygen portables
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COMPANION 1000
CAIRE Inc.
COMPANION T
L I Q U I D
O X Y G E N
P O R T A B L E S
TECHNICAL MANUAL
CAIRE Inc.
Part Number B-701964-00 Rev. C

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Summary of Contents for CAIRE COMPANION 1000

  • Page 1 COMPANION 1000 CAIRE Inc. COMPANION T L I Q U I D O X Y G E N P O R T A B L E S TECHNICAL MANUAL CAIRE Inc. Part Number B-701964-00 Rev. C...
  • Page 3 Ball Ground, GA 30107 USA Customer Service & Technical Support: 1-800-482-2473 TECHNICAL MANUAL CAIRE Inc. Companion 1000/Companion T Liquid Oxygen Portables Part Number B-701964-00 Rev. C CAUTION: Federal (U.S.A.) law restricts this device to sale by or on the order of a physician.
  • Page 4 This page intentionally left blank.
  • Page 5 CAUTION Cautions alert the user to exercise care necessary for the safe and effective use of the Companion 1000/T Liquid Oxygen System, or situations that may cause reduced or no oxygen flow. Indicates points of particular interest or emphasis for more efficient and convenient operation..
  • Page 6 Companion is a trademark of CAIRE Inc. The information contained in this manual is the sole property of CAIRE Inc. and may not be reproduced without the permission of the company.

  • Page 7: Table Of Contents

    SECTION 2: THEORY OF OPERATION ..........2-1 Companion 1000/T Component Descriptions ....... . . 2-1 2.1.1...
  • Page 8 Table of Contents SECTION 3: PERFORMANCE VERIFICATION ........3-1 Equipment Required .
  • Page 9 5.11 Warming Coil (Companion 1000) ........
  • Page 10 Companion 1000/T Liquid Oxygen System Technical Manual This page intentionally left blank. B-701964-00 Rev. C...

  • Page 11: Section 1: Introduction

    The Companion 1000 (Figure 1-1) and Companion T (Figure 1-2) are nearly identical in features and operational characteristics. The difference in the two units is primarily in the oxygen flow delivery capabilities.

  • Page 12: Product Description

    2 L/min. The liquid oxygen contents of the Companion 1000/T is measured by a weight scale that is activated by suspending the unit by one end of the carrying strap. An external moisture collection cup is attached to the bottom of the Companion T.

  • Page 13: Safety Precautions

    Companion 1000/T Liquid Oxygen System Technical Manual SAFETY PRECAUTIONS This section covers precautions and safe practices as they apply to facilities and personnel involved in servicing medical oxygen equipment. These precautions are divided into three main areas: cold safety, expansion safety, and fire safety. To ensure reliability and safety, the service techniques, work area, and equipment used in the storage, service, and handling of this system must be of the highest standard.

  • Page 14: Expansion Safety

    Companion 1000/T Liquid Oxygen System Technical Manual 1.3.2 Expansion Safety WARNING Explosive hazard. Extreme high pressure can rupture container or plumbing components. Be sure specified pressure relief devices are present, in the proper location, and functioning properly. Important Facts: •...
  • Page 15 Companion 1000/T Liquid Oxygen System Technical Manual WARNING Keep oxygen equipment in a well-ventilated area at all times. These units periodically release small amounts of oxygen gas that must be ventilated to prevent buildup. Do not store liquid oxygen equipment in a car trunk, closet, or other confined area.

  • Page 16: Companion 1000/T Specifications

    ** Flow set points for flow control valves are as follows: Companion 1000, 0-6 L/min valve: 0, .25, .5, .75, 1, 1.5, 2, 2.5, 3, 4, 5, 6 Companion 1000, 0-4 L/min valve: 0, .12, .25, .5, .75, 1, 1.5, 2, 2.5, 3, 3.5, 4 Companion T, 0-15 L/min valve: 0, .5, 1, 1.5, 2, 3, 4, 5, 6, 8, 10, 15...

  • Page 17: Unpacking, Installation, And Repacking

    2. Place the shipping carton on a flat surface with the shipping arrows pointing upwards. 3. Carefully lift the Companion 1000/T out of the carton and remove it from the plastic bag. 4. Compare the packing list attached to the carton’s exterior with the shipment received.

  • Page 18: Repackaging For Return

    Companion 1000/T. The patient pulls the lever down and holds it in the extended position to begin filling the Companion 1000/T. When the unit is full, the patient moves the lever up to close the valve and terminate the filling process.

  • Page 19: Flow Control

    Figure 1-6: Controls, Indicators, and Connectors FILLING INSTRUCTIONS FOR TECHNICIANS The Companion 1000/T can be filled from a Companion Stationary or a Companion Low Loss Stationary reservoir that contains liquid oxygen at proper saturation pressure (nominal 22 psig/152 kPa saturation). Perform the pre-fill and post-fill procedures on the patient’s C1000/T whenever you fill the patient’s Stationary unit.

  • Page 20: Pre-Fill Inspection

    5. Move the flow control knob to each flow setting. Verify that the knob moves smoothly and encounters a detent at each setting. 6. Hold the Companion 1000/T on a table and carefully pull up on the end of the carrying strap nearest the contents indicator. Verify that the indicator mechanism moves smoothly.
  • Page 21 5. Lower the Companion 1000/T carefully into place, ensuring the fill connectors are properly aligned. 6. Place one hand on top of the Companion 1000/T (directly over the fill connectors) and press straight down. This will lower the unit about 3/8-in., properly engaging the fill connectors.
  • Page 22 10. Check the liquid oxygen contents indicator. The amount of liquid oxygen in the Companion 1000/T is measured by an internal scale on top of the unit. Actuate the scale by lifting the unit by the strap nearest the indicator. The color-coded gauge indicates the liquid level (Figure 1-11).

  • Page 23: Post-Fill Inspection

    Correct observed problems before placing the unit in service. 1. Verify that the Companion 1000/T fill connector poppet is closed and not leaking. 2. Verify that the vent valve is completely closed and not leaking.

  • Page 24: Maintenance

    The Companion 1000/T Pre-Fill Inspection, Filling, and Post-Fill Inspection procedures should be performed every time the patient’s Stationary reservoir is filled. This provides routine assessment of the functional status of the Companion 1000/T. Functional problems observed during these procedures must be corrected before placing the unit in service.

  • Page 25: Recommended Tools, Test Equipment, And Service Materials

    Companion 1000/T Liquid Oxygen System Technical Manual COMPANION 1000/T MAINTENANCE GUIDE Inspection con’t Verify that the vent extension tube is centered in the clearance hole on the bottom of the side cover. Verify that the fill connector poppet is not worn or broken and that the lip seal is not cracked.

  • Page 26: Calibrating Test Equipment

    CALIBRATING TEST EQUIPMENT Periodically calibrate test equipment (pressure gauges, weight scales, flowmeters, etc.) to ensure the reliable operation of the Companion 1000/T. Use your prior experience to determine calibration frequency for test equipment. Using a default six-month schedule is typically acceptable; however, check test equipment with a high usage rate once a month.

  • Page 27: Accessories

    Test instruments that are used to test the performance of the Companion 1000/T can be sent to an accredited calibration lab for calibration testing. Another option is to keep a calibrated master test instrument (pressure gauge, flowmeter, etc.) on site as a reference to check your field test instruments.
  • Page 28 Companion 1000/T Liquid Oxygen System Technical Manual This page intentionally left blank. 1-18 Introduction B-701964-00 Rev. C...

  • Page 29: Section 2: Theory Of Operation

    2.1.1 Cryogenic Container Liquid oxygen is stored in the Companion 1000/T Portable at a temperature of approximately -276°F (-171°C) and a pressure of 22 psig (152 kPa). The cryogenic container (Figure 2-1) minimizes the transfer of ambient heat to the liquid oxygen contents.

  • Page 30: Fill Connector

    2.1.2 Fill Connector The female fill connector (Figure 2-2) is a fluid coupling on the Companion 1000/T that mates with the male fill connector on a Companion Stationary. The fill connectors allow liquid oxygen to transfer from the Stationary unit into the Companion 1000/T Portable.

  • Page 31: Warming Coil

    The calibrated orifice delivers the selected flow when gaseous oxygen at 22 psig (152 kPa) is present at the valve inlet port. The standard Companion 1000 flow control valve has a flow range of 0 to 6 L/min, and an optional valve is available with a flow range of 0 to 4 L/min.

  • Page 32: Vent Valve

    Venting of the inner container is required to fill the Companion 1000/T Portable with liquid oxygen. To open the vent valve, position the valve lever parallel to the portable side cover, moving the spring-loaded poppet off its seat and allowing flow through the valve.

  • Page 33: Contents Indicator Scale

    Suspending the unit from the end of the carrying strap closest to the indicator activates the weight scale mechanism. The contents indicators for the Companion 1000 and Companion T, although similar in design, are different due to the different empty weight of each unit.

  • Page 34: Companion 1000/T Operation

    Maintaining liquid oxygen saturation at approximately 22 psig (152 kPa) is important. The liquid oxygen transferred into the Companion 1000/T Portable must be saturated at 22 psig (152 kPa) to ensure proper oxygen flow to the patient. Also, as liquid oxygen...

  • Page 35: Fill Termination

    Companion 1000/T Liquid Oxygen System Technical Manual Flow Control alve Secondary Relief alve Manifold Warming Coils 30 PSI (207 kPa) ent Tube 22 PSI (152 kPa) Primary Relief alve Fill Tube Liquid Withdrawal ressure 14-16 SI Tube (96-110 k a)

  • Page 36: Standby

    Gaseous oxygen enters the flow control valve at approximately 22 psig (152 kPa). If the Companion 1000/T is accidentally tipped over, the primary relief valve circuit delays liquid oxygen leakage from the primary relief valve for approximately 60 seconds.
  • Page 37 Companion 1000/T Liquid Oxygen System Technical Manual Flow Control Valve Secondary Relief Valve arming Coils Manifold 30 PSI (207 kPa) 22 PSI Vent Tube (152 kPa) Primary Relief Valve Tube Pressure Fill Tube 22 PSI (152 kPa) Liquid ithdrawal Tube...
  • Page 38 Companion 1000/T Liquid Oxygen System Technical Manual This page intentionally left blank. 2-10 Theory of Operation B-701964-00 Rev. C...

  • Page 39: Section 3: Performance Verification

    LEAKAGE TEST Any amount of liquid oxygen leakage from the Companion 1000/T is unacceptable and calls for immediate removal from service. Minor gas leaks in connections and fittings will not affect system operation, provided they do not exceed the unit's NER.

  • Page 40: Liquid Leak Detector Test

    Figure 3-1: Pressurizing the Companion 1000/T through the Vent Circuit Connect the test pressure gauge to the oxygen outlet barbed fitting and set the flow control valve to the highest setting. Place the Companion 1000/T in the portable test fixture (Figure 3-2).

  • Page 41: Pressure Hold Test

    5. With pressure remaining in the unit, place a small amount of SNOOP on the tip of the Companion 1000/T fill connector. A small amount of leakage around the poppet of the fill connector is acceptable, provided that the total leakage rate of the unit is not greater than the NER.

  • Page 42: Gaseous Oxygen Tests

    Companion 1000/T Liquid Oxygen System Technical Manual 4. Do not disturb the Companion 1000/T for 8 to 9 hours. At the end of this evaluation period, verify the unit maintains at least 15 psig (104 kPa). Should the pressure be less than 15 psig (104 kPa), repressurize the unit to approximately 22 psig (152 kPa) and locate the leak by testing all components, fittings, and tubing with liquid leak detector.

  • Page 43: Vent Valve Test

    The Companion 1000/T side covers must be in place when performing this test. 1. Place the Companion 1000/T Portable on a table and hold it down while gently pulling up on the end of the carrying strap nearest the contents indicator. Verify that the indicator operates smoothly and without binding.
  • Page 44 Refer to Figure 6-1 and 6-2 to identify parts with bold number references. PROCEDURE 1. Fill the Companion 1000/T Portable with liquid oxygen. Allow approximately one hour for the system pressure to stabilize. Verify that the primary relief valve is venting and that the system pressure is 20.5 to 24.0 psig (141 to 165 kPa).

  • Page 45: Normal Evaporation Rate Test

    Some venting of gaseous oxygen through the relief valve is normal. PROCEDURE 1. Perform a leakage test (Section 3.2) on the Companion 1000/T Portable and verify that the results are acceptable. 2. Perform the primary relief valve test (Section 3.3.2) to verify that the primary relief valve is operating properly.
  • Page 46 Companion 1000/T Liquid Oxygen System Technical Manual This page intentionally left blank. 3-8 Performance Verification B-701964-00 Rev. C...

  • Page 47: Section 4: Troubleshooting

    Section TROUBLESHOOTING Troubleshooting procedures are listed in Table 4-1. 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. When more than one probable cause is identified, the causes are listed in order of most likely to least likely reasons for failure.
  • Page 48 Companion 1000/T Liquid Oxygen System Technical Manual SYMPTOM PROBABLE CAUSE ACTION Unit will not Unit contains unsaturated Allow liquid to saturate at 22 psig maintain liquid (152 kPa). May require as long as 30 acceptable minutes at no flow. operating Gas leak Locate leak;...

  • Page 49: Section 5: Service And Repair

    Injury to eyes from flying objects possible. Wear eye protection when servicing the Portable. The Companion 1000/T can be emptied by setting the flow control at its highest setting and allowing the unit to run until all liquid oxygen is depleted. When the liquid oxygen is depleted, you can leave a flow set on the control while working on the unit to provide continuous system venting.

  • Page 50: Compression Fitting Makeup

    5.1.1 Compression Fitting Makeup The compression fittings used in the Companion 1000/T consist of a fitting body, tube, ferrule, and nut (Figure 5-1). These fittings typically connect the aluminum tubing to other components in the system. In a properly made-up compression fitting, sealing occurs at two points: between the ferrule and the fitting body;...

  • Page 51: Compression Fitting Remake

    5.1.4 Tapered Pipe Thread Makeup Some components used in the Companion 1000/T have NPT threads (Figure 5-3). NPT threads create leak-tight connections provided a thread sealant (such as Teflon tape) is used on the threads.

  • Page 52: Tapered Pipe Thread Troubleshooting

    SIDE COVERS The Companion 1000/T side covers are molded polycarbonate components. When assembled, they form a clamshell-like enclosure for the Companion 1000/T. Side cover A has threaded inserts that receive retaining screws from side cover B, as well as retaining screws for the bottle assembly. The bottom of side cover A also has a clearance hole for the vent tube and a pad for mounting one of the rubber feet.

  • Page 53: Service

    Install the side covers by reversing the Removal procedure (Section 5.2.1). TOP BEZEL The top bezel on the Companion 1000/T forms the top surface of the unit between the front and rear side covers. It has a recessed opening for the oxygen outlet barbed fitting, as well as an opening for the window of the contents indicator weight scale mechanism.

  • Page 54: Service

    CONTENTS INDICATOR The contents indicator mechanism on the Companion 1000/T is a mechanical, spring- balanced weight scale that measures the liquid contents in the unit. The needle on the weight scale mechanism deflects an amount proportional to the amount of liquid in the unit.

  • Page 55: Removal

    Companion 1000/T Liquid Oxygen System Technical Manual 5.5.1 Removal Refer to Figures 6-1 or 6-2 and 6-3 to identify parts with bold number references. 1. Remove the carrying strap (Section 5.4.1). 2. Loosen and remove the four socket head cap screws 6 (Figure 6-1 or 6-2) from the base of the contents indicator weight scale mechanism.

  • Page 56: Inspection

    Companion 1000/T Liquid Oxygen System Technical Manual 5. Remove the indicator needle 4 from the base (Figure 5-8). Figure 5-8 6. Use a small screwdriver to remove one E-clip 8 from the pivot shaft 7. Remove the pivot shaft. Remove the lever 5 (Figure 5-9).

  • Page 57: Flow Control Valve

    Companion 1000/T Liquid Oxygen System Technical Manual FLOW CONTROL VALVE The Companion 1000/T flow control valve is a rotary, fixed-orifice device that consists of a moveable rotor with 11 individually-sized orifices. The desired flow rate is achieved when the selected orifice in the rotor is aligned between the inlet and outlet ports of the valve.

  • Page 58: Repair

    PRIMARY RELIEF VALVE The primary relief valve is a poppet-type, pressure-regulating valve that controls the Companion 1000/T system pressure. The primary relief valve is not field serviceable. If it is not operating properly, replace it. 5-10 Service and Repair...

  • Page 59: Removal

    Companion 1000/T Liquid Oxygen System Technical Manual 5.7.1 Removal Refer to Figure 6-5 to identify parts with bold number references. 1. Remove side cover B (Section 5.2.1, steps 1 and 2). 2. Loosen and remove the silencer 6 from the end of the primary relief valve 5 (Figure 5-13).

  • Page 60: Installation

    VENT VALVE The vent valve is a lever-operated, poppet-type valve that you open to begin a Companion 1000/T fill and close to terminate the fill. Service to the valve is limited to replacing the valve lever and lever pin. 5.9.1 Removal Refer to Figures 6-1 or 6-2 and 6-7 to identify parts with bold number references.

  • Page 61: Adjustment

    Companion 1000/T Liquid Oxygen System Technical Manual Figure 5-15 3. Use a -in. open-end wrench to disconnect the -in. tube nut that connects the long vent tube 26 to the vent valve 10 (Figure 5-16). Figure 5-16 4. Use a -in.

  • Page 62: Installation

    Companion 1000/T Liquid Oxygen System Technical Manual 1. With the vent valve in the closed position, check the clearance between the vent valve lever 7 and the plastic spacer 8. The clearance should be 0.005 to 0.010 in. (.127 to 0.254 mm) or about the thickness of this page (Figure 5-18).

  • Page 63: Female Fill Connector

    FEMALE FILL CONNECTOR The female fill connector assembly is a special valved coupling that enables liquid oxygen to transfer from a Companion Stationary unit to the Companion 1000/T Portable. An internal cartridge assembly with a spring-loaded Kel-F poppet creates a pressure-tight seal when the female fill connector is not coupled to a Stationary unit.

  • Page 64: Disassembly

    Companion 1000/T Liquid Oxygen System Technical Manual 5.10.2 Disassembly 1. Hold the female fill connector body 11 with a -in. open-end wrench placed on the machined flats. Use an adjustable wrench to remove the female adaptor 4 (Figure 5-21). Figure 5-21 2.

  • Page 65: Inspection

    Companion 1000/T Liquid Oxygen System Technical Manual Figure 5-24 5.10.3 Inspection 1. Inspect the Kel-F poppet in the cartridge assembly for wear, damage or embedded contaminants. Replace the cartridge assembly as required. 2. Inspect the lip seal for cracks, wear, or other damage. Replace the lip seal as required.

  • Page 66: Installation

    Companion 1000/T Liquid Oxygen System Technical Manual 4. Firmly hold the fill connector and installation sleeve together, while using the installation plunger (marked "I") to push the spiral retaining ring down until it snaps into the female fill connector body (Figure 5-26).

  • Page 67: Warming Coil (Companion 1000)

    The purpose of the warming coil on the Companion 1000 is to vaporize the liquid oxygen and warm the resulting gaseous oxygen entering the breathing circuitry. The warming coil on the Companion 1000 is not field serviceable.

  • Page 68: Warming Coil Part 1 Removal

    1, warming coil part 2, and the spined tube heat exchanger. The warming coil used on the Companion T has more capacity than the warming coil used on the Companion 1000 and accounts for the increased maximum flow capability of the Companion T.

  • Page 69: Warming Coil Part 1 Installation

    Companion 1000/T Liquid Oxygen System Technical Manual 5.12.2 Warming Coil Part 1 Installation Install the warming coil by reversing the removal procedure (Section 5.12.1). Be sure to replace the wire tie after reinstalling the warming coil. 5.12.3 Warming Coil Part 2 Removal Refer to Figure 6-2, 6-4, and 6-8 to identify parts with bold number references.

  • Page 70: Manifold

    Companion 1000/T Liquid Oxygen System Technical Manual 5.13 MANIFOLD The Companion 1000/T manifold seals the cryogenic container from the atmosphere. Most of the major functional components of the portable are directly or indirectly mounted to the manifold. All liquid or gaseous oxygen withdrawal from the unit originates from the manifold.

  • Page 71: Cryogenic Container

    Leak Test section (Section 3.2). 5.14 CRYOGENIC CONTAINER The Companion 1000/T Portable cryogenic container is a stainless steel, double-walled, vacuum-insulated container that holds liquid oxygen. The container's main function is to limit the amount of heat that leaks into the container from the surrounding atmosphere.

  • Page 72: Installation

    Companion 1000/T Liquid Oxygen System Technical Manual -in. open-end wrench to loosen the jam nut 3 that holds the stationary. Use a vent valve to the mounting bracket. Remove the vent valve and tube assembly from the mounting bracket. 3. Use side-cut pliers to cut the wire tie 22 from the warming coil.

  • Page 73: Section 6: Parts Lists And Illustrations

    Section PARTS LISTS AND ILLUSTRATIONS...
  • Page 74 Companion 1000/T Liquid Oxygen System Technical Manual FIGURE 6-1 PARTS LIST - COMPANION 1000 Item Part Number Description B-775888-00 Set Screw, Flow Control Knob (Old Style) B-776168-00 Knob w/Spring Clip, Flow Control Valve, 12 Position B-775834-00 Decal, Flow Control Valve (0-6 L/min)
  • Page 75 Companion 1000/T Liquid Oxygen System Technical Manual See Fig. 6-6 See Fig. 6-3 See Fig. 6-5 See Fig. 6-4 See Fig. 6-8 See Fig. 6-7 Figure 6-1: Companion 1000 Exploded View Parts Lists and Illustrations 6-3...
  • Page 76 Companion 1000/T Liquid Oxygen System Technical Manual FIGURE 6-2 PARTS LIST - COMPANION T Item Part Number Description B-775888-00 Set Screw, Flow Control Knob (Old Style) B-776168-00 Knob w/Spring Clip, Flow Control Valve, 12 Position B-775836-00 Decal, Flow Control Valve (0-15 L/min)
  • Page 77 Companion 1000/T Liquid Oxygen System Technical Manual See Fig. 6-6 See Fig. 6-3 See Fig. 6-5 See Fig. 6-4 See Fig. 6-8 See Fig. 6-7 Figure 6-2: Companion T Exploded View Parts Lists and Illustrations 6-5...
  • Page 78 Companion 1000/T Liquid Oxygen System Technical Manual FIGURE 6-3 PARTS LIST Item Part Number Description B-775029-00 Screw (PH 6-32 x 1.75”) B-775242-00 Indicator (includes lens cap, needle, decal, helix, and base)- (Companion 1000) B-775892-00 Indicator (includes lens cap, needle, decal, helix, and base)-...
  • Page 79 Companion 1000/T Liquid Oxygen System Technical Manual " " & & Figure 6-3: Contents Indicator Assembly " Figure 6-4: Manifold Assembly Parts Lists and Illustrations 6-7...
  • Page 80 Companion 1000/T Liquid Oxygen System Technical Manual FIGURE 6-5 PARTS LIST Item Part Number Description B-776817-00 Primary Relief Valve Tube ( -in.) B-775067-00 Tube Nut ( -in., Aluminum) B-775068-00 Ferrule ( -in., Brass) B-775078-00 Relief Valve Adapter B-776892-00 Primary Relief Valve (22 psig)
  • Page 81 Companion 1000/T Liquid Oxygen System Technical Manual Figure 6-5: Primary Relief Valve Circuit " Figure 6-6: Secondary Relief Valve Circuit Parts Lists and Illustrations 6-9...
  • Page 82 Companion 1000/T Liquid Oxygen System Technical Manual FIGURE 6-7 PARTS LIST Item Part Number Description B-775063-00 Ferrule ( in., Brass) B-775062-00 Tube Nut ( in., Aluminum) B-775296-00 Jam Nut B-775287-00 Adjustment Lock Nut B-775088-00 Spacer B-775089-00 Spring Pin ( in. x in., SS)
  • Page 83 Companion 1000/T Liquid Oxygen System Technical Manual " & Figure 6-7: Vent Valve Assemblies Figure 6-8: Female Fill Connector Parts Lists and Illustrations 6-11...
  • Page 84 Companion 1000/T Liquid Oxygen System Technical Manual This page intentionally left blank. 6-12 Parts Lists and Illustrations...
  • Page 86 Toll Free: 1.800. Rx ONLY © 20 Inc. All rights reserved. B-701964-00 Rev.

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