Companion
Portables

Technical Service Manual

1I Preface
Companion Portables

SERVICE MANUAL

Companion Portables
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
Fax: 888-932-2473
US:
770-721-7759
Fax: 770-721-7758
Asia, Australia, Pacific Rim
Phone:
770-721-7759
Fax: 770-721-7758
EuropePhone:+44 (0) 119-939-7060 Fax: +44 118 9799245
The following document contains additional information useful in servicing this equipment:
For Customer or Technical Service needs (product assistance, ordering, part numbers, specifications, unexpected events, etc.) contact:
CAIRE Inc.
2200 Airport Industrial Dr., Ste. 500
Customer & Technical Service:
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 a physician.
NOTE: SI pressure values expressed in manual are referenced to atmosphere.
HELiOS™and Companion® 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 Portables Technical Service Manual • PN 20562220 Rev F

1

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

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

Companion Portables

Abbreviations

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.
Definition of Product Symbols
Table 1: Definition of Product Symbols

SymbolDefinition

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.
Companion Portables Technical Service Manual • PN 20562220 Rev F

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

Companion Portables

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

VI. Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
VII. Saturation Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
VIII. Unpacking and Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
IX. Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
X. Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
XI. Troubleshooting & Repair Procedures. . . . . . . . . . . . . . . . 24
XII. Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
XIII. Ordering Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
XIV. Return & Restocking Policy . . . . . . . . . . . . . . . . . . . . . . . . . . 44
XV. Service Tools/Equipment/Supplies. . . . . . . . . . . . . . . . . . . 45

3Companion Portables Technical Service Manual • PN 20562220 Rev F 3

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: 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.

Companion Portables

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.

WARNING: Always wear goggles, a face shield, and insulated
gloves when working with or around liquid oxygen.

Companion Portables Technical Service Manual • PN 20562220 Rev F

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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: Extreme high pressure can rupture container orplumbing components. Be sure specified pressure relief devices
are present, in the proper location, and functioning properly.
WARNING: During transfer of liquid oxygen gas blow offfrom the vent valve creates a loud horn-like noise. Ear protection is recommended.
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 Portables

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

GAS

LOX
Figure 1: Fire/Combustion Triangle

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

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.

• Keep the reservoir upright at all times. Secure liquid oxygen equipment when transporting to prevent accidental
tipover and spillage.

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.

• Use only recommended oxygen compatible cleaning andleak detection products.

• 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 Portables Technical Service Manual • PN 20562220 Rev F

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III Safety
Guidance and Manufacturer’s declaration—electromagnetic emissions
The Companion 1000/T is intended for use in the electromagnetic environment specified below. The customer or the user of theCompanion 1000/T should assure that it is used in such an environment.
Emissions test

Compliance

RF emissions

Group 1CISPR 11		

Electromagnetic environment—guidance
The Companion 1000/T uses RF energy only for internal function.
Therefore, its RF emissions are very low and are not likely toCompanion Portables

Table 2

cause any interference in nearby electronic equipment.
RF emissions CISPR 11

Class B

Harmonic emissions
IEC 61000-3-2

The Companion 1000/T is suitable for use in all establishments,
Not applicable

Voltage fluctuations/		
flicker emissions

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

Not applicablefor domestic purposes.

IEC 61000-3-3• Medical Electrical Equipment needs special precautions regarding EMC and needs to be installed and put into service according
to the EMC information provided in this manual.
• Portable and mobile RF communications equipment can affect Medical Electrical Equipment.

• The use of Accessories, transducers, and cables other than those specified, with the exception of transducers and cables sold by
the Manufacturer of this device as replacement parts for internal components, may result in increased Emissions or decreased
Immunity of the Companion 1000/T.

• The Companion 1000/T should not be used adjacent to or stacked with other equipment and that if adjacent or stacked use isnecessary, the Companion 1000/T should be observed to verify normal operation in the configuration in which it will be used.

Companion Portables Technical Service Manual • PN 20562220 Rev F

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III Safety
Guidance and manufacturers declaration—electromagnetic immunity
The Companion 1000/T is intended for use in the electromagnetic environment specified below. The customer or the user of theCompanion 1000/T 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

Companion Portables

Table 3humidity 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 1000/Ts are foundto be compliant with regulations.

Companion Portables Technical Service Manual • PN 20562220 Rev F

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III Safety
Guidance and manufacturers declaration—electromagnetic immunity
The Companion 1000/T is intended for use in the electromagnetic environment specified below. The customer or the user of theCompanion 1000/T 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 1000/T,
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 Portables

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 1000/T is used exceeds the applicable RF compliance level above, the Companion 1000/T
should be observed to verify normal operation. If abnormal performance is observed, additional measures may be necessary, such as
reorienting or relocating the Companion 1000/T.
b
Over 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 Portables Technical Service Manual • PN 20562220 Rev F

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III Safety
Recommended separation distances between portable and mobile
RF communications equipment and the Companion 1000/T
The Companion 1000/T is intended for use in an electromagnetic environment in which radiated RF disturbances are controlled. The
customer or the user of the Companion 1000/T can help prevent electromagnetic interference by maintaining a minimum distance
between portable and mobile RF communications equipment (transmitters) and the Companion 1000/T as recommended below, 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 MHz

Companion Portables

Table 5*m

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 Portables Technical Service Manual • PN 20562220 Rev F

4 9

IV
1 Equipment Description

The CAIRE Companion C1000 and C1000T units are theportable components of a supplemental oxygen system. The
Companion 1000 provides continuous oxygen flow up to 6LPM,
and the Companion 1000T provides continuous oxygen flow up
to 15LPM. The C1000 and the C1000T are nearly identical infeatures and operational characteristics. The difference in the
two units is primarily the oxygen flow delivery rate capabilities.
Enclosed in a plastic case, the C1000/T incorporates a stainlesssteel cryogenic container with the valves, plumbing, and associated hardware necessary to deliver gaseous oxygen to a patient at
or near room temperature.
The Companion portable units are composed of four major assemblies, grouped according to function:

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.
2. Plumbing System The plumbing system consists of thewarming coils, vent valve, PRV, SRV, FCV and QDV (fillconnector). It is responsible for filling the unit with liquid
oxygen, as well as removing the liquid oxygen from thecryogenic container and warming it to a gas for delivery to
the patient.

Companion Portables

NOTE: Throughout this manual the CAIRE Companion 1000
and CAIRE Companion 1000 T will be referred to as theCompanion 1000/T whenever information that is applicable toboth models is presented.

3. Case Assembly The C1000/T side covers are molded polycarbonate plastic. When assembled, they form a clam-shell
enclosure of the plumbing and cryogenic container.

4. Liquid Content/Level Indicator The system uses a weightscale system to measure the level of LOX remaining in the
cryogenic container. It is activated by suspending the unit by
one end of the carrying strap and reading the needle gauge
built into the top cover.

Figure 3: Companion portables components

Companion Portables Technical Service Manual • PN 20562220 Rev F

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V Theory of Operation
The C1000/T portable units are designed to be filled from any
top-fill (TF) reservoir with a compatible male QDV. The following CAIRE reservoirs are compatible with the C1000/T for
filling:• Liberator (TF/DF) 10, 20, 30, 37, 45, 60• Companion C21, C31, C41• Low Loss (TF/DF) 31, 42• HELiOS Universal U36, U46

As with all vacuum-insulated cryogenic containers, the liquid
oxygen in the C1000/T is always evaporating into a gas. The rateof generation of this gas (called “head gas”) is called the normal
evaporation rate (NER). When the flow control knob is in the off
position, this gas will build up pressure in the headspace above
the liquid oxygen. When the pressure reaches the PRV setting,this gas is released through the primary relief valve into the atmosphere. The vented gas represents the system’s NER loss.­­
Oxygen Withdrawal

The C1000/T is filled by coupling its female quick disconnect
valve (QDV) with the male QDV on the reservoir and opening
the vent valve.

With oxygen in the unit, and the vent valve closed, the pressure in the inner vessel will remain at or near the primary relief
valve opening pressure. At operating pressure and with the flow
control valve open, pressure forces liquid oxygen up the liquid
withdrawal tube and into the warming coils. In the warming coils,
liquid oxygen absorbs heat and vaporizes, warming to almost ambient temperature by the time gas is dispensed by the flow control
valve to the patient.

Once the QDV’s have been connected, the vent valve on the portable unit must be opened to initiate flow of liquid into the unit.
When the vent valve is opened, it vents the contents of the innercontainer to the atmosphere.

A moisture collection pad is an internal component of the
C1000, and a moisture collection cup is externally attached to theC1000T. These collect the additional condensed water that is created when the Companion is operated at higher flow-rates.

Venting the gas inside of the container creates a pressure drop inside of the C1000/T. This pressure differential causes liquid oxygen to flow up the reservoir fill tube, through the coupled QDV’s,and into the inner container of the C1000/T

Liquid Contents/Level Indicator Operation

NOTE: The Companion T moisture cup must be removed fromthe unit before filling.

At the beginning of a fill, the liquid oxygen that leaves the reservoir will vaporize into a gas because the inside of the C1000/T
container is relatively warm. This gas is discharged through thevent valve. After a short time, the container cools and liquid oxygen is contained.

Companion Portables

Filling

The C1000/T is equipped with a spring scale liquid level measurement system. The spring scale is incorporated into the strap
assembly of the portable and the display is built in to the top
bezel. Suspending the unit from the carrying strap closest to thecontents indicator activates the weight-scale mechanism. The
needle on the weight scale display moves an amount proportional
to the amount of LOX in the unit.

When the unit is full, liquid oxygen is expelled through the ventvalve. The venting sound also changes and the liquid oxygen
creates a dense vapor cloud coming from under the reservoir’s
shroud. Closing the vent valve and separating the C1000/T fromthe reservoir terminates the fill process.
The saturation pressure (explained in section VII of this manual)of the liquid oxygen in a reservoir can seriously affect the overall
efficiency and operation of the C1000/T.
Standby/Normal Evaporation Rate
When the C1000/T contains liquid oxygen, the vent valve isclosed, and there is no flow demand, the pressure in the system
will remain at or near its PRV pressure. The liquid oxygen maintains saturation at this pressure due to the normal evaporation rate(NER) of the system. The NER is a function of the rate at whichambient heat “leaks” into and warms the liquid oxygen in the inner container.
Companion Portables Technical Service Manual • PN 20562220 Rev F

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V Theory of Operation
Each C1000/T is identified by a unique serial number. The serial
number is crucial if a problem arises with the unit or support isever needed through CAIRE Customer or Technical Service.
Prior to June 2010, the serial number for the C1000/T was etchedon the vent valve mounting bracket. The vent valve is pulled
down to view the serial number when the side covers of the unit
are in place. As of June 2010, the serial number location haschanged. The serial number is now found on a white, rectangular
sticker placed on the outside of the cryogenic container. It can beseen through the vents on the side of the outer case.
Figure 4 shows a history of the serial number structure forCompanion portables.

Portables Manufactured prior to January 1985

4 - 6 - 25 - 1

Designates Year
(4 represents
1984)

Designates
Month

Designates Day
of Month

Designates Numberof Specific Unit
Produced that Day

Portables Manufactured in and after January 1985 andprior to October 1994

Companion Portables

Figure 4

Portable Serial Number Identification

88 06 25 01
Designates Year

Designates
Month

Designates Day
of Month

Designates Numberof Specific Unit
Produced that Day

Portables 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

Portables Manufactured after June 2010

CB B30 10 29 0964

Designates
Designates
Portable
Manufacturing
Product Code
Location

Designates Designates DesignatesYear
Week of
Number of
the Year Specific Unit
Producedthat Week

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VI
1 Specifications
Companion C1000

Companion C1000T

Volume of LOX (Typical)

1.23 L / 0.04 ft3

1.23 L / 0.04 ft3

Weight of LOX (typical)

1.41 kg / 3.1 lb

1.41 kg / 3.1 lb

Gaseous Oxygen Equivalent

1058 L / 37.36 ft31058 L / 37.36 ft3

Height35 cm / 13.8 in

36.8 cm / 14.5 in

Empty Weight

2.3 kg / 5.0 lb

2.5 kg / 5.6 lb

Full Weight

3.7 kg / 8.1 lb

3.9 kg / 8.7lb

Outlet Pressure

1.28 – 1.62 bar / 18.5 – 23.5 psi

1.28 – 1.62 bar / 18.5 – 23.5 psi

Primary Relief Valve Opening Pressure<1.62 bar / <23.5 psi<1.62 bar / <23.5 psi

Primary Relief Valve Reseat Pressure>1.28 bar / >18.5 psi>1.28 bar / >18.5 psiSecondary Relief Valve Opening Pressure

1.97-2.17 bar / 28.5-31.5 psi

1.97-2.17 bar / 28.5-31.5 psiSecondary Relief Valve Reseat Pressure>1.86 bar / >27 psi>1.86 bar / >27 psi

0.59-0.68 kg/day
1.3 - 1.5 lb/day
0.0, 0.25, 0.5, 0.75, 1.0, 1.5, 2.0, 2.5, 3.0,
4.0, 5.0, 6.0

0.59-0.68 kg/day
1.3 - 1.5 lb/day
0.0, 0.5, 1.0, 1.5, 2.0, 3.0, 4.0, 5.0, 6.0, 8.0,
10.0, 15.0

Normal Evaporation Rate (NER) (typical)
Selectable Flow Rates (LPM)
Contents Indicator

Mechanical, Spring Scale

Companion Portables

Table 6

Mechanical, Spring Scale

Operating Temperature-10°C to 40°C / 95% max relative humidity -10°C to 40°C / 95% max relative humidity

Storage Temperature-40°C to 70°C / 95% max relative humidity -40°C to 70°C / 95% max relative humidity

Companion Portables Technical Service Manual • PN 20562220 Rev F

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VII 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 1).
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 1.52 bar (22 psi), 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, theliquid oxygen must be in a state of saturation. Let’s take a look at what liquid saturation is all about.

Companion Portables

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 5).

Figure 5: 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 6).

Figure 6: Saturated (Boiling) Water at Higher Pressure

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VII Saturation Principles
Companion Portables

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 7).

Figure 7: 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 8).

Figure 8: Liquid Oxygen Saturation Curve
It is important to maintain liquid oxygen saturation (boiling) at the specified operating pressure of a liquid oxygen 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 the liquid oxygen saturation temperature is too low, the corresponding lower saturation pressure causes low oxygen flows to thepatient.
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VII Saturation Principles• Increased product loss and evaporation rate
• Decreased durations• High flow rates• Venting from relief valves• Relief valves frozen open
If the saturation pressure of the liquid in the portable unit is lower than 1.2 bar (18 psi) the following symptoms may occur:• Decreased evaporation rates• Low flow rates• No oxygen flow
• Portable will not fill

Companion Portables

If the saturation pressure of the liquid in the portable unit is greater than 1.93 bar (28 psi) the following symptoms may occur:

High saturation pressure in portables can be prevented by always ensuring that the reservoir being used to fill the portable is filledaccording to its respective service manual. The saturation pressure of a portable unit is equal to the saturation pressure of the LOX
inside of the reservoir used to fill the portable.

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VIII Unpacking and Setup
1. Inspect carton for shipping damage. Report any damage tothe freight company before signing the bill of lading.
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.

Transport
The C1000/T are designed with carrying straps. Portable units
may be moved about or transported in a vehicle while full
without damage. However, they should not be dropped, placedon their side, or handled roughly to prevent physical damage.
Maintain unit in the upright position at all times.

Setup
1. Locate and record the C1000/T serial number.

Companion Portables

Unpacking

2. Visually inspect the C1000/T for damage from improper
handling. Note any dents in the container, cracks in thecase, missing or loose hardware, and bent or damaged components.
3. Check the vent valve for smooth operation by moving thevent valve lever down to the open position. Verify that thelever moves smoothly when opening and closing the valve.
4. Move the flow control knob to each flow setting. Verify
that the knob moves smoothly and encounters a detent at
each setting.
5. If possible, connect the portable to a reservoir to check forsmooth coupling, and to make sure the portable unit is inproper alignment with the reservoir when mated and there
is no interference with the shroud or case of the portable
unit.
6. Verify operation of the liquid level contents indicator bysuspending the portable. Hold the C1000/T on a table andcarefully pull up on the end of the carrying strap nearest
the contents indicator. Verify that the indicator mechanism
moves smoothly. If the unit is empty, the contents should
display empty.
7. Inspect the carrying strap and buckle for abnormal wear.
8. Companion 1000 T Only: Inspect the moisture cup forcracks. Verify the presence of a clean moisture pad in the
moisture cup. Verify that the quarter-turn fastener operates
properly and secures the moisture cup to the bottom of theCompanion T.
9. Check all labels for damage and wipe away any dust on
unit with a clean, dry, lint-free cloth.

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IX Operation
1. Fill Source Preparationa. Ensure that the liquid reservoir contains a sufficient amountof liquid oxygen to completely fill the portable.
b. Ensure the liquid oxygen in the fill source is properly saturated according to its technical manual filling instructions.

WARNING: Fill source must be in a well ventilated area to prevent development of an oxygen enriched atmosphere.
NOTE: Reference section VII for information on the effects of an
improperly saturated reservoir on the C1000/T
2. Fill Procedurea. Companion T Only: Remove the moisture cup from the bottom of the unit
b. Using a clean, dry, lint-free cloth, dry the male QDV on thereservoir and the female QDV on the C1000/T.

WARNING: The fill connectors must be clean and dry before
filling the C1000/T. Moisture on the fill connectors can lead toleakage of liquid oxygen. Moisture can also cause the units tofreeze together, and can lead to malfunctions of the portable orreservoir.
CAUTION: Do not depress or disturb the plastic poppet in thecenter of the reservoir fill connector. This will cause an uncontrolled release of liquid oxygen from the fill connector.
c. Hold the C1000/T with both hands and position its female
QDV over the male QDV of the reservoir.
d. Lower the C1000/T carefully into place, ensuring the fillconnectors are properly aligned.

CAUTION: Do not leave the Companion 1000/T unattended
during the filling operation. Excessive liquid oxygen discharge
can occure. Place one hand on top of the C1000/T and press straight
down. This will lower the unit about 3/8 in, properly engaging the fill connectors.
f. While holding the C1000/T in this position, move the ventlever to the open position. A hissing sound will be heard indicating liquid flowing into the portable.

i. When you notice a change in the sound of the venting gas,followed by the emission of a dense, white vapor around thereservoir shroud, close the vent valve to terminate the fill.

j. Disengage the C1000/T from the reservoir by holding thecarrying strap above the unit and pressing the release buttonon the reservoir. Should the units not disengage easily, they
may be frozen together. Do not use force. Allow a few moments for the frozen parts to warm. Disengage the units after
the ice has melted.
k. Check the liquid oxygen contents indicator to verify that theC1000/T is full of liquid oxygen.

Companion Portables

Filling

CAUTION: If the vent valve fails to close and the hissing continues, remove the Companion 1000/T by pressing the release button on the stationary. Keep the Companion 1000/T in an uprightposition. The unit will stop venting in a few minutes. Allow theunit to warm until you can close the vent valve. It may requireas much as two to three hours with the flow control off for theCompanion 1000/T to restore adequate pressure for accurate
oxygen delivery.
CAUTION: Liquid oxygen discharge from the fill connector canoccur. When disconnecting the Companion 1000/T, never standdirectly over the reservoir QDV. If the reservoir QDV stays open
and minor liquid oxygen discharge occurs, carefully re-engage
and disengage the Companion 1000/T to help dislodge any ice
or other obstruction. If major liquid oxygen discharge (steadystream) occurs, open the reservoir vent valve (if safely possible)
to vent pressure and stop the release of liquid oxygen. Openwindows and doors to ventilate the room. Do not walk on areas
exposed to liquid oxygen for 60 minutes after frost disappears.
NOTE: The pressure in the Companion 1000/T may be slightly
lower than normal for up to 20 minutes after filling the unit. Thismay cause actual oxygen flows to be slightly lower than normal.
Liquid Level Measurement
1. Suspend the C1000/T by the strap nearest the liquid level
gauge.

2. Observe the location of the needle on the liquid level gauge.
3. The green section of the color coded gauge indicates a fullunit.

g. During the filling operation, maintain a slight downward
pressure on the C1000/T with one hand to ensure stability
and proper filling position.

h. Approximately 20-30 seconds into the fill, close and reopen
the vent valve one or more times to prevent the vent valve
from freezing open.

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IX Operation
1. Verify that there is enough liquid oxygen to meet anticipatedneeds by checking the liquid level indicator.

2. Attach the oxygen cannula tube to the oxygen outlet connector.

TABLE 7: Recommended Cleaning and Disinfectant Solutions
Sporicidin Disinfectant Solution
Cleaning

Mild dish washing detergent/warm water solution

3. Properly position the nasal cannula on the patient’s face.

4. Turn the flow control knob to the prescribed oxygen flow
rate. Verify that oxygen is indeed flowing from the nasal
cannula.

Sporicidin Disinfectant Solution
Disinfecting

5. To stop oxygen flow, turn the flow control knob to a settingof “0”.

Cleaning & Disinfecting

HydroPure / HydroKlean Disinfectant Solution

HydroPure / HydroKlean Disinfectant Solution
Household Bleach (1:10 dilution with water,
freshly made within 24 hours)

NOTE: After performing the cleaning/disinfecting process, it issuggested to preform the following inspections and testing.

To ensure proper functioning and end-user safety, CAIRE portables 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.

Inspection

Preparation

2. Verify that all warning labels are present and legible on theunit

Prior to cleaning or disinfecting, the unit should be completely
purged of LOX. The technician should wear appropriate safety
gear when performing the following procedures.
Cleaning
1. Remove the front and rear cover (RP4).

2. Spray an approved cleaner (Table 7) onto a clean, dry, lintfree cloth.

3. Clean the interior and exterior of each cover with the cloth.
Use cotton swabs in tight places.

4. Wipe the covers dry with a towel.

5. Use a Scotch-Brite pad lightly with detergent to remove
scuff marks on the case.

6. Clean the plumbing with water.

7. Dry the plumbing with a towel and oil-free compressed gas.

8. Inspect the C1000/T moisture pad and replace if necessary.

NOTE: Make sure that the fill connector and vent valve shaft are
thoroughly dry before proceeding.

Companion Portables

Operation

1. Inspect the case for cracks, warpage, and discoloration.

3. Verify that the fill connector is not worn or damaged andthat the poppet is not broken.

4. Verify that the vent valve moves smoothly when opening
and closing the valve.

5. Verify that the contents indicator works properly and reads
empty when the strap is suspended.

Testing
1. Perform Leak Test

2. Perform Liquid Oxygen Functional Tests

3. Perform Gaseous Oxygen Functional Tests
Product Disposal
At the end of the unit’s life, all portable units must be returned
to a recycling facility in compliance with the Waste Electricaland Electronic Equipment Directive (WEEE), or other applicable
codes and regulations. Alternatively, CAIRE may be contacted
for disposal information.

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4 19

X Maintenance (Schedule A, 30-Month)mal).

b. Perform NER Test (RP23)

4. Prepare for Usea. Empty Contents (RP3)b. Clean and/or disinfect the unit following instructions set
forth in the Operation section.

Schedule A – 30 Month

Companion Portables

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. Maintenance Checklists are provided for eachschedule. See Below.
CAIRE, Inc. recommends returning the unit to a CAIRE service
facility every 10 years for vacuum check and re-evacuation
if necessary.

Introduction
Routine maintenance is a series of steps used to assure that theequipment is functioning properly.
1. If a unit fails a given test, one of two things may be done:
a. Refer to Troubleshooting section of this manual.
		 -or-b. Return the unit to CAIRE, Inc. for repair.

2. Schedule – Maximum of 30 months between routine
mainte-nance testing. Unit should be tested whenever a
problem is suspected.
Procedure
Follow the steps in order listed. If the unit fails any step, refer toTroubleshooting section of this manual.
1. Visual Inspection

a. Remove all LOX prior to maintenance (RP3).
b. Look for damaged or missing partsc. Verify the contents indicator reads empty and that the
spring scale moves freely.

2. Component Test

a. Remove Case (RP4)b Perform Leak Test (RP2)c. Preform PRV Test (RP9)d. Preform SRV Test (RP11)e. Pressure Retention Test (RP13)
f. Replace Case (RP4)

g. Liquid Contents/Level Indicator Test (RP7)h. Flow Rate Test (RP19)

3. Check Efficiency of Unit:

a. Inspect the unit for cold or sweaty condition and for excessive venting from relief valve (some venting may be nor-

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X Maintenance (Schedule A, 30-Month)
Step 10 Year Service Life

Year 2

1

LOX Purged From Reservoir (Repair Procedure RP3)

Performed or Verified By/Date2

Inpection for Damaged/Missing Parts

Performed or Verified By/Date

3

Contents Indicator Reads Empty and Spring Scale
Moves Freely

Performed or Verified By/Date

4

Remove Cover (Repair Procedure RP4)

Performed or Verified By/Date5

Perform Leak Test (Repair Procedure RP2)

Performed or Verified By/Date6

Perform PRV Test (Repair Procedure RP9)

Performed or Verified By/Date

Year 4

Year 6

Year 8Year 10Companion Portables

Schedule A (30-Month) Maintenance Checklist

PRV Crack Pressure
PRV Reseat Pressure
7

Perform SRV Test (Repair Procedure RP11)

Performed or Verified By/Date
SRV Crack Pressure
SRV Reseat Pressure

8

Pressure Retention Test (Repair Procedure RP13)

Performed or Verified By/Date
Internal Pressure at initial reading
Internal Pressure after 8-9 hours

9

Replace Case (Repair Procedure RP4)

Performed or Verified By/Date

10

Liquid Contents/Level Indicator Test (Repair
Procedure RP7)

Performed or Verified By/Date

Color-Coded gauge reads red when empty andgreen (1/1) when full.
11

Flow Rate Test (Repair Procedure RP19)

Performed or Verified By/Date
C1000

C1000T

Flow Rate at:

0.25

0.5

Flow Rate at:

0.5

1.0

Flow Rate at:

0.75

1.5

Flow Rate at:

1.00

2.0

Flow Rate at:

1.50

3.0

Flow Rate at:

2.00

4.0

Flow Rate at:

2.50

5.0

Flow Rate at:

3.00

6.0

Flow Rate at:

4.00

8.0

Flow Rate at:

5.00

10.0

Flow Rate at:

6.00

15.0

12

Inspect for Cold or Sweaty conditon/ Excessive
Venting from RV

Performed or Verified By/Date

13

Perform NER Test (Repair Procedure RP23)

Performed or Verified By/Date
NER Results

14

Empty Contents from Portable (Repair Procedure
RP3)

Performed or Verified By/Date

15

Clean and/or Disenfect Outside of Unit

Performed or Verified By/Date

16

10-Year Vacuum check

Performed or Verified By/Date

NA

NA

NA

NA

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X Maintenance (Schedule B, Continuous)
Companion Portables

Schedule B – Continuous Pre and Post Fill Inspection
A. Introduction
Continuous maintenance is a set of tests and inspections done
periodically to ensure equipment is functioning properly. It canbe performed by drivers or other personnel while the equipment
is in service.
1. If a unit fails a given test, it should be taken out of service
and sent to the Repair Center/Department for further inspection.
2. Schedule – Checks should be made before and after thedriver fill the reservoir at a patient location.

B. Pre Fill Procedure
1. Visually Inspect For:a. Cracks, warping, or discoloration on the case, bezel, flow
knob, and vent lever.
b. QDV deformation. Verify that the poppet is not worn or
damaged and that the lip seal is not cracked or worn.
c. Liquid Contents/Level Indicator functionality
d. Cryogenic container damage (dents, dings).

e. Visible dirt or contaminants inside or outside of the case.

f. Cracks on the moisture cup (C1000T only). Verify thepresence of a clean moisture pad in the moisture cup. Verify
that the fastener opens properly and secures the moisture cup
to the bottom of the C1000T.
g. Presence of all required labels

f. If LOX is still present in the unit, inspect for heavy frost
or condensation.
h. Vent vale functionality (opens and closes smoothly)i. FCV knob moves smoothly and encounters a detent at
each setting.
j. Abnormal wear to the carrying strap and buckle.
C. Post Fill Procedure
1. Visually Verify

a. QDV poppet is closed and not leaking

b. Vent valve is completely closed and not leakingc. No heavy frost or condensation is present on the exteriorof the unit
d. Liquid Level Contents Indicator reads the accurate
amount.

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X Maintenance (Schedule B, Continuous)
Pre Fill Visual Inspection
1

Cracks, warming or discoloration

Verified By/Date2

QDV Deformation

Verified By/Date3

Liquid Contents/Level Indicator Functionality

Verified By/Date

4

Cryogenic Reservoir Damage (Dents,Dings)

Verified By/Date

5

Visible Dirt or Contamination

Verified By/Date

6

Presence of All Required Labels

Verified By/Date7

If LOX is present in Unit, Inspect for Heavy Frost or Condnesation on
the Exterior of the Unit

Verified By/Date

8

Vent Valve Functionality Ensuring that All Parts are Present and the
Valve Functions as it Should

Verified By/Date9

FCV knob moves smoothly and encounters a detent at each setting

Verified By/Date10

Abnormal wear to carrying strap & buckle

Verified By/Date

Companion Portables

Schedule B (Continuous Pre and Post Fill Inspection) Maintenance Checklist

Post Fill Visual Inspection
1

QDV Poppet is Closed and Not Leaking

Verified By/Date

2

Vent Valve is Not Leaking

Verified By/Date

3

No Heavy Frost or Condensation is Present on the Exterior of the Unit

Verified By/Date

4

Liquid Level Contents/Indicator Reads the Accurate Amount

Verified By/Date

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

Introduction------------------------------------------------------------------------------------------ 24
Troubleshooting Chart------------------------------------------------------------------------------ 25
Repair Procedures
RP1
General----------------------------------------------------------------------------------- 30
RP2A
Leak Test (Warm & Empty Unit)---------------------------------------------------- 30
RP2B
Leak Test (Unit Containing Oxygen)------------------------------------------------ 31
RP3
Emptying/Warming Portable RR----------------------------------------------------- 31
RP4
Side Cover RR-------------------------------------------------------------------------- 31
RP5
Top Bezel RR--------------------------------------------------------------------------- 31
RP6
Carrying Strap RR---------------------------------------------------------------------- 32
RP7
Liquid Contents/Level Indicator Test------------------------------------------------ 32
RP8
Liquid Contents/Level Indicator RR------------------------------------------------- 32
RP9
PRV Test--------------------------------------------------------------------------------- 33
RP10
PRV RR---------------------------------------------------------------------------------- 33
RP11
SRV Test--------------------------------------------------------------------------------- 34
RP12
SRV RR---------------------------------------------------------------------------------- 34
RP13
Pressure Retention Test---------------------------------------------------------------- 34
RP14A Warming Coil Assembly RR (C1000)----------------------------------------------- 35
RP14B Warming Coil Assembly RR (C1000T)--------------------------------------------- 35
RP15
Vent Valve Test------------------------------------------------------------------------- 35
RP16
Vent Valve RR-------------------------------------------------------------------------- 36
RP17
QDV Assembly RR-------------------------------------------------------------------- 37
RP18
Lip Seal RR------------------------------------------------------------------------------ 37
RP19
Flow Rate Test Test-------------------------------------------------------------------- 38
RP20
FCV RR---------------------------------------------------------------------------------- 39
RP21
Back Flushing the FCV---------------------------------------------------------------- 39
RP22
Operating Pressure Test---------------------------------------------------------------- 39
RP23
NER Test-------------------------------------------------------------------------------- 40
RP24
Manifold RR---------------------------------------------------------------------------- 40
RP25
Cryogenic Container RR--------------------------------------------------------------- 41

Companion Portables

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 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 8 - Troubleshooting

1)

Symptom

Unable to start fill or ex- a)
cessively long fill times

Probable Cause

Corrective Action

QDV not properly engaged on
the reservoir

Make sure the QDV on the portable and reservoir are properlyaligned and ensure that a downward force is being applied to theportable.

b)

Reservoir is empty

Swap or re-fill the reservoirc)Vent valve not openg)Ensure that the vent valve lever is fully in the open position.
The lever must be open to begin a fill.
FCV is open
Be sure that the FCV knob is in the off (“0”) position. If thevalve is open, fill times can increase.
Reservoir saturation pressure is Swap reservoirs or allow the reservoir time to stabilize andtoo lowbuild pressure
Vent valve is obstructed
Inspect the vent tubes for blockages. Clean by blowing out withcompressed gas or replace parts if necessary.
Leak in the system
Check the portable for leaks (RP2) and repair if needed.

h)

QDV damaged or faultyi)Faulty vent valve

d)
e)
f)

Inspect the QDV and be sure the poppet opens properly andsmoothly. If necessary, replace the QDV (RP17)
Replace the vent valve (RP16)

2)

Liquid leaks from thecoupled QDVs during
the filla)Worn or damaged lip seal

Replace the QDV lip seal (RP18)

3)

Unable to disconnect the a)poratble from the reservoirb)

Pop-off assembly not being
utilized
QDVs are frozen together

Ensure that the pop-off assembly on the reservoir is being used.
Do not use force to separate the QDVs.
Leave the units coupled with the vent valve closed and let themsit until they warm up enough to disconnect. Always ensure thatmale and female QDV’s are cleaned and dried prior to each fill.

4)

Liquid leaks from thea)
QDV poppet after filling

Ice crystal preventing the QDV Engage and disengage the portable onto the reservoir several
from closing properly.
times to dislodge the ice crystal. Always be sure that the maleand female QDVs are wiped clean and dry before filling.

b)Companion Portables

Table 5 below provides troubleshooting procedures for the Companion Portables. 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.

Dirty or damaged QDV poppet Replace the QDV (RP17)

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XI
1 Troubleshooting & Repair ProceduresCompanion Portables

Table 8 (cont.)

5)6)

Symptom

Liquid leaks from a)the vent valve tube/
outletb)

Excessive venting
from relief valves(hissing sound)

No Flow

Vent valve is not fully
closedCorrective Action

Ensure that the vent valve lever is fully in the closed position.

The portable has been
Return the portable to an upright or acceptable operating position andtransported or laid in an im- allow several minutes for stabilization.
proper operating positionc)

Vent valve is frozen open

Allow the portable to warm until the vent valve can close. After thewarm up, allow up to 60 minutes for the portable to stabilize and buildpressure before operating.

d)Faulty vent valve

Replace the vent valve (RP16)b)

Saturation pressure too
high.

Inspect the saturation pressure of the reservoir used for filling. Allowat least 30 minutes at no flow for the portable to saturate properly.

c)Relief valve frozen open

Allow the portable to warm and thaw. Attempt to re-fill the portable.

d)Faulty relief valve

Partial or complete loss of
vacuumTest the relief valve (RP9) and replace if necessary (RP10)

Conduct the NER test (RP23) and return the unit to CAIRE, Inc. ifnecessary.

a)Portable is empty

Check the contents indicator/level gauge and fill the portable ifneeded.

b)

Flow control valve turned
off

Ensure the flow control knob is not in the off (“0”) position.

Nasal cannula kinked or
disconnected

Ensure proper nasal cannula functionality and positioninge)Saturation pressure is too
low

Inspect the saturation pressure of the reservoir used for filling. Allowat least 30 minutes at no flow for the portable to saturate properly.

f)Leak in the systemg)

Relief valve is open

Perform a leak check on the plumbing (RP2). Repair leaks as necessary.

h)Vent valve is open

Ensure that there is no venting from the vent valve outlet/tube. If there
is refer to the corrective actions for “Liquid leaks from the vent valve
tube/outlet”

i)

FCV inlet filter is obstructed
Blockage in the liquid
withdrawal circuit

Clean or replace (RP20) the filter screen.

FCV Faulty

Replace the FCV (RP20)

a)

e)
7)

Probable Cause

c)

j)
k)

The portable has been
Return the portable to an upright or acceptable operating position andtransported or laid in an im- allow several minutes for stabilization.
proper operating position

Ensure that there is no venting from the relief valves. If there is refer tothe corrective actions for “Excessive venting from relief valves (hissing sound)”Check the warming coils and withdrawal tubes for blockages. Replace
if necessary.

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XI
1 Troubleshooting & Repair Procedures
8)9)

SymptomLow flow at all
LPM settings

Increased NER

Probable Cause

Corrective Actiona) Nasal cannula kinked or
leaking

Inspect the functionality of the nasal cannula.

b) Saturation pressure is too
low

Inspect the saturation pressure of the reservoir used for filling. Allow atleast 30 minutes at no flow for the portable to saturate properly.

c) Leak in the system

Perform a leak check on the plumbing (RP2). Repair leaks as necessary.

d) Flow control valve inlet
filter screen dirty

Clean or replace (RP20) the filter screen.

f) Blockage in the liquid
withdrawal circuit

Check the warming coils and withdrawal tubes for blockages. Replace ifnecessary.

e) PRV faulty

Test the PRV (RP9) and replace (RP10) if necessary.

g) FCV faulty

Replace the FCV (RP20)a) Saturation Pressure is too
highInspect the saturation pressure of the reservoir used for filling. Allow atleast 30 minutes at no flow for the portable to saturate properly.

b) Leak in the system

Perform a leak check on the plumbing (RP2). Repair leaks as necessary.

c) Relief valve open

Ensure that there is no venting from the relief valves. If there is refer tothe corrective actions for “Excessive venting from relief valves (hissing
sound)”d) Partial or complete loss of
vacuum10) Excessive Frosta)
NOTE: Minimal
frost on the case andon the plubming isnormal. This sympb)
tom applies to frostthat is much greater c)than what is normally observed.
d)

Frost is acceptable

Conduct the NER test (RP23) and return the unit to CAIRE, Inc. if necessary.
Some frost on the outer case and on the plumbing is acceptable, especially at high flow rates during continuous use. This is due to the evaporation of LOX to gas and the temperature difference between the LOX
and room temperature.

High humidity level

High humidity levels can increase frost accumulation.

Leak in the system

Perform a leak check on the plumbing (RP2). Repair leaks as necessary.

e) Relief valve open

Ensure that there is no venting from the relief valves. If there is refer tothe corrective actions for “Excessive venting from relief valves (hissing
sound)”

Saturation pressure is too
highf) Partial or complete loss of
vacuum11) Unit will not main- a) Saturation pressure is out
tain acceptable presof specification
sure when in use

Companion Portables

Table 8 (cont.)

Inspect the saturation pressure of the reservoir used for filling. Allow atleast 30 minutes at no flow for the portable to saturate properly.

Conduct the NER test (RP23) and return the unit to CAIRE, inc. if necessary.
Inspect the saturation pressure of the reservoir used for filling. Allow atleast 30 minutes at no flow for the portable to saturate properly.

b) Leak in the system

Perform a leak check on the plumbing (RP2). Repair leaks as necessary.

c) PRV faulty

Test the PRV (RP9) and replace (RP10) if necessary.

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XI Troubleshooting & Repair ProceduresCompanion Portables
Companion Portables Technical Service Manual • PN 20562220 Rev F

4 28

XI Troubleshooting & Repair ProceduresCompanion Portables(RP23)To use the Troubleshooting Chart:• Start at the upper left corner.
• The top line shows the steps of routine maintenance.
• Unless otherwise noted by the arrows, the flow through the chart is down or to the right.
Companion Portables Technical Service Manual • PN 20562220 Rev F

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XI Troubleshooting & Repair Procedures
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.
WARNING: Make sure the unit is empty and vent valve is open
before replacing any component, except seals.
WARNING: Parts that are welded in place must not be replacedin the field. Should these parts fail, return complete assembly or
sub-assembly to factory for repair. DO NOT use solder or silver
solder to repair broken welds.

RP2A - Leak Test (Warm & Empty Unit)
1) Remove the covers (RP4).

2) Set the flow control valve to 0 LPM (Off).

3) Pressurize the C1000/T portable to approximately 1.52 bar(22 psi) with gaseous oxygen using the portable pressurizing
setup and gaseous oxygen supply (Figure 9). Close the ventvalve after pressurizing the unit and remove the pressurizing
setup from the vent tube.
4) Connect the test pressure gauge to the oxygen outlet barbed
fitting and set the flow control valve to its highest setting.
Place the C1000/T in the portable test fixture (Figure 10).

Companion Portables

RP1 – General

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.

Figure 9: Pressurizing the Companion Portable

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XI Troubleshooting & Repair Procedures
1) Turn the FCV knob to the highest flow setting.

2) Allow unit to sit for 24 hours before proceeding.
RP4 – Side Cover RR
1) C1000T only: Remove the moisture cup by turning the quarter-turn fastener counter clockwise and pulling the cup awayfrom the unit.

2) Place the unit on its side with the back side cover facing you.
Use a 7/64 in Allen wrench to remove five socket head cap
screws located underneath the vent valve lever and the corners of the side cover.

Figure 10: Pressure Gauge Connection5) Wet a finger with leak detector and lightly place it against
the open end of the vent tube located near the bottom of theunit. If bubbling occurs, replace the vent valve (RP16).

6) Use SNOOP liquid leak detector to test all fittings and connections. Verify that the unit maintains 1.52 bar (22 psi)pressure during the leak test.

7) With pressure remaining in the unit, place a small amount of
SNOOP on the tip of the C1000/T QDV. A small amount ofleakage around the poppet of the fill connector is acceptable,
provided that the total leakage rate of the unit is not greaterthat the NER.

8) Blow dry with compressed gas the QDV poppet and the ventvalve.
RP2B - Leak Test (Unit Containing Liquid Oxygen)
1) Remove the case (RP4).

2) Connect the test pressure gauge to the oxygen outlet barbed
fitting and set the flow control valve to the highest setting.
3) Place the C1000/T in the portable test fixture (Figure 10).

4) Wet a finger with leak detector and lightly place it against
the open end of the vent tube located near the bottom of theunit. If bubbling occurs, replace the vent valve (RP16)5) Use SNOOP liquid leak detector to test all fittings and connections. Verify that the unit maintains 1.52 bar (22 psi)pressure during the leak test.

Companion Portables

RP3 – Emptying/Warming Portable RR

3) Carefully separate the two side covers from each other.

4) Use a 7/64 in Allen wrench to remove the two socket headcap screws and the two lockwashers located in the tables on
the bottom of the container.
5) Use a 1/16 in Allen wrench to loosen the set screw in theflow control valve knob.

6) Remove the flow control valve knob and the decal. If theknob does not use a set screw, insert the Allen wrench into
the hole in the knob.

7) Simultaneously push in and pull up on the Allen wrench to
remove the knob.

8) Use a small flat-blade screwdriver to loosen and remove thetwo flat-head screws from the flow plate. Remove the flow
plate.
9) Remove the front side cover.

10)Install the side covers by reversing the above procedure.
RP5 – Top Bezel RR
1) Remove the side covers (RP4)2) Use a 7/16 in deep well socket and a T-handle or ratchet
wrench to remove the oxygen outlet barbed fitting. Do not
lose the O-ring3) Remove the top bezel.

4) Install the top bezel by reversing steps 1-3.

6) With pressure remaining in the unit, place a small amount of
SNOOP on the tip of the C1000/T QDV. A small amount ofleakage around the poppet of the fill connector is acceptable,
provided that the total leakage rate of the unit is not greaterthat the NER.

7) Blow dry with compressed gas the QDV poppet and the ventvalve.

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XI Troubleshooting & Repair Procedures
1) Remove the covers (RP4) and top bezel (RP5).

2) Use a small screwdriver to remove the outermost E-clip
from the pivot shaft. Remove the pivot shaft.

5) Use a medium-blade screwdriver to remove the four panhead screws from the indicator. Remove the four screws andthe four upper spacers from the indicator.

NOTE: Some older models may contain hitch pins in place of
the E-clips. If the unit has hitch pins, it will also contain a different pivot shaft.
3) Remove the carrying strap from the portable

Companion Portables

4) Remove the lever spacer, the spring, and the spring rod.

RP6 – Carrying Strap RR

4) Install the carrying strap by reversing steps 1-3.
RP7 - Liquid Contents/Level Indicator Test
NOTE: Disconnect the plastic buckle in the carrying strap before
performing the following steps. The C1000/T side covers must
be in place when performing this test.
1) Place the C1000/T on a table and hold it down while gently
pulling up on the end of the carrying strap nearest the contents indicator.
2) Verify that the indicator operates smoothly and withoutbinding3) C1000T Only – Verify that “Transport” is present on the indicator dial.
4) Suspend the unit by the end of the carrying strap nearest thecontents indicator. Verify that the needle appears in the red
EMPTY region at the end of the indicator window.
5) Fill the unit with liquid oxygen. Suspend the unit by the endof the carrying strap nearest the contents indicator. Verify
that the needle is in the upper portion of the green FULL region.

Figure 126) Pry the lens cap away from the base.

7) Remove the indicator needle from the base

Figure 138) Use a small screwdriver to remove one E-clip from the pivot
shaft. Remove the lever.

RP8 - Liquid Contents/Level Indicator RR
1) Remove the carrying strap (RP6).

2) Loosen and remove the four socket head cap screws fromthe base of the contents indicator weight scale mechanism.
Remove the contents indicator assembly.

3) While holding the lever down, remove the hitch pin from theend of the spring rod.

Figure 149) Reassemble and install the contents indicator by reversing
steps 1-8.

NOTE: Be sure to lubricate the O-ring with a small amount of
Krytox grease. This allows the helix to easily rotate in the indicator.

Figure 11

NOTE: Be sure to put the weight scale mechanism in the proper
orientation. The slotted hole in the mounting bracket should benext to the flow control valve.
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XI Troubleshooting & Repair Procedures

RP10 – PRV RR
1) Remove the covers (RP4).

2) Loosen and remove the silencer from the end of the primary
relief valve (Figure 15).

Companion Portables

RP9 - PRV Test
1) Remove the covers (RP4).
2) Connect the pressurizing setup to the C1000/T as shown in
Figure 9.
3) Place one drop of SNOOP on the PRV or PRV silencer.
4) Slowly pressurize the unit with gaseous oxygen by adjusting
the oxygen regulator until tiny, foam-like bubbles begin toform to indicate that the PRV has opened. You can also listen for an audible hissing sound.
5) Verify that the PRV opens (bubbles appear on the silencer)
at a pressure less than 1.62 bar (23.5 psi).
6) If the opening pressure is not within the specified range, repeat the procedure. If the PRV fails to open in the specified
range a second time, replace the PRV (RP10).
7) Slowly reduce the gaseous oxygen source pressure until thestream of bubbles begins to diminish.
8) Verify the PRV closes (bubbles begin to diminish) at a pressure greater than 1.28 bar (18.5 psi).
9) If the closing pressure does not meet the acceptable
range,repeat the procedure. If the PRV fails to close at the
specified range a second time, replace the PRV (RP10).
10) Remove the pressurizing setup and reinstall the covers(RP4).

Figure 16: PRV Removal
NOTE: Inspect the relief valve adapter for cracks caused fromovertightening. Replace as necessary.
NOTE: Some older models contain a blue, anodized relief valve
adapter. Some of these adapters may be susceptible to cracking.
The blue relief valve adapter has been replaced by a clear anodized adapter that has a longer thread engagement length.
NOTE: The primary relief circuit tubing on some older models
consists of a “pig-tailed” section of aluminum tubing. The current primary relief circuit tube is a long, U-shaped section of aluminum tubing.

NOTE: Some older models may not be equipped with a silencer.
These units may be retrofitted with a silencer, but this will require
replacing the primary relief valve.

Figure 15: Removing the PRV Silencer
3) Use a 1/2inch open-end wrench to loosen and remove theprimary relief valve while simultaneously holding the relief valve adapter stationary with another 1/2inch open-end
wrench.
4) Install the PRV by reversing steps 1-3.

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XI Troubleshooting & Repair Procedures
1) Remove the covers (RP4).

2) Connect the pressurizing setup as shown in Figure 9.

3) Remove the silencer from the PRV.

4) Hold the PRV closed while pressurizing the portable.

5) Slowly pressurize the C1000/T by adjusting the gaseous oxygen source regulator.
6) Verify that the SRV opens (audible hiss) at 1.97-2.17 bar(28.5-31.5 psi).

7) If the SRV does not open within these specified ranges,
repeat the procedure. If it fails to open the second time, replace the SRV (RP12).

8) Slowly reduce the pressure of the gaseous oxygen source
until the audible hissing noise is no longer heard, indicatingthat the SRV has closed.

9) Verify that the SRV closes at a pressure greater than 1.86 bar(27 psi).
10) If the SRV does not close within this specified range thefirst time, repeat the test. If it fails to open in an acceptable
range the second time, replace the SRV (RP12).

NOTE: Do not release the PRV poppet unit pressure in the unit
is reduced below 1.52 bar (22 psi) by removing the pressurizing
setup and opening the vent valve. Replace the PRV silencer.

RP13 – Pressure Retention Test
1) Empty the unit and remove the covers (RP4).
NOTE: Perform RP13 only on warm, empty portable units.
Performing this test on Portable units containing liquid oxygen
will yield inaccurate results.
2) Set the flow control valve to 0 LPM (Off).

3) Use the pressurizing setup show in Figure 9 to pressurize the C1000/T until the PRV vents (approximately 1.52
bar/22psi). This is indicated by an audible hissing noise.

Companion Portables

RP11 – SRV Test

4) Close the vent valve and remove the pressurizing setup.
Connect the test pressure gauge to the oxygen outlet barbed
fitting and set the flow control valve to the highest setting.
Record the pressure gauge reading and the time.
5) Set the flow control valve to 0 and remove the test pressuregauge from the oxygen outlet.
6) Do not disturb the C1000/T for 8 to 9 hours.

7) At the end of this period, verify that the unit maintains atleast 1.04 bar (15 psi). Should the pressure be less, re-pressurize the unit to approximately 1.52 bar (22 psi) and locate
the leak by testing all components, fittings, and tubing withliquid leak detector (RP2). Make repairs as needed, taking
care not to over tighten connections.

RP12 – SRV RR
1) Remove the covers (RP4)2) Use a 1/2 inch open-end wrench to loosen the 3/16inch tube
nut connected between the secondary relief valve and thesecondary relief valve adaptor. Simultaneously, hold the relief valve adapter stationary with another 1/2inch open-end
wrench while removing the secondary relief valve.
3) Install the SRV by reversing steps 1-2.

NOTE: Before installing the SRV, wrap the SRV threads with
Teflon tape, starting two threads back from the end.

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XI Troubleshooting & Repair Procedures
1) Remove the covers (RP4).

2) Use side-cut pliers to cut the two wire ties from the warmingcoil.

3) Use a 5/8inch open-end wrench on the vent valve body hex
flats to hold the body stationary. Use a 11/16inch open-end
wrench to loosen the jam nut that holds the vent valve to themounting bracket.
4) Use a 9/16inch open-end wrench to disconnect the 1/4inch
tube nut where the vent tube connects to the manifold.
Remove the vent valve and tube assembly (Figure 17).

NOTE: Do not overtighten the tube nuts on the warming coil.
Overtightening may result in a cracked fitting. Only a slight increase in torque is required to seal a compression fitting that has
already been made up. When making up a new fitting, three-quarters of a turn from finger-tight is required for 3/16inch tubing.
RP14B – Warming Coil Assembly RR (C1000T)
1) Remove the covers (RP4)2) Use side-cut pliers to cut the wire tie from the warming coil.
3) Use a 1/2inch open-end wrench to disconnect the 3/16inch
tube nuts where the warming coil connects to the two brasstees. Remove the warming coil.

Companion Portables

RP14A – Warming Coil Assembly RR (C1000)

4) Use a 9/16inch open-end wrench to disconnect the 1/4inch
tube nut where the fill tube connects to the female fill connector adapter.
5) Use a 9/16inch open-end wrench to disconnect the 1/4inch
tube nut where the fill tube connects to the manifold.
Remove the fill tube.

6) Use a 1/2inch open-end wrench to disconnect the 3/16inch
tube nut where the warming coil connects to the flow control
valve.
Figure 17: Warming Coil Removal
5) Use a 1/2inch open-end wrench to disconnect the 3/16inch
tube nut where the warming coil connects to the flow control
valve.
6) Use a 1/2inch open-end wrench to disconnect the 3/16inch
tube nut where the warming coil connects to the manifold.
Remove the warming coil (Figure 18).

Figure 18:Warming Coil Removal

7) Use a 1/2inch open-end wrench to disconnect the 3/16inch
tube nut where the warming coil connects to the brass tee.
Remove the warming coil.
8) Use a 1/2inch open-end wrench to disconnect the 3/16inch
tube nut where the spined tube connects to the manifold.
9) Use a 1/2-in open-end wrench to disconnect the 3/16inch
tube nut where the spined tube connects to the brass tee.
Remove the spined tube.
10)Install the warming coils by reversing steps 1-9.

NOTE: Be sure to replace the wire tie after reinstalling the warming coil.
RP15 – Vent Valve Test
1) Remove the covers (RP4) and set the FCV to off (0 LPM).
2) Connect the pressurizing setup to the C1000/T as shown in
Figure 9 and pressurize the unit to approximately 1.52 bar(22 psi), or fill the unit with liquid oxygen.
3) Wet a finger with leak detector and lightly place it against
the open end of the vent tube located near the bottom of theunit. Verify that no leaks are present and no bubbling occurs.
4) Open the vent valve and listen for a sudden exhaust of gaseous oxygen.

7) Install the warming coils by reversing steps 1-6.
NOTE: Be sure to replace the wire ties after reinstalling thewarming coil. The wire ties hold the warming coil away from any
moisture that may accumulate in the moisture pad at the bottomof the unit.
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XI Troubleshooting & Repair ProceduresCompanion Portables

RP16 - Vent Valve RR1) Remove the covers (RP4).

2) Use a 9/16 inch open-end wrench to disconnect the 1/4inch
tube nut that connects the vent extension tube to the ventvalve (Figure 19).

Figure 21: Vent Valve Removal
5) Slide the vent valve out of the mounting bracket.

6) Position the new vent valve in the mounting bracket slot. Do
not tighten the jam nut at this time.

Figure 19: Vent Extension Tube Removal
3) Use a 9/16inch open-end wrench to disconnect the 1/4 inchtube nut that connects the long vent tube to the vent valve(Figure 20).

NOTE: The mounting bracket should be between the jam nut andthe valve body hex flats. The valve flow direction arrow should
point downward.
7) Align the short vent tube and long vent tube with the proper
vent valve ports. Thread the tube nuts onto the valve andtighten.
NOTE: Do not over tighten the vent tube nuts. Over tightening
may result in a cracked fitting. Only a slight increase in torqueis required to seal up a compression fitting that has already been
made up. For 1/2 inch tubing, 1/4 turn from finger-tight is required when making up a new fitting.

Figure 20: Vent Tube Removal
4) Use a 5/8inch open-wrench on the vent valve body hex
flats to hold the body stationary. Use a 11/16 inch open end
wrench to loosen the jam nut that holds the vent valve to themounting bracket (Figure 21).

8) Push the vent valve fully into the slot in the mounting
bracket. Hold the valve in this position with a 5/8 inch openend wrench placed on the valve body hex flats. Use a 11/16
inch open-end wrench to tighten the jam nut.
NOTE: Check for proper vent valve lever operation after installing the side cover. Adjust the vent valve horizontally by shifting
the valve in the mounting bracket. Adjust vertically by loosening
the two socket head cap screws mounted in the tabs on the bottomof the bottle and shifting the entire bottle assembly up or down.
Make sure that the vent extension tube outlet is centered in thecorresponding side cover clearance hole.
9) Install the side covers (RP4).

Companion Portables Technical Service Manual • PN 20562220 Rev F

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XI Troubleshooting & Repair Procedures
RP18 – Lip Seal RR

1) Remove the covers (RP4).

1) Remove the QDV (RP17).

2) Use a 9/16inch open-end wrench to disconnect the tube nut
at the female adaptor (Figure 22).

Companion Portables

RP17 – QDV Assembly RR2) Hold the QDV body with an adjustable wrench placed on
the machined flats. Use a second adjustable wrench to remove the lip seal retainer sleeve.
3) Pull the lip seal out of the fill connector body.

Figure 22: QDV Tube Nut Removal
3) Use a 7/8inch open-end wrench to loosen the jam nut (earlier models may have a 5/8inch jam nut) that holds the female adapter to the mounting bracket. Pull the fill connector
assembly down slightly to clear the fill tube and then slide itout of the mounting bracket (Figure 23).

Figure 24: Lip Seal Removal
4) Insert the stepped (spring) end of the new lip seal into thecorresponding recess in the large end of the QDV body.
Make sure that it is squarely seated.

5) Thread the lip seal retainer onto the large end of the fill connector body and tighten to a torque of 35 lb/ft (511 n/m).
6) Replace the QDV assembly (RP17).

Figure 23: QDV Removal
4) Install the QDV assembly by reversing steps 1-3.
Figure 25: Lip Seal Replacement

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XI Troubleshooting & Repair Procedures
1) Fill the C1000/T with liquid oxygen. Allow approximately
one hour for the system pressure to stabilize. Verify that the
PRV is venting and that the system pressure is 1.28 – 1.62
bar (18.5 – 23.5 psi).
2) Attach a calibrated flow meter to the oxygen outlet barbed
fitting.

3) At each flow setting, check the flow control valve.
Acceptable flow ranges are given below in Table 9 and 10.

NOTE: Data listed in Table 9 and 10 is based on an operatingpressure range of 1.41-1.66 bar (20.5-24 psi). If the flow measurements are out of specification, check the pressure in the unit. A
combination of high or low pressure and the tolerance of the particular flow meter you are using can result in inaccurate readings.

Nominal Setting (LPM)

Allowable Range (LPM)

1.00

0.83 - 1.17

0.50
1.50
2.00
3.00

0.33 - 0.67
1.18 - 1.82
1.61 - 2.43
2.55 -3.51

4.00

3.43 - 4.62

6.00

5.14 -6.92

5.00
8.00

10.00
15.00

Companion Portables

Table 10 C1000T FCVRP19 - FCV Test

4.33 - 5.77
6.72 - 9.28

8.42 - 11.53

12.97 - 17.28

Table 9 C1000 FCV
Nominal Setting (LPM)
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

Allowable Range (LPM)
0.02 - 0.22
0.08 - 0.42
0.33 - 0.67
0.58 - 0.92
0.83 - 1.17
1.18 - 1.82
1.61 - 2.43
2.08 - 2.97
2.55 - 3.51
2.92 - 4.04
3.43 - 4.62
4.33 - 5.77
5.14 - 6.92

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XI Troubleshooting & Repair Procedures
RP21 – Back Flushing the FCVWARNING: Liquid oxygen discharge from the FCV can occur
if a 0-15LPM C1000T FCV is installed on a C1000. Always
check the flow rating decal on the FCV before installing thevalve on a portable. DO NOT install a 0-15LPM valve on a
C1000.

2) Temporarily reinstall the oxygen outlet barbed fitting in theflow control valve. Connect 3.45-5.18 bar (50-75 psi) oxygen to the valve’s outlet barbed fitting. Temporarily installthe valve knob on the rotor shaft.

1) Remove the top bezel (RP5).

2) Use a 1/2 inch open-end wrench to loosen the 3/16inch tube
nut on the back of the flow control valve. Remove the tube
and nut from the flow control valve.

1) Remove the FCV (RP20) and its filter screen.

3) Slowly rotate the valve knob through all flow settings(Figure 28). Gas flow should be audible at each flow position, indicating that the appropriate orifice is open.

Companion Portables

RP20 – FCV RR

3) Use a 1/16 inch Allen wrench to loosen the set screw in theflow control valve knob. Remove the flow control valve
knob and decal. If the knob does not use a set screw, insert
the Allen wrench into the hole in the knob. Simultaneously
push in and pull up on the Allen wrench to remove the knob.
4) Use a small flat-blade screwdriver to loosen and remove thetwo flat-head screws from the flow plate. Remove the flow
plate and the flow control valve.
5) Use a dental pick or similar tool to carefully remove the inlet filter screen from the flow control valve. Be careful not
to scratch any part of the flow control valve inlet port whenremoving the screen (Figure 26).

Figure 28: Backflushing the FCV

6) Install the FCV by reversing steps 1-5.

RP22 – Operating Pressure Test
1) Fill the C1000/T with liquid oxygen from a properly saturated reservoir.

2) Attach the test pressure gauge w/ tubing (B-701732-00) to
the cannula outlet barb on the top of the C1000/T.
3) Open the FCV to the highest flow setting.

4) Read the operating pressure on the gauge. The pressure
should be between 1.28 – 1.62 bar (18.5 – 23.5 psi).
Figure 26: Removing the Filter Screen

Figure 27: FCV AssemblyCompanion Portables Technical Service Manual • PN 20562220 Rev F

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XI Troubleshooting & Repair Procedures
RP24 – Manifold RR

1) Perform a leak test (RP2) and verify that the results are acceptable.

1) Remove the covers (RP4).

2) Perform the PRV test (RP9) and verify that the PRV is functioning properly.
3) Set the flow control valve to 0LPM and fill the unit from aproperly saturated liquid oxygen source.
4) Allow 30 minutes for the unit to stabilize.

5) Record the initial weight of the unit and the time (w1).

6) After an elapsed time of 18 to 24 hours, record the weight
and time (w2).

7) Calculate the NER using the following formula.
NER =(24 hrs.) x (w1 - w2)(Time between w1 and w2 in hrs.)8) Verify that the NER is less than 1.5 lb/day (0.7 kg/day).

Companion Portables

RP23 – NER Test

2) Remove the top bezel (RP5).

3) Loosen and remove the four socket head cap screws fromthe base of the contents indicator assembly. Remove the assembly.
4) Use a 1/2inch open-end wrench to disconnect the 3/16inch
tube nut where the warming coil connects to the manifold.

5) Use a 9/16inch open-end wrench to disconnect the 1/4inch
tube nut where the vent tube connects to the manifold.
6) Use a 9/16inch open-end wrench to disconnect the 1/4inch
tube nut where the fill tube connects to the manifold.

7) Use a 1/2inch open-end wrench to disconnect the 3/16inch
tube nut where the primary relief valve tube connects to the
manifold.
8) Use a 1/2inch open-end wrench to disconnect the 3/16inch
tube nut where the secondary relief valve tube connects tothe manifold.

9) Use a 3/16inch nut driver to remove the four standoffs fromthe manifold (Figure 29). Remove the manifold.

Figure 29: Manifold Removal
NOTE: To prevents contaminants from entering the cryogenic
container, place a clean plastic bag over the neck of the containerand seal tightly.
10)Install the manifold by reversing steps 1-9.

11)Use the specified torque wrench to the standoffs of 10in-lb(115 N-cm) in an alternating sequence (Figure 30).

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XI Troubleshooting & Repair Procedures
1) Remove the manifold (RP24).

2) Use a 5/8inch open-end wrench on the vent valve body hex
flats to hold the body stationary. Use an 11/16inch open-end
wrench to loosen the jam nut that holds the vent valve to themounting bracket. Remove the vent valve and tube assemblyfrom the mounting bracket.
3) Use side-cut pliers to cut the wire tie from the warming coil.

Figure 30: Manifold Torque Sequence12)Follow up by torquing the standoffs to 22 in-lb (253 N-cm) inan alternating sequence.
NOTE: Verify that the O-ring seal between the manifold and thecontainer does not have any nicks, scratches, or tears. Also, checkto see that the O-ring is not flat-spotted. Replace as necessary.

4) Use a 7/8inch open-end wrench to loosen the jam nut (someearlier models may have a 5/8inch jam nut) that retains thefemale adapter to the mounting bracket. Remove the female
fill connector and tube assembly from the mounting bracket.

Companion Portables

RP25 – Cryogenic Container RR5) Install the cryogenic container by reversing steps 1-4.

NOTE: To prevent contaminants from entering the cryogenic container, place the container in a clean plastic bag and seal tightly.

NOTE: When installing the manifold, position the vacuum portof the bottle between the secondary relief valve and warming coilports on the manifold.
NOTE: Do not overtighten the tube nuts of a compression fitting.
Over-tightening may result in a cracked fitting. Only a slight increase in torque is required to seal a compression fitting that has
already been made up. When making up a new fitting, tighten 3/4
turn from finger-tight for 3/16inch tubing; 11/4 turns from fingertight for 1/4inch tubing.
NOTE: Before installing the side covers, pressurize the systemwith gaseous oxygen and test for leaks according to the Leak Test
(RP2).

Companion Portables Technical Service Manual • PN 20562220 Rev F

4 41

XII Parts List

Companion Portables Technical Service Manual • PN 20562220 Rev F

Companion Portables

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

4 42

XIII Ordering Information
Companion Portables

Ordering Information
The following steps should be used when ordering a new C1000/T
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:		770 257 1299
Fax:
		770 257 1300

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) 119 939 7060
+44 118 9799245

For additional ordering and contact

information, visit www.caireinc.com.

Companion Portables Technical Service Manual • PN 20562220 Rev F

4 43

XIV Return & Restocking Policy
If a problem with the unit should be encountered, reference
should be made to the Troubleshooting Chart in Section XII. If
these procedures do not provide a solution for the problem, thefollowing steps should be taken:
1. Call CAIRE, Inc. Customer Service.

North and South America/Asia/Pac Rim:
Phone (US Only)
Phone

Africa/Europe/Middle East:
Phone

2. State the problem with the unit.

800-482-2473

770-721-7759+44 (0) 1189 367080

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

Restocking Policy
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.

Companion Portables

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

c. State the equipment purchase date.

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.

Companion Portables Technical Service Manual • PN 20562220 Rev F

4 44

XV Service Tools/Equipment/Supplies
Tools and Accessories available from CaireHex Wrenches (various sizes)
Flat Blade Screwdriver
Needle Nose Pliers

Adjustable Wrench—8 inch

Open End Wrenches (various sizes)

Socket Wrench – 5/16 inch deep well
Socket Wrench – 1/4 inch drive

Required Fixtures/Equipment
Calibrated Flow Meter
Calibrated Weight Scale
Gaseous Oxygen Source 0-6.89 bar (0-100 psi)
Liquid Oxygen Source
Portable Test Fixture
Test Pressure Gauge (0-60 psi) w/ Tubing
Required Supplies

Household Glass Cleaner
Lint-Free Cloth

Description­

Item Number

Backpack C1000/T

10018138

Erie Liter Meter (0-8 LPM)

B-775311-00

Erie Liter Meter (6-15 LPM)

10995620

Fluoro-Lubricant

CA200071

Krytox Lubricant (2 oz tube)

20605136

Oxygen Compatible Tubing – 3/16 in(0.48 cm) Diameter

B-778214-SV

Portable Test Fixture

B-778202-00

Pressure Gauge (0-60 psi)

97403577

Rolling Cart C1000/T

20765565

Shipping Carton C1000/T

B-775095-00

Shipping Insert – Top

B-778068-00

Shipping Insert – Sides

B-778069-00

Teflon Tape

SNOOP Liquid Leak Detector (8 oz bottle) B-775272-00

SNOOP Leak Detection Fluid

Tee Connector

B-778211-CK

Teflon Tape

B-775036-00

Test Pressure Gauge w/ Tubing

B-701732-00

Scotch-Brite Adhesive Pad
Isopropyl Alcohol
Cotton Swaps

Krytox Lubricant

Companion Portables Technical Service Manual • PN 20562220 Rev F

Companion Portables

Required Tools

4 45

www. ca i re i n c. co m

CAIRE Inc.
2200 Airport Industrial Dr., Ste. 500 Ball Ground, GA
30107 U.S.A.
CAIRE Medical Ltd
Unit 6 Ashville Way
Wokingham
Berkshire, RG41 2PL, United Kingdom

CAIRE and CAIRE Inc. are registered trademarks of CAIRE Inc. Please visit our website
below for a full listing of trademarks. Trademarks: www.caireinc.com/corporate/
trademarks/.
© 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 Portables Technical Service Manual • PN 20562220 Rev F

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