Companion 5™
Oxygen Concentrator

PROVIDER TECHNICAL MANUALTable of Contents
General Information ............................................................ 3
Warning and Caution Statements ..................................... 3
User Controls And System Status Indicators ...................3
Introduction to the Companion 5 Oxygen Concentrator . 4
Companion 5 Oxygen Concentrator Speciﬁcations ......... 5
Provider Support Policy ...................................................... 6
Electromagnetic Compatibility ........................................... 7
Guidance and Manufacturer’s Declaration - electromagnetic
emissions .................................................................... 7
Guidance and manufacturer’s declaration–electromagnetic
immunity .................................................................... 8
Guidance and manufacturer’s declaration–electromagnetic
immunity .................................................................... 9
Recommended separation distances
between portable and mobile RF communications equipment and the Companion 5 ...................................... 10
Theory of Operation .......................................................... 11
Introduction.................................................................... 11
Flow Delivery ................................................................ 12
Electrical Operation ......................................................12
Microprocessor .............................................................. 13
Solenoid Valve .............................................................. 13
LCD Display .................................................................. 13
Audible Alarm ................................................................ 13
LED Lights ..................................................................... 13
OCSI Sensor – (OCSI units only) ................................. 14
Serial Number Identiﬁcation ........................................... 14
End of Life ...................................................................... 14
Indications for Use ............................................................. 15
Contraindications ................................................................ 15
Introduction ........................................................................ 15
Pre-Delivery Check List .................................................. 15
Using Around the House ................................................ 16
Locating the Companion 5 for Proper Use and Ventilation ......16
Power On and Warm Up .................................................16
Adjust Flow Control Rate ............................................... 17
Maintenance–Patient .......................................................... 17
Optional Handle Gross Particle Filter(if installed) ................................................................ 17
Bottom Gross Particle Filter............................................. 17
Clean and Care for Tubing and
Cannula ..................................................................... 18
Clean the Cabinet .......................................................... 18
Patient Training Checklist ............................................... 18
Preventive Maintenance—Provider .................................. 19
Introduction.................................................................... 19
Maintenance Check List ................................................ 19

Maintenance Schedule ....................................................... 19
Handle Gross Particle Filter (Optional) ......................... 19
Bottom Gross Particle Filter .......................................... 19
Air Intake Filter (Cartridge) ............................................ 19
Internal HEPA Disc Filter ............................................... 19
Oxygen Concentration Check ........................................ 19
Maintenance Procedures ................................................... 20
Bottom Gross Particle Filter ........................................... 20
Oxygen Concentration Test ............................................ 20
Record Hours of Operation ............................................ 21
Hour Meter ..................................................................... 21
Cleaning the Companion 5 ............................................ 21
Shipping and Transporting theCompanion 5 ............................................................ 21
Storing the Companion 5 ............................................... 21
Discarding ...................................................................... 21
Provider Service and Maintenance Record .................... 22
Troubleshooting, Service, and Repair Procedures............23
General Troubleshooting ................................................. 23
Troubleshooting Table ......................................................24
Alarm Conditions and Alarm Codes .................................. 26
Warning Alarms .............................................................. 26
Repair and Testing Procedures.......................................... 28
Start-up Veriﬁcation Test ................................................ 28
Power Failure Alarm Test ................................................ 28
Flow Rate Test................................................................. 28
Product Regulator Check and Setting ............................ 29
Outer Case ..................................................................... 29
HEPA Filter.............. ....................................................... 30
Outlet Pressure Test ....................................................... 30
Adjusting the Product
Regulator for Normal Operation ................................ 31
Pressure Regulator Replacement .................................. 31
Flapper (Check) Valve..................................................... 31
2-Way Solenoid Valve .................................................... 32
Compressor ................................................................... 32
Cooling Fan .................................................................... 33
Printed Circuit Board (PCB) ............................................ 34
Sieve Bed Assembly ....................................................... 34
Power Switch ................................................................. 36
Flow Meter .................................................................... 36
Power Cord .................................................................... 36
Leak Testing .................................................................... 36
Spare Parts, Tools, and Accessories ................................ 37
Optional Accessories ...................................................... 37
CAIRE Inc. Customer Service Contact Information ......... 382

Oxygen Concentrator

SymbolDefinition
Read user manual before operation. See user manual
for instructions.

02

SymbolDefinition

I/O On/Off Switch

No Smoking Icon: Do not smoke near unit.

Use no oil or grease.

Warnings / ALERT (Yellow) Indicator

1RRSHQRUQDNHGÀDPHV

Class II equipment

No serviceable parts inside. Do not open cover.

Oxygen Output&HUWL¿HGIRUERWKWKH86DQG&DQDGLDQPDUNHWVWR
the applicable U.S. and Canadian standards.

Type BF Applied Part (degree of protection againstelectric shock)This symbol is to remind the equipment owners
to return it to a recycling facility at the end of its
OLIHSHU:DVWH(OHFWULFDODQG(OHFWURQLF(TXLSPHQW(WEEE) Directive.
Authorized representative in the European
Community

IPX1

Drip Proof Equipment-IPX1: The Companion 5
provides protection against the harmful effects of the
LQJUHVVRIOLTXLGV ,3;SHU,(&
Name and address of manufacturer

Buzzer: An audible alarm (or buzzer) is used to alert you to the operating condition of the device, either a warning or failure.

General Information
This technical manual will familiarize you with Provider-speciﬁc
information regarding the Companion 5 oxygen concentrator.
Instructions in this manual are intended to help ensure that:• Providers are familiar with Companion 5 system components andsystem principles of operation• Providers are given proper guidance in the use of the Companion
5 and its accessories that can be conveyed to patients• Providers are made aware of the care, diagnostics, maintenance,and repair of the Companion 5

Warning and Caution
Statements
Safety instructions are deﬁned as follows:
WARNING:CAUTION

Note:

Important safety information for hazards
that might cause serious injury.

Important information for preventing damage
to the Companion 5.
Places emphasis on an operating characteristic
or important consideration.
3

Oxygen Concentrator

Introduction to the Companion 5 Oxygen Concentrator
Companion 5
FRONTPower Switch

Outer Case

OxygenOutlet Barb
LED Display
LCD Display
Humidiﬁer
Bottle Support
Stand (Bottle
optional)

Carrying
HandleFlow Meter

BACK

Cooling Air
IntakeAir Intake

Exhaust Vent

4

Oxygen Concentrator

Companion 5 Oxygen Concentrator Speciﬁcations
Dimensions (H x W X D)
WeightCompanion 5

21.5 x 12.5 x 13.5 inches(54.6cm x 31.8cm x 34.3cm)
36.0 lb (16.3 kg)

Flow Settings
Continuous Flow (measured in Liters Per MinuteLPM)

0.5 to 5.0 LPM

Continuous Flow Accuracy+/- 10% or 200ml/min, whichever is greater

Oxygen Concentration

90% (+5.5/-3%) for all ﬂow settings

Oxygen Output Pressure

4.6 psig (31.7 kPa) nominal
Green Light = Normal Operation

LED Status Indicators

Nominal Sound Level
2.0 LPM Continuous Flow
Operating Environment
Temperature
Humidity
Storage Environment
Temperature
Humidity

Red = Indicates ﬂow rate error, loss of power, ambientpressure reading out of range, or general system malfunction.
Yellow Light = Poor Oxygen Concentration below 85%

50 dB(A)41º F to 104º F (5° to 40°C)
15% to 90%, Non-condensing, 82.4°F (28°C) Maximum Dew point-13º F to 158º F (-25°C to 70°C)
Up to 90% Non-condensing

Altitude Operating Range-1253 to 9879 ft (-382 to 3011 m)

Nominal Power285 watts at 2.0 LPM, 350 Watts Maximum

Fuse Rating

230VAC unit: T4AL, 250V
120VAC unit: T8AL, 250V

Continuous Flow Indication

Expressed in liters per minute (LPM)

Audible Alarm Indicators

See ALARM CONDITION AND ALARM CODES

Back-Up Alarm Power

Capacitor

Filters

HEPA, Compressor Intake Filter

Device Classiﬁcation

IEC Class II, Type BF Applied Part, IPX1

Note:

To ensure there is no power to the Companion 5
oxygen concentrator, please unplug cord.

5Oxygen Concentrator

Independent Safety Testing
SafetyIEC 60601-1 :1988 + A1 :1991 + A2 :1995 + Corrigendum (6/95)
EN 60601-1(1990) + A1(1993) + A2(1995) + A12(1993) + A13(1996) + Corrigenda (7/94)

Electromagnetic
Compatibility

FCC 15B (Sec. 107 & 109), EN55011, EN60601-1-2 :2001, EN61000-3-2,
EN61000-3-3, IEC61000-4-2, IEC61000-4-3, IEC61000-4-4, IEC61000-4-5,
IEC61000-4-6, IEC61000-4-8, IEC61000-4-11, IEC 60601-1-2 :2001

The CAIRE Companion 5 is designed to comply with the following standards:• EN 60601-1-2—Electromagnetic Compatibility• IEC 60601-1—General Requirement for Basic Safety of Electrical Medical Equipment• ISO 8359—Oxygen Concentrators For Medical Use• ISO 13485—Medical Device Quality System• UL 60601-1 – General Requirement for Basic Safety of Electrical Medical Equipment
It is classiﬁed as Class 2 Medical Device by the United States Food and Drug Administration (FDA) and as a Class IIA device by
the European Medical Device Directive (MDD).

Provider Support Policy
Objective: As a manufacturer our organizational goal is to provide customer support and assistance to the highest level of excellence.
Customers are Providers (which include Dealers, Distributors and Agents).
Support includes, but is not limited to, troubleshooting and Return Material Authorizations (RMA).
Business Hours are Monday – Friday, 8:30am – 5:00pm EST.
CAIRE Inc. can only support customers who are recognized as Providers, Dealers, Distributors and/or Agents.
These partnerships are qualiﬁed as having an existing account or are in the process of credit application completion. All patient or
end-user inquiries including but not limited to RMA, warranty or serial number questions must be handled by their Provider.
Provider Support Policy: CAIRE Inc. is unable to provide direct assistance, clinical advice or recommendations to a patient or
end-user. Providers have sole responsibility in assisting their patients.

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Oxygen Concentrator

Electromagnetic Compatibility
Medical Electrical Equipment needs special precautions regarding EMC and needs to be installed and put into service according
to the EMC information provided in this manual.
Portable and mobile RF communications equipment can affect Medical Electrical Equipment.
The use of Accessories, transducers, and cables other than those speciﬁed, with the exception of transducers and cables soldby the Manufacturer of this device as replacement parts for internal components, may result in increased Emissions ordecreased Immunity of the Companion 5.
The Companion 5 should not be used adjacent to or stacked with other equipment and that if adjacent or stacked use isnecessary, the Companion 5 should be observed to verify normal operation in the conﬁguration in which it will be used.

Guidance and Manufacturer’s Declaration - electromagnetic emissions
The Companion 5 is intended for use in the electromagnetic environment speciﬁed below. The customer or the userof the Companion 5 should assure that it is used in such an environment.
Emissions Test
RFemissions
EN 55011
RF emissions
EN 55011

ComplianceGroup 1

Electromagnetic environment - guidance
The Companion 5 uses RF energy only for its internal function.
Therefore, its RF emissions are very low and are not likely tocause any interference in nearby electronic equipment.

Class B

Harmonic emissions
IEC 61000-3-2Class A

Voltage ﬂuctuations/
ﬂicker emissions IEC
61000-3-3

Complies

The Companion 5 is suitable for use in all establishments, including
domestic establishments and those directly connected to the public low- voltage power supply network that supplies buildings used fordomestic purposes.

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Oxygen Concentrator

Guidance and manufacturer’s declaration–electromagnetic immunity
The Companion 5 is intended for use in the electromagnetic environment speciﬁed below. The customer or the user of
the Companion 5 should assure that it is used in such an environment.
Immunity test

IEC 60601 test level

Compliance level

Electromagnetic environment –guidance

Electromagneti
c environment– guidance±6 kV contact±6 kV contact±8 kV air

±8 kV airFloors should be wood, concrete or
ceramic tile. If ﬂoors are covered withsynthetic material, the relative humidity
should be at least 30 %.

IEC 61000-4-2
Electrical fasttran-sient/burst±2 kV for power
supply lines

IEC 61000-4-4±1 kV for input/output
lines

N/A

Surge

±1 kV line(s) to line(s)±1 kV line(s) to line(s)IEC 61000-4-5±2 kV line(s) to earth<5 % UT±2 kV line(s) to earth<5 % UT

Voltage dips,
shortinterruptions andvoltage variations
on power supply
input lines IEC
61000-4-11±2 kV for power
supply lines(>95 % dip in(>95 % dip in

UT ) for 0,5 cycle

UT ) for 0,5 cycle

40 % UT

40 % UT(60 % dip in UT )(60 % dip in UT )for 5 cycles

for 5 cycles

70 % UT

70 % UT(30 % dip in UT )(30 % dip in UT )for 25 cycles

for 25 cycles<5 % UT<5 % UT(>95 % dip in(>95 % dip in

UT ) for 5 sec

UT ) for 5 sec

Power frequency 3 A / m(50/60 Hz)
magnetic ﬁeld IEC
61000-4-8

3A/m

Mains power quality should be that of atypical commercial or hospitalenvironment.

Mains power quality should be that of atypical commercial or hospitalenvironment.
Mains power quality should be that of atypical commercial or hospitalenvironment. If the user of theCompanion 5 requires continued
operation during power mains
interruptions, it is recommended that theCompanion 5 be powered from anuninter-ruptible power supply or a battery.

Power frequency magnetic ﬁelds should
be at levels characteristic of a typicallocation in a typical commercial or
hospital environment.

NOTE UT is the a.c. mains voltage prior to application of the test level.

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Oxygen Concentrator

Guidance and manufacturer’s declaration–electromagnetic immunity
The Companion 5 is intended for use in the electromagnetic environment speciﬁed below. The customer or the user of theCompanion 5 should assure that it is used in such an environment.

Immunity test

IEC 60601 test level

Compliance level

Electromagnetic environment –guidance
Portable and mobile RF communications
equipment should be used no closer to any
part of the Companion 5, including cables,
than the recommended separation distancecalculated from the equation applicable to thefrequency of the transmitter.

Recommended separation distance
Conducted RF
IEC 61000-4-6

3 Vrms3 Vrmsd = 1.2

P

d = 1.2

P

80 MHz to 800 MHz

d = 2.3

P

800 MHz to 2,5 GHz

150 kHz to 80 MHz

Radiated RF

3 V/m

IEC 61000-4-3

80 MHz to 2,5 GHz

3 V/mwhere P is the maximum output power rat-ingof the transmitter in watts (W) according to thetransmitter manufacturer and d is therecommended separation distance in metres(m).
Field strengths from ﬁxed RF transmitters, as
determined by an electromagnetic site survey,a.
should be less than the compliance level ineach frequency range.
b.
Interference may occur in the vicinity ofequipment marked with the following symbol:

NOTE 1 At 80 MHz and 800 MHz, the higher frequency range applies.
NOTE 2 These guidelines may not apply in all situations. Electromagnetic propagation is affected by absorption and reﬂec-tionfrom structures, objects and people.
ab

Field strengths from ﬁxed transmitters, such as base stations for radio (cellular/cordless) telephones and land mobile radios,amateur radio, AM and FM radio broadcast and TV broadcast cannot be predicted theoretically with accuracy. To assess theelectromagnetic environment due to ﬁxed RF transmitters, an electromagnetic site survey should be considered. If themeasured ﬁeld strength in the location in which the Companion 5 is used exceeds the applicable RF compliance level above,
the Companion 5 should be observed to verify normal operation. If abnormal performance is observed, additional measures
may be necessary, such as re-orienting or relocating the Companion 5.
Over the frequency range 150 kHz to 80 MHz, ﬁeld strengths should be less than 3 V/m.

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Oxygen Concentrator

Recommended separation distances
between portable and mobile RF communications equipment and the Companion 5
The Companion 5 is intended for use in an electromagnetic environment in which radiated RF disturbances are controlled. The
customer or the user of the Companion 5 can help prevent electromagnetic interference by maintaining a minimum distance between
portable and mobile RF communications equipment (transmitters) and the Companion 5 as recommended below, according to the
maximum output power of the communications equipment.

Rated maximum
output power oftransmitter

Separation distance according to frequency of transmitterm
150 kHz to 80 MHz
d = 1.2 P

80 MHz to 800 MHz
d = 1.2 P

800 MHz to 2,5 GHz
d = 2.3 P

0,01

0.12

0.12

0.23

0,1

0.38

0.38

0.73

1

1.2

1.2

2.3

10

3.8

3.8

7.3

100

12

12

23

W

For transmitters rated at a maximum output power not listed above, the recommended separation distance d in metres (m) can be
estimated using the equation applicable to the frequency of the transmitter, where P is the maximum output power rating of thetransmitter in watts (W) according to the transmitter manufacturer.
NOTE 1 At 80 MHz and 800 MHz, the separation distance for the higher frequency range applies.
NOTE 2 These guidelines may not apply in all situations. Electromagnetic propagation is affected by absorption and reﬂection fromstructures, objects and people.

10

Oxygen Concentrator

Theory of Operation

HEPA Disc Filter

Board (PCB)

Responsible for all of the electrical operation of
the concentrator. Contains a programmablemicroprocessor that controls valve timing, alarmindications, and OCSI functions (if applicable).

Optional Gross
Particle Filter(Top Handle)

Provides gross particle ﬁltration for intake
to compressor.

Required Gross
Particle Filter(Bottom)

Provides gross particle ﬁltration for
intake to compressor.

Printed Circuit

Introduction

The Companion 5 is a stationary medical device used to extract
oxygen from the atmosphere, concentrate it, and present the oxygento the patient. The device will operate in Continuous Flow Mode. In
Continuous Flow Mode the oxygen is provided at a con-stant ﬂow rate
between 0.5 and 5.0 LPM (Continuously Variable).
Table 2 below lists the major internal components of the concentrator
and their functions. Reference Table 2 and Figure 3 (on the followingpage) for clariﬁcation while reading the Theory of Operation Sectionof the manual.

HEPA level ﬁltration of outlet ﬂow.

Table 2: Internal Components of Concentrator

Item

Function

Pressure Swing Adsorption

HEPA AirIntake Filter

Provides HEPA level ﬁltration for
intake to compressor.

Compressor

Pump that routes air into and throughthe concen-trator.

Cooling Fan

Cools the compressor area.

Solenoid
Valve

Routes air ﬂow through one sieve bed andvents the purged air to the atmosphere from theother bed. Responsible for alternating ﬂow
between the beds.

Sieve Beds

Chemically adsorbs nitrogenmolecules from the air.

The CAIRE Companion 5 utilizes the Pressure Swing Adsorption(PSA) Process to concentrate oxygen gas from ambient air. In the PSA
process, a compressor draws ambient air into the machine through an
intake ﬁlter. The compressor then forces the ﬁltered air into a solenoid
valve which directs the air into one of two tanks that are full of amolecular sieve material, referred to as sieve beds. As the pressure insieve bed 1 increases, nitrogen molecules are removed from theambient air and are stored in the sieve material. The gas that exits
sieve bed 1 is highly-concentrated oxygen. The majority of this gas
ﬂows through an oriﬁce to sieve bed 2 and is used to purge the stored
nitrogen gas from its sieve material. The remainder of the oxygen gas
is directed through a ﬂapper valve to the product holding tank. Here, it
is stored for delivery to the patient.

OriﬁceRoutes a larger portion of air exiting one sieve
bed back through the other bed for purging.

Flapper Valve

Routes a smaller portion of air exiting one sieve
bed into the product holding tank. Prevents backﬂow from product tank to sieve bed

Product
Holding Tank

Holds concentrated oxygen prior to its
regulation and delivery to the patient.

Pressure
Regulator

Reduces the outlet pressure to be compatible
with the ﬂow meter and accessories.

OCSI Sensor

Detects oxygen concentration of ﬂow exiting theconcentrator. Sends a signal to activate alarm if
concentration is too low.

Flow Control
Valve

Integral needle valve that controls
volumetric ﬂow (LPM) to the patient. Is readagainst the printed scale.

Sieve bed 1 continues to pressurize until the sieve material iscompletely saturated with nitrogen. At this time the printed circuitboard (PCB) switches the state of the solenoid valve, dumping
pressurized air in sieve bed 1 back into the atmosphere via the purge
mufﬂer. Simultaneously, the valve now directs the compressed air into
sieve bed 2, which has been completely purged of nitrogen gas and isready for nitrogen adsorption/oxygen concentration. This cycle
continuously repeats pressurizing and depressurizing the sieve beds,
feeding concentrated oxygen to the product holding tank.

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Oxygen Concentrator

Flow Delivery

Oxygen exiting the product holding tank ﬂows through a pressure
regulator that reduces the high pressure oxygen to a lower, moremanageable pressure before it is delivered to the patient. This
ensures that the oxygen ﬂowing from the device will work
appropriately with accessories and provide a safe pressure for patientdelivery.
The Companion 5 oxygen concentrator may be equipped with an
Oxygen Concentration Status Indicator (OCSI). In that case, oxygengas exiting the pressure regulator ﬂows through a check valve andthen through the OCSI sensor. This is the same area of theconcentrator where the ﬂow is measured. The PCB monitors theconcentration and the ﬂow measured by these sensors, and it will
activate a warning light and audible alarm if the concentra-tion drops
below predetermined levels described in the Warning Alarms sectionof the manual.

Electrical Operation

All electrical components of the CAIRE Companion 5 are all controlled
by a PCB. The electrical cord supplies mains AC power (120 VAC @60 Hz or 230 VAC @ 50 Hz) to the main circuit board when the powerswitch is in the “ON” (|)position. The PCB dis-tributes the mains power
to all of the electrical components. The AC mains power is distributed
and routed directly to the compres-sor and the cooling fan. The
compressor and cooling fan both operate at 120 VAC @ 60 Hz or 230
VAC @ 50 Hz. The remaining power travels to a DC power convertor/
regulator. Figure 4 is a block diagram showing the ﬂow and distributionof mains power into the concentrator.

orAfter exiting the concentration and ﬂow rate sensors, oxygen ﬂows
through the ﬂow control valve (FCV) at the LPM ﬂow rate selected by
the patient and indicated on the ﬂow meter. The oxygen gas then ﬂows
through the HEPA ﬁlter where unwanted contaminants are removed.
The oxygen is then delivered to the patient through the outlet barb.

oror

Figure 4: Diagram of Mains Electrical Distribution

Figure 3: Schematic Diagram of Pneumatic Operation

12

Oxygen Concentrator

Microprocessor

The microprocessor is the only processing element of the CAIRE
Companion 5. It contains embedded software which is pro-grammedwith all of the parameters for alarm conditions and settings of theconcentrator. The microprocessor is directly respon-sible for thefollowing functions of the concentrator:• Cycling (timing) of the solenoid valve• Driving the LCD display• Controlling the audible alarm• Controlling the operational and warning LED lights• Reading input from the OCSI sensor (OCSI models only)
The microprocessor is programmed with the alarm thresholds
and trigger points, as well as the timing of the solenoid valve tocycle between sieve beds. A diagram of the input and output of
the microprocessor is shown below in Figure 5. Each input andoutput is described further in the following sections.

Solenoid Valve

The solenoid valve is connected to the circuit board’s microproces-sor
by a 4-pin connector. The microprocessor is responsible for sending
the signal to open and close the valves. This cycles the air throughalternating sieve beds for the PSA process. The timing for alternating
the sieve beds is programmed into the microprocessor.

LCD Display

The 6-digit digital LCD display is mounted on the PCB and is vis-ibleon the front of the concentrator. Its purpose is to continually count anddisplay the hours that the concentrator has been in operation and to
display alarm conditions. The LCD display cannot be re-set anddisplays time to the nearest tenth of an hour.

Audible Alarm

The CAIRE Companion 5 contains an audible buzzer that is sur-facemounted on the PCB. Its purpose is to alert users of alarm conditions.
The microprocessor detects alarms by reading the input from the OCSI
sensor and the mains power switch. When there is an alarm condition,
the microprocessor sends a signal to activate the audible alarm.

LED Lights

There are three (3)(OCSI) LED lights that are surface mounted on the
PCB. They are visible from the front of the concentrator and their
purpose is to alert the user of operating conditions or alarms.
The top LED indicator is green. It remains on at all times when the
power switch is in the “ON” (|) position and the electrical cord isplugged in. A continuous green light indicates normal operation.
The next LED indicator will be red. This light will indicate mal-functions
with the device. When the microprocessor detects an alarm condition
from the power switch or the ﬂow rate sensor, it will send a signal forthe red LED to illuminate. The red LED will indicate a system
malfunction, loss of power, or ﬂow rate is out of speciﬁcations.
The bottom LED indicator will be yellow. This light will only indicate low
oxygen concentration. This LED will illuminate when the
microprocessor detects an alarm condition from the OCSI sensor. The
LED will be solid if the oxygen concentration is less than 85%. The
warning alarms section will describe these alarm conditions in detail,and provide basic troubleshooting steps.

Figure 5: Microprocessor Operation Block Diagram

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Oxygen Concentrator

OCSI Sensor

Serial Number Identification

The OCSI sensor detects the oxygen concentration of the air
being delivered to the patient. The sensor consists of an intake
and outlet port on each end of a ﬂow path that is encased in an
air-tight cover. The microprocessor determines concentrationfrom the OCSI sensor output, and activates alarms whenappropriate. The limits for alarm conditions are programmed
into the software of the microprocessor and are described in
the Warning Alarms section of this manual. The concentrator
takes several minutes to build internal pressure andconcentration. This is known as the warm-up period, and thesignal from the sensor is ignored by the PCB for ten (10)minutes. This means that the alarms associated with the OCSI
will not activate until this predetermined amount of time has
passed.

The serial number of the CAIRE Companion 5 is located on theback label of the outer case. The serial number is in the middleof the label, just below the bar code. A sample label is shown
below.

Figure 7: Serial Number LabelEnd of LifeAt the end of the service life of the CAIRE Companion 5, it
should be disposed of in accordance with local regulations.

14

Oxygen Concentrator

Indications for Use

The Companion 5 is indicated for the administration of supplemental oxygen. The device is not intended for life support nor doesit provide any patient monitoring capabilities.
A physician must prescribe a speciﬁc oxygen ﬂow rate setting tomeet patients’ individual needs.
Recommended oxygen ﬂow rates should be adjusted only under theadvice of a physician.

WARNING:

Federal law restricts this device to sell by or on
the order of a physician.

Contraindications
WARNING: The Companion 5 is not intended for life supporting or life sustaining applications, nor doesit provide any patient monitoring capabilities.
WARNING: In certain circumstances, the use of non-prescribedoxygen can be hazardous. This device should only
be used when prescribed by a physician.

WARNING:Not for use in the presence of
ﬂammable anesthetics.

WARNING: As with any electrically powered device, theuser may experience periods of non-operation
as a result of electrical power interruption, orthe need to have the Companion 5 serviced
by a qualiﬁed technician.
The Companion 5 is not appropriate for any
patient who would experience adverse healthconsequences as a result of such temporaryinterruption.

Introduction

Welcome to the CAIRE Companion 5 oxygen concentrator. Setting up
and training your patient to use the Companion 5 has never beeneasier! You can expect your patients and care providers to easily
learn how to use the device by following the directions in this section.
While setting up and training a patient, be sure to point out theadvantages of the Companion 5. For example:• Easy-to-use controls• Quiet operation• Self-monitoring alarm system

After completing each training procedure, ask your patient if
he or she has any questions. Proper training of your patients
will result in fewer service calls, improved compliance andincreased patient satisfaction.

Pre-Delivery Check List

Verify that the Companion 5 is provided to the patient with thefollowing items:• Users’ Manual• Required Oxygen Delivery Accessories (Cannula,
Tubing, Humidiﬁer, etc.)• Power - Insert the AC power cord into an electricaloutlet to check for proper operation• Before delivering the device, check and log the status of
the following using the LCD Display:
Hours on the hour meter
Software Revision (The LCD Display will show
this upon startup)

You may adjust the liter ﬂow settings to your patient’sprescription when you deliver and set up the device.

Connecting the AC PowerThe Companion 5 operates from external power.
1. Plug the power cord into an AC outlet.
2. The Companion 5 is now ready for use.
Note:
WARNING:

If the Companion 5 is not receiving power when
it is turned on, the unit will alarm and display
a solid red light.
Ensure adequate clearance around the AC Cord.

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Oxygen Concentrator

CAUTION• DO NOT connect the Companion 5 to an
extension cord or electrical outlet controlled
by a switch.
• Always check to see that the Air Inlet andthe Exhaust Vent are not blocked.

Disconnecting the AC PowerTo ensure that there is no power to the Companion 5,
unplug from AC power.
Note: Turn the Companion 5 to the “Off” (O) position to avoid
alarming before disconnecting the AC Power cord.

Note: After completing this training procedure, ask your patient if
he/she has any questions.

Power On and Warm Up
Plug the electrical cord of the CAIRE Companion 5 into an
AC outlet.
WARNING: INSPECT THE ELECTRICAL CORD FOR DAMAGE
BEFORE USE. IF THE CORD IS DAMAGED, DO NOT PLUG IT INTO
AN ELECTRICAL OUTLET OR ATTEMPT TO OPERATE THE
CONCENTRATOR.

Using Around the House
Patient may use up to 50 ft (15.24 m) of oxygen tubing and a 7 ft (2.14m) standard nasal cannula with the Companion 5. If using ahumidiﬁer bottle with long tubing runs, always verify the ﬂow meter stillreads the patient’s prescribed rate after installation.

CAUTION

When using a humidiﬁer adapter of any kind,
the Companion 5 unit must remain stationary,meaning that the unit must NOT be moved ortransported in any manner to avoid damage to
the Companion 5.

Press the power switch in the “ON” (I) position.

Locating the Companion 5 for Proper
Use and Ventilation
Ask your patient where they would like to set up the device.
Whenever possible, the Companion 5 should be in the sameroom as the patient for convenience and assurance that thepatient can adequately hear and respond to Companion 5 alerts
and alarms. While unpacking and setting up the device, tell
your patient about these important cautions and warnings:
WARNING: LOCATE THE COMPANION 5 IN A WELL-VENTILATEDSPACE THAT PROVIDES ADEQUATE AIRFLOW.
WARNING: ENSURE THAT FURNITURE, DRAPERIES OR CLOTHING
WILL NOT IMPEDE AIR CIRCULATION.
WARNING: AVOID PLACING THE UNIT OVER A FLOOR HEAT REGISTER ORAGAINST A BASEBOARD HEATING SYSTEM.
WARNING: DO NOT USE IN THE PRESENCE OF FLAMMABLE ANESTHETICS,SOLVENTS, AEROSOLS OR FLAMMABLE CLEANING AGENTS.

When the Companion 5 is plugged in properly and turned on,
a green indicator on the LED Display will light up. All LED
lights will illuminate upon start up. After the concentrator
completes the warn-up cycle, only the green light will remainon.
The O2 Light will illuminate for four (4) seconds upon start-up.
After this initial start-up, this light is disabled for approximatelyten (10) minutes while the concentration rises tospeciﬁcations.
Note: After Initially powering on, the O2 light will illuminate
and “O2 UP” will display on the screen until the concentration
reaches specifications.

WARNING: AVOID HIGH POLLUTANT ENVIRONMENTS.

CAUTION

Some patients are highly mobile and may use
the device under varying circumstances. Make
sure your patient or patient caregivercompletely understands the basic precautions
to safely locate the device.

16

Oxygen Concentrator

Adjust Flow Control Rate
Turn the flow control knob to the oxygen flowrate (LPM) prescribed by your physician.

Maintenance–Patient
Optional Handle Gross Particle Filter(if installed)
The patient should clean the handle gross particle ﬁlter weekly if
installed. Replace ﬁlter as needed.

1. Remove dirty ﬁlter from inside unit
handle.
2. Wash dirty ﬁlter in warm
soapy water and rinse
thoroughly.
To adjust ﬂow rate:
Turn counter-clockwise to increase ﬂow.
Turn clockwise to decrease ﬂow.
The middle of the ball indicates ﬂow rate.
There are two sets of lines (front and back). In theexample below, the ﬂow meter would read “4LPM”.

3. Use a soft, absorbent towel toremove excess water.
4. Ensure ﬁlter is completely dry
before reinstalling in the unit.
5. Reinstall clean ﬁlter in handle.
Replace with new ﬁlter as needed.

Bottom Gross Particle Filter
The patient should clean the handle gross particle ﬁlter weekly if
installed. Replace ﬁlter as needed.

1. Remove dirty ﬁlter.
2. Wash dirty ﬁlter in warm
tap water using a mild soap detergent
solution.
WARNING: IT IS VERY IMPORTANT TO SELECTONLY THE PRE-SCRIBED LEVEL OF OXYGEN. DO
NOT CHANGE THE FLOW SELECTION UNLESS YOUHAVE BEEN DIRECTED TO DO SO BY A
LICENSED CLINICIAN. THE OXYGEN CONCENTRATOR
MAY
BE
USED
DURING
SLEEP
UNDER
THE
RECOMMENDATION OF A QUALIFIED CLINICIAN.

3. Rinse the filter thoroughly and usea soft, absorbent towel toremove excess water.
4. Allow filter to completely air dry.
5. Reinstall clean ﬁlter into thecabinet.
Replace with new ﬁlter as needed.

17

Oxygen Concentrator

Clean and Care for Tubing and
CannulaProvide your patient instructions on cleaning, disinfection
and/or replacement information for the tubing and cannula.

Clean the Cabinet

To clean the cabinet do the following:
1. Turn OFF the Companion 5 and disconnect from AC
power before any cleaning or disinfection activity.
2. Use mild detergent and water solution.
3. Use a damp (not soaking wet) cloth or sponge.
4. Spray or wet the cloth or sponge with the mild detergent
solution. DO NOT spray the cabinet.
5. Wipe down the cabinet.
6. To disinfect the Companion 5, use Lysol® Brand II
disinfec-tant (or equivalent). Spray or wet a cloth orsponge with the disinfectant. DO NOT spray the cabinetor the LED/LCD display. Proceed as directed by the
manufacturer.

Patient Training Checklist
Use the following checklist as a guide to assist in setup and training a patient on the use of the Companion 5 and its accessories.

Patient Name:
Companion 5 Serial #:Training Topic

Initials

Pre-Delivery Check List
Indications for Use
Contraindications
Basic Concept Training
Advise to read the Users Manual
Safety Guidelines and Operational Safety Warnings/Cautions
Locating the Companion 5
Indicators
Alerts and Alarms
Companion 5 Maintenance
Clean and Care for the Cannula per manufacturer’s instructions.
Clean the Cabinet as needed.
Schedule Intake Filter Replacement and bottom gross particle ﬁlter replacement every 2 Years.
Cleaning of optional handle gross particle ﬁlter weekly (if present).
Trained By:

Date:
18

Oxygen Concentrator

Preventive Maintenance—
ProviderIntroduction

Properly maintaining the Companion 5 will ensure longer
life and higher performance.
CAUTION The Companion 5 contains electrostatic sensitive

components. Do not open or handle except at a
static free workstation. Do not remove cover without
electrostatic discharge (ESD) protection.

Maintenance Check List

Perform the following maintenance procedures at least every
two years or more often, as needed. The frequency of theperiodic maintenance should be based on the environment inwhich the Companion 5 is used.

Air Intake Filter (Cartridge)

The air intake ﬁlter should be replaced at least once every 2
years or as needed. The frequency of the maintenance should
be based on the environment in which the Companion 5 isused. Harsh environments may require air intake ﬁlter
replacement more frequently than every 2 years.

Internal HEPA Disc Filter

The internal HEPA Filter does not have a requirement for
replacement. It is designed to last the life of the unit.

Oxygen Concentration Check

Oxygen concentration should be tested upon delivery to apatient and at periodic intervals determined by the equipment
provider. Equipment providers should establish andimplement a protocol to check oxygen concentration.

• Inspect AC Power cord and plug for damage• Read and record hour meter• Check ﬂow rate, concentration, and alarmfunctions• Replace air intake ﬁlter

Maintenance Schedule
Handle Gross Particle Filter(Optional)
Patient should clean the handle gross particle ﬁlter weekly if
installed. The frequency of the maintenance should be basedon the environment in which the Companion 5 is used. Harshenvironments may require more frequent ﬁlter cleaning and/or
replacement.

Bottom Gross Particle Filter
Patient should clean bottom gross particle filter weekly. The
bottom gross particle ﬁlter should be replaced as needed. The
frequency of the maintenance should be based on theenvironment in which the Companion 5 is used. Harshenvironments may require ﬁlter replacement more frequently
than every 2 years.

19

Oxygen Concentrator

Maintenance Procedures
The following section lists procedures that are necessary tomaintain the Companion 5. Service should only be performed bya qualified technician. To perform periodic maintenance, the only
tools that should be necessary are:•••

#1 Phillips Screwdriver
Flow Meter/Oxygen Analyzer
Replacement Filters

WARNING:

Disconnect all power supplies going to the unit
prior to performing the following steps

Bottom Gross Particle Filter
1. Remove dirty gross particle filter from bottom of unit.
2. Install new, clean filter.

Filter Cover

6. Pull outward on the intake filter to remove from its
compartment.
7. To replace, reverse steps 1–5.

Oxygen Concentration Test
CAIRE recommends testing the oxygen concentration at least once
every six months for non-OCSI units.

Air Intake Filter (Cartridge)
1. Remove bottom gross particle filter (if present)
2. Press the power switch in the “OFF” position and unplug theelectrical cord.
3. Lay the concentrator gently on its side to access the bottomof the unit.
4.Remove screw with Phillips Screw Driver from the filter cover.
See picture below.

1. Plug the AC Power Cord into an electrical outlet, and turnthe power switch in the “ON” (I) position.
2. Allow the concentrator to run continuously for a minimumof 10 minutes.
3. Disconnect the tubing and/or cannula from the outlet barb if
one is attached.
4. Turn the flow control knob to 5LPM
5. Connect a calibrated oxygen analyzer to the outlet barb.
6. Verify that this display reads between 87–95.5%.

Note:• If the oxygen concentration is not between
87–95.5%, refer to the troubleshooting section of this manual for “Low Oxygen Concentration.”• If the concentrator is alarming and the oxygen
concentration measured is greater than 85%,
replace the main PCB.

Filter Cover

5. Pull outward to remove filter cover.

20

Oxygen Concentrator

Record Hours of Operation

To help maintain the Companion 5, you may obtain the total
hours of operation.

Hour Meter
A digital hour meter is mounted on the PCB and is displayed on
the concentrator’s front panel. Its purpose is to continually countand display the hours that the concentrator has been in
operation. The hour meter cannot be re-set and displays time to
the nearest tenth of an hour.

Cleaning the Companion 5

Clean inside the unit, as needed, using a small vacuum
cleaner or brush to remove any accumulation of dust or debris
prior to at-taching the covers.
Use mild detergent solution to clean the cabinet. Turn OFF theCompanion 5 and disconnect from AC power before any
cleaning or disinfection activity. DO NOT spray the cabinet. Usea damp (not soaking wet) cloth or sponge. Spray the cloth orsponge with a mild detergent solution to clean the cabinet andpower cord. To disinfect the Companion 5, use Lysol® Brand II
disinfectant or equivalent. Dilute as directed by manufacturer ofcleaning the product, but do not spray liquid directly on
Companion 5.
WARNING: Turn off the Companion 5 and disconnect fromAC power. DO NOT use denatured alcohol orapply liquid spray or aerosol cleaners.

Shipping and Transporting theCompanion 5
When shipping the Companion 5, use original packaging if
possible. If original packaging material is not available, thenplace the Companion 5 in a plastic bag and surround theconcentrator with a minimum of two inches of soft foam
packing material or bubble wrap. Place the Companion 5 inan appropriate cardboard box for shipping.
WARNING: DO NOT expose the Companion 5 to water.
Electrical shock or damage to the unit may
result.

Storing the Companion 5
Heat and humidity may degrade performance or severely
damage the Companion 5. Store the device in a cool, dry,
protected area away from high temperatures, moisture andhumidity.

Discarding
Local environmental laws may prohibit disposal of electricaland/ or electronic equipment such as the Companion 5.
Contact the local city or town ofﬁces for instructions on
proper disposal of electrical or electronic equipment.
Alternately, CAIRE Inc. may be contacted for disposal
information.

21

Oxygen Concentrator

Provider Service and Maintenance Record
Whenever maintenance or service is performed on an Companion 5 unit, an entry should be made in the service log for that concentrator or recorded in accordance with your company’s standard procedure. Whenever the case of the Companion 5 is opened, the flow
rate, concentration, and alarm status should be verified per the Test Procedures in this manual.

Companion 5 Serial Number _________________________________________
Date

Hour meter
Reading

System Checkout
InitialsService Performed

Concentration

Flow

AlarmsComments

22

Oxygen Concentrator

Troubleshooting, Service,
and Repair Procedures
CAUTION The Companion 5 contains electrostatic
sensitive components. Do not open or handle
except at a static free workstation. Do notremove cover with-out ESD protection.

General Troubleshooting

Before reviewing the troubleshooting chart, the following
steps may be useful to isolate any malfunctions:
1. Turn on the concentrator. If the unit does not turn on, referto the troubleshooting chart.
2. Allow the unit to warm up for approximately 10 minutes andcheck oxygen concentration.
3. Perform the ﬂow rate test. Verify ﬂows are within
acceptable range per Table 8.
4. Make sure the unit is cycling properly by observing the ﬂow
meter ball is stable (ﬂow meter ball does not move up anddown more than ¼ liter.)
5. Place your thumb over outlet of unit. The ﬂowmeter ballshould drop to the bottom of the ﬂowmeter. If the ball does
not drop completely to the bottom, there is a leak present
between the top of the ﬂowmeter and the outlet of the unit.
6. If concentrator is not meeting speciﬁcations, make surethat the unit is leak-free by testing all tubing connections
and ﬁt-tings with leak testing solution. Protect circuit board
and all electrical components from leak test solution andstart leak test at the compressor, following air ﬂow tooxygen outlet. Repair all leaks by tightening connec-tions
and ﬁttings.
7. If unit is alarming, refer to the Alarm Indicator Chart for
probable solutions.

23

Oxygen Concentrator

Troubleshooting Table
Symptom

Possible Cause
1

Oxygen Tubing
Kinked/Leaking

Check the nasal cannula and any extension tubing being used for kinks, blockages, orleaks. Verify that all tubing connections are secure. Replace and tubing if necessary.

2

Humidiﬁer Bottle
Restriction (if used)

Check the humidiﬁer bottle and tubing for blockages or restrictions.

No Oxygen Flow 3 Flow Meter Closed (off)4

Low or Fluctuating Oxygen
Flow Rates

Overheating

Internal Tubing
Kinked/Leaking

Inspect the ﬂow meter and verify that the ball is not at the bottom of the meter. If it is,
turn the knob to increase the ﬂow. Replace the ﬂow meter if necessary.
Check all internal tubing for leaks. Verify that there are no leaks and that allconnections are secure. Replace any tubing or parts if necessary.

5 HEPA Filter Restriction

Inspect the HEPA ﬁlter for a blockage. Replace if found to be clogged.

6 Compressor Malfunction

Verify that the compressor is operating properly. Replace the compressor if necessary.

1

Oxygen Tubing
Kinked/Leaking

Check the nasal cannula and any extension tubing being used for kinks, blockages, orleaks. Verify that all tubing connections are secure. Replace any tubing if necessary.

2

Humidiﬁer Bottle
Restriction (if used)

Check the humidiﬁer bottle and tubing for blockages or restrictions.

3 Poor Concentrator Location

Verify that the concentrator is in a well-ventilated location and that air ﬂow into
the device is not impeded.

4 Intake Filter Restriction

Inspect the intake ﬁlter for a blockage. Replace if found to be clogged.

5 HEPA Filter Restriction

Inspect the HEPA ﬁlter for a blockage. Replace if found to be clogged.

6

Low Oxygen
Concentration

Corrective Action

Internal Tubing
Kinked/Leaking

Check all internal tubing for leaks. Verify that there are no leaks and that all connections
are secure. Replace any tubing or parts if necessary.

7 Flow Meter Malfunction

Verify the functionality and accuracy of the ﬂow meter. Replace if necessary.

8 Regulator Malfunction

Check the outlet pressure. If it is out of the acceptable range, adjust or replace
the regulator.

9 Compressor Malfunction

Verify that the compressor is operating properly. Replace if necessary.

1 Intake Filter Restriction

Inspect the intake ﬁlter for a blockage. Replace if found to be clogged.

2 HEPA Filter Restriction

Inspect the HEPA ﬁlter for a blockage. Replace if found to be clogged.

3 Poor Concentrator Location

Verify that the concentrator is in a well-ventilated location and that air ﬂow into
the device is not impeded.

4Internal Tubing
Kinked/Leaking

Check all internal tubing for leaks. Verify that there are no leaks and that
all connections are secure. Replace any tubing or parts if necessary.

5 Solenoid Valve Malfunction

Verify the operation of the 2-way solenoid valve. Replace if necessary.

6 Compressor Malfunction

Verify that the compressor is operating properly. Replace if necessary.

7 Sieve Bed Failure

Replace the sieve beds assembly.

1 Poor Concentrator Location

Verify that the concentrator is in a well-ventilated location and that air ﬂow into
the device is not impeded.

2 Cooling Fan Malfunction

Verify that the cooling fan is connected properly to the circuit board and check thecontinuity of the connection. Replace the cooling fan if it is not functioning.

Outlet Pressure 1 Internal Tubing
Kinked/Leaking
Out ofAcceptable
2 Regulator Out of Adjustment
Range (4.3 - 4.9
3 Regulator Malfunction
PSI)
4 Sieve Bed Failure

Check all internal tubing for leaks. Verify that there are no leaks and that all connections
are secure. Replace any tubing or parts if necessary.
Adjust the regulator.
Replace the regulator.
Replace the sieve beds assembly.

24

Oxygen Concentrator

SymptomIntermittent
Audible Buzzer
With Red Light(Alarm Code:
AL-P02)

Will Not Turn On
When On When
Power Switch is"ON" (I)

Possible Cause

Corrective Action

1 Power Failure

Verify that the electrical cord is plugged into an outlet and that there is power being
supplied to the outlet. Replace the electrical cord if necessary.

2 Blown Fuse

Replace circuit board.

1 No Power Being Supplied

Verify that the electrical cord is plugged into an outlet and that there is power being
supplied to the outlet. Also check the household circuit breaker.

Power Switch Malfunction

Verify that the power switch is plugged into to the main circuit board. Replace thepower switch if necessary.

3Electrical Cord Malfunction

Verify that the electrical cord is plugged into to the main circuit board. Replace theelectrical cord if necessary

4

Blown Fuse

Replace circuit board.

1

No Power Being Supplied

Verify that the electrical cord is plugged into an outlet and that there is power being
supplied to the outlet.

2

Circuit Board Malfunction

Verify that all connections to the circuit board are intact. Replace the main circuitboard if necessary.

3

Blown Fuse

Replace circuit board.

4

Defective Power Switch

Replace power switch.

Audible Alarm
1
Does Not Sound

Circuit Board Malfunction

Verify that all connections to the circuit board are intact. Replace the main circuitboard if necessary.

LED Lights Will
Not Illuminate25

Oxygen Concentrator

Alarm Conditions and Alarm
Codes
Use the alarm table on the next page to decode Companion
5 alarm conditions. If other alarm codes are displayed by theCompanion 5, contact CAIRE Technical Support forassistance.
Note:

The following table is intended as a guide forthe provider, not the user.

Warning Alarms

The CAIRE Companion 5 contains both visual and audible
alarms to alert the user when there is a malfunction with theunit. The audible buzzer and the LED lights work in
conjunction to display operating and alarm conditions of theconcentrator. The audible buzzer will alarm intermittently.
There are 3 LED warning lights that are visible on the front of
the Companion 5:
1) Green LED - Indicates normal operation. Illuminates
when power is supplied to the concentrator and the powerswitch is in the “ON” (I) position.
2) Red LED - Indicates ﬂow rate error, loss of power, ambientpressure reading out of range, or general system malfunction. The concentrator requires service if this light is on,with the exception of “ﬂow rate alarm”.
3) Yellow LED - Indicates poor oxygen concentration below
85% (ﬂashing) or 70% (solid). See the following table formore information. The concentrator requires service if thislight is on.

Ref 15067540 Rev D

LED Display OCSI

Note:

Version 1.11 firmware will change the way
some alarms appear. All alarms will now be anintermittent audible beep with the 1.11 version.

26

Oxygen Concentrator

The table below shows all of the alarm conditions that can be experienced by the CAIRE Companion 5:
Alarm
Code

Audible
Alarm

None

Off

AL-P01

Itermittent

Red Solid

AL-P02Itermittent

Red Solid

AL-P20Itermittent

Red Solid

Low ProductFlow Rate

AL-P40Itermittent

Red SolidHigh ProductFlow Rate

AL-P04Itermittent

Yellow Solid

AL-P08Itermittent

AL-P80Itermittent

Note:

ColoredLED

Possible Cause

Green Solid The Companion 5
is working properly

None

System Malfunction Turn the power switch to the “OFF” position immediately.
Disconnect the AC Power from the wall outlet. Wait 5
minutes. Connect the AC Power back into the wall outlet
and turn the concentrator back on again. If the alarm
continues, service is required. Connect to a backup oxygen
supply and contact your healthcare provider immediately.
The concentrator Verify that the concentrator’s electrical cord is plugged into an
has lost power but outlet and that the outlet has power. Try a different outlet. If thethe power switch is problem continues, connect to a back-up oxygen supply andstill in thecontact your healthcare provider.
“ON” (I) position.

Failed O2 Alarm
Condition (O2Levels Less
Than 70%)
Poor
O2 Alarm
Yellow Solid
Condition (O2Levels Between
70% and 85%)
Red Solid

Patient Action

Ambient
pressure reading
unstable or out ofrange.

1. Ensure that the cannula is not kinked or blocked. If used witha humidiﬁer bottle, ensure that it is ﬁlled properly and not
creating a blockage.
2. Ensure that the Companion 5 has proper ventilation. Make
sure there are at least 12 inches between the back and sides of
the Companion and any obstructions (furniture, curtain, etc.)
3. If the problem persists, switch to an alternate source ofoxygen and contact healthcare provider for assistance.
1. Ensure the air intake ﬁlter is not is not clogged or restricted.
2. Ensure the Companion 5 is in a well ventilated area. Make
sure there are at least 12 inches between the back and sides of
the Companion 5 and any obstructions (furniture, curtain, etc.)
3. If the condition persists, switch to an alternate source ofoxygen and contact your healthcare provider immediately.

Turn the power switch in the “OFF” position immediately.
Disconnect the AC Power from the wall outlet. Wait 5
minutes. Connect the AC Power back into the wall outlet
and turn the concentrator back on again. If the alarm
continues, service is required. Connect to a backup oxygen
supply and contact your healthcare provider immediately.

Note: The alarm codes will be additive if more than one code is active. For example, if the unit is undergoing a highproduct ﬂow rate alarm and a poor O2 alarm condition, the alarm code will be P40 + P08 = P48.
The concentrator will continue normal operation even though an alarm condition is in effect.

The power failure alarm will have the ability to sound for a period after power has been disrupted to the device. The audible
alarm is powered by a super capacitor that is charged by the PCB while the concentrator is in operation. It takes the audible
alarm approximately 30 minutes to fully charge. The capacitor has a set of contacts that is activated when the power switch is in
the “ON” position and no AC power is being supplied. The alarm is stopped by resupplying power to the concentrator.
All other alarms will continue until the alarm condition has been corrected. Service to the concentrator by authorized personnel
is recommended anytime an alarm condition is experienced. Procedures for servicing and testing the unit are outlined in the
Troubleshooting section of this manual.
27

Oxygen Concentrator

Repair and Testing
Procedures

The following test and repair procedures have been developed toallow for both performance veriﬁcation of the CAIRE Companion 5 aswell as proper removal and replacement of defective parts. If a unit
fails any given test, refer to the Troubleshooting section of the manual.
Please carefully read and understand the following safety adviso-ries
before performing repair procedures.

WARNING:CAUTION

Note:• Verify that the power switch is in the “OFF”
position and the electrical cord is
unplugged before performing any repairs
unless otherwise noted.
• Make sure your hands are free of oils andgreases.

Do not allow liquid leak detector to come incontact with electrical parts.
• All replacement parts must be factory approved. They should be marked “Cleaned
for Oxygen Service” and should be stored
in sealed plastic bags.
• Use only replacement parts authorized by
CAIRE, Inc.
• Service of the CAIRE Companion 5 shouldbe performed by authorized personnel only.

Power Failure Alarm Test

1. Connect the electrical cord to a power source.
2. Turn the power switch in the “ON” position and let the unit
run for a few minutes.
3. Keeping the switch in the “ON” (I) position, disconnect theelectrical cord from its outlet power.
4. Verify that the audible alarm begins to sound.
If the audible alarm does not sound, refer tothe Troubleshooting section of the manual for“No Power Failure Audible Alarm.”

Note:

5. Turn the power switch in the “OFF” (O) position. The
alarm should stop.
6. Plug the electrical cord back into an electrical outlet.
7. Turn the power switch in the “ON” (I) position. The green
light should remain lit continuously.

Flow Rate Test

1. Turn the power switch in the “ON” position.
2. Allow the concentrator to run continuously for a minimumof 10 minutes.
3. Connect a ﬂow meter to the outlet barb.
4. Turn the ﬂow knob to the position of 0.5 LPM.
5. Verify that the ﬂow displayed by the ﬂow meter is within
the tolerances shown in table below.
6. Flow Rate must be +/- 10% or 200ml/min, whichever isgreater. See table below.
Table 8: Flow Rate Tolerances

Start-up Veriﬁcation Test
1. Connect the electrical cord to a power supply.
2. Turn the power switch in the “ON” position.
3. Initially, all LED lights will illuminate and the audible alarm
will beep. After a few seconds, the yellow and red LED
lights should turn off and the audible alarm will stop.
4. Upon startup the O2 warning light will illuminate and thedisplay screen will read "O2 UP". Once the concentrator
reaches an acceptable purity the display screen willchange to the number of hours and the O2 warning lightwill turn off.
5. Verify that the green LED turns on and stays lit
continuously during operation.

Flow Setting(LPM)

Minimum Actual
Flow (LPM)

Maximum Actual
Flow (LPM)

0.5

0.30

0.70

1.0

0.80

1.20

1.5

1.30

1.70

2.0

1.80

2.20

2.5

2.25

2.75

3.0

2.70

3.30

3.5

3.15

3.85

4.0

3.60

4.40

4.5

4.05

4.95

5.0

4.50

5.50

7. Repeat steps 4 and 5 with each incremental ﬂow setting.
Note:

If any ﬂow rates are out of tolerance, refer tothe Troubleshooting section of this manual andthe steps for Low or Fluctuating Flow Rates.

28

Oxygen Concentrator

Product Regulator Check and Setting
The product regulator is factory set at 4.6 psig (31.7 kPa) andshould not require adjustment.

3. Using standard pliers remove the ratchet clamp holding
the braided tubing to the manifold.

To check for proper adjustment of the product regulator, take thefollowing steps:
1. Set the unit’s I/0 power switch to the “I” position.
2. Turn the ﬂow meter adjustment knob counter-clockwise
until it reaches 5 LPM.
3. Allow the unit to run for ten minutes.
4. Install test pressure gauge to the outlet of the Companion 5
unit.
5. The outlet pressure should be 4.3-4.9 psig (29.6-33.8 kPa).
If the outlet pressure is not within this range, the productregulator needs to be adjusted.

Outer CaseWARNING:CAUTION• Keep hands out of moving parts• Disconnect power before removing theunit cover.
• ESD Safety procedure must be in place.

• The Companion 5 contains electrostatic
sensitive components. Do not open or handle
except at a static free workstation. Do notremove cover without ESD protection.
• Avoid possible eye injury by wearing protective eye wear or shielding the eyes from possible ﬂying debris.

4. Disconnect the braided tubing from the manifold.
Note:

Sieve bed is now exposed. Recommend plugging or
capping the valve to avoid sieve bed moisture
contamination

5. Disconnect both the 2-way solenoid and power cord
electrical wires from the main circuit board.
6. Carefully remove the tubing connection located on
the right side of the O2 monitor of the circuit board.

1. Use a long-stem phillips toremove the 6 screws from theback case. Remove the four
wheels.

7. Cut zip tie securing all wires together.
8. The two cases should now separate completely forservice to the internal components.
2. Separate the front case fromthe back case.

29

Oxygen Concentrator

HEPA Filter
1. Press the power switch in the “OFF” position and unplug
the electrical cord.
2. Use a long-stem Phillips to remove the 6 screws fromthe back case.
3. Remove the four wheels.

4. Separate the frontcase from the back case.

Note:• Direction of ﬂow on the ﬁlter is indicated by
the text “IN”. HEPA ﬁlter is ﬂow directional.
• In the picture above, “IN” should be facing
down or opposite of the ﬂow control valve.

WARNING: DO NOT use any petroleum based or otherlubricants. A spontaneous and violent ignition
may occur if oil, grease or other petroleum
substances come into contact with oxygen
under pressure. Keep these substances awayfrom the oxygen concentrator, tubing andconnections and any other oxygen source.

Outlet Pressure Test
1. Open up the unit.
2. Remove the black plug from the side of the ﬂow sensor
3. Connect 5/32nd size tubing to the side of the ﬂow sensor.
4. Connect the other end of the tubing to a pressure analyzer.

5. Disconnect the HEPA ﬁlter from the outlet barb
tubing.
6. Disconnect the HEPA ﬁlter from ﬂow meter tubing.

5. Turn the power switch to the “ON” position.
6. Allow the concentrator to run for a minimum of 10 minutes
prior to testing the pressure.
7. Observe the reading on the pressure analyzer. Acceptableread-ings should range between 4.3-4.9 psig.
8. Turn the power switch to the “OFF” position.
9. Remove the pressure analyzer from the ﬂow sensor andreplace the black cap.

Note:

Be careful of the cooling fan while performing
the pressure test. Only attach/detach the test
tubing when the unit is turned off and thepower cord is unplugged.

HEPA Filter

7. Remove the ﬁlter.
8. To replace, reverse steps 1-8.
Note:

Always cut the heads of cable ties to avoid
damaging the tubing.

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Oxygen Concentrator

Adjusting the Product
Regulator for Normal Operation
1. Disconnect the humidiﬁer bottle, if used, and the tubingfrom oxygen outlet.
2. Remove the outer case.
3. Connect the electrical cord to a power source.
4. Set the unit’s I/0 power switch to the “I” position, andallow unit to run at least ten minutes to build up pressure.
5. Turn the ﬂow meter adjustment knob counter-clockwise
until it reaches 5 LPM.
6. Install pressure gauge as directed in the Outlet Pressure
Test section.
7. Turn the adjustment screw using a 3/32” Allen wrench
until the outlet pressure is 4.6 psig (31.7 kPa).
8. Remove the test pressure gauge and replace the outercase.
9. Perform ﬂow rate test to ensure ﬂow rates are still within
speciﬁcations.

Pressure Regulator Replacement
1. Press the power switch in the “OFF” position and unplug theelectrical cord.
2. Remove the outer case.
3. Disconnect the clear tubing from the regulator.
4. Turn the regulator counter-clockwise to disconnect it fromthe sieve bed base.
5. . To replace, reverse steps 1–4.

Flapper (Check) Valve

1. Press the power switch in the “OFF” position and unplug
the electrical cord.
2. Remove the outer case.
3. Disconnect the clear tubing from each side of the ﬂapper
valve that will be replaced.
4. Remove the ﬂapper valve from the concentrator.
5. To replace reverse steps 1–4.

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Oxygen Concentrator

2-Way Solenoid Valve

Compressor

1. Press the power switch in the “OFF” position and unplug
the electrical cord
2. Remove the outer case.
Note:

Sieve bed is now exposed. Recommend thatthe tubing be capped to limit exposure of sieve
bed to moisture.

3. Disconnect the capacitor’s wires.
CAUTION

Do not touch capacitor wire contacts becauseof risk of electrical shock.

1. Press the power switch in the “OFF” position and unplug
the electrical cord.
2. Remove the outer case.
3. Disconnect the solenoid’s wires from the PCB.
4. Remove the 3 screws that mount each solenoid to thesieve bed assembly.

4. Pull upward to remove capacitor.
5. Pull outward to remove each 2-way solenoid valve.
6. Install pressure gauge as directed in the Outlet Pressure
Test section.
7. After performing the replacement check for leaks using
Snoop.
Make sure to use a torque driver that is set to 20 in-lbs.

5. Remove the four (4) screws from the compressor coverusing a Phillips screwdriver.

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Oxygen Concentrator

Cooling Fan

1. Press the power switch in the “OFF” position and unplug
the electrical cord.
2. Remove the outer case.
3. Disconnect the cooling fan’s wires from the PCB.
4. Remove the 4 screws from the compressor cover using aPhil-lips head screwdriver.

6. Disconnect the black hose from the intake on the compressor

7. Lift the compressor upward from the bottom of the caseto remove it from the concentrator.
8. To replace, reverse steps 1–7.

5. Pull outward to slide the compressor cover out fromthe body of the concentrator.
6. Slide the cooling fan out of the fan shelf.

7. To replace, reverse steps 1–6. Upon replacement,
assure airflow direction is blowing toward
compressor, foam is correctly installed around fan
housing, and fan wires are routed properly as shownin the photo above.

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Oxygen Concentrator

Printed Circuit Board (PCB)

Note:

Generation 1 Companion 5 sieve bed assemblies are not compatible with Version 1.8
circuit board software. The sieve bed
assembly will have to be replaced with ageneration 2 sieve bed assembly. This will
also require changing the heat exchanger to a
generation 2 heat exchanger. The software
version can be checked on the display screen
during startup.

1. Press the power switch in the “OFF” position and unplug
the electrical cord.
2. Remove the outer case.
3. Disconnect all wires from the PCB, noting location of wires
connected to PCB.

Sieve Bed Assembly
Note:

If replacing generation 1 sieve bed assemblywith a generation 2 sieve bed assembly, thenthe heat exchanger must also be replaced bygeneration 2 heat exchanger. The circuitboard will also have to be replaced with aversion 1.8 or above board.

Note:

CAIRE offers a complete Gen 1 to Gen 2
factory upgrade under part number 21164063.

WARNING:

Do not open the sieve beds or handle
the molecular sieve.

1. Press the power switch in the “OFF” position and unplug
the electrical cord.
2. Remove the outer case.
3. Carefully cut the head of the cable tie securing wires
together, assuring not to cut any of the secured wires.

PCB connections & Mounting Screws

4. Remove the four (4) mounting screws on the PCB usinga Phillips-head screwdriver.
5. Pull the PCB outward to remove it from the concentrator.

6. To replace, reverse steps 1–5.

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Oxygen Concentrator

4. Unplug valve and power cord wire connections fromPCB.

8. Pull outward on the top of the sieve bed assembly toremove it from the grommet at the top of the case.

9. Lift upward to remove the beds and product chamber,while holding camber, from the base of the concentrator.
5. Remove power cord by removing the cable tie or pulling
the power cord through the securing cable tie.
6. Carefully remove the tubing from the right side of the O2
monitor of the PCB.
7. Using standard pliers remove the ratchet clamp holding
the braided tubing to the manifold.

10. To replace, reverse steps 1-935

Oxygen Concentrator

Power Switch

1. Press the power switch in the “OFF” position and unplug
the electrical cord.
2. Remove the outer case.
3. Review current orientation of the switch and wire
connection locations to assure correct installation.
4. Disconnect the wires from the back of the power switch.
5. Push the switch out through the front of the case.

5. Pull outward on the ﬂow meter from the outside of theconcentrator to remove it.
6. To replace, reverse steps 1–5.

Power Cord

1. Press the power switch in the “OFF” position and unplug
the electrical cord
2. Remove the outer case.
3. Review current placement of wire connections anddisconnect the electrical cord’s wires from the PCB.
4. Release the strain relief surrounding the power cord on theback cabinet using strain relief pliers.
5. Pull the power cord out of the concentrator.
6. To replace, reverse steps 1–5, assuring the power cord isrouted back through the large tie wrap.

6. To replace, reverse steps 1–5.

Flow Meter

Prior to removing the flowmeter it isrecommended to also remove the PCB toavoid damaging the PCB.

1. Press the power switch in the “OFF” position and unplug
the electrical cord
2. Remove the outer case.
3. Remove the two (2) clear tubes that are connected to
the ﬂow meter barbs. These barbs are surrounded by
the PCB.
4. Loosen the nuts from the threaded ﬁtting on the back of
the ﬂow meter using pliers.

Leak Testing
Prior to leak testing:Protect circuit board and all electrical components
from leak test solution and start leak testing atcompressor, following air flow to oxygen outlet. Repair
all leaks by replacing tubing or tightening connections
and fittings as needed.

Note:

For potential leak areas around thePCB(flow meter, check valve, HEPA filter,outlet fitting and O2 sensor connections),
it is recommended to apply leak test
solution to an applicator to avoid damage
to PCB.

1. Turn on concentrator and allow unit to operate for a few
minutes to build up pressure.
2. Press the power switch in the “OFF” position and unplug
the electrical cord
3. Remove the outer case.
4. Apply a stream of liquid leak detector (Snoop®) or a mild
solution of soap and water all ﬁttings and tubing
connections. Excessive bubbling indicates a leak.
5. Replace any tubing that leaks or that appears cracked andworn.
6. Replace the outer case.

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Oxygen Concentrator

Spare Parts, Tools, and Accessories
PN
15062925
21127244
21127245
20843882
15063426
20852059
20852060
20852061
20852062

Optional Accessories

Visit us at www.caireinc.com for more information about
optional accessories. There are many different types of oxygen
tubing, cannula, and humidiﬁers. The following items arerecommended by CAIRE Inc. for use with the Companion 5.
Salter Labs® Humidiﬁer, CAIRE Item Number HU003-1, or
equivalent: If your physician has prescribed an optional
humidiﬁer, follow the manufacturer’s instructions for use. Attach
the humidiﬁer to the oxygen outlet port of the Companion 5.
Use of optional humidiﬁers not recommended for theCompanion 5 may impair performance of the device and may
void the warranty.
CAIRE Humidiﬁer Adapter – Part Number 20843882: If yourphysician has prescribed an optional humidiﬁer, you may need
to use the CAIRE Humidiﬁer Adapter. Follow the instructions
for use. Attach the Humidiﬁer Adapter to the oxygen outlet portof the Companion 5 and then to the humidiﬁer. Attach thecannula, or oxygen tubing to the humidiﬁer outlet.

Description
Air Intake Filter (Cartridge)
Handle Gross Particle Filter
Bottom Gross Particle Filter
Humdiﬁer adapter tubing (ships standard withall new units)Internal Disc Filter, HEPA
Companion 5 Toolkit. Includes Groove Jawed
Pliers(20852060), Screwdriver (20852061)
and Magnetizer (20852062)
Groove Jawed Pliers
Screwdriver, Phillips #2 X 10"
Magnetizer

Salter Labs Oxygen Supply Tubing, Part Number Series
2000, or equivalent: The internal diameter should be no lessthan3/16” (0.48 cm). Connect the oxygen tubing to the outlet port of
the humidiﬁer, or directly to the oxygen outlet port of the Companion 5 if you do not use a humidiﬁer. Connect the other endof the tube to the nasal cannula, if oxygen supply tubing is notalready attached to the cannula. Tubing not speciﬁed for use
with this Companion 5 may impair the performance of thedevice.
Salter Labs Oxygen Cannula, Part Number 1600 Series, or
equivalent: Your physician will have prescribed a cannula todeliver oxygen. In most cases they are already attached to theoxygen tubing. If not, follow the instructions included with thecannula to attach it to the oxygen tubing. Use of an oxygen
cannula not speciﬁed for use with this Companion 5 may impair
the performance of the device.

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Oxygen Concentrator

CAIRE Inc. Customer Service Contact Information
If you need any additional assistance, contact CAIRE Inc:

By mail:
CAIRE, Inc.
2200 Airport Industrial Drive, Suite 500
Ball Ground, GA 30107 USA
By telephone: 800.482.2473
By E-mail:
TechService.global@caireinc.com
www.caireinc.com
Authorized European Union Representative:
Medical Product Services GmbH
Borngasse 20
35619 Braunfels, Germany

E-mail: TechService.global@caireinc.com
www.caireinc.com

Companion 5™ are registered trademarks of CAIRE Inc.
PRO2 Check Elite™ is a trademark of Salter Labs Inc.
Lysol® is a registered trademark of Reckitt Benckiser,UK.

Copyright © 2022. 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, asapplicable.

Date: 04/12/2022
PN 14940837 G — 38