Companion
Reservoirs

Technical Service ManualI Preface
Companion Reservoirs

SERVICE MANUAL

Companion Reservoir
CAIRE, Inc.
2200 Airport Industrial Dr., Ste. 500
Ball Ground, GA 30107
www.caireinc.com
Customer/Technical Service:North and South America
Phone (US Only):
800-482-2473
US:
770-721-7759
Asia, Australia, Pacific Rim
Phone:
770-721-7759
EuropePhone:+44 (0) 1189 367060

Fax: 888-932-2473
Fax: 770-721-7758
Fax: 770-721-7758
Fax: +44 118 9799245

For Customer or Technical Service needs (product assistance, ordering, part numbers, specifications, unexpected events, etc.) contact:
CAIRE Inc.
2200 Airport Industrial Dr., Ste. 500
1-800-482-2473
www.caireinc.com

NOTE: CAIRE Reservoir and Portable units are intended only for the delivery of medical grade oxygen as prescribed by aphysician.
NOTE: SI pressure values expressed in manual are referenced to atmosphere.
HELiOS™, Companion®, and Liberator are trademarks of CAIRE INC.
SNOOP® is a trademark of the SWAGELOK Co.
Teflon® and Krytox® are trademarks of E. I. DUPONT DE NEMOURS & Co.
Kel-F® and Scotch-Brite™ are trademarks of the 3M Co.
Magnehelic® is a trademark of the DWYER INSTRUMENT Co.
QUICK-GRIP® is a trademark of the AMERICAN TOOL Co.
Sporicidin® is a trademark of SPORICIDIN INTERNATIONAL.

Disclaimer

This manual is intended for use by experienced personnel only. No attempt should be made to fill or maintain this equipment until both thismanual and the Patient Operating Instruction booklet have been read and fully understood.

Companion Reservoir Technical Service Manual • PN 20559263 Rev G

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I Preface
FCV
LED
LOX
LPM
NER
POI
N2
TF
DF
DISS

Flow Control Valve
Light Emitting Diode
Liquid Oxygen
Liters Per Minute
Normal Evaporation Rate
Patient Operating Instructions
Nitrogen Gas
Top Fill
Dual Fill
Diameter Index Safety System

PRV
QDV
RMA
RP
RR
SRV
O2
SF
PTFE

Companion Reservoirs

Abbreviations

Primary Relief Valve
Quick Disconnect Valve
Return Materials Authorization
Repair Procedure
Removal and Replacement
Secondary Relief Valve
Oxygen Gas
Side Fill
Polytetrafluoroethylene (“Teflon”)

Definition of Terms

WARNING Description of a condition that can result in personal injury or death.
CAUTION Description of a condition that can result in equipment or component damage.
NOTE
A statement containing information important enough to emphasize or repeat.
(ITEM)
Item numbers used throughout this manual are shown on the illustrations beginning on page 34.

Definition of Product Symbols

SymbolTable 1: Definition of Product Symbols

Definition

SymbolRead instruction manual
The unit contains liquid oxygen
which is extremely cold, almost-300°F. Exposure to such a low temperature can cause severe frostbite.
Do not touch frosted parts
Liquid and gaseous oxygen are nonflammable. However, they cause
other materials to burn faster thannormal. This hazard, along with the
low temperatures of liquid oxygen,warrants certain safety precautions.
Do not smoke near unit or while operating unit

Definition
Name and address of manufacturer
Authorized representative in theEuropean Communityor

Caution, consult accompaning documents
Non-flammable gas
Oxidizing substances
Portable Full

Keep unit well ventilated at all times
Portable Empty
Keep unit in upright position
For use by doctor’s prescription
only.
Drip Proof
Type BF (Electrical Safety)

WEEE and RoHS
This symbol is to remind theequipment owners to return it to a
recycling facility at the end of its life,
per Waste Electrical and Electronic
Equipment (WEEE) Directive.
Our products will comply with therestriction of Hazardous Substances(RoHS) directive. They will not contain more than trace amounts of leador other hazardous material content.

2Companion Reservoir Technical Service Manual • PN 20559263 Rev G

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II
1 Table of Contents
II. Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . .  3
III. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4
IV. Equipment Description . . . . . . . . . . . . . . . . . . . . .  10
V. Theory of Operation . . . . . . . . . . . . . . . . . . . . . . .  11

Companion Reservoirs

I. Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1

VI. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .  14
VII. Saturation Principles. . . . . . . . . . . . . . . . . . . . . . .  15
VIII. Unpacking and Setup . . . . . . . . . . . . . . . . . . . . . .  17
IX. Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  18
X. Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20
XI. Troubleshooting & Repair Procedures . . . . . . . . .  24
XII. Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  39
XIII. Ordering Information. . . . . . . . . . . . . . . . . . . . . . .  40
XIV. Return & Restocking Policy. . . . . . . . . . . . . . . . . .  41
XV. Service Tools/Equipment/Supplies. . . . . . . . . . . .  42

Companion Reservoir Technical Service Manual • PN 20559263 Rev G

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III Safety
Oxygen, as it exists at standard atmospheric pressure and temperature, is a colorless, odorless, and tasteless gas. Oxygen constitutes 21% of the atmosphere, by volume. Aside from its welldocumented ability to sustain life, oxygen also supports combustion, even though it is nonflammable. Many substances which
will burn in air, burn at a faster rate and at a higher temperature inan oxygen enriched atmosphere. Other materials that do not burnin air will burn as oxygen concentration increases. Additionally,
many greases and liquid solvents become extremely hazardous
materials when placed in an oxygen-enriched environment. In its
liquid form, oxygen is still odorless and tasteless, but is pale bluein color. At an operating pressure of 1,4 bar /20 psig, the temperature of liquid oxygen is about -173°C/-280° F. Skin exposed
to such a low temperature can become severely frostbitten.
Contraindications
While CAIRE, Inc. equipment is designed and built to the mostrigid standards, no piece of mechanical equipment can ever bemade 100% foolproof. Strict compliance with proper safety practices is necessary when using any CAIRE unit. We recommendthat our distributors emphasize safety and safe handling practices
to their employees and customers. While safety features havebeen designed into the unit and safe operations are anticipated, it
is necessary that all distributor personnel carefully read and fully
understand WARNINGS, CAUTIONS, and NOTES throughout
the manual. Periodic review of this information is recommended.
These hazards require certain safety precautions to be taken whenworking around gaseous and/or liquid oxygen.
WARNING: Never permit combustible substances such as
greases, oils, solvents, or other compounds not oxygen compatible to contact any component of the unit exposed to higherthan atmospheric concentrations of gaseous or liquid oxygen.
This especially applies to tubing, fittings, and valves.
WARNING: Keep oxygen equipment away from open flames
or electrical appliances such as heaters, stoves, toasters, andother devices with heating elements.
WARNING: Never permit smoking in an area where oxygen
equipment is repaired, filled, or used.
WARNING: Always wear goggles, a face shield, and insulated
gloves when working with or around liquid oxygen.
WARNING: Do not modify equipment without authorizationfrom the manufacturer.

WARNING: These devices are not intended for life supporting
applications nor do they provide patient monitoring capabilities.
WARNING: In certain circumstances, the use of non-prescribed oxygen can be hazardous. These devices should only
be used when prescribed by a physician.
WARNING: Not for use in the presence of flammable anesthetics.
CAUTION: All CAIRE reservoir units should be moved by utilizing the roller base or hand truck. Do not roll units on theirside or edge as insulation damage can occur. All CAIRE reservoir units must be used, stored, and transported in a vertical
position. Do not lay, store, or ship on its side.

Companion Reservoirs

Safety Guidelines and Operational Safety

WARNING: Excess accumulation of oxygen creates anoxygen-enriched atmosphere (defined by the Compressed Gas
Association as an oxygen concentration above 23%). In an
oxygen-enriched atmosphere, flammable items may burn vigorously and may explode. Certain items considered noncombustible in air may burn rapidly in such an environment. Keep allorganic materials and other flammable substances away frompossible contact with oxygen; particularly oil, grease, kerosene,
cloth, wood, paint, tar, coal dust, and dirt which may contain oilor grease. DO NOT permit smoking or open flame in any area
where oxygen is stored, handled, or used. Failure to comply
with this warning may result in serious personal injury.
WARNING: In the event a unit is dropped, tipped over, or
unreasonably abused, immediately, but cautiously, raise thecontainer to its normal vertical position. If substantial container damage has occurred, remove the liquid oxygen fromthe vessel in a safe manner (RP3). Purge the unit with an inert
gas (nitrogen) and promptly return it to CAIRE for inspection.
The container should be prominently marked “CONTAINERDROPPED, INSPECT FOR DAMAGE.” Failure to comply
with these procedures may result in personal injury and can seriously damage the container.
WARNING: Personnel must remove liquid oxygen and depressurize the unit before removing parts or loosening fittings froma unit. Failure to do so may result in personal injury from theextreme cold of liquid oxygen and/or the pressure in the vessel.
WARNING: During transfer of liquid oxygen, components will
become extremely cold. Care should be used to avoid any contact with these components, as serious frostbite may result.

Companion Reservoir Technical Service Manual • 01/19 PN 20559263 Rev G

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III Safety
WARNING: The possibility of fire exists when the combination of a fuel, source of ignition, and oxygen is present. Highconcentrations of oxygen (air is approximately 21% oxygen)greatly enhance the possibility of combustion.
NOTE: Figure 1 below is referred to as the fire/combustion triangle. This triangle describes the three factors required for fire/combustion to occur.

WARNING: During transfer of liquid oxygen gas blow offfrom the vent valve creates a loud horn-like noise. Ear protection is recommended.
WARNING: Extreme high pressure can rupture container orplumbing components. Be sure specified pressure relief devices
are present, in the proper location, and functioning properly.
NOTE: Liquid oxygen at atmospheric pressure expands at aratio of approximately 860:1 (at 0 bar/ 0psig) when vaporizing
into a gas. This can occur very rapidly when exposed to theheat in the atmosphere. See Figure 2 for comparison.

Companion Reservoirs

WARNING: When using concentrated oxygen, the risk of fireis increased.

GAS

LOX

Figure 1: Fire/Combustion Triangle
NOTE: To reduce the risk of combustion/fire when dealing
with LOX, please refer to the following suggestions

1

860
Figure 2: LOX to Gas ratio• Obtain all replacement parts for medical oxygen equipmentfrom the manufacturer.

WARNING: Do not smoke or keep burning tobacco near thisequipment. Death or injury may occur.

• Use only recommended oxygen compatible cleaning andleak detection products.

WARNING: Keep flammable materials away from this equipment. Oils, grease, including facial creams and petroleum jelly,asphalt, and synthetic fibers ignite easily and burn rapidly inthe presence of concentrated oxygen. If needed, use only specified oxygen compatible lubricants as directed.

• Keep the reservoir upright at all times. Secure liquid oxygen equipment when transporting to prevent accidental
tipover and spillage.
• If a liquid oxygen spill occurs indoors, open doors andwindows to ventilate the area. Avoid sources of ignitionand do not walk on or roll equipment over the affectedarea.
• Any clothing or porous material that is splashed with liquid oxygen or otherwise absorbs high concentrations ofoxygen should be removed and aired for at least one houraway from any source of ignition.

WARNING: Liquid oxygen vessels periodically release small
amounts of oxygen gas that must be ventilated to prevent pressure buildup. Do not store liquid oxygen equipment in a car
trunk, closet, or other confined area. Do not place bags, blankets, draperies, or other fabrics over the equipment when it
contains liquid oxygen.

Companion
Reservoir Technical Service Manual • 01/19 PN 20559263 Rev G
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III Safety
WARNING: The use of Accessories, transducers, and cables otherthan those specified by the manufacturer may result in increased
Emissions or decreased immunity of the Companion Reservoir.

WARNING: Portable and mobile RF communications equipment
can affect Medical Electrical Equipment.

WARNING: The Companion Reservoir should not be used adjacent to or stacked with other equipment, and that if adjacent or
stacked use is necessary, the Companion Reservoir should be observed to verify normal operation in the configuration in which it
will be used.

Table 2Companion Reservoirs

WARNING: 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.

Guidance and Manufacturer’s declaration—electromagnetic emissions
The Companion Reservoir is intended for use in the electromagnetic environment specified below. The customer or the user of theCompanion Reservoir should assure that it is used in such an environment.
Emissions test

Compliance

RF emissions

Group 1CISPR 11		

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

RF emissions CISPR 11

Class B

Harmonic emissions
IEC 61000-3-2

The Companion Reservoir is suitable for use in all establishments,
Not applicable

Voltage fluctuations/		
flicker emissions

including domestic establishments and those directly connected tothe public low-voltage power supply network that supplies buildings

Not applicableused for domestic purposes.

IEC 61000-3-3Companion Reservoir Technical Service Manual • 01/19 PN 20559263 Rev G

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III Safety
Companion Reservoirs

Table 3
Guidance and manufacturers declaration—electromagnetic immunity
The Companion Reservoir is intended for use in the electromagnetic environment specified below. The customer or the user of theCompanion Reservoir should assure that it is used in such an environment.
Immunity test

IEC 60601 test level

Compliance level

Electrostatic±6 kV contact±6 kV contact±8 kV air

±8 kV airdischarge (ESD)
IEC 61000-4-2			

Electromagnetic environment—guidance
Floors should be wood, concrete or ceramic tile. If floors
are covered with synthetic material, the relative
humidity should be at least 30%.*

Electrical fast

±2 kV for powerNot applicabletransient/burst

supply lines

DC powered device

IEC 610004-4±1 kV forNot applicable		Not applicable

input/output lines No data input/output lines±1 kV line(s)SurgeIEC 61000-4-5

to line(s)Not Applicable±2 kV line(s)DC powered device

Not Applicableto earth
Voltage dips,<5% UT (>95% dip		short interruptionsin UT) for 0,5 cycle		and voltage

40% UT (60% dip		variations on

in UT) for 5 cycles

Not Applicable

power supply

70% UT (30% dip

DC powered device

input lines

in UT) for 25 cycles		IEC 61000-4-11<5% UT (>95% dip

Not Applicablein UT) for 5 sec
Power frequency

3 A/m

3 A/m

Power frequency magnetic fields should be at levels(50/60 Hz)

characteristic of a typical location in a typicalmagnetic fieldcommercial or hospital environment.

IEC 61000-4-8
Note: UT is the a.c. mains voltage prior to application of the test level.

* This statement indicates that the required testing was performed in a controlled environment and the Companion Reservoir are foundto be compliant with regulations.

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III Safety
Guidance and manufacturers declaration—electromagnetic immunity
The Companion Reservoir is intended for use in the electromagnetic environment specified below. The customer or the user of theCompanion Reservoir should assure that it is used in such an environment.
Immunity test
Conducted RF
IEC 61000-4-6

Radiated RF
IEC 61000-4-3

IEC 60601 test level
3Vrms
150kHz to 80 MHz

3 V/m
80 MHz to 2,5 GHz		

Compliance level
Not Applicable
Battery powered
device3 V/mElectromagnetic environment—guidancePortable and mobile RF communications equipment should
be used no closer to any part of the Companion Reservoir,
including cables, than the recommended separation distancecalculated from the equation applicable to the frequencyof the transmitter.
Recommended separation distanced = 1.2 √P
d = 1.2 √P 80 MHz to 800 MHz
d = 2.3 √P 800 MHz to 2,5 GHz

Companion Reservoirs

Table 4*

where P is the maximum output power rating of thetransmitter in watts (W) according to the transmitter
manufacturer and d is the recommended separation
distance in meters (m).
Field strengths from fixed RF transmitters, as determinedby an electromagnetic site surverya, should be less thanthe compliance level in each frequency rangeb.
Interference may occur in the vicinity of equipment 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 reflection fromstructures, objects and people.
aField 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 asses the electromagnetic environment due to fixed RF transmitters, an electromagnetic site survey should be considered. If the measured field strength
in the location in which the Companion Reservoir is used exceeds the applicable RF compliance level above, the Companion
Reservoir should be observed to verify normal operation. If abnormal performance is observed, additional measures may be necessary, such as reorienting or relocating the Companion Reservoir.
bOver the frequency range 150 kHz to 80 MHz, field strengths should be less than 3 V/m.

* This table is included as a standard requirement for equipment which has been tested to specific test levels and over specificfrquency ranges and been found compliant with regulations.

Companion Reservoir Technical Service Manual • 01/19 PN 20559263 Rev G

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

150 kHz to 80 MHzm

Companion Reservoirs

Table 5*80 MHz and 800 MHz 800 MHz to 2,5 GHz

d=1.2√P

d=1.2 √P

d=2.3 √P

0,01

0.12 m0.12 m

0.23 m0,10.38 m0.38 m0.73 m

1

1.2 m

1.2 m

2.3 m

10

3.8 m

3.8 m

7.3 m

100
12 m
12 m
23 m
For transmitters rated at a maximum output power not listed above, the recommended separation distance (d) in meters (m) canbe 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.
* This table is included as a standard requirement for equipment which has been tested to specific test levels and over specificfrquency ranges and been found compliant with regulations.

Companion Reservoir Technical Service Manual • 01/19 PN 20559263 Rev G

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IV Equipment Description
Top Cover

1. Cryogenic Container This assembly is a double walledvacuum insulated Dewar for storing liquid oxygen (LOX) atapproximately -173°C/-280°F. The inner vessel is designed
to safely hold liquid oxygen and is protected from over pressurization by the primary relief valve. Vacuum insulation
between the inner and outer vessel keeps outside heat from
causing the cold liquid inside to evaporate.

Shroud

2. Plumbing System The plumbing system consists of thewarming and breathing coils, vent valve, R/E valve, SRV,
high and low pressure lines, pressure gauge (European units
only), FCV and QDV (fill connector).

Fill Connector
Vent Valve
Pressure Gauge
Contents Indicator
Pop-Off Actuator
Low Pressure
Sense Line
Breathing CoilSRV**
R/E Valve**

FCV
Humidifier Adaptor

PRV Outlet**Plumbing Manifold**

The CAIRE Companion Reservoir units are the stationary components in a liquid oxygen system. The Companion Reservoir
incorporates a stainless steel cryogenic container with thevalves, plumbing, and associated hardware required to deliver
gaseous oxygen to the patient at near ambient temperature. The
Companion Reservoir is comprised of four major assemblies,
grouped according to function.

Companion Reservoirs

Figure 3: Companion reservoirs components

Vacuum Port

Warming Coil3. Shroud Assembly The reservoir unit’s shroud assembly includes a shroud and top cover. The shroud is made of durable plastic and designed to protect the internal componentsof the plumbing system.

High Pressure
Sense Line
Serial Number
Identification Label

Condensate
BottleCondensation Ring

Cryogenic Container

4. Liquid Content/Level Indicator This system uses differential
pressure to measure the level of LOX remaining in the cryogenic vessel and displays the level with an integral indicatorthat is viewed through the top cover. The liquid contents areindicated by aligning the colored line on the piston with thegraduated markings on the cylinder.

* = Units manufactured for sales in Europe (TPED) contain aninternal pressure gauge. Please contact Technical Service withany questions regarding unit identification.
** = Units manufactured for sales in Europe (TPED) and/or units
manufactured after June 2011 will have a “3 Port” manifold design. These units will also contain an internal pressure gauge andan R/E valve assembly. Please contact Technical Service withany questions regarding unit identification.

Companion Reservoir Technical Service Manual • 01/19 PN 20559263 Rev G

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IV Equipment Description
Each Companion reservoir is identified by a unique serial number. For reservoirs manufactured prior to January 1985, the number begins with a single digit signifying the year of manufacture,
followed by digits signifying the month of manufacture, followedby digits signifying the calendar day of manufacture, and ends
with digits signifying the unit’s production number for that day.
For reservoirs manufactured between January 1985 andOctober 1994, the number begins with a double digit signifying
the year of manufacture, followed by digits signifying the monthof manufacture, followed by digits signifying the calendar day of
manufacture, and ends with digits signifying the unit’s production number for that day.
For reservoirs manufactured in and after October 1994, thenumber begins with a double digit signifying the year of manufacture, followed by digits signifying sequential day of the year
on which the unit was manufactured, and ends with digits signifying the unit’s production number for that day.
For reservoirs manufactured after June 2010, the number
begins with the letters CB signifying the manufacturing location,
followed by the reservoir product code B30, followed by digits
signifying the year of manufacture, followed by a two digit number to signify the week of the year that the unit was manufactured
and ends with digits signifying the unit’s production number forthat week.
For all units manufactured prior to June 2010, the serial
number is etched handle of the cryogenic container. For units
manufactured after June 2010, a label containing the serial number is placed on or above the handle of the reservoir. This Serial
Number is crucial if a problem arises with the unit or if support
is ever needed through CAIRE Customer Service or Technical
Service.

Figure 8
Reservoirs Manufactured prior to January 1985

4 - 6 - 25 - 1

Designates Year DesignatesMonth(4 represents
1984)

Designates Day Designates Numberof Monthof Specific Unit
Produced that Day

Reservoirs Manufactured in and after January 1985
and prior to October 1994

Companion Reservoirs

Reservoir Serial Number Identification

88 06 25 01

Designates Year Designates
Month

Designates Day Designates Numberof Monthof Specific Unit
Produced that Day

Containers Manufactured in and after October 1994

95 176 001

Designates Year
(4 represents
1984)

Designates Sequential Day
of Year(Jan 1 = 001, Dec 31 = 365)

Designates Numberof Specific Unit
Produced that Day

Reservoirs Manufactured after June 2010

CB B30 10 29 0964

Designates
Designates
Manufacturing Reservoir
Product
Location
Code

Designates Designates DesignatesYear
Week of
Numberthe Year of Specific
Unit
Producedthat Week

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V Theory of Operation

As in all vacuum-insulated cryogenic containers, some liquid(oxygen in this case) is always evaporating into a gas. The rateof generation of this gas, with the flow control valve closed, iscalled the normal evaporation rate (NER). This gas is lost throughthe primary relief valve.
WARNING: Low oxygen flow rates to the patient may result
if CAIRE reservoirs are filled with improperly saturated liquid
oxygen.
WARNING: The vent valve orifice does not guarantee properly
saturated LOX. The filling source tank must have a minimum
2,4 bar/35 psig (optimum 3,4 bar/50 psig) to transfill into
CAIRE reservoirs or low saturation will occur.

When the FCV is at any setting other than off, and the economizer valve is open (pressure over 1,3 bar/19.5 psig), gaseous oxygen is forced from the head space in the inner vessel,through the economizer valve, to the warming coil and breathingcoil. This process conserves or “economizes” liquid oxygen by
withdrawing the head gas first, instead of allowing it to escapethrough the relief valve. While flowing through the breathingcoil, the cold gaseous oxygen is warmed to near-ambient temperature before being metered and dispensed by the flow control
valve. Whenever gas is removed from the space above the liquid
oxygen (head space), the inner vessel internal pressure begins todrop slightly. When the pressure drops to 1,3 bar/19.5 psig, theeconomizer valve closes, forcing liquid oxygen up the withdrawal
tube, through the bypass tee and through the warming coil where
it becomes gas, then through the FCV, providing gaseous oxygento the patient.

Companion Reservoirs

The Companion reservoir provides a source of liquid oxygen to
fill portable units. It also provides gaseous oxygen to a patient
through the 12 position, 0-6 LPM FCV. If all reservoir outlets areclosed (Vent Valve, PRV, SRV, FCV, QDV) with LOX in theunit, then the pressure in the inner vessel will remain near the primary relief valve setting of less than 1,7 bar/25 psig.

NOTE: In Figure 5, the operating pressure is at or below
1,3 bar/19.5 psi.

NOTE: In Figure 4, the operating pressure is above
1,3 bar/ 19.5 psi.

Figure 4

Gas

Gas

LiquidLiquidFigure 5Companion Reservoir Technical Service Manual • 01/19 PN 20559263 Rev G

12

V Theory of Operation
Companion Reservoirs

Liquid Contents/Level Indicator Operation

The contents indicator, visible through the top cover of the reservoir, measures and displays the amount of liquid oxygen remaining in the Companion reservoir. It consists of a moveable piston/rolling diaphragm assembly that is sealed within a plastic cylinder. The system is based on the principle that the pressure createdat the bottom of a tank of liquid is proportional to the height of
the liquid. The pressure signal is also a function of gaseous headspace pressure acting on the top of the liquid. A differential pressure between the liquid and the headspace gas causes the piston
to move in the cylinder a distance proportional to the amount ofliquid oxygen in the container. The liquid oxygen contents are indicated by aligning the colored line on the piston with the graduated markings on the cylinder.
Internal Pressure Gauge Operation (If Equipped)

The pressure indicator is a bourdon tube pressure gauge that indicates the status of the system pressure in the head space. The indicator is not calibrated in units of pressure. However, a dark blue
shaded region on the indicator dial marks an acceptable operatingpressure range of approximately 1.0-1.7 bar/15-25 psig. The pressure indicator is used to evaluate the reservoir system headspacepressure during a fill and during system operation. The pressure
indicator does not indicate oxygen outlet pressure.

Figure 6

2.0

CAIRE

xx

xx

xx

Rev

A

1.1 bar

USE NO OIL

xx

60 psiFigure 7

Companion Reservoir Technical Service Manual • 01/19 PN 20559263 Rev G

4 13

VI
1 Specifications
COMPANION RESERVOIR SPECIFICATIONS
MODEL

C21

C31

C41

­Volume of LOX (typical)

21.3 liters / .021 m3

31.6 liters / .032m3

41.7 liters / .042 m3

Weight of LOX @ 1,5 bar/22
psig Saturation (typical)

23,29 kg / 51.34 lbs

34,58 kg / 76.24 lbs

45,68 kg / 100.71 lbs

Gaseous Oxygen Equivalent @ 1
atm. And 21°C/70°F

18,318 liters / 646.9 ft3

27,176 liters / 959.7 ft3

35,862 liters / 1,266.5 ft3

Height69.9 cm/27.5 in

83.8 cm/33.0 in

97.8 cm/38.5 in

Diameter

36.2 cm/14.25 in

36.2 cm/14.25 in

36.2 cm/14.25 in

Empty Weight

20,41 kg / 45.00 lbs

23,13 kg / 51.00 lbs

27,22 kg / 60.00 lbs

Full Weight

43,70 kg / 96.34 lbs

57,72 kg / 127.24 lbs

72,90 kg / 160.71 lbs

Outlet Pressure

1,3 bar/19.5 psig

1,3 bar/19.5 psig

1,3 bar/19.5 psig

Nominal Operating/Economizer
Pressure

1,3 bar/19.5 psig

1,3 bar/19.5 psig

1,3 bar/19.5 psig

Density (Weight of LOX) @Nominal Operating / Economizer
Pressure

1.095kg/L(2.415lbs/L)

1.095kg/L(2.415lbs/L)

1.095kg/L(2.415lbs/L)

Primary Relief Valve Opening
PressureLess than 1,7 bar/25 psig

Less than 1,7 bar/25 psig

Less than 1,7 bar/25 psig

Primary Relief Valve Reseat
Pressure

Greater than 1,4 bar/21 psig

Greater than 1,4 bar/21 psig

Greater than 1,4 bar/21 psig

Secondary Relief Valve Opening
Pressure

2,1 bar/30 psig+/- 5%

2,1 bar/30 psig+/- 5%

2,1 bar/30 psig+/- 5%

Secondary Relief Valve Reseat
Pressure

Greater than 1,9 bar/27 psig

Greater than 1,9 bar/27 psig

Greater than 1,9 bar/27 psig

Normal Evaporation Rate (NER)(typical).84 kg / 1.85 lbs.87 kg / 1.92 lbs.87 kg / 1.92 lbs

10 L/min10 L/min10 L/min

Mechanical, Differential
Pressure Based

Mechanical, Differential
Pressure Based

Mechanical, Differential
Pressure BasedOperating Temperature

10°C to 40°C/50°F to 104°F
95% max. relative humidity

10°C to 40°C/50°F to 104°F
95% max. relative humidity

10°C to 40°C/50°F to 104°F
95% max. relative humidity

Storage Temperature-40°C to 70°C/-40°F to 158°F
90% max. relative humidity-40°C to 70°C/-40°F to 158°F
90% max. relative humidity­-40°C to 70°C/-40°F to 158°F
90% max. relative humidity

Maximum Outlet Flow
Contents Indicator

Companion Reservoirs

Table 6Note:
All specifications are based upon optimum environmental and pressure conditions as stated above.
Listed capacities have incorporated a 2% ullage in compliance with ADR requirements.

At optimum operating conditions, the conversion factor of liquid oxygen to gaseous oxygen is 1:860.
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VII
1 Saturation Principles
Oxygen, like most gases, will condense into a liquid with an increase in pressure or decrease in temperature. As a liquid, oxygen ispale blue in color and is about 860 times as dense as its gaseous form. At atmospheric pressure (14.7 psia), oxygen condenses into its
liquid form at a temperature of about -297°F (-184°C). Liquid oxygen (LOX) is an efficient form of oxygen to meet a patient’s portable, ambulatory oxygen needs. A volume of liquid oxygen, when vaporized, yields about 860 volumes of gaseous oxygen (Figure 2).
As you can see, a relatively small volume of liquid oxygen provides a much larger volume of gaseous oxygen for a patient to use.
In medical liquid oxygen systems, liquid oxygen, and the gaseous oxygen resulting from its vaporization or boiling, is stored underpressure. The elevated pressure, typically 22 psig (152 kPa), enables oxygen to flow to the patient at a selected, prescribed rate. To
sustain this oxygen flow to the patient, the liquid oxygen must be in a state that allows vaporization to readily occur. In other words,
the liquid oxygen must be in a state of saturation. Let’s take a look at what liquid saturation is all about.

Companion Reservoirs

Oxygen, in its normal state, is a colorless, tasteless, and odorless gas that is non-flammable, although it greatly accelerates combustionin high concentrations. It constitutes about 21% of the Earth’s atmosphere by volume. Oxygen in higher concentrations is medicallybeneficial to patients suffering from certain respiratory diseases.

A saturated liquid is one that absorbs the maximum amount of heat possible at a given pressure without vaporizing into a gas. If additional heat is added, the saturated liquid begins to vaporize (boil) while remaining at a constant temperature until all of the liquid
is vaporized. A common example of a saturated liquid is water at its boiling point of 212°F (100°C) at sea level. The constant addition of heat to the boiling water does not cause it to become hotter, but instead causes part of the liquid water to turn to water vapor(Figure 9).

Figure 9: Saturated (Boiling) Water at Sea Level
The saturation (boiling) point of a liquid depends not only on temperature but also on pressure. If the pressure in a container of saturated liquid increases, the temperature required for saturation to occur will also increase. This leaves the liquid unsaturated, that is,capable of accepting more heat before it will boil (Figure 10).

Figure 10: Saturated (Boiling) Water at Higher Pressure
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VII
1 Saturation Principles
Companion Reservoirs

If the pressure in a container of saturated liquid decreases, the temperature required for saturation to occur will decrease. This leaves
the liquid “super saturated” or too warm. When this occurs, rapid boiling and vaporizing of some of the liquid occurs. The rapid boiling and evaporation of the liquid dissipates the excessive heat until the remaining liquid cools down to the new saturation temperatureassociated with the decreased pressure (Figure 11).

Figure 11: Saturated (Boiling) Water at Lower Pressure
Oxygen, which is normally a gas at atmospheric pressure, changes into liquid form when it is cooled to about -297°F (-183°C) at
atmospheric pressure. It is saturated at this temperature (and pressure) which means it will remain a liquid as long as no additional
heat is added. However, the large quantity of heat present in the atmosphere constantly enters the liquid oxygen and causes it to boil
and vaporize back into a gas. Since it is virtually impossible to keep all of the heat in the atmosphere from entering the liquid oxygen,constant boiling and vaporization occurs.
Now when liquid oxygen is placed in a closed container, the vaporizing gas is trapped and begins to build pressure. As pressure increases above atmospheric pressure, more heat is needed for boiling to occur at the higher pressure. The heat that is constantly available from the atmosphere warms the liquid to a higher temperature where boiling again occurs. The vaporizing gas builds pressure
and the process continues. As the pressure on liquid oxygen builds, the related saturation temperature of the liquid increases proportionally (Figure 12).

Figure 12: Liquid Oxygen Saturation Curve
It is important to maintain liquid oxygen saturation (boiling) at the specified operating pressure of the system. As an oxygen flow
demand is put on the system, a slight decrease in pressure occurs due to oxygen withdrawal. The saturated liquid oxygen in the system vaporizes enough gaseous oxygen to maintain system operating pressure. This ensures proper oxygen flow to the patient. If theliquid oxygen saturation temperature is too low, the corresponding lower saturation pressure causes low oxygen flows to the patient.
the patient. If the liquid oxygen saturation temperature is too high, the corresponding high saturation pressure causes inaccurate flow
oxygen flow to the patient, as well as increased NER, loss of product, damage to components, etc. In both instances of either too low
or too high saturation temperatures, the same effects will be seen in portable devices that are filled off of the reservoirs.
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VIII Unpacking and Setup
Transport

1. Inspect carton for shipping damage. Report any damage tofreight company before signing bill of lading.

Specifically designed roller bases are available for moving
CAIRE reservoirs short distances on smooth surfaces. Hand
trucks can also be utilized for transport as well. CAIRE reservoirs may be moved about or transported in a vehicle while full
without damage; however, they should not be dropped, placed on
their sides or handled roughly in order to prevent damage.

2. Check description on carton against your order.
3. Unpack unit, including all accessories and documentation.
4. Set aside packing materials in case unit must be returned to
the factory.
Setup

NOTE: It is never acceptable to tip the reservoir to one side to“roll” the unit, even if the unit is empty.

Companion Reservoirs

Unpacking

1. Locate and record the reservoir serial number. Reinstall the
shroud.
2. Visually inspect the reservoir for damage from improper
handling. Note any dents in the container, cracks in the
shroud, missing or loose hardware, and bent quick disconnect valves.
3. Check the vent valve for smooth operation. If possible,
connect a portable unit to the reservoir to check for smooth
coupling, and to make sure the portable unit is in properalignment with the reservoir when mated and there is no interference with the shroud or or case of portable unit.
4. Check all labels for damage and wipe away any dust on unit
with a clean, dry, lint-free cloth.
5. Verify the fill connector release button and mechanism
move freely.
6. Verify that an appropriate vent wrench is available for fillingof reservoir.

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IX Operation
NOTE: The fill source should have the correct fitting (5/8” x 45°
male flare) to connect to transfer line.
WARNING: Filling must be performed in a well-ventilated area
to prevent development of an oxygen-enriched atmosphere.
WARNING: Wear insulated gloves and eye protection whenever working with liquid oxygen.
1. Fill Source Preparationa. Ensure the source contains a sufficient amount of liquid oxygen to completely fill the reservoir.
b. Ensure the liquid oxygen in the fill source is saturated at 2,43,4 bar (35-50 psig).
NOTE: Proper saturation is critical when filling a CAIRE reservoir. If the fill source is not properly saturated, the unit will not
function correctly, resulting in inaccurate flow rates and excessive
boil off of liquid oxygen. This will cause portable units which arefilled off the reservoir to act in the same manner. Please refer to theSaturation Principles section to learn more about the importance ofproper saturation.
2. Fill Procedurea. Required Equipment:o Fill source as outlined above
o Liquid oxygen transfer lineo Appropriate transfer line fill adapter
o Appropriate vent valve wrencho Eye protectiono Pressure gauge (for reservoirs not equipped with aninternal pressure gauge)o Insulated gloves
NOTE: Ensure Compliance with All Local Regulations when
Filling LOX Reservoir Units.
b. Verify that the liquid level meter is operating properly.
NOTE: If liquid level meter operates improperly, refer toTroubleshooting section of the corresponding technical manual.
c. Connect transfer line to fill source. Connect proper transfer
line adapter to transfer line.
d. Fully open liquid valve on fill source.

e. Purge transfer line for a minimum of 5 seconds ensuring gas
is safely piped away from operator:
i. Connect transfer hose fill adapter to a securely
mounted mating QDV.
-OR-

		 ii. If the transfer hose fill adapter is equipped with a male
QDV, push the adapter poppet against an unpainted stainless steel surface.
f. Wipe both reservoir and transfer line adapter fill connectors
with lint free rag to remove residual moisture.

Companion Reservoirs

Filling

NOTE: Purge the transfer line any time fill source valve has
been closed.
g. Using vent valve wrench, fully open reservoir vent valve.
h. Connect transfer line to reservoir to begin fill.
i. While filling, throttle the vent valve with the vent valve wrench
as needed to keep the reservoir pressure at the nominal fill pressure of 1,34 bar (19.5 psig). Monitor the pressure using one of
the following techniques:i. Monitor the internal pressure gauge if equipped.
				-ORii. For reservoirs that are not equipped with an internal pressuregauge, connect a pressure gauge to the oxygen outlet and open
the FCV to 2 LPM or greater.
j. When liquid flows from the vent outlet, terminate the fill bydisconnecting the transfer line fill adapter from the reservoir
using the reservoir’s pop-off assembly.
k. Close reservoir vent valve immediately after disconnecting
the transfer line from the reservoir.
l. Disconnect the pressure gauge from the oxygen outlet andturn off flow control valve.
Caution: Do not allow excessive venting of liquid oxygen
through the vent valve. Prolonged exposure may freeze the ventvalve in the open position.
m. Replace protective cover on the QDV adapter. Close the liquid valve on the fill source and properly store the transfer
line and fill adapter.
n. Verify that the liquid level meter indicates full.
NOTE: The liquid level indicating system is only accurate after
the vent valve is closed, and the oxygen has stabilized for fiveminutes.
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IX Operation
Table 7 shows the approved cleaning and disinfecting
solutions are acceptable for use with Companion reservoirs.

NOTE: The liquid level indicating system is accurate only after
the vent valve is closed, and the oxygen has stabilized for approximately five minutes.

TABLE 7: Recommended Cleaning and Disinfectant Solutions

As noted in the Theory of Operation, the Companion reservoirs
are equipped mechanical liquid level meters. The meter measuresthe level of LOX remaining in the cryogenic vessel and displays
it on an integral indicator that is viewed through the top cover.
The liquid contents are indicated by aligning the colored line on
the piston with the graduated markings on the cylinder.
Cleaning and Disinfection
To insure proper functioning and end-user safety, CAIRE reservoirs should be cleaned whenever dirt or grime is visually apparent. The unit should be disinfected if required by applicable local
regulations or the home healthcare distributor’s own decontamination schedule.
Preparation

Prior to cleaning or disinfection, the unit should be completely
purged of LOX. The technician should wear appropriate safety
gear when performing the following procedures.
Cleaning

1. Remove the shroud and top cover and clean the interior andexterior using only water. Wipe dry with a towel. Use cottonswabs in tight places. Use Scotch- Brite pad lightly with detergent to remove scuff marks on the shroud.

2. Clean the contents indicator using one of the approved cleaners in Table 7. Do not spray cleaners directly onto the contents indicator. Spray cleaners onto a cloth and apply themusing the cloth. Make sure to rinse the surface of the contents indicator thoroughly with water after cleaning and thenwipe it dry.
NOTE: Make sure that the fill connector and vent valve shaft are
thoroughly dry before proceeding.
3. Clean the reservoir plumbing and lower shroud with water.
Dry with a towel and oil-free compressed gas.

4. Remove the condensate bottle and thoroughly clean and dry
it. Verify that the drain hole on the condensation ring and thedrain tube are open and unobstructed.
5. Clean the stainless steel container with oil-free cleaner andtowel.

NOTE: Only use disinfectants or cleaning agents approved
for use with this equipment by CAIRE such as Sporicidin,
Hydroklean, or others as specified by CAIRE.

Cleaning

Disinfecting

Sporicidin Disinfectant Solution
Mild dish washing detergent/warm water solution
Sporicidin Disinfectant Solution

Household Bleach (1:10 dilution with water,
freshly made within 24 hours)

Companion Reservoirs

Liquid Level Measurement

NOTE: After performing the cleaning/disinfecting process, it issuggested to perform the following inspections and testing.
Inspection• Inspect the shroud and top cover for cracks, warpage, and discoloration.
• Verify that the warning labels are present and legible on the
shroud and top cover.
• Verify that the Portable release mechanism moves freely andis not worn. Verify that the release button is secure on thelever and is not cracked.
• Verify that the fill connector is not worn or damaged and thatthe poppet is not broken.
• Verify that the vent valve shaft pin and valve stops are notbent or broken.
• Verify that the contents gauge is reading empty.
• Verify that the aluminum tubing is not bent or kinked and thata uniform air gap exists between each coil.
Testing
1. Perform Leak Test.
2. Perform Liquid Oxygen Functional Tests.
3. Perform Gaseous Oxygen Functional Tests.
Disposal ProductAt the end of the unit’s life, all reservoir units must be returned
to a recycling facility in compliance with the Waste Electricaland Electronic Equipment Directive (WEEE), or otherapplicable codes and regulations. Alternatively, CAIRE may becontacted for disposal information.
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X Maintenance (Schedule A, 30-Month)

Routine maintenance is a series of steps used to assure that
equipment is functioning properly.
1. If a unit fails a given test, one of two things may be done:
a. Refer to the Troubleshooting section of the corresponding
technical manual.
-orb. Return the unit to CAIRE, Inc. for repair.
2. Schedule – Maximum of 30 months between routine
mainte-nance testing. Unit should be tested whenever a
problem is suspected.
B. Procedure
Follow the steps in order listed. If the unit fails any step, refer toTroubleshooting section of the corresponding technical manual.

e. Pressure Retention Test (RP14).
f. Replace shroud (RP5).
g. Liquid Contents/Level Indicator Test (RP6).
h. Flow Rate test (RP20).
3. Check Efficiency of Unit:
a. Inspect unit for cold or sweaty condition and for excessive
venting from relief valve (some venting is normal).

Companion Reservoirs

There are two schedules for routine maintenance which thehome health care distributor may follow. These schedules allow
the distributor maximum flexibility while assuring that equipment is operating properly. The healthcare distributor may follow either Schedule A or Schedule B, or a combination of thetwo schedules.
CAIRE, Inc. recommends returning the unit to a CAIRE service
facility every 10 years for vacuum check and re-evacuation
if necessary.
Schedule A – 30 Monthb. If the dewar bottle is cold and sweating, and/or there isexcessive venting from the relief valve, an NER test shouldbe performed (RP23).
4. Prepare for Use:a. Empty contents (RP3).
b. Clean and/or disinfect outside of unit following instructions
set forth in the Operation section of the corresponding
technical manual.
NOTE: Only use disinfectants or cleaning agents approved for use
with this equipment by CAIRE such as Sporicidin, Hydroklean, orothers as specified by CAIRE.

NOTE: See the Troubleshooting and Repair section of the corresponding technical manual on the detailed procedures for the tests
mentioned below.
1. Visual Inspection:
a. Remove any LOX prior to maintenance (RP3).
b. Look for damaged or missing parts.
c. Verify the meter reads empty. For reservoirs equippedwith electronic level gauges, verify the low battery LED is
not lit and no error codes appear on the meter.
2. Component Test:
a. Remove shroud (RP5).
b. Perform Leak Test (RP 2)
c. Perform PRV test (RP11).
d. Perform SRV test (RP12).

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X Maintenance (Schedule B, Continuous)
A. Introduction
Continuous maintenance is a set of tests and inspections done
periodically to ensure equipment is functioning properly. It canbe performed by drivers or other personnel while the equipment
is in service.
1. f a unit fails a given test, it should be taken out of service andsent to the Repair Center/Department for further inspection.
2. Schedule – Scheduled intervals should be determined by theequipment service provider.
B.

f. If LOX is still present in the unit, inspect for heavy frost
or condensation on the exterior of the unit, which would indicate poor vacuum.
g. Visible dirt or contaminants inside and outside of theupper shroud, as well as inside and outside of the condensate
collector.
h. Vent valve functionality (all parts are present and thevalve functions as intended)
C. Post-Fill Procedure
1. Visually verify:

Pre Fill Procedurea.

QDV poppet is closed and not leaking

1. Visually inspect for:b.

Vent valve is not leaking

a.

Broken shrouds or shroud componentsb.

QDV deformationc.

Level indicator functionalityd.

Presence of all required labelse.

Cryogenic reservoir damage (dents, dings)

Companion Reservoirs

Schedule B – Continuousc. No heavy frost or condensation is present on the exteriorof the vessel of the reservoird.

Liquid level indicator reads accurate amounte.

Pressure gauge is reading accurate pressure (if equipped)

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XI
1 Troubleshooting & Repair Procedures
A.
B.
C.

Introduction------------------------------------------------------------------------------------------ 24
Troubleshooting Charts----------------------------------------------------------------------------- 25
Repair Procedures
RP1
General---------------------------------------------------------------------------------- 30
RP2
Leak Test-------------------------------------------------------------------------------- 30
RP3
Emptying/Purging Reservoir RR---------------------------------------------------- 31
RP4
Condensation Collector RR---------------------------------------------------------- 31
RP5
Shroud Assembly RR----------------------------------------------------------------- 31
RP6
Liquid Contents/Level Indicator Test----------------------------------------------- 32
RP7
Liquid Contents/Level Indicator RR------------------------------------------------ 32
RP8
Purging Liquid Contents/Level Indicator RR-------------------------------------- 32
RP9Internal Pressure Gauge Test (if Equipped)---------------------------------------- 33
RP10Internal Pressure Gauge RR (if Equipped)----------------------------------------- 33
RP11
PRV Test-------------------------------------------------------------------------------- 33
RP12
SRV Test-------------------------------------------------------------------------------- 33
RP13
PRV, SRV, R/E Valve RR------------------------------------------------------------ 34
RP14
Pressure Retention Test--------------------------------------------------------------- 34
RP15
Warming Coil Assembly RR--------------------------------------------------------- 35
RP16
Vaporizer Coil Assembly RR (if Equipped)--------------------------------------- 35
RP17
Vent Valve RR------------------------------------------------------------------------- 35
RP18
Fill Connector Release Assembly RR----------------------------------------------- 36
RP19
QDV Assembly RR-------------------------------------------------------------------- 36
RP20
Flow Rate Test------------------------------------------------------------------------- 37
RP21
Operating Pressure Test--------------------------------------------------------------- 37
RP22
Economizer Test----------------------------------------------------------------------- 37
RP23
NER Test-------------------------------------------------------------------------------- 38
RP24
FCV RR--------------------------------------------------------------------------------- 38
RP25
Calculating Liquid and Gaseous Oxygen Capacity........39

Companion Reservoirs

Table of Contents

Introduction
1. These procedures are designed to be performed only by qualified personnel with proper equipment.
2. Any failure during routine maintenance checks will refer you to this section. See troubleshooting chart for appropriate
procedure.

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XI
1 Troubleshooting & Repair Procedures
When more than one probable cause is identified, the causes are listed in order of most likely to least likely reasons for the problem.
Table 8Symptom

Probable Cause

Corrective Action

1. Unable to start fill orexcessively long filltimes

a. Transfer line not engaged fully on Reservoir
QDVa. Make sure the QDV on the transfer line and reservoir are properly aligned and ensure that a downward force is being applied to the transfer line
assembly.
b. Verify that pressure from the source is within the
35-50 psi range to fill the reservoir.
c. Ensure that the vent valve is able to be turned to thefully open position.
d. Allow LOX to saturate to proper pressure.
e. Check fill connector and cartridge assembly fordamage; make sure fill connectors fully engage.
f. Inspect the valve for blockages and verify that flow
passes through during a fill. Clean by blowing out
with compressed gas or replace parts if necessary.
g. Check the reservoir for leaks (RP2) and repair ifneeded.
a. Replace the QDV lip seal on the portable unit ortransfill adaptor.

b. Low source pressurec. Vent valve not open or is blockedd. Source tank is either under or oversaturated
e. Fill connector not opening properly
f. Vent valve is obstructedg. Leak in the system
2. Liquid leaks from thecoupled QDVs during
the filla. Worn or damaged lip seal

3. Unable to disconnect
the transfer line or
portable unit from thereservoir after a filla. Pop-off assembly not being utilized

4. Liquid leaks from the
QDV poppet after
fillinga. Ice crystal preventing the QDV from closing
properly.

5. Excessive venting fromrelief valves (hissing
sound)

b. QDVs are frozen together

b. Dirty or damaged QDV poppet

a. Saturation pressure too high.
b. Relief valve frozen open
c. Faulty relief valve

d. Partial or complete loss of vacuum

Companion Reservoirs

Table 5 below provides troubleshooting procedures for the Companion reservoir. This guide is not all-inclusive but is intended toserve as a general outline for solving operational problems. The table describes symptoms, identifies probable causes, and suggests
corrective actions.

a. Ensure that the pop-off assembly on the reservoir
is being used. Do not use force to separate theQDVs.
b. Leave the units coupled with the vent valve closed
and let them sit until they warm up enough todisconnect. Always ensure that male and female
QDV’s are cleaned and dried prior to each fill.
a. Engage and disengage the transfer line onto thereservoir several times to dislodge the ice crystal.
Always be sure that the male and female QDVs are
wiped clean and dry before filling.
b. Replace the QDV assembly (RP19)

a. Inspect the saturation pressure of the reservoir used
for filling. Allow at least 30 minutes at no flow for
the portable to saturate properly.
b. Allow the portable to warm and thaw. Attempt to
re-fill the portable.
c. Test the relief valves (RP11/RP12) and replace ifnecessary (RP13)
d. Conduct the NER test (RP23) and return the unit to
CAIRE, inc. if necessary.

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XI Troubleshooting & Repair Procedures
Symptom

6. No flow at oxygen outlet

Probable Cause

Corrective Action

a. Reservoir is empty

b. Flow control valve turned off
c. Nasal cannula kinked or disconnected
d. Saturation pressure is too low
e. Leak in the system
f. Relief valve is open

g. Vent valve is open
h. Blockage in the liquid withdrawal circuit
7. Low flow at oxygen outlet
on all LPM settings

i. FCV Faulty
a. Nasal cannula kinked or leaking
b. Saturation pressure is too low
c. Leak in the system
d. Economizer valve faulty
e. Blockage in the liquid withdrawal circuitor the flow restrictor

8. Increased NER

f. FCV faulty
a. Saturation Pressure is too highb. Leak in the system
c. Relief valve open

d. Partial or complete loss of vacuum

a. Check the contents indicator/level gauge and fill
the reservoir if needed.
b. Ensure the flow control knob is not in the off (“0”)
position.
c. Ensure proper nasal cannula functionality and positioning
d. Inspect the saturation pressure of the reservoir.
Allow at least 30 minutes at no flow for the reservoir to saturate properly.
e. Perform a leak check on the plumbing (RP2).
Repair leaks as necessary.
f. Ensure that there is no venting from the relief
valves. If there is refer to the corrective actions
for “Excessive venting from relief valves (hissing
sound)”
g. Ensure that the vent valve is fully closed and notleaking.
h. Check the warming coils and withdrawal tubes forblockages. Replace if necessary.
i. Replace the FCV (RP24)
a. Inspect the functionality of the nasal cannula.
b. Inspect the saturation pressure of the reservoir.
Allow at least 30 minutes at no flow for the reservoir to saturate properly.
c. Perform a leak check on the plumbing (RP2).
Repair leaks as necessary.
d. Test the economizer (RP22) and replace (RP13) if
necessary.
e. Check the warming coils and withdrawal tubes aswell as the flow restrictor for blockages. Replace
if necessary.
f. Replace the FCV (RP24)
a. Inspect the saturation pressure of the reservoir.
Allow at least 30 minutes at no flow for the reservoir to saturate properly.
b. Perform a leak check on the plumbing (RP2) anda pressure retention test (RP14). Repair leaks asnecessary.
c. Ensure that there is no venting from the relief
valves. If there is refer to the corrective actions
for “Excessive venting from relief valves (hissing
sound)”
d. Conduct the NER test (RP23) and return the unit
to CAIRE, inc. if necessary.

Companion Reservoir Technical Service Manual • 01/19 PN 20559263 Rev G

Companion Reservoirs

Table 8 (cont.)

4 24

XI Troubleshooting & Repair Procedures
Symptom

Probable Cause

Corrective Action

a. Frost is acceptable
9. Excessive Frost
NOTE: Minimal frost on
the shroud and on theplubming is normal. Thissymptom applies to frost
b. High humidity levelthat is much greater thanwhat is normally observed.
c. Saturation pressure is too highd. Leak in the system
e. Relief valve open

f. Partial or complete loss of vacuum
10. Unit will not maintain acceptable system pressurea. Saturation pressure is unacceptable
b. Vent valve not completely closedc. Leak in the system
d. Economizer valve faulty
e. Primary releif valve faulty

11. High Pressure at Reservoir a. Saturation pressure is too highoxygen outlet
b. Primary releif valve set too high or relief
valve operating improperlyc. Economizer valve stuck in closed stated. Partial or complete loss of vacuum
12. Contents indicator reads
incorrectly

a. Some frost on the shroud and on the plumbing is
acceptable, especially at high flow rates duringcontinuous use. This is due to the evaporation of
LOX to gas and the temperature difference between the LOX and room temperature.
b. High humidity levels can increase frost accumulation.
c. Inspect the saturation pressure of the reservoir.
Allow at least 30 minutes at no flow for the reservoir to saturate properly.
d. Perform a leak check on the plumbing (RP2).
Repair leaks as necessary.
e. Ensure that there is no venting from the relief
valves. If there is refer to the corrective actions
for “Excessive venting from relief valves (hissing
sound)”
f. Conduct the NER test (RP23) and return the unit
to CAIRE, inc. if necessary.
a. Inspect the saturation pressure of the reservoir
used for filling. Allow at least 30 minutes at noflow for the portable to saturate properly.
b. Close vent valve. Leak check vent valve outlet andstem. Replace or repair as needed.
c. Perform a leak check on the plumbing (RP2).
Repair leaks as necessary.
d. Test the economizer (RP22) and replace (RP13) if
necessary.
e. Test the primary relief valve (RP11) and replace(RP13) if necessary
a. Inspect the saturation pressure of the reservoir.
Allow at least 30 minutes at no flow for the reservoir to saturate properly.
b. Perform relief valve test (RP11). Replace (RP13) asneeded.
c. Perform Economizer test (RP22). Replace (RP13)
as needed.
d. Conduct the NER test (RP23) and return the unit
to CAIRE, inc. if necessary.
a. Perform leak test (RP2). Repair leaks as needed.

Companion Reservoirs

Table 8 (cont.)

a. Leak in the sensing tubes,fittings, or theContents Indicator.
b. Flexible contents indicator pressure sens- b. Visually inspect the flexible pressure sense tubes
ing tube pinched.
and remove pinching conditions.
c. Ice blockage in contents indicator (liquid) c. Perform the Purging Liquid Contents/Levelpressure sense tube.
Indicator (RP8) procedure.
d. Contents indcator damaged
d. Replace contents indicator (RP7) as needed.

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XI Troubleshooting & Repair ProceduresCompanion Reservoirs
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XI Troubleshooting & Repair ProceduresCompanion Reservoirs

To use the Troubleshooting Chart:• Start at the upper left corner.
• The top line shows the steps of routine maintenance.
• Unless otherwise noted by the arrows, the flow through the chart is down or to the right.
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XI Troubleshooting & Repair Procedures
RP2 – Leak Test

The following procedures have been carefully prepared to allow
proper removal and replacement of defective components andshould be used in conjunction with the Troubleshooting Chart andthe tests in this section.

1. Attach the pressurizing fixture (PN B-701731-SV) to thefill connector on the reservoir unit and secure it with the attached strap.

CAUTION: When replacing components, make sure the newpart is oriented exactly the same as the original part prior to
installation.
CAUTION: Some components require a specific amount of
torque when assembling. Follow torque requirements where
specified.
NOTE: All replacement parts must be factory approved, cleaned
for oxygen service, and stored in sealed plastic bags. The repair
area must be clean and separate from other areas. Room air should
be filtered, and free from dust, soot, and other contaminants.
NOTE: When replacing components with pipe threads, use PTFE
tape thread sealant. Apply two rounds of PTFE tape to threads
near end of component, avoiding first thread.
NOTE: When assembling new compression fittings, tighten 1/8”,
1/4” and 1/2” nuts eight flats past finger tight and 3/16” nuts fiveflats past finger tight. When reassembling previously used compression fittings, tighten nuts one to two flats past finger tight.

Companion Reservoirs

RP1 – General

2. If the reservoir contains liquid oxygen, verify that it is pressurized between 1.4 to 1.7 bar/21-25 psi.
3. If the reservoir does not contain liquid oxygen, connect anadjustable 0 to 6,9 bar/0 to 100 psig source of gaseous oxygen to the DISS oxygen inlet on the pressurizing fixture.
4. Pressurize the reservoir with gaseous oxygen to between 1.4
to 1.7 bar/21-25 psi.
5. Use SNOOP to test all reservoir fittings and connections.
NOTE: When using SNOOP on the stem of the vent valve, besure to blow it dry with gaseous oxygen or nitrogen before andafter test.
6. Place a finger wetted with Snoop lightly against the ventvalve outlet to test for leakage.
7. Disconnect and remove the pressurizing fixture from the reservoir fill connector.
8. Apply SNOOP to the fill connector poppet and check forleakage.
9. Use dry Nitrogen or Oxygen gas to dry SNOOP off poppet.
10. Make repairs to leaking fittings or connections as needed
and perform leak check on those fittings again.
NOTE: A small amount of leakage around the poppet of the malefill connector is acceptable. Acceptable leaks appear as white,foam-like bubbles in the liquid leak detector. If the bubbles created by the leak detector are considerably large, make necessary
repairs to the male fill connector.
11. Make repairs to leaking fittings or connections as needed
and perform leak check on those fittings again.

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XI Troubleshooting & Repair Procedures
NOTE: Ensure that the area in which the following procedure will
be performed is properly ventilated and free of ignition sources.
NOTE: Ensure vent valve on reservoir is placed in a manner so
as not to vent in the direction of technician or individuals nearby
or walking by.
1. Connect an adjustable 0-6,9 bar/0-100 psig pressure regulator to oxygen or nitrogen gas source.

RP4 – Condensation Collector RR
1. Remove condensate drain tube from bottle and remove bottle from bracket.
2. Remove condensate bottle bracket squeezing legs together
and pulling straight down.
3. To replace bracket and bottle, reverse above procedure.

RP5 – Shroud Assembly RR

2. Attach the pressurizing fixture (PN. B-701731-SV) to thefill connector on the reservoir unit and secure it with the attached strap.

1. Unscrew the screw in the top center of the top cover.

3. Connect the pressurizing fixture to the regulator on the gas
source using a pneumatic hose or similar tubing.

3. To remove the cover body from the top cover, unscrew thefive small pan head screws on the underneath side of the top
cover.

4. Open the main valve on the gas source.
5. Open vent valve on reservoir to allow slow venting.
NOTE: If the reservoir is near full of LOX, some LOX may momentarily spray from vent valve.
6. Adjust regulator to a pressure setting that is slightly higher
than the internal pressure of the unit (Example: If the internal pressure gauge or gauge on the pressurizing fixture
reads 1,5 bar/22 psig, adjust the regulator attached to the gas
source to approximately 1,7-1,8 bar/24-26 psig).

Companion Reservoirs

RP3 – Emptying/Purging Reservoir

2. Carefully lift up to remove the entire shroud assembly.

NOTE: New labels must be installed any time the shroud is replaced. Make sure that the front warning label is the correct one
for the model of reservoir it is to be used on.
NOTE: Be sure to align the shroud so that the access holes are
positioned directly over the corresponding reservoir plumbing
components. Also, be sure that the shroud is seated uniformly on
the lower shroud lip.
4. To replace the cover body, reverse the above procedure.

7. Allow unit to purge until the exhaust that is released out ofthe vent valve is clear and the internal components are freeof frost. (Approximately 45 minutes)
NOTE: This process can be time consuming depending on thelevel of LOX in the unit. The pressurizing fixture can be secured
to the reservoir using straps, bungee cord, etc., as long as the ventvalve is open.
8. Remove pressurizing fixture from reservoir.
9. Close main valve on gas source.

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XI Troubleshooting & Repair Procedures
1. Verity that when the tank is empty the colored line on thecontents indicator is aligned with the “0” marking.
2. Fill the reservoir so it contains 9 to 11 kg/ 20 to 25 lbs. ofliquid oxygen.
2. Verify that within five minutes, the center of the coloredline on the contents indicator piston is within the proper
range indicated by the shaded bar in Figure 11.

Companion Reservoirs

RP6 – Liquid Contents/Level Indicator Test

RP8 – Purging Liquid Contents/Level Indicator RR
1. Ensure reservoir is empty, warm and free of internal pressure per RP3.
2. Remove the shroud per RP5.
3. Use the vent wrench to open the vent valve on the reservoir
unit.
4. Connect a pressurizing fixture (B-701731-SV or similar) to
the fill connector on the reservoir unit and secure it with theattached strap.
5. Attach an adjustable 0-6,9 bar/0-100 psig source of gaseous
oxygen to the DISS oxygen inlet on the pressurizing fixture.

Companion 41

6. Adjust the regulator on the gaseous source until the gauge
on the pressurizing fixture reads approximately 1,0 bar/15
psig.
7. With only the vent valve open, allow the system to purge forabout 45 minutes.

Figure 13

RP7 – Liquid Contents/Level Indicator RR
CAUTION: Damage to contents/level indicator or barbed fittings
can occur. Ensure reservoir is empty and has pressure vented
before removing either contents indicator tube. Use care whenremoving flexible tubes from barbed fittings or contents/levelindicator
1. Remove shroud per RP5.
2. Remove the flexible pressure sensing lines from the barbed
fittings on the contents gauge by carefully sliding the brasscollar away from the barbed fitting and then disconnecting
the sensor line.
3. Use a medium flat blade screwdriver to remove the twoscrews that fasten the contents gauge to the mounting plate.
4. To replace the contents gauge, reverse the above procedures.

8. Disconnect the pressurizing fixture.
9. With no pressure in the unit, disconnect both pressure
sensing tubes from the contents indicator. Using a wire tie,
lightly secure the tubes to the vent valve to prevent themfrom moving around.
CAUTION: Damage to the contents indicator can occur.
Disconnect both contents indicator tubes before pressurizing thereservoir. Vent the reservoir before connecting or disconnecting
indicator tubes.
10. Close the vent valve. Reconnect the pressurizing fixture andadjust the regulator until the pressurizing fixture reads approximately 1,0 bar/15 psig.
11. Allow an additional 15 minutes for gas to flow through andpurge the contents indicator tubes.
12. Disconnect the pressurizing fixture and open the reservoir
vent valve.
13. Reconnect both pressure sense tubes to the contents indicator.
14. Perform the contents indicator test (RP6).

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XI Troubleshooting & Repair Procedures
1. Engage the pressurizing fixture to the fill connector on thereservoir and secure it with the attached strap.
2. Attach an adjustable 0-6,9 bar/0-100 psig source of gaseous
oxygen to the Diameter Index Safety System (DISS) oxygen
inlet on the pressurizing fixture.

Companion Reservoirs

RP9 – Internal Pressure Gauge Test (If Equipped)

8. If either the opening pressure or closing pressure readings of
the PRV do not meet the specifications stated in previous
steps, replace the R/E valve.
9. Disconnect the pressurizing fixture and open the reservoir
vent valve to reduce the pressure below 1,4 bar/20 psig.

RP12 – SRV Test

3. Slowly pressurize the reservoir until the needle of the reservoir pressure gauge lines up with the 20 psig mark.

1. Remove shroud per RP5.

4. Verify that the reading on the pressurizing fixture gauge iswithin the blue acceptable region.

2. Engage the pressurizing fixture to the fill connector on thereservoir and secure it with the attached strap.

NOTE: It may be necessary to tap on top of the indicator withyour finger to assure that the indicator is operating properly.

3. Attach an adjustable 0-6,9 bar/0-100 psig source of gaseous
oxygen to the DISS oxygen inlet on the pressurizing fixture.
4. Obtain a type of temporary clamp.

RP10 – Internal Pressure Gauge RR (If Equipped)
1. Remove the shroud and top cover per RP5.
2. Use a 5/8 in. or 3/4 in. open end wrench to hold the brassfitting below the pressure gauge which is attached to thegauge.

NOTE: If the R/E valve contains a muffler or any other type of
exhaust fitting, remove fitting prior to installing clamp.
5. Position the movable bar clamp arm over the R/E valve ventand position the fixed bar clamp arm.
6. Tighten the clamp to seal the vent port.

3. Use a 1/2 in. or 9/16 in. open end wrench to loosen the pressure gauge from the brass fitting until the gauge is free.

7. Slowly pressurize the reservoir by adjusting the oxygen
source regulator.

4. Reverse the procedures above to reinstall the internal pressure gauge.

8. Verify that the secondary relief valve opens (audible hiss) at
2,5 bar/37 psig.

RP11 – PRV Test
1. Remove the shroud per RP5.

NOTE: If the secondary relief valve does not open within thisrange the first time, first increase the pressure to ensure the SRV
has cracked, then reduce the pressure in the reservoir and repeat
the test a second time. If it fails to open within the acceptable
range the second time, replace the valve SRV.

NOTE: If the R/E valve contains a muffler or any other type of
exhaust fitting, remove fitting prior to testing.

9. Slowly reduce the pressure within the reservoir until the audible hissing noise is no longer heard.

2. Engage the pressurizing fixture to the fill connector on thereservoir and secure it with the attached strap.

10. Verify that the SRV closes (audible hiss is no longer heard)
at a pressure greater than 1,9 bar/27 psig.

3. Attach an adjustable 0-6,9 bar/0-100 psig source of gaseous
oxygen to the DISS oxygen inlet on the pressurizing fixture.

NOTE: If the secondary relief valve does not close within thisrange the first time, repeat the SRV testing. If it fails to open
within the acceptable range the second time, replace the SRV
valve. ­4. Slowly pressurize the reservoir until a “hiss” is heard coming from the PRV.
5. Verify that the PRV opens (hissing) at less than 1,7 bar/25
psig

11. Disconnect the pressurizing fixture and open the reservoir
vent valve to reduce the pressure below 1,4 bar/20 psig.

­6. Slowly reduce the pressure within the reservoir until thehissing through the PRV stops.

12. Remove the clamp blocking the R/E valve vent port.

7. Verify that the PRV closes (hissing stops) at a pressure
greater than 1,4 bar/20.5 psig.
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XI Troubleshooting & Repair Procedures
RP14 – Pressure Retention Test

1. Remove the shroud per RP5.

WARNING: Reservoir must be empty and vented before starting procedure.

2. Use a 5/8-in. open-end wrench to remove the SRV from the
PRV, R/E valve.

1. Attach pressurizing fixture to the QDV on the reservoir.

3. Slide the press-on tubing clamp back and disconnect theflexible (gas) pressure sense tube from the 1/16-in. barbed
fitting on the PRV, R/E valve.

2. Connect an adjustable 0-6,9 bar/0-100 psig source of gaseous oxygen to the DISS oxygen inlet on the pressurizing
fixture.

4. Use a 1/4-in. open-end wrench to remove the 1/16-in. barbed
fitting.

3. Pressurize the unit to 1,5 bar/22 psig.

5. Use a 1/2 -in. open-end wrench to remove the economizer
tube assembly inverted compression nut from the PRV, R/E
valve.

Companion Reservoirs

RP13 – PRV, SRV, R/E Valve RR

NOTE: Lightly tap the pressure gauge with your finger to assurethat the needle is reading properly.
4. Remove the pressurizing fixture.

6. Carefully pull the economizer tube down until it clears the
PRV, R/E valve.

5. Let the unit stand for 10 minutes to allow the pressure inside
the reservoir to stabilize.

7. Use a 3/4 -in. open-end wrench to remove the PRV, R/E
valve from the threaded manifold extension tube.

6. Engage te pressurizing fixture (without the gaseous oxygen
source) to the QDV on the reservoir.

8. Apply Teflon tape sealant to the threaded manifold tube facing the embossed circular index mark on the top of the lower
shroud.

7. Verify internal pressure is approximately 1,4–1,7 bar/20.5–
25 psig.

9. Install the PRV, R/E valve on the threaded manifold tube
and tighten so that the SRV port is in a vertical, up position.
10. Install the end of the economizer tube with the inverted
compression nut in the bottom port of the PRV, R/E valve.

8. Record the initial time and pressure.
NOTE: Lightly tap the pressure gauge with your finger to assurethat the needle is reading properly.
9. Allow unit to sit undisturbed for 60 minutes.

11. Make sure the tube end is aligned properly in the port andthen tighten the inverted compression nut.

10. Engage the pressurizing fixture (without the gaseous oxygen
source) and take a final reading.

12. Install the 1/16-in. barbed fitting in the PRV, R/E valve portthat faces the center of the reservoir.

11. Verify that the pressure is greater than1 bar/15 psig.

13. Connect the flexible tube and the tubing clamp to the barbed
fitting.
14. Apply Teflon tape sealant to the SRV threads.

NOTE: If the pressure is out of specification, perform the leakDetector Test to determine the source of the leak.
12. Disconnect the pressurizing fixture.

15. Install the secondary relief valve in the PRV, R/E valve port
and tighten until snug.
16. Perform leak test.
17. Install the shroud.

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XI Troubleshooting & Repair Procedures
1. Remove shroud per RP5.

4. Remove the coil.

2. Remove three screws from mounting brackets that
attach warming coil to the condensation ring usinga Phillips head screwdriver.

5. To reinstall or replace the warming coil, reverse the above
procedure.

3. Slightly lift warming coil up from condensate ring toallow access to tee fitting on top of outer shell.
4. Use a 9/16 in. open end wrench to remove the compression
nut from the tee fitting while holding the tee fitting stationary with an adjustable wrench.
5. Use a 9/16-in. open-end wrench to remove the warming coilcompression nut from the tee fitting on the FCV.
6. Pull the aluminum warming coil tube away from the tee andcarefully guide the small Teflon liquid withdrawal tube outof the aluminum tube.
11. To reinstall or replace the warming coil, reverse the above
procedure.
All domestic units and TPED units manufactured after June2011
1. Remove shroud per RP5.
2. Use a 9/16 in. open end wrench to remove the compression
nut from the tee fitting while holding the tee fitting stationary with an adjustable wrench.
3. Use a second 9/16-in. open-end wrench to remove thewarming coil compression nut from the bottom of the FCV.
4. Pull the aluminum warming coil tube away from the tee andcarefully guide the small Teflon liquid withdrawal tube outof the aluminum tube.
5. To reinstall or replace the warming coil, reverse the above
procedure.

Companion Reservoirs

TPED Models manufactured prior to June 2011

3. Use a 9/16 in. open end wrench to remove the compression
nut from the tee that connects to the manifold while holding
the tee stationary with an adjustable wrench.

RP15 – Warming Coil Assembly RR

RP17 – Vent Valve RR
1. Remove shroud per RP5.
2. Use a 3/4-in. open-end wrench to remove the vent valve.
Place the wrench on the valve hex flats closest to the manifold to prevent disassembly of the valve as you remove it.
3. Inspect the valve stem O-ring and spring pin for wear ordamage.
4. Inspect the vent wrench stops on the valve body for wear ordamage.
5. Use a 3/4-in. open-end wrench to hold the outer hex flatsof the vent valve stationary while using a 9/16-in. open-end
wrench to remove the vent extension.
6. Lightly clamp the vent valve in a vise.
7. Use a pin punch and a hammer to drive the spring pin out ofthe valve stem.
8. Use a small screwdriver to carefully pry the retainer ring offof the valve stem.
9. Use a dental pick or similar object to lift the O-ring off thevalve stem.
10. To reinstall or replace the vent valve, reverse the above procedure.
NOTE: Before installing the vent valve, wrap the threaded manifold extension tube with Teflon tape starting two threads backfrom the end. Verify that the arrow on the vent valve body points
away from the manifold.

RP16 – Vaporizer Coil Assembly RR (if equipped)
1. Remove shroud per RP5.
2. Use a 9/16 in. open end wrench to remove the compression
nut from the dropout tee while holding the dropout tee stationary with an adjustable wrench.
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XI Troubleshooting & Repair ProceduresCompanion Reservoirs

RP18 – Fill Connector Release Assembly RR
1. Remove shroud per RP5.
2. Use needle nose pliers to remove one E-clip from the release
lever pivot pin.
3. Remove the pin from the release lever.
4. Remove the lever from the mounting bracket.
5. Use a No. T10 Torx driver to remove two Torx screws fromthe release button.
6. Remove the button from the lever.
7. To reinstall or replace the fill connector release assembly,
reverse the above procedure.
RP19 – QDV Assembly RR
1. Remove shroud per RP5.
2. Remove the fill connector release assembly.
3. Use a 7/8-in. open-end wrench to hold the body of the fillconnector stationary.
4. Use a 10-in. adjustable wrench to loosen the compression
nut on the fill connector.
5. Remove the fill connector.
6. To reinstall or replace the QDV, reverse the above procedure.
7. Ensure to add a small amount of Krytox lubricant on thethreads of the QDV.

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XI Troubleshooting & Repair Procedures
1. Ensure unit is at least ½ to ¼ full of LOX.
2. If LOX is added to reservoir, allow unit to sit for a minimumof 1.5 hours prior to beginning test.
3. Verify internal operating pressure as per RP21 or using
QDV test fixture. Vessels internal operating pressure should
be at 19.5 psi before beginning flow rate test. This can beaccomplished in different ways:
Option A.) If reservoirs internal operating pressure is below
19.5 psi (134 kPA) let unit sit overnight after filling, with
FCV and vent valve closed, to stabilize to normal operatingpressure. Pressure should then be verified again prior toperforming flow test.
Option B.) If reservoirs internal pressure is above 19.5 psi (134kPA) allow unit to flow at a rate of 4 LPM for 1.5 hours
minimum prior to beginning the flow rate test.
Or
Option C.) If reservoirs internal pressure is above 19.5 psi (134kPA) open vent valve and wait for internal pressure tostabilize at 19.5 psi (134 kPa). Ensure the pressure gauge
does not rise above 19.5 psi (134 kPa) after FCV is closed.
This will indicate the tank is ready for beginning the flowrate test.
4. Attach a DISS fitting adapter (PN B-775269-00) to thehumidifier adapter which is attached to the FCV.
5. Connect flow meter inlet to the DISS fitting adapter (PN
B-775269-00) using respiratory tubing.
6. Make sure flow meter outlet is open and unobstructed andflow meter is properly positioned.
7. Test flow rate at each FCV position.
8. Compare flow rates to the table below.

NOTE: Be careful to allow for accuracy tolerances of flow meter.
Table 9 below does not account for these tolerances.

Table 9FCV Setting
OFF
0.12
0.25
0.50
0.75
1.00
1.50
2.00
2.50
3.00
3.50
4.00
5.00
6.00
8.00
10.00

LPM
0
0.08 to 0.16
0.17 to 0.33
0.35 to 0.65
0.52 to 0.98
0.70 to 1.30
1.05 to 1.95
1.60 to 2.40
2.00 to 3.00
2.40 to 3.60
2.80 to 4.20
3.20 to 4.80
4.00 to 6.00
4.80 to 7.20
6.40 to 9.60
8.00 to 12.00

Companion Reservoirs

RP20 – Flow Rate Test

Note: SLPM is corrected to normal temperatureand pressure (70˚F & 14.7 psig or 21˚C & 1.01
Bar). The above acceptable flow rates areintended for field testing only of flow control
valves to account for variation in elevation andtemperature. This table reflects tolerance requirements of ISO 10524. This does not affect Chart’s
factory compliance with the +/-10% tolerance
requirement of ISO 18777.
NOTE: Factory flow rate specifications are within the +/- 10%
tolerance required by ISO 18777 for environmental conditionsof temperature between 10°C – 32.2°C to (50°– 90°F) andelevations up to 527 m (1730 ft).

NOTE: If testing operating pressure because of improper flow
rates, test pressure immediately after flow rate test.

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XI Troubleshooting & Repair Procedures
RP23 – NER Test

1. Ensure unit contains at least 9 kg/20 lbs. of LOX.

1. Fill the unit with 9 to 11 kg/20 to 25 lbs. of properly saturated liquid oxygen.

2. If LOX is added to reservoir, allow unit to sit for a minimumof 1.5 hours prior to beginning test.
3. Attach a DISS fitting adapter (PN B-775269-00) to the humidifier adapter which is attached to the FCV.
4. Attach a 0-6,9 bar/0-100 psig pressure gauge to the DISS fitting adapter (PN B-775269-00).

2. Allow unit to sit undisturbed for a minimum of 12 hours.
3. Weigh unit.
4. Record weight and time (1st Recorded Weight).
5. Allow unit to sit undisturbed for a minimum of 24 hours.

5. Open the FCV to any setting above 2 LPM.

6. Weigh unit.

6. Pressure gauge should read between 1,2-1,4 bar/18.5-20.5
psig.

7. Record weight and time (2nd Recorded Weight).

RP22 – Economizer Test

1st Recorded Weight - 2nd Recorded Weight

1. Verify that the reservoir contains at least 9 kg/20 lbs of
LOX.

Elapsed Time Between Weights in hrs

2. If LOX is added to reservoir, allow unit to sit for a minimumof 1.5 hours prior to beginning test.
3. Engage the pressurizing fixture (PN B-701067-SV) to thefill connector on the reservoir and secure it with the attachedstrap.

Companion Reservoirs

RP21 – Operating Pressure Test

8. Calculate liquid loss rate (NER) using the following formula:
X 24 Hours

9. The NER should be between .73 - 1.0 kg/1.6 - 2.2 lbs perday.

4. Adjust FCV knob to a setting of 4 LPM.
5. With the unit delivering an oxygen flow, record the pressure
readings on the pressurizing fixture gauge every half hour
until the pressure stabilizes.
6. Stabilization occurs when two consecutive readings arewithin .01 bar/.2 psig of each other.
7. If the readings do not stabilize, replace the economizer
valve.

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XI
On units without an Internal Pressure Gauge:
1. Use a 1/2-in. open-end wrench to remove the humidifier
adapter.
2. Remove the shroud per RP5.
3. Use a 1/2-in. open-end wrench to hold the elbow fitting anduse a 9/16-in. open-end wrench to remove the breathing coilnut from the elbow.
4. Use a 1/2-in. open-end wrench to remove the elbow fittingfrom the bottom of the FCV.
5. Use a Phillips head jeweler’s screwdriver to remove the two
Phillips head screws on the bottom of the mounting bracket
which secure the FCV to the bracket.
6. Replace FCV.
7. To reinstall the FCV, simply reverse the instructions above.
On units with Internal Pressure Gauges
1. Use a 1/2-in. open-end wrench to remove the humidifier
adapter.
2. Remove the shroud per RP5.
3. Use a 1/2-in. open-end wrench to hold the tee fitting and use
a 9/16-in. open-end wrench to remove the breathing coil nut.
4. Use a 1/2-in. open-end wrench to hold the tee fitting and use
a 9/16-in. open-end wrench to remove the pressure gauge
tube nut.
5. Use a 1/2-in. open-end wrench to hold the tee fitting and use
a 9/16-in. open-end wrench to remove the tee adapter going
into the bottom of the FCV.
6. Use a Phillips head jeweler’s screwdriver to remove the two
Phillips head screws on the bottom of the mounting bracket
which secure the FCV to the bracket.
7. Replace FCV.
8. To reinstall the FCV, simply reverse the instructions above.

RP25 – Determining Liquid and Gaseous Oxygen
Capacity
1. Weigh the empty reservoir and record the weight (kg/lb)
2. Fill the unit with properly saturated liquid oxygen (Per
Filling Procedure in Operation section of manual)
3. Weigh the full reservoir and record the weight (kg/lb)
4. Subtract the empty reservoir weight (STEP 1) from the fullreservoir weight (STEP 3) to determine the weight of liquid
oxygen that is inside of the reservoir

Companion Reservoirs

RP24 – FCV RR

5. Take the weight of liquid oxygen (calculated in STEP 4) anddivide it by the LOX density to calculate the liters of liquid
oxygen in the reservoir
oxygen in the reservoir
NOTE: The density of liquid oxygen will vary based on operation and saturation pressures. The densities provided in Table#6, which are to be used in the above calculation, are representative of optimum operation and saturation pressures. Dueto rounding and conversion accuracy, a range of 0.10 L is acceptable in calculation.
NOTE: If proper filling procedures (primarily source pressure)are not followed per the filling procedure in operation sectionof this manual, reservoir will not be at nominal pressure immediately following the fill process. In addition, if PRV, SRV
and/or Economizer are not performing within ranges specified
in Table #6 Reservoir Specifications, the reservoir will not be
at nominal pressure immediately following the fill process. If
either or both of these conditions occur, calculations using thenominal densities listed in Table #6 Reservoir Specifications
will not be accurate.
Example: Calculation of Liquid Oxygen in a full C41 reservoir:
1. Empty weight of C41 Reservoir: 27,22 kg (60.00 lbs)
2. Filled unit with properly saturated liquid oxygen
3. Full weight of C41 Reservoir: 72,90 kg (160.71 lbs)
4. 72,90 kg (160.71 lbs) – 27.22 kg(60.00 lbs) = 45,68 kg (100.71
lbs)
5A. 45,68kg/1.095kg/L = 41,7 Liquid Liters of Oxygen
5B. 100.71lbs/2.415lbs/L= 47.1 Liquid Liters of Oxygen

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37

XII
1 Parts List

Companion Reservoir Technical Service Manual • 01/19 PN 20559263 Rev G

Companion Reservoirs

Contact Customer Service or visit www.caireinc.com to
obtain your parts list.

38

XIII Ordering Information
The following steps should be used when ordering a new
Companion or replacement parts for an existing unit:
1. Compile a list of all equipment and replacement parts to beordered.
2. Fill out a purchase order containing the following information:a. Purchase order number.
b. Name and address of billing location.
c. Name and address of shipping location.
d. Quantity, part number, description, and unit costfor each item ordered.
3. Telephone or fax CAIRE Inc. at one of the numbers listed
below to begin immediate processing of the order:
USA
Toll Free Phone:

800 48 CAIRE
			(800 482 2473)
Toll Free Fax:
888 WE CAIRE(To place an order):		(888 932 2473)
Phone:
770 721 7759
Fax:		770 721 7758

4. E-Mail or fax the completed purchase order for confirmation to:
North and South America/Asia/Pac Rim email to:customerservice.europe@caireinc.com
Africa/Europe/Middle East email to:customerservice.usa@caireinc.com

North and South America fax to: 888-932-2473

Companion Reservoirs

Ordering Information

Asia/Pac Rim fax to: 770-721-7758

Africa/Europe/Middle East fax to: +44 118 9799245
All new equipment will be shipped either “prepaid”,, F.O.B. fromthe factory, or collect via your specified carrier. All replacement
parts will be sent by UPS “prepaid”, and the shipping charges forequipment and parts will be added to the final invoice. Payment for
replacement parts are located on CAIRE, Inc.’s, invoice with payment date indicated. All shipments will originate from the factory. If
a particular carrier or method of shipment is desired, specify whenplacing order.

Asia, Australia, Pacific Rim
Phone:+61 297 494333
Fax:
888 932 2473
EuropePhone:
Fax:+44 (0) 1189 367060+44 118 9799245

For additional ordering and contact

information, visit www.caireinc.com.

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XIV Return & Restocking Policy
If a problem with the unit should be encountered, reference
should be made to the Troubleshooting Chart. If these procedures
do not provide a solution for the problem, the following steps
should be taken:
1. Call CAIRE, Inc. Customer Service.
North and South America/Asia/Pac Rim:
Phone (US Only)

800-482-2473

Phone

770-721-7759

If it becomes necessary to cancel an order with CAIRE Inc. after the shipment has been received, use the following “Restock
Policy” procedure:
1. Call CAIRE, Inc. Customer Service.
2. When contacting Customer Service personnel, it will be necessary to relay the following information:a. State the quantity and description of equipment to be returned.
b. Give the Serial Number of each unit to be returned.
c. State the equipment purchase date.

Africa/Europe/Middle East:
Phone

Restocking Policy

Companion Reservoirs

When a CAIRE unit is received, it should be inspected immediately, as outlined in Section VII, Unpacking and Setup
Instructions.

+44 (0) 1189 367060

2. State the problem with the unit.
3. If it is determined that the problem cannot be solved by the
distributor, a Return Material Authorization (RMA) number
will be assigned to the unit or part(s).
4. If a Purchase Order Number is to be referenced, please givethis number to the Customer Service Representative at thattime.
5. Carefully package the parts, or repack the unit in its original
shipping container, precisely as shipped.
6. Write the Return Authorization Number on the top of theshipping container.
7. Customer Service will provide the correct shipping location
once the RMA is provided

3. An RMA number will be issued in the name of the distributor by CAIRE, Inc. for the equipment to be returned.
4. When the equipment is shipped to the factory, the RMA
number must appear on the packing slip and shipping boxes.
5. Customer Service will provide the correct shipping location
once the RMA is provided
6. Finally, a “Credit Memo”, minus a 15% restocking fee, will
be issued to the distributor when all equipment has been received, inspected, and restocked by CAIRE, Inc
Return of Unused Non-Defective Merchandise
CAIRE Inc., at its discretion, charges a 15% restocking fee forunused non-defective merchandise that is returned. An RMA
number must be obtained from CAIRE Inc. Customer Service
prior to return of any goods. Merchandise cannot be returned for
credit after sixty (60) days. Customer to pay all freight charges.
Tracking capability and insurance on all returned goods is advised. CAIRE Inc. will not be responsible for misdirected shipments.

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XV Service Tools/Equipment/Supplies
Table 12Required Tools

Required Supplies

Hex Wrenches (various sizes)

Household Glass Cleaner

Phillips Blade Screwdriver

PTFE TapeTorx T 10 Screwdriver

Leak Detection Fluid

Flat Blade Screwdriver

Lint-Free Cloth

10 in. Adjustable Wrench

Fluorolubricant

Open End Wrenches (1/2” to 1-1/8”)

Isopropyl Alcohol

Side Cutters

Companion Reservoirs

Table 10PliersClamp or Hemostat
6 in. Bar Clamp
Dental Pick

Table 11Required Fixtures/Equipment
Oxygen Regulator
Vent Valve Wrench
0-6,9 bar/0-100 psig Pressure Gauge
Pressurizing Fixture
Flowmeter
Gaseous Oxygen Source 0-6.89 bar (0-100 psi)
O2 Liquid Source
N2 Gas or Clean, Dry Compressed Air Source
Tubing (O2 compatible)
O2 Tubing Tee Connector
LO2 Transfer Line
Transfer Line Adapter with Filter
Dewar Cap
Scale 0-92 kg/0-200 lbs, 0.05 lb/0.02 kg increments
Size 00 Rubber Stopper
DISS O2 Outlet Connector
Small Tie Wrap/Zip Tie
Oxygen Supply Tube Coupler

For a complete list of accessories, see catalog ML120071 on www.caireinc.com
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XV Service Tools/Equipment/Supplies
Description­

Item Number

Vent Wrench

B-775182-00

0-6,9 bar/0-100 psig Pressure Gauge

B-776004-00

0-4,1 bar/0-60 psig Pressure Gauge

97403577

Pneumatic Hose w/DISS Fittings

97405279

Small Tie Wrap

B-775091-00

Tubing Barb Adaptor

B-775269-00

Disposable Tubing Barb Adaptor

B-776945-00

O2 Compatible Tubing

B-778214-SV

Test Pressure Gauge w/Tubing Adapter
0-6,9 bar/0-100 psig

B-701732-00

Test Pressure Gauge w/Tubing Adapter
0-4,1 bar/0-60 psig

B-775270-SV

Reservoir Pressurizing Fixture0-6,9 bar/0-100 psig

B-701731-SV

8oz Oxygen Compatible Leak Detector(SNOOP)
Gallon Oxygen Compatible Leak Detector(SNOOP)
Erie Liter Meter, 0-8LPM

B-775272-00
B-778894-00
B-775311-00

Description­

Item Number

Transfer Line Assembly (10 ft./3 m)

B-775289-00• Transfer Hose (6 ft./1.8 m)

B-775280-00• Transfer Hose (10 ft./3 m)

B-775281-00• Source Adapter Assembly

B-775279-00• Relief Valve (10,4 bar/150psi)

B-775273-00• Source Adapter

B-775313-00• Fill Adapter Assembly

B-775278-00• Fill Adapter

B-775312-00• Fill Adapter Seal

B-775262-00• Female Fill Connector

20553105

Companion Reservoirs

Tools and Accessories available from CAIRE• Union, 5/8-in. Flare (2 per Transfer Line) B-775277-00
Female Top Transfill Line Adaptor

10678157

Dual Fill Adaptor TF&SF

10897958

Transfill Line Swivel

97404564

Super Flex LOX Transfer Line
m/6 FT

1.8

5/8” LOX Transfer Line w/Swvl Nuts
m/4 FT

1.2

5/8” LOX Transfer Line w/Swvl Nuts
m/6 FT

1.8
2.4

97406555
9713139

Erie Liter Meter, 6-15 LPM

10995620

Fluoro-Lubricant-2 oz Tube

CA200071

Lubricant - Krytox 240 AC FluorinatedGrease20605136

Roller Base Assembly (Non-CE Marked)

10855678

5/8” LOX Transfer Line w/Swvl Nuts
m/8 FT

Rollerbase Assembly (CE Marked)

10585866

5/8” LOX Transfer Line w/Swvl Nuts 10 FT 10565161

Casters (set of 5; CE Marked)

14880379

Casters (set of 5; non-CE Marked)

14880361

5/8” LOX Transfer Line w/Swvl Nuts
m/12 FT

Shipping Carton C21/C31

10004081-SV

Shipping Carton C41

10004082-SV

3.0

971311910546550

10562411

Replacement Inline Filter, Male Transfer Line
CA400004
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www.caireinc.com

CAIRE Inc.
2200 Airport Industrial Dr., Ste. 500
Ball Ground, GA 30107
Ph 770-721-7700 • Toll Free 1-800-482-2473
Fax 770-721-7701

CAIRE Biomedical, Ltd.
Unit 6, Ashville Way Wokingham
Berkshire, RG41 2PL United Kingdom
Ph +44 (0) 1189 367060 Fax +44(0) 0118 979 9245

© Copyright 2021 CAIRE Inc. All Rights Reserved. CAIRE Inc. reserves the right todiscontinue its products, or change the prices, materials, equipment, quality,
descriptions, specifications and/or processes to its products at any time without priornotice and with no further obligation or consequence. All rights not expressly statedherein are reserved by us, as applicable.

18 March 2021 Companion Reservoir Technical Service Manual • 01/19 PN 20559263 Rev G