IT IS FURTHER ORDERED that the certification valid through September 1,2009.
of the Healy Phase II EVR System
IT IS FURTHER ORDERED that Executive Order VR-201-F issued on March 21, 2008, is hereby superseded by this Executive Order. Healy Phase II EVR Systems certified under Executive Order VR-201-A through F may remain in use at existing installations. This Executive Order shall apply to new installations or major modification of Phase II Systems with a throughput of less than or equal to 600,000 gallons per year. A new installation or a major modification at a GDF with a throughput of more than 600,000 gallons per year is not authorized.
Executed at Sacramento, California, this

day of June 2008.

~William V. , Chief( / (J Monitoring and Laboratory ~ivision
Attachments: Exhibit 1 Exhibit 2 Exhibit 3 Exhibit 4 Exhibit Exhibit Exhibit Exhibit 7 8
Equipment List System Specifications Healy Manufacturing Performance Standards and Specifications Determination of Static Pressure Performance of the Healy Clean Air Separator Vapor to Liquid Volume Ratio Warranty Nozzle Bag Test Procedure Required Items in Conducting TP-201.3

Healy Phase

II EVR System

-VR-201-G

Executive Order VR-201-G Healy Phase II EVR System Not Including ISD Exhibit 1 Equipment List
Component Manufacturer/Model Nozzle Clean Air Separator
Healy Model 9001 (Figures 1A-1 and 1A-2) Healy Model 9961 Clean Air Separator (Figures 1A-3 and 1A-4) Healy Model 9961H Clean Air Separator (Figures 1A-3H and 1A-6)
Inverted Coaxial Hoses Healy Model 75 Series (3/4 I.D.) (Figures 1A-5, 1A-8 and 1A-9) 75W-XXX-YZYZ Where W represents color of hose (varies) Note: Product label will have an X in this position for all hose colors XXX represents hose length First two digits for length in feet Last digit - length in tenths of foot Note: Product label will have XXX in this position for hose length Y represents hose end type S = Swivel End F = Fixed End Z represents thread type 2 = Healy Straight Thread 3 = Metric Thread 4 = Balance-Type Thread
Nozzle can have either a two position or three position hold open clip (see Figure 1A-1).

Healy Phase II EVR System, Exhibit 1 VR-201-G
-2Component Dispenser Conversion Adaptors (Optional)2 Manufacturer / Model
Healy Model CX6-A (Required on Gasboy, Global Century, Reliance and Select Dispensers) Healy Model CX6-VV1A* Healy Model CX6-VV2A* Healy Model CX6-VV3A EBW Model 303-301-01 (Figures 1A-9 and 1A-10) Note: Items marked with asterisk (*) are no longer manufactured, but may be used for dispenser retrofit.
Reconnectable Breakaway Coupling Healy Model 8701VV (Figures 1A-11 and 1A-12) Healy Model 807 Swivel (Figures 1A-13 and 1A-14) Flow Limiter3 Healy Model 1301 (Figures 1A-15 and 1A-16) Healy Model 1302 (Figures 1A-17 and 1A-18)

Dispenser Vacuum Pump

Healy Model VP1000 Vacuum Pump Healy/Franklin Electric Model VP1000 Vacuum Pump (Figure 1A-19)
If optional components are installed or required by regulations of other agencies, the components and model numbers manufactured by Franklin Fueling Systems may be used to facilitate installation. The use of dispenser conversion adaptors not listed above may be used to facilitate installation provided that all applicable performance standards are met. 3 Flow limiter is mandatory when the flow rate is greater than 10.0 gallons per minute to comply with US EPA requirement. 1301 is used with 8701VV breakaway. 1302 is used with 807 swivel breakaway.
-3Component Manufacturer / Model
Dispensers Note: Unihose dispensers shall be required unless as provided by Section 4.10 of CP-201. Gilbarco Encore Series4 Healy Kit VP1000R5 or VP1000S6 Model #s Description: NAO Encore 1 Grade Multi-hose NA1 Encore 2 Grade Multi-hose NA2 Encore 3 Grade Multi-hose NA3 Encore 4 Grade Multi-hose NG0 Encore 3 Grade Single-Hose NG1 Encore 4 Grade Single-Hose plus 1 NG4 Encore 2 Grade Single-Hose NJ0 Multi-hose Blender NJ2 Multi-hose Blender plus 1 NL0 NL1 NL2 NL3 Encore X+1 Blender NN0 NN1 NN2 NN3Encore X+0 Blender GasBoy 9800 Series (Gilbarco) Healy Kit VP1000M7 Model #s Description: 9852 Suffix1 SuffixSuffix1 Suffix2 Where: Suffix1 can be: A = Factory fabrication and assembly modifications to chassis HC = High capacity model M = Manifold supply inlet at the pumping unit inlet TW1= Manifold supply inlet TW2= Two individual supply inlets X = Dispenser supplied by a submersible pump Q = Utilizes an alternate meter and Pump
Encore Dispensers factory equipped with Healy VP1000 will now have an angled (~13) outlet casting. Kit used to install Healy components in Encore Balance series dispenser. VP1000R previously sold as equivalent to VP1000L. 6 Kit used to install Healy components in Encore Assist series dispenser. VP1000S previously sold as equivalent to VP1000K. 7 Kit used to install Healy components in GasBoy 9800 series dispenser

Vapor Recovery Piping Configurations NOTE: Vapor Return Piping shall meet the requirements specified in section 4.11 of CP-201. 1. Vapor Return and Vent Lines a. For facilities installed on or after April 1, 2003, all vapor return and vent lines shall be a minimum nominal internal diameter of 2 inches from the dispensers or the vent stacks to the first manifold. All lines after the first manifold and back to the underground storage tank shall have a minimum nominal internal diameter of 3 inches. Note: Facilities permitted by a local district prior to April 1, 2003 shall be required to meet the three inch diameter standard only upon facility modification requiring exposing at least 50 percent of the underground vapor return piping.
After backfilling the vapor return and vent lines, the maximum pressure drop shall not exceed 0.5 inches WC at 60 cubic feet per hour as determined by TP-201.4, Dynamic Backpressure. The pressure drop shall be measured from the dispenser riser to the UST with pressure/vacuum vent valves installed and with the poppeted Phase I vapor connection open. For existing installations, the maximum pressure drop through the system shall not exceed 0.5 inches WC at 60 cubic feet per hour as determined by TP-201.4, Dynamic Backpressure. The pressure drop shall be measured from the dispenser riser to the UST with the pressure/vacuum vent valves installed and with the poppeted Phase I vapor connection open.
Note: The V/L test from Exhibit 5 may be used to verify proper operation of the system, in lieu of measuring the pressure drop through the lines, provided that at least two gallons of product are introduced into the system through each dispenser riser, prior to the test. 2. All vapor return lines shall have a minimum slope of 1/8 inch per foot from the dispenser riser to the riser of the UST. A slope of 1/4 inch or more per foot is recommended wherever feasible. The vapor return path from any dispenser riser to the underground storage tank shall be free of liquid or fixed blockage. The dispenser shall be connected to the riser with either flexible or rigid material that is listed for use with gasoline. The dispenser-to-riser connection shall be installed so that any liquid in the lines will drain toward the gasoline storage tank. The internal diameter of the connector, including all fittings, shall not be less than one-half inch (1/2). Note: The dispenser-to-riser connection is defined as the piping connection between the outlet of the vacuum pump and the inlet of the dispenser riser. A vapor shear valve may also be part of the riser connection. 4. There is no length restriction for the vapor return piping of the system as long as the system complies with the maximum pressure drop requirement of Item 1 (or the V/L option). No product shall be dispensed from any fueling point at a GDF installed with the Healy Phase II EVR System if there is a vapor line that is disconnected and open to the atmosphere. No liquid condensate traps are allowed with this system.

2 PRINCIPLE AND SUMMARY OF TEST PROCEDURE 2.1 The Clean Air Separator, while isolated from the vapor recovery system, is evaluated for vapor integrity using a vacuum decay procedure. The vacuum decay after 5 minutes is compared with an allowable value. The allowable value is based upon the initial vacuum level when conducting the test using the table provided in this test procedure.
2.2 A positive pressure decay procedure is included that conducts the same evaluation as the vacuum decay but with positive pressure. This test is conducted if there is insufficient vacuum (not greater than 2.00 wc) to conduct the vacuum decay. Districts have the authority to specify in the permit conditions that this positive pressure test is to be conducted even if the vacuum test has been conducted. 3 RANGE 3.1 The full-scale range of the electronic measuring device shall not exceed 0-20.00 wc with a minimum accuracy of not less than 0.25 percent of full-scale.
4 INTERFERENCES 4.1 Leaks in the piping for the Clean Air Separator could bias the test results toward non-compliance.
Healy Clean Air Separator Test Procedure, Exhibit 4 Executive Orders VR-201-G and VR-202-G
Introduction of gaseous nitrogen into the system at flow rates exceeding 4 CFM (240 CFH) may bias the results of the test toward non-compliance. Only gaseous nitrogen shall be used to conduct this test. Pressurizing the Clean Air Separator bladder greater than 14.00 wc could damage the bladder, biasing the test toward non-compliance. Thermal Bias for Electronic Manometers Electronic manometers shall have a warm-up period of at least 15 minutes followed by a drift check of 5 minutes. If the drift exceeds 0.01 wc, the instrument should not be used.

4.3 4.4

5 APPARATUS 5.1 Nitrogen Use commercial grade gaseous nitrogen in a high pressure cylinder, equipped with a two-stage pressure regulator. 5.2 Pressure Measurement Device Use an electronic pressure measurement device to monitor the pressure decay in the Clean Air Separator. The pressure measurement device shall, at a minimum, be readable to the nearest 0.01 wc. 5.3 Test Port Assembly Use a test port assembly constructed similar to the one in Figure A. The assembly should have an 8 oz. Pressure Relief valve, to ensure that the Clean Air Separator is not over pressurized. The Model 9968 Clean Air Separator Test Port Assembly can be purchased from Healy Systems, Inc.
Figure A Clean Air Separator Test Port Assembly
Stopwatch Use a stopwatch accurate to within 0.2 seconds.
Flow Meter Use a flow meter to determine the required pressure setting of the delivery pressure gauge on the nitrogen supply pressure regulator. This pressure shall be set such that the nitrogen flow rate is between 2.0 CFM (120 CFH) and 4.0 CFM (240 CFH).

Leak Detection Solution Any liquid solution designed to detect vapor leaks may be used to verify the pressure integrity of the test equipment prior to conducting the test.
Condensate Collection Vessel A container approved for use with gasoline that can hold at least a half gallon of material.
Graduated Cylinder A graduated cylinder suitable for use with gasoline capable of measuring to the nearest ounce or mL.
6 PRE-TEST PROCEDURES 6.1 The following safety precautions shall be followed: Only gaseous nitrogen shall be used to pressurize the system. An 8 oz. pressure relieve valve shall be installed on the Test Port Assembly to prevent the possible over-pressurizing of the Clean Air Separator. A ground strap should be employed during the introduction of nitrogen into the system.

6.1.1 6.1.2 6.1.3 6.2

There shall be no Phase I bulk product deliveries into or out of the gasoline storage tank(s) within the three (3) hours prior to the test or during the performance of this test procedure. All pressure measuring device(s) shall be bench calibrated using a reference standard. Calibration shall be performed at 20, 50, and 80 percent of full scale. Accuracy shall be within two percent at each of these calibration points. Calibrations shall be conducted on a frequency not to exceed 180 days. Calibration documentation shall be maintained with the equipment at all times.
Use the flow meter to determine the nitrogen regulator delivery pressures that correspond to nitrogen flow rates of 2.0 CFM (120 CFH) and 4.0 CFM (240 CFH). These pressures define the allowable range of delivery pressures acceptable for this test procedure. The flow meter shall be connected in-line between the nitrogen supply regulator and the Test Port Assembly during pressurization. The flow meter may be connected in-line between the nitrogen supply regulator and the Test Port Assembly during the test. The electronic pressure measurement device shall be subject to warm-up and drift check before use; see Section 4.5. The four ball valves used in the installation of the Clean Air Separator are lockable and shall be locked in the position shown in Figure 2B-2 or 2B-2H of Exhibit 2 and in Figure 1 or Figure 1H of this Exhibit during normal operation. Figure 1 and 2B-2 apply to vertical CAS installations and Figure 1H and 2B2H apply to horizontal CAS installations. The four padlocks provided by Healy Systems, Inc. in their installation kit are keyed the same. However, it is possible that one or more of the padlocks on the Clean Air Separator could have been replaced (seizing, damage, broken key, etc.). Conducting this test will require a set of keys necessary to unlock all padlocks. Verify that the Clean Air Separator is in its normal operating configuration by confirming that all components are as indicated (See Figure 1 or Figure 1H): Valve A - Open Valve B, C and D - Closed Pipe End E - Plugged Tee Branch F - Plugged

7 TESTING 7.1 Open the ball valve marked B from Figure 2 or Figure 2H. The pressure measurement device installed on the Test Port Assembly should now be reading UST and Clean Air Separator ullage pressure (or vacuum). If the station vacuum is greater than (more negative) than -2.00 wc, then proceed to Section 7.2.1. If less than 2.00 wc, then proceed to Section 7.3: Close the ball valves marked A and B from Figure 2. Open the ball valve marked C from Figure 2 and wait one minute. If necessary, use the needle valve on the Test Port Assembly to bleed air into the bladder until the vacuum level reaches as close to a whole number on the pressure measurement device as the accuracy of the device will provide (ie. -2.00, -3.00, -4.00, -5.00, -6.00, -7.00, -8.00). Make sure the needle valve is closed. Record this vacuum and start the stop watch to begin a 5 minute decay. Record the vacuum at one-minute increments up to 5 minutes. Using the information from Table 1, verify that the vacuum after 5 minutes is equal to or greater than the allowable minimum for the initial vacuum recorded from Section 7.2.3. If the vacuum is greater than the allowable minimum, the Clean Air Separator passed the test. If the vacuum is less than the allowable minimum, the Clean Air Separator failed the test. TABLE 1 Allowable 5 Minute Vacuum Decay for Clean Air Separator Vacuum at Start of Test Allowable Minimum Vacuum after 5 min. (inches wc) (inches wc) 8.0 5.5 7.0 4.7 6.0 3.8 5.0 3.0 4.0 2.2 3.0 1.5 2.0 0.8

7.2.1 7.2.2 7.2.3

7.2.4 7.2.5

7.2.6 7.2.7

If the station vacuum is less than 2.00 wc (from Section 7.2), or at the direction of district (refer to Section 2.2), conduct the following: Close the ball valves marked A and B from Figure 2. Open the ball valve marked C from Figure 2. Open the ball valve of the Test Port Assembly and flow nitrogen into the Clean Air Separator bladder at a flow rate between 2 and 4 CFM until the pressure in the bladder reaches 2.20 wc. Depending upon the nitrogen flow rate used, the bladder could take up to 30 minutes to fill completely. Because of the close proximity of the pressure measurement device to the nitrogen inlet of the Test Port Assembly, the pressure measurement device may read a higher pressure when nitrogen is flowing. The pressure measurement device is usually steady, but will start to increase rapidly when the bladder is getting full. Periodically stopping nitrogen flow will provide an accurate reading of the pressure in the bladder.

7.3.1 7.3.2 7.3.3

7.3.3.1 7.3.3.2
7.3.3.3 7.3.4 7.3.5 7.3.6
Once the pressure reaches 2.20 wc, shut off the flow of nitrogen to the Clean Air Separator bladder and close the ball valve of the Test Port Assembly. Wait 5 minutes or until pressure stabilizes above 2.00 wc. If the pressure does not stabilize, repeat steps 7.3.3 and 7.3.4. Use the needle valve on the Test Port Assembly to bleed off the nitrogen until the pressure reaches 2.00 wc. Make sure the needle valve is closed. Record the pressure. Start the stop watch to begin a 5 minute decay. Record the pressure in one-minute increments up to 5 minutes. If the pressure in the bladder is greater than 1.77 wc at the end of 5 minutes, then the Clean Air Separator passed the test. If the pressure in the bladder is less than 1.77 wc at the end of 5 minutes, then the Clean Air Separator failed the test.

7.3.7 7.3.8 7.3.9 7.3.10

If the bladder was evaluated using the vacuum procedure (Section 7.2), close the ball valve C to keep it in a vacuum condition. If the bladder was evaluated using the pressure procedure (Section 7.3), open the needle valve on the Test Port Assembly to bleed off all pressure from the bladder. Close the ball valve marked C, if not already done. Remove the Test Port Assembly from location E and install the 1 pipe plug. Use a pipe sealant approved for use with gasoline on the threads and tighten to 60 ft-lbs. Install the 1 pipe plug to location F. Use a pipe sealant approved for use with gasoline on the threads and tighten to 60 ft-lbs. Open the ball valve marked A. Lock all ball valves using the padlocks. The Clean Air Separator should now be in normal operation configuration. Verify this by using the outline from Section 6.7 and Figure 1 or Figure 1H.

7.5 7.6

7.7 7.8 7.9
8 REPORTING 8.1 Record test data on the form shown in Figure 3. Districts may require the use of an alternate form, provided that the alternate form includes the same minimum parameters as in Figure 3.
-14Figure 3 Data Form for Determination of Static Pressure Performance of the Healy Clean Air Separator for Executive Orders VR-201-G and VR-202-G SOURCE INFORMATION GDF Name and address GDF Represenative and title

Healy Model 900 Nozzle V/L Test Procedure, Exhibit 5 Executive Orders VR-201-G and VR-202-G
-23.2 Refueling points not capable of achieving dispensing rates (see Equation 9-2) required for conducting the V/L test, as specified in Exhibit 2 of ARB Executive Orders VR-201-G and VR-202-G, preclude the use of this test for determining in-use compliance of certified systems. 3.3 Bagging, or otherwise sealing any nozzle associated with the vacuum pump serving the nozzle being tested, may bias the test results towards compliance. The V/L test to verify compliance shall be conducted without bagging any of the nozzles served by a common vacuum device. 3.4 If the nozzle being tested introduces liquid into the V/L adaptor, gas volume meter or the adaptor supply hose, the V/L of that nozzle shall be deemed a failure of the V/L standard. 3.5 Do not drain or remove liquid in either the vapor passage of the hoses or the dispenser vapor piping prior to performing the test. Draining of this liquid gasoline will bias the test toward compliance. 3.6 The O-ring in the V/L adaptor that is not properly lubricated may bias the results toward noncompliance. See Section 5.7 for lubrication requirements. Motor oil (any weight) is acceptable for lubricating the O-ring. Contact Healy Technical Services with any questions about other lubricants that may be used in conducting this test. 3.7 Conducting V/L testing with an improperly conditioned portable test tank (not saturated with gasoline vapors) will bias the test results of the as found V/L of the fueling point. Refer to Section 6.6 for proper portable test tank conditioning. 4.sENSITIVITY, rANGE, AND accuracy 4.1 The maximum rated capacity of the gas volume meter shall be at least 800 CFH and not greater than 3,000 CFH. 4.2 The minimum rated capacity of the gas volume meter shall be 25 CFH. 4.3 The minimum readability of the gas volume meter shall be 0.01 cubic feet. 4.4 Accuracy, determined during calibration, will be 5 percent of the gas volume meter reading.
-35. EQUIPMENT 5.1 Vapor to Liquid Adaptor and Surrogate Spout A Vapor to Liquid Adaptor. Only the Healy Systems, Inc. V/L Test Sleeve (figures 1, 4 and 5), Part No. 8034-1, can be used to conduct V/L testing on the Healy Phase II EVR System (Executive Order VR201 series or Executive Order VR-202 series). The nominal inside diameter of the flexible tubing shall be between 0.75 and 1.00 inches, and the length of the tubing shall be between 3.0 and 6.0 feet. Surrogate Spout. Only the Healy Systems, Inc. V/L Surrogate Spout (figures 1 and 5), Part No. 8175, can be used to conduct the pre-test and post-test leak check.

Figure 3 Portable Tank Assembly
-86. Pre-Test Procedures 6.1 Assemble the portable tank assembly and gas volume meter as shown in Figure 4. The minimum and maximum dimensions shown in Figure 4 shall be adhered to in all cases. Ensure that the ground strap is properly connected to an acceptable ground. Note: A one-time test to verify proper design of the tee connection at the gas volume meter shall be conducted. Disconnect the V/L adaptor from the nozzle. Insert the nozzle into the portable test tank so that there is no visible gap between the nozzle boot/portable test tank fill pipe interface. Dispense between four and one-half and five (4.5 - 5.0) gallons into the portable test tank. The tee connection design passes the test if the displacement on the gas volume meter is less than 0.01 cubic feet. The result of this test shall be kept with the test equipment. If the tee connection is altered or changed, the above test must be repeated to ensure proper design.
6.2 The gas volume meter shall be calibrated, within 180 days prior to conducting this procedure. In addition, calibration shall be conducted after any repairs or alterations (changes to the operation or configuration of the meter) to the meter. Calibrations, at a minimum, shall be conducted at flowrates of 30, 60, and 90 CFH (3.7, 7.5, and 11.2 gallons/minute) in accordance with one of the following: (a) ARB Air Monitoring Quality Assurance, Volume VI, Standard Operating Procedures for Stationary Source Emission Monitoring, January 1979, or (b) US EPA Quality Assurance Handbook for Air Pollution Measurement Systems, Volume III, Stationary Source Specific Methods, or (c) EPA Method 2A, Measurement of Gas Volume Through Pipes and Small Ducts (40 CFR Part 60, Appendix A), or (d) Appropriate calibration procedures in accordance with California Department of Food and Agriculture, Division of Measurement Standards and County Department of Weights and Measures (title 4, CCR, section 3.33). A copy of the most current calibration shall be kept with the meter.
-9 Figure 4 Assembled Vapor to Liquid Volume Ratio Test Equipment
-106.3 Verify that the O-ring in the V/L adaptor is present and in good condition. An O-ring with nicks, tears, or other deformations shall be replaced prior to the test. The O-ring shall be properly lubricated (see Section 5.7) to ensure a vapor tight connection. 6.4 Conduct a pre-test leak check of the V/L adaptor, the gas volume meter and the adaptor supply hose by connecting the V/L adaptor to a surrogate spout as shown in Figure 5 and described in Section 5.1B. Raise the test pressure to 5.00 0.50 WC. There shall not be a pressure drop of more than 1.00 WC from the above starting pressure for 30 seconds from the start of the test. If the leak test passes, proceed with the V/L testing. If the leak test fails, proceed to isolate the source of the leak by pressurizing the test equipment again. Squirt liquid leak detector solution on interfaces and other potential leak sources and watch for the formation of bubbles. Once leak(s) are repaired, repeat the leak test procedure. Note: Leak checks shall be conducted in a shaded area or away from direct sunlight. Leak checks may be conducted during V/L testing to ensure leak integrity of test equipment. 6.5 This test procedure shall be conducted with the storage tank pressure/vacuum (P/V) valve(s) installed and the Phase I vapor coupler(s) poppet(s) in the closed position with the adaptor dust cap(s) installed. 6.6 With the portable tank and V/L test equipment assembled, dispense gasoline into the portable test tank until at least 10% of the tanks total capacity has been reached. This will condition the portable tank with gasoline vapors. This conditioning shall be conducted each time the test tank is emptied prior to conducting testing at each facility. 6.7 All pressure measuring device(s) shall be bench calibrated using a reference gauge, incline manometer or NIST traceable standard at least once every six (6) months. Calibration shall be performed at 20, 50, and 80 percent of full scale. Accuracy shall be within five (5) percent at each of these calibration points.

-148. Post-Test Procedures 8.1 Remove the V/L adaptor from the nozzle. 8.2 Drain the dispensed product into the appropriate gasoline storage tank at the facility. Ground the portable tank assembly to the storage tank before draining. Do not mix product grades in the portable tank assembly without approval of the facility owner and use caution to drain the portable tank into the correct facility storage tank. If blending valves are utilized to produce product grades that do not have a dedicated storage tank, product from the blended grade shall be returned to the lower octane tank. 8.3 After concluding testing at the facility, perform a post-test leak check of the V/L adaptor, the gas volume meter and the adaptor supply hose by connecting the V/L adaptor to a surrogate spout as shown in Figure 5 and described in Section 5.1B. Raise the test pressure to 5.00 0.50 WC. There shall not be a pressure drop of more than 1.00 WC from the above starting pressure for 30 seconds from the start of the test. The data collected during the V/L testing between the last valid test equipment leak check (see Section 6.4) and the post-test leak check is invalid if the test equipment fails this post-test leak check. Note: Leak checks shall be conducted in a shaded area or away from direct sunlight. 8.4 Prior to transportation, the inlet and outlet of the gas volume meter shall be carefully sealed to prevent foreign matter from entering the meter. 8.5 The Authority Having Jurisdiction (AHJ) may be contacted on the requirements for storage and transportation of the portable test tank. This would typically be the local fire department.
-159.CalculatiNG RESULTS 9.1 The V/L Volumetric Ratio shall be calculated as shown in Equation 9-1. V/L=

y (Vf Vi) Gf Gi

x 7.481

[Equation 9-1]

V/L y Vi Vf Gi Gf 7.481

Where:

= = = = = = =
Vapor to Liquid Volumetric Ratio, dimensionless Correction factor for gas volume meter. See Equation 9-3 Initial gas volume meter reading, cubic feet Final gas volume meter reading, cubic feet Initial totalizer reading from the dispenser, gallons Final totalizer reading from the dispenser, gallons Conversion factor from gallons to cubic feet, gallons per cubic foot
9.2 The gasoline dispensing rate during the V/L test shall be calculated as shown in Equation 9-2. Qg =

Gf Gi t

7.7.7 Final Dispenser Totalizer, Gallons
7.7.4 Initial Meter Reading, ft3
7.7.6 Final Meter Reading, ft3
7.8, 7.9 or 7.10 Pass or Fail
Healy Model 900 Nozzle V/L Test Procedure,, Exhibit 5 Executive Orders VR-201-G and VR-202-G
Executive Order VR-201-G Healy Phase II EVR System Not Including ISD Exhibit 6 Healy Phase II EVR System Limited Warranty Franklin Fueling Systems/Healy (FFS/Healy) products are warranted to the initial purchaser, and any subsequent purchaser within the warranty period, for workmanship, performance, and materials when properly installed, used and maintained using the ARB Approved Installation, Operation and Maintenance Manual. All FFS/Healy products, subassemblies, and raw materials are fully inspected and tested at the manufacturing facility. FFS/Healy warrants the workmanship and materials to be free of defects for a period in accordance with the provisions stated below: The equipment has been installed according to the ARB Approved Installation, Operation and Maintenance Manual. A Healy Certified Technician qualified to perform service on the defective equipment must perform warranty service. Only Healy Certified Technicians are allowed to perform warranty service. Use of service personnel other than qualified Healy Certified Technicians without prior written approval by FFS/Healy will void the warranty. Claims for warranty repair or replacement service must have a written Returned Material Authorization (RMA) from FFS/Healy, and must be shipped freight prepaid to FFS/Healy for inspection. FFS/Healy, upon inspection at its facilities, and after determination of a warranty claim, will, at its option, repair or replace defective parts returned to its factory. Repaired or replaced parts will be returned freight prepaid by FFS/Healy. FFS/Healy is not responsible for labor or materials necessary to disconnect or connect the warranted product for return to FFS/Healy. FFS/Healy reserves the right to make changes in the design or to make additions or improvements with respect to its products without incurring any obligation to modify or install same on previously manufactured products, upon written California ARB approval. FFS/Healy warrants the workmanship and materials of the following products to be free of defects and will comply with the performance standards of California ARB CP-201 for a period of one (1) year from the date of installation or eighteen months from the date of manufacture from FFS/ Healy: Inverted coaxial hoses, Hose adapters, Flow limiters and Breakaways. EVR Nozzles 900 Series New & Rebuilt: Healy Systems Inc. warrants the workmanship and materials to be free of defects and will comply with the performance standards of California ARB CP-201 for a period of one (1) year from the date of installation or eighteen months from the date of manufacture from FFS/Healy. Exclusions: This warranty excludes the field replaceable rubber/ plastic parts at the front of the nozzle (i.e., boot, scuffguard, face seal assembly, etc.) or the spout or parts that have been subjected to misuse, mishandling or incorrect installation. Vacuum Pump VP1000: FFS/Healy warrants the workmanship and materials to be free of defects and will comply with the performance standards of California ARB CP-201 for a period of one (1) year from date of installation or twenty-six months from the date of manufacture from FFS/ Healy. This applies to the vacuum pump and motor assembly only. The Hardware Kits, Vapor Kits, Electrical Kits and Interface modules are warranted for workmanship and materials to be free of defects for a period of one (1) year from date of installation or eighteen months from the date of manufacture from FFS/Healy.

Exhibit 7 Nozzle Bag Test Procedure (Executive Orders VR-201-G and VR-202-G) Verification of the integrity of the vapor valve shall be performed on installed nozzles by use of the following test. Note: The following procedure requires that all nozzles on a dispenser be bagged at the same time. Bagging only one nozzle on a dispenser during this procedure may bias the results toward compliance. a. Seal all nozzles on a dispenser in plastic bags, using tape or other means to secure the bag around the base of the nozzle (see Figure 1). Any plastic bag large enough to enclose the nozzle and having a thickness of no greater than 2 mils can be used. In California, 12 x 26 x 2 mil thick bags are available from the Air Resources Board by calling 800-952-5588. Initialize the dispenser for fueling as follows: 1. Inform the station operator that you are running a test and ask the operator to initialize the dispenser; or 2. Swipe a credit card in the dispenser card reader. c. d. Activate the Healy vacuum pump by lifting one of the nozzles off the dispenser holster and selecting a grade of fuel. Do not dispense any fuel. With the dispenser initialized and the vacuum pump activated, observe all bagged nozzles for 30 seconds. Any nozzle where the bag can be seen visually collapsing has a defective vapor valve and the dispenser shall be removed from service immediately. Record the test results on the Nozzle Bag Test Results form provided in this Exhibit. Districts may require use of an alternate form, provided that the alternate form includes the same minimum parameters. Remove the bags from all the nozzles tested and disengage the dispenser by returning the nozzles to the dispenser holsters. Repeat steps a through f for each dispenser.
Nozzle Bag Test Procedure, Exhibit 7 Executive Orders VR-201-G and VR-202-G

-2Figure 1

NOZZLE BAG TEST RESULTS

SOURCE INFORMATION

Facility (DBA)/Site Address:

Print Name

TEST COMPANY INFORMATION
Test Company Name/Address
Facility Representative/Title:
# of Nozzles: # Nozzles Tested: # Nozzles Passed: # Nozzles Failed: # Nozzles not Tested: Time of Test: Bag Collapse after 30 Seconds Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes No No No No No No No No No No No No No No No No No No No

Street Address

Phone No.

District Inspector:

Date of Test:

Number: Gas Grade

Dispenser

Nozzle Type
Exhibit 8 Required Items in Conducting TP-201.3 (Executive Orders VR-201-G and VR-202-G) The instructions below are required when conducting TP-201.3 for these systems. The tester shall document that each step was followed as indicated below and shall include this page of the Exhibit with the submission of TP-201.3 test results. Note that districts may require use of an alternate form to meet these requirements, provided the alternate form includes the same minimum parameters. 1. Prior to conducting TP-201.3, all four ball valves on the Healy Clean Air Separator (CAS) shall be closed, as shown in Figure 1 or Figure 1H, to isolate it from the Underground Storage Tank (UST) system to permit the pressurization of the UST system. Figure 1 applies to vertical CAS installations and Figure 1H applies to horizontal CAS installations. Conducting TP-201.3 with any dispenser piping test valve in the closed position is not permitted. Any dispenser with a dispenser piping test valve in the closed position while conducting TP-201.3 will bias the test towards compliance. After conducting TP-201.3, the four ball valves on the Healy Clean Air Separator (CAS) shall be locked in their normal operating positions as shown in Figure 2B-2 or 2B-2H, Exhibit 2 of Executive Orders VR-201-G and VR-202-G. Figure 2B-2 applies to vertical CAS installations and Figure 2B-2H applies to horizontal CAS installations. Required Steps 1. All four CAS ball valves closed before conducting TP-201.3 2. All dispenser piping test valves open before conducting TP-201.3 3. All four CAS ball valves in normal operating positions after conducting TP-201.3. Verification (please circle) Yes Yes Yes No No No

Test Company: ____________________ Facility Name:____________________
________________________________________________________________ Print Name (Technician) Signature Date ________________________________________________________________ Technician Certification Number and Expiration Date (ICC or District Training Certification, as applicable)
Items Required in Conducting TP-201.3, Exhibit 8 Executive Orders VR-201-G and VR-202-G
-2Figure 1 Configuration of Healy Clean Air Separator to Conduct TP-201.3
-3Figure 1H Configuration of Healy Clean Air Separator to Conduct TP-201.3

COMPANION 1000 COMPANION T
LIQUID OX Y G E N P O RTA B L E S

TECHNICAL MANUAL

Puritan-Bennett
5647 Dividend Drive Indianapolis, IN 46241 USA Customer Service: 1-800-635-5267, press 2 Technical Support: 1-800-255-6774, press 2
Part Number B-701964-00 Rev. A
Companion 1000/T Liquid Oxygen System Technical Manual

B-701964-00 Rev. A

LIST OF EFFECTIVE PAGES
This list of effective pages represents manual P/N B-701964-00, Revision A. REVISION A DESCRIPTION Initial Release DATE 02/01

EFFECTIVE PAGES All

REVISION A

DEFINITION OF STATEMENTS

Statements in this manual preceded by the following words are of special significance: WARNING
A warning describes conditions that concern your personal safety and the safety of others. It includes the actions required to prevent injury. Ignoring warnings can lead to injury or death.

CAUTION:

A caution informs you about conditions that may cause possible damage to the equipment or other property, or situations that may cause reduced or no oxygen flow.
NOTE: Notes provide important information about using the equipment properly. NOTE: SI pressure values expressed in this manual are referenced to atmosphere.
INTELLECTUAL PROPERTY NOTICES
Companion is a trademark of PURITAN-BENNETT. 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.

PREFACE

This manual provides the information needed to service both the Puritan Bennett Companion 1000 and the Puritan Bennett Companion T Portable liquid oxygen units. This information is intended for use by technicians or personnel qualified to repair and service medical liquid oxygen equipment. Do not attempt to fill or repair these units until you read and understand the information in this manual. The following document contains additional information useful in servicing this equipment: Companion Liquid Oxygen Systems Operating Instructions: P/N B-701417-00 For product assistance contact: Puritan-Bennett 5647 Dividend Drive Indianapolis, IN 46241 Customer Service: 1-800-635-5267, press 2 Technical Support: 1-800-255-6774, press 2
NOTE: Companion 1000 and Companion T Portable units are intended only for the delivery of
medical grade oxygen as prescribed by a physician.

WARNING

Improper usage hazard. Oxygen supplied from this equipment is for supplemental use and is not intended to be life supporting or life sustaining. This equipment is not intended for use by patients who would suffer immediate, permanent, or serious health consequences as a result of an interruption in their oxygen supply.
Information contained in this document, including performance specifications, is subject to change without notice. Puritan-Bennett makes no warranty of any kind with regard to the material in this manual, including, but not limited to, the implied warranties of salability and fitness for a particular purpose. Puritan-Bennett shall not be liable for errors contained herein or for incidental or consequential damages in connection with either providing this manual or the use of material in this manual. Companion is a trademark of Puritan-Bennett. The information contained in this manual is the sole property of Puritan-Bennett and may not be reproduced without the permission of the company. Copyright 2001 by Puritan-Bennett. All rights reserved.

TABLE OF CONTENTS

1-4 Introduction

Keep oxygen equipment in a well-ventilated area at all times. These units periodically release small amounts of oxygen gas that must be ventilated to prevent buildup. Do not store liquid oxygen equipment in a car trunk, closet, or other confined area. Do not place bags, blankets, draperies, or other fabrics over the equipment when it contains liquid oxygen. Do not place the Portable unit under clothing. These units normally vent oxygen. Placing a Portable unit under clothing may saturate fabrics with oxygen and cause them to burn rapidly if exposed to sparks or flame. It may take several hours for oxygen levels in the fabric to return to normal.
Important Facts: The possibility of fire exists when the combination of a fuel, source of ignition, and oxygen is present (Figure 1-5). High concentrations of oxygen (air is approximately 21% oxygen) greatly enhance the possibility of combustion. Obtain all replacement parts for medical oxygen equipment from the manufacturer. Before servicing, clean all tools that come into contact with the oxygen system. Use only recommended oxygen compatible cleaning and leak detection products. Keep the Portable and Reservoir upright at all times. Secure liquid oxygen equipment when transporting to prevent accidental tipover and spillage. If a liquid oxygen spill occurs indoors, open doors and windows to ventilate the area. Avoid sources of ignition and do not walk on or roll equipment over the affected area. Any clothing or porous material that is splashed with liquid oxygen or otherwise absorbs high concentrations of oxygen should be removed and aired for at least one hour away from any source of ignition.
OXYGEN SOURCE Approximately 16% required for combustion. Normal air contains 21% oxygen. Some fuel materials contain sufficient oxygen within their make-up to support burning. IGNITION SOURCE Open flame - the sun Hot surfaces Sparks and arcs Friction - chemical action Electrical energy Compression of gases
GASES Propane Butane Hydrogen Acetylene Carbon Monoxide Others Natural Gas
LIQUIDS Gasoline Kerosene Turpentine Alcohol Paint Cod Liver Oil Varnish Lacquer Lotions Olive Oil Creams Others
SOLIDS Coal Plastic Wood Sugar Paper Grain Cloth Hay Wax Cork Grease Others
Figure 1-5: Combustion Triangle

Introduction 1-5

COMPANION 1000/T SPECIFICATIONS*
1.4.1 Table 1-1: Performance Specifications:
Model Volume of Liquid Oxygen (typical) Weight of Liquid Oxygen at Saturation (22 psig/152 kPa) Gaseous Oxygen Equivalent (1 atm and 70F/ 21.1C) Height Empty Weight Full Weight Operating Pressure Primary Relief Valve Pressure Secondary Relief Valve Pressure Normal Evaporation Rate (NER) Typical: Maximum: Fill Time (warm container) Flow Ranges** Environmental Operating Temperature: Storage Temperature: Companion 1000 1.23 L (0.043ft 3) 3.1 lb. (1.4 kg) Companion T 1.23 L (0.043 ft 3) 3.1 lb. (1.4kg)

Oxygen Outlet Connector The oxygen outlet connector is located on the top of the unit. The oxygen cannula attaches to this connector to receive oxygen flow from the unit.
Moisture Cup Assembly (Companion T) The moisture cup assembly collects water that is created when humidity in the air condenses on the cold heat exchange coils in the Companion T. It is connected to the bottom of the Companion T with a quarter-turn fastener. A moisture pad, located in the cup, can be removed and dried as needed.

Buckle Assembly

Contents Indicator
Oxygen Outlet Connector Flow Control Valve Vent Valve Female Fill Connector Moisture Pad (Companion T) Moisture Cup (Companion T)
Figure 1-6: Controls, Indicators, and Connectors
FILLING INSTRUCTIONS FOR TECHNICIANS
The Companion 1000/T can be filled from a Companion Stationary or a Companion Low Loss Stationary reservoir that contains liquid oxygen at proper saturation pressure (nominal 22 psig/152 kPa saturation). Perform the pre-fill and post-fill procedures on the patients C1000/T whenever you fill the patients Stationary unit.

Introduction 1-9

Pre-Fill Inspection Perform the following procedure to visually inspect the Companion 1000/T and determine its operational status before filling. Correct observed problems before proceeding to fill the unit. 1. Visually inspect the Companion 1000/T unit for overall product integrity (for example, cracked or damaged components). 2. Verify that the warning labels are present and legible on the unit (Figure 1-7). 3. Verify that the fill connector poppet is not worn, leaking, or damaged. Inspect the circular, white lip seal in the fill connector for cracks or signs of wear. 4. Move the vent valve lever down to the open position. Verify that the lever moves smoothly when opening and closing the valve. 5. Move the flow control knob to each flow setting. Verify that the knob moves smoothly and encounters a detent at each setting. 6. Hold the Companion 1000/T on a table and carefully pull up on the end of the carrying strap nearest the contents indicator. Verify that the indicator mechanism moves smoothly. 7. Inspect the carrying strap and buckle for abnormal wear. 8. Companion T: Inspect the moisture cup for cracks. 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 the Companion T.

PORTABLE LIQUID OXYGEN UNIT WARNING
To Avoid Serious Safety Hazard, Read Patient Operating Instructions Before Use and Follow All Warnings. Contents vigorously accelerate combustion. Keep oils and combustibles away. Keep away from heat, flame, or sparks. Do not smoke. Extremely cold oxidizing liquid, gas, and any frosted parts may cause severe frostbite on contact. Always keep unit upright. Store and use with adequate ventilation. Keep away from untrained children. For supplemental use as directed by a physician. CAUTION: Federal (USA) Law restricts this device to sale by or on the order of a physician. Puritan-Bennett Corp. Cryogenic Equipment Division Indianapolis, IN 46241 Max. Content 1000 Gas Liters Oxygen Refrigerated Liquid, USP PART NO. 775009 REV. D

P/N: B-776574-00

P/N: B-775009-00
Figure 1-7: Companion 1000/T Warning Labels
Filling Procedure Fill the Companion 1000/T with liquid oxygen from a Stationary unit as follows:

1-10 Introduction

1. Companion T: Remove the moisture cup from the bottom of the unit. 2. Using a clean, dry, lint-free cloth, dry the male fill connector on the Stationary and the female fill connector on the Companion 1000/T. 3. Check the Stationary contents indicator to make sure there is enough liquid oxygen for the filling operation. 4. Hold the Companion 1000/T with both hands and position the contoured case over the matching recessed area in the Stationary cover (Figure 1-8).
Extreme cold hazard. Do not depress or disturb the plastic poppet in the center of the Reservoir fill connector. This will cause an uncontrolled release of liquid oxygen from the fill connector.
Figure 1-8: Positioning the Companion 1000/T for Filling
5. Lower the Companion 1000/T carefully into place, ensuring the fill connectors are properly aligned. 6. Place one hand on top of the Companion 1000/T (directly over the fill connectors) and press straight down. This will lower the unit about 3/8-in., properly engaging the fill connectors. 7. While holding the Companion 1000/T in this position, move the vent valve lever to the open position, 90 from the normal OFF position (Figure 1-9). A loud hissing noise will result.

Vent Valve

DANGER OF FROSTBI TE KEEP NT EQUIPME UPRIGHT ATALL TIMES

Push Down

Figure 1-9: Opening the Vent Valve

Introduction 1-11

Extreme cold hazard. Do not leave the Companion 1000/T unattended during the filling operation. Excessive liquid oxygen discharge can occur.
NOTE: During the filling operation, maintain a slight downward pressure on the Companion 1000/T with one hand to ensure stability and proper filling position. 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.
8. When you notice a change in the sound of the venting gas, followed by the emission of a dense, white vapor around the Stationary shroud, close the vent valve. Fill times may vary according to the temperature of the container before filling and the Stationary pressure. Maximum fill time is approximately 1 3/4 minutes.

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 (Figure 1-10). Keep the Companion 1000/T in an upright position. The unit will stop venting in a few minutes. Allow the unit to warm until you can close the vent valve. It may require as much as two to three hours with the flow control off for the Companion 1000/T to restore adequate pressure for accurate oxygen delivery.
Extreme cold hazard. Liquid oxygen discharge from the fill connector can occur. When disconnecting the Companion 1000/T, never stand directly over the Stationary fill connector. If the Stationary fill connector 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 (steady stream) occurs, open the reservoir vent valve (if safely possible) to vent pressure and stop the release of liquid oxygen. Open windows and doors to ventilate the room. Do not walk on areas exposed to liquid oxygen for 60 minutes after frost disappears.
9. Disengage the Companion 1000/T from the Stationary by holding the carrying strap above the unit and pressing the release button (Figure 1-10). Always hold the Companion 1000/T with one hand when attempting to disengage it. 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. 10. Check the liquid oxygen contents indicator. The amount of liquid oxygen in the Companion 1000/T is measured by an internal scale on top of the unit. Actuate the scale by lifting the unit by the strap nearest the indicator. The color-coded gauge indicates the liquid level (Figure 1-11).
NOTE: Disengage the plastic buckle in the carrying strap before checking liquid oxygen contents level.

1-12 Introduction

Lift Portable Release Button
Figure 1-10: Disengaging Companion 1000/T
Figure 1-11: Checking Liquid Oxygen Contents
Post-Fill Inspection Perform the following procedure to inspect the Companion 1000/T and determine its operational status after filling it with liquid oxygen. Correct observed problems before placing the unit in service. 1. Verify that the Companion 1000/T fill connector poppet is closed and not leaking. 2. Verify that the vent valve is completely closed and not leaking. 3. Connect a test flowmeter to the oxygen outlet connector. Rotate the flow control through each flow setting. Verify the measured flow increases with each increase in flow setting.

Puritan-Bennett B-775270-00 Puritan-Bennett B-775272-00 Local Source Local Source Brooks Instrument Co., Hatfield, PA or Fischer & Porter Co., Warminster, PA Puritan-Bennett B-778214-00 Puritan-Bennett B-775239-00 Puritan-Bennett B-778202-00 Local Source Local Source Local Source
/16-in. I.D. Vinyl Tubing (4-ft. length)

SERVICE MATERIALS

Lubricant, Krytox 240 AC Fluorinated Grease (DuPont) Thread Sealant, 3/16 in. (5 mm) Teflon Tape Isopropyl Alcohol Cloth, lint-free Cotton Swabs
Companion Adapter P/N B-778203-00 Baseplate P/N B-778204-00
60 PSIG Gauge P/N B-775257-00 Tubing Adapter P/N B-775269-00 Tie Wrap P/N B-775091-00 Tubing Adapter P/N B-776945-00 Tubing (4 ft./1.2m) P/N B-778214-00
Figure 1-12: Portable Test Fixture P/N B-778202-00
Figure 1-13: Test Pressure Gauge P/N: B-775270-00
CALIBRATING TEST EQUIPMENT
Periodically calibrate test equipment (pressure gauges, weight scales, flowmeters, etc.) to ensure the reliable operation of the Companion 1000/T. Use your prior experience to determine calibration frequency for test equipment. Using a default six-month schedule is typically acceptable; however, check test equipment with a high usage rate once a month. Once you have begun using the piece of test equipment, you may adjust the calibration schedule. If, for example, you begin calibrating your test pressure gauge every six months and it is repeatedly out of calibration when you check it, you should test calibration more frequently. Eventually, you should determine an interval where your equipment is in calibration each time you check it.

1-16 Introduction

Before using any piece of test equipment that has been dropped or mishandled, always perform a calibration check. Test instruments that are used to test the performance of the Companion 1000/T can be sent to an accredited calibration lab for calibration testing. Another option is to keep a calibrated master test instrument (pressure gauge, flowmeter, etc.) on site as a reference to check your field test instruments. Look in the telephone yellow pages under Calibration for the location of an accredited calibration lab. An example of an accredited calibration lab is:

Jam Nut

Female Adapter
Cartridge Assembly Lip Seal Retainer Sleeve
Figure 2-2: Female Fill Connector
When the female fill connector is engaged with the male fill connector to begin a fill, both fill connector poppets move back off of their seats (Figure 2-3), opening a path for liquid oxygen transfer to the Companion 1000/T. A lip seal in the female fill connector assembly prevents liquid oxygen leakage between the female and male fill connector during liquid oxygen transfer.

Female Fill Connector

Male Fill Connector
Figure 2-3: Male/Female Connectors Fully Engaged

2-2 Theory of Operation

Warming Coil The warming coil (Figure 2-4) acts as a heat exchanger that transfers heat from the surrounding atmosphere to the fluid inside the coil. This action vaporizes the liquid oxygen and warms the resulting gaseous oxygen for breathing. The warming coil on the Companion 1000 is a series of 3/16 in. wound-aluminum tubing that connects between the flow control valve and the manifold. The warming coil on the Companion T consists of two sections of 3/16-in. wound-aluminum tubing and a section of spined aluminum tubing. The spined tubing enhances the heat transfer characteristics of the system. This is essential to the operation of the Companion T due to the higher flow capability (15 L/min) of the unit.

Gaseous Oxygen to FCV

Gaseous Oxygen to FCV Liquid Oxygen From Manifold

Spined Tubing

Warming Coils
Liquid Oxygen From Manifold

HEAT HEAT HEAT

Companion T

Figure 2-4: Warming Coil

Companion 1000
Flow Control Valve The flow control valve (Figure 2-5) is a rotary, fixed-orifice device consisting of a moveable rotor with 11 individually sized orifices. When you select a specific flow rate on the flow control valve, the corresponding orifice aligns between the inlet and outlet ports of the valve. The calibrated orifice delivers the selected flow when gaseous oxygen at 22 psig (152 kPa) is present at the valve inlet port. The standard Companion 1000 flow control valve has a flow range of 0 to 6 L/min, and an optional valve is available with a flow range of 0 to 4 L/min. The Companion T flow control valve has a flow range of 0 to 15 L/min.

Liquid Leak Detector Test
Note: You may perform the Liquid Leak Detector Test on units that contain liquid and/or gaseous oxygen.
PROCEDURE 1. Set the flow control valve to 0 L/min (off). 2. Warm, Empty Unit: Pressurize the Companion 1000/T Portable to approximately 22 psig (152 kPa) with gaseous oxygen using the portable pressurizing setup and gaseous oxygen supply (Figure 3-1). Close the vent valve after pressurizing the unit and remove the pressurizing setup from the vent tube.
Adjustable 0-50 psig (0-345 kPa) Gaseous Oxygen Source
Tubing P/N B-778214-00 Vent Valve Open Vent Tube Clamp Portable Test Fixture P/N B-778202-00
Tee P/N B-778211-00 Test Pressure Gauge P/N B-775270-00
Figure 3-1: Pressurizing the Companion 1000/T through the Vent Circuit
Connect the test pressure gauge to the oxygen outlet barbed fitting and set the flow control valve to the highest setting. Place the Companion 1000/T in the portable test fixture (Figure 3-2).
3-2 Performance Verification
Figure 3-2: Placing Companion 1000/T Portable in Test Fixture
Unit Containing Liquid Oxygen at 22 psig (152 kPa): Connect the test pressure gauge to the oxygen outlet barbed fitting and set the flow control valve to the highest setting. Place the Companion 1000/T in the portable test fixture (Figure 3-2). 3. Wet a finger with leak detector and lightly place it against the open end of the vent tube located near the bottom of the unit. If bubbling occurs, refer to Section 5.9.2, Service and Repair. 4. Use SNOOP liquid leak detector to test all fittings and connections. Verify that the unit maintains 22 psig (152 kPa) pressure during the leak test. 5. With pressure remaining in the unit, place a small amount of SNOOP on the tip of the Companion 1000/T fill connector. A small amount of leakage around the poppet of the fill connector is acceptable, provided that the total leakage rate of the unit is not greater than the NER. 6. Blow dry with compressed gas the fill connector poppet and the vent valve.

Pressure Hold Test

Note: Perform the Pressure Hold Test only on warm, empty Portable units. Performing this test on Portable units containing liquid oxygen will yield inaccurate results.
PROCEDURE 1. Set the flow control valve to 0 L/min (off). 2. Warm, Empty Unit: Use the pressurizing setup (Figure 3-1) to pressurize the Companion 1000/T until the primary relief valve vents (approximately 22 psig/152 kPa). 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. 3. Set the flow control valve to 0 and remove the test pressure gauge from the oxygen outlet.

Performance Verification 3-3
4. Do not disturb the Companion 1000/T for 8 to 9 hours. At the end of this evaluation period, verify the unit maintains at least 15 psig (104 kPa). Should the pressure be less than 15 psig (104 kPa), repressurize the unit to approximately 22 psig (152 kPa) and locate the leak by testing all components, fittings, and tubing with liquid leak detector. Make repairs as needed, taking care not to overtighten connections.

GASEOUS OXYGEN TESTS

Conduct the following tests on an empty unit that has warmed to room temperature.
Secondary Relief Valve Test The secondary relief valve serves as a safety or backup to the primary relief valve. Under normal operating conditions, the secondary relief valve remains closed. The relief valve opens if the system pressure reaches 25 to 37 psig (172 to 255 kPa). This test uses gaseous oxygen to determine if the secondary relief valve opens within its acceptable range. Refer to Figures 6-1, 6-2, 6-5 and 6-6 to identify parts with bold number references. PROCEDURE 1. Connect the pressurizing setup to the Companion 1000/T (Figure 3-1). 2. Remove the silencer 6 from the primary relief valve 5. 3. Hold the primary relief valve closed while pressurizing the Portable. Increase the pressure until the secondary relief valve 1 opens (audible hiss) between 25 to 37 psig (172 to 255 kPa). If the secondary relief valve does not open within this range the first time, repeat the procedure. If it fails to open within the acceptable range the second time, replace the secondary relief valve (Section 5.8, Service and Repair).
NOTE: Do not release the primary relief valve poppet until pressure in the unit is reduced below 22 psig (152 kPa) by removing the pressurizing setup and opening the vent valve. Replace the primary relief valve silencer.
Primary Relief Valve Test The primary relief valve maintains system pressure at a preset value when the Companion 1000/T Portable contains liquid oxygen. This test uses only gaseous oxygen to determine if the primary relief valve opens within the acceptable range. Perform a primary relief valve function test when the Portable contains liquid oxygen. Refer to Figure 6-5 to identify parts with bold number references. PROCEDURE 1. Connect the pressurizing setup to the Companion 1000/T (Figure 3-1). 2. Place one drop of Snoop on the silencer 6. Slowly pressurize the unit with gaseous oxygen by adjusting the oxygen regulator. 3. Verify that the primary relief valve 5 opens (bubbles appear on silencer) at 20.5 to 24.0 psig (141 to 165 kPa). The primary relief valve vents through the silencer 6. If the valve does not open within the specified range, replace the primary relief valve (Section 5.7, Service and Repair).

Unable to start fill or excessive fill time
Excessive venting after fill Liquid leakage from coupled fill connectors during fill Liquid or excessive gas leakage at the fill connector poppet Unable to disconnect Companion 1000/T after fill
Partial or complete loss of vacuum Companion 1000/T fill connector lip seal worn or damaged Ice crystal preventing proper closure of poppet Dirty or damaged poppet Fill connectors frozen together due to presence of moisture
Engage and disengage mating fill connectors several times to dislodge ice crystal. Replace female fill connector assembly. Allow unit to sit until connections warm enough to disconnect. (Fill connectors should be dried with lintfree cloth before filling.)

4-2 Troubleshooting

SERVICE AND REPAIR
This section provides procedures for servicing the individual components of the Companion 1000/T Portable. Where applicable, instructions are included for removal, disassembly, operational check, cleaning, inspection, adjustment, reassembly, and installation. After removing a component, visually inspect it for damage or any indication that the part should be replaced. Unless otherwise specified, replace as needed with a new part. Refer to the exploded view illustrations and the Companion 1000/T parts list in Section 6.
Personal injury can occur from the uncontrolled release of pressurized gaseous and liquid oxygen. Empty liquid oxygen contents and vent system pressure before servicing.
Concentrated oxygen. Increased risk of fire. Place unit in a wellventilated area away from sources of ignition when setting a flow to empty unit.
Injury to eyes from flying objects possible. Wear eye protection when servicing the Portable.
The Companion 1000/T can be emptied by setting the flow control at its highest setting and allowing the unit to run until all liquid oxygen is depleted. When the liquid oxygen is depleted, you can leave a flow set on the control while working on the unit to provide continuous system venting.
NOTE: After making repairs, always verify proper system operation by performing the functional tests in Section 3.
PRESSURE FITTINGS AND CONNECTIONS
The Companion 1000/T Portable uses two types of fittings: compression tube fittings and National Pipe Tapered (NPT) fittings. Proper make-up of these pressure fittings is essential to leak-free operation.

Figure 5-16

4. Use a /8-in. open-wrench on the vent valve body hex flats to hold the body stationary. Use a 11/16-in. open end wrench to loosen the jam nut 3 that holds the vent valve to the mounting bracket (Figure 5-17).

Figure 5-17

5. Slide the vent valve out of the mounting bracket.

Adjustment

NOTE: Newer vent valves use a spring instead of an adjustment nut and are nonadjustable.
1. With the vent valve in the closed position, check the clearance between the vent valve lever 7 and the plastic spacer 8. The clearance should be 0.005 to 0.010 in. (.127 to 0.254 mm) or about the thickness of this page (Figure 5-18).

Spring

Spacer Adjustment Lock Nut Jam Nut
Lever.005.010 in. (.127.254mm)

Non-Adjustable

Figure 5-18: Vent Valve Adjustment

Adjustable

Service and Repair 5-13
2. If the clearance is less than the specification, the valve may leak in the closed position. Use a 11/16-in. open-end wrench to turn the adjustment lock nut 4 clockwise to increase the clearance. 3. If the clearance is greater than the specification, the valve may not open fully, resulting in longer fill times. Use a 11/16-in. open-end wrench to turn the adjustment lock nut counterclockwise to decrease the clearance.
Installation 1. Position the vent valve in the mounting bracket slot. Do not tighten the jam nut at this time.
NOTE: The mounting bracket should be between the jam nut and the valve body hex flats. The valve flow direction arrow should point downward.
2. Align the short vent tube 9 and long vent tube 26 with the proper vent valve ports. Thread the tube nuts onto the valve and tighten.
NOTE: Do not overtighten the vent tube nuts. Overtightening may result in a cracked fitting. Only a slight increase in torque is required to seal up a compression fitting that has already been made up. For 1/2-in. tubing, 11/4 turns from finger-tight is required when making up a new fitting.
3. Push the vent valve fully into the slot in the mounting bracket. Hold the valve in this position with a 5/8-in. open-end wrench placed on the valve body hex flats. Use a 11 /16-in. open-end wrench to tighten the jam nut 3. 4. Install the side covers by reversing the side cover removal procedure (Section 5.2.1).
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 bottom of the bottle and shifting the entire bottle assembly up or down. Make sure that the vent extension tube outlet is centered in the corresponding side cover clearance hole.

Item Part Number B-775029-00 B-775242-00 Screw (PH 6-32 x 1.75) /4 Indicator (includes lens cap, needle, decal, helix, and base)(Companion 1000) Indicator (includes lens cap, needle, decal, helix, and base)(Companion T) Lens Cap Indicator Needle Lever Upper Spacer Pivot Shaft A E-Clip Spring Rod Hitch Pin (SS) Spring Mounting Plate Lever Spacer Pivot Shaft B Spring Spacer (Companion T only) Contents Indicator Assembly (Companion 1000) Contents Indicator Assembly (Companion T)

Description

B-775892-16 B-775012-00 B-775014-00 B-775018-00 B-775027-00 B-777507-00 B-777505-00 B-775021-00 B-775028-00 B-775022-00 B-775024-00 B-775023-00 B-777506-00 B-701272-00 B-775011-00 B-775535-00

FIGURE 6-4 PARTS LIST

Item 7 Part Number B-775067-00 B-775068-00 B-775318-00 B-775038-00 B-775063-00 B-775062-00 B-776436-00 Tube Nut 3/16 -in., Aluminum Ferrule 3/16 -in., Brass Lockwasher #6 Internal Tooth, SS Standoff Ferrule 1/4 in., Brass Tube Nut 1/4 in., Aluminum Manifold Assembly Description

! " #

"

& $

# ' &
Figure 6-3: Contents Indicator Assembly
Figure 6-4: Manifold Assembly
Parts List and Parts Illustration 6-3

FIGURE 6-5 PARTS LIST

Item 7 Part Number B-776817-00 B-775067-00 B-775068-00 B-775078-00 B-776892-00 B-776827-00 B-775091-00
Description Primary Relief Valve Tube ( /16 -in.) Tube Nut (3/16 -in., Aluminum) Ferrule (3/16 -in., Brass) Relief Valve Adapter Primary Relief Valve (22 psig) Silencer (for Primary Relief Valve) Wire Tie (Small)

FIGURE 6-6 PARTS LIST

Item 5 Part Number B-775082-00 B-775078-00 B-775068-00 B-775067-00 B-775081-00 B-775529-00 Relief Valve Adapter Ferrule (3/16 -in., Brass) Tube Nut (3/16 -in., Aluminum) Secondary Relief Valve Tube (3/16 -in.) - Companion 1000 Secondary Relief Valve Tube (3/16 -in.) - Companion T Description Secondary Relief Valve (30 psig)
Figure 6-5: Primary Relief Valve Circuit
Figure 6-6: Secondary Relief Valve Circuit
Parts List and Parts Illustration 6-4

FIGURE 6-7 PARTS LIST

Item 9 Part Number B-775063-00 B-775062-00 B-775296-00 B-775287-00 B-775088-00 B-775089-00 B-775004-00 B-701303-00 B-775084-00 B-775539-B-775243-00 Ferrule (1/

Description in., Brass)

Tube Nut (1/4 in., Aluminum) Jam Nut Adjustment Lock Nut Spacer Spring Pin (5/64 in. x 11/16 in., SS) Vent Valve Lever Lever Spring Extension, Vent Valve (Companion 1000) Extension, Vent Valve (Companion T) Vent Valve Assembly

FIGURE 6-8 PARTS LIST

Item 13 Part Number B-775064-00 B-775264-00 B-775262-00 B-775263-00 B-775261-00 B-775063-00 B-775062-00 B-775061-00 B-775267-00 B-775259-00 Reference B-775260-00 B-775268-00 Description Female Fill Connector Assembly (includes items 2, 3, 4, & 5) Female Fill Connector (includes items 3, 9, 10, 11, 12, & 13) Seal, Female Adaptor Female Adaptor Jam Nut, Female Adaptor Ferrule (1/4 in., Brass) Tube Nut (1/4 in., Aluminum) Fill Tube (1/4 in.) Retainer Ring Cartridge Assembly (includes item 9) Female Fill Connector Body Lip Seal Lip Seal Retainer Sleeve

" !

& !
Figure 6-7: Vent Valve Assemblies
Figure 6-8: Female Fill Connector
Parts List and Parts Illustration 6-5