Helium-Oxygen Blender Service Manual Model No. PM5400 Series PM5500 Series (shown) SAVE THESE INSTRUCTIONS 300 Held Drive Northampton, PA 18067 USA Tel: (+001) 610-262-6090 Fax: (+001) 610-262-6080 www.precisionmedical.
CONTENTS SECTION 1: SAFETY INFORMATION - WARNINGS AND CAUTIONS ......................................................................................... 1 EXPLANATION OF ABBREVIATIONS ..................................................................................................................................... 2 Blender Diagrams ................................................................................................................................................................
SECTION 1: SAFETY INFORMATION - WARNINGS AND CAUTIONS WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. WARNING Disconnect the Heliox-Oxygen Blender from all connections prior to disassembly. Use Medical Heliox and Medical Oxygen when servicing to avoid contamination.
EXPLANATION OF ABBREVIATIONS FIHeO2 Fractional Concentration of Inspired Helium-Oxygen FIO2 Fractional Concentration of Inspired Oxygen Heliox Helium-Oxygen DISS Diameter Indexed Safety System NIST Non-Interchangeable Screw Thread lpm Liters Per Minute psi Pounds Per Square Inch Nm Newton meter Blender Diagrams Note: PM5480 Model Shown Heliox / Oxygen Blender Service Manual Page 2
ITEM COMPONENT DESCRIPTIONS in Blender Diagrams A Primary Outlet Port A male DISS Oxygen fitting with check valve that delivers flow when engaged to any controlling device, such as a flowmeter. Oxygen Inlet Fitting A female DISS or NIST Oxygen fitting with one way valve that is used to connect an Oxygen supply hose. Heliox Inlet Fitting A male DISS or NIST Heliox fitting with one way valve that is used to connect a Heliox supply hose.
WARNING When pressurizing the Blender inlets avoid pressure surges greater than 100 psi (6.9bar). Always use a Heliox regulator when using Heliox cylinders to supply gas to the Heliox inlet of the Blender. Always use an Oxygen regulator when using Oxygen cylinders to supply gas to the Oxygen Inlet of the Blender. Example of set-up using a Heliox Cylinder NOTE: Heliox regulator in use.
SECTION 2: TECHNICAL DESCRIPTION The HELIO 2 Blender is a medical device used to mix Medical Heliox and USP Oxygen into a gas source ranging from 20-100% or 30-100% Oxygen. The inlet gas connections are standard DISS or NIST for each gas. The inlets are clearly marked and labeled on the bottom of the Blender. The outlets are standard DISS male Oxygen connections. The front panel of the Blender has a dial that is used to set the specific FIO2 blend.
Gas Outlets The Primary and Auxiliary Outlets are DISS male adapters with check valves.
SECTION 3: MAINTENANCE PROCEDURES, REPAIR AND CALIBRATION I. LOW FLOW (PM5400 Model) Step 1: DISASSEMBLY Tools Required #2 Phillips Screwdriver #3 Phillips Screwdriver 1/2 in. Open End Wrench 11/32 in. Nut Driver 5/32 in. Long Hex Key Small Retaining Ring Pliers Figure A 1. Rotate dial [1] to the 60 graduation. 2. Remove the two flat head screws [2] on each side of the top cover [3]. 3. Remove top cover by pulling upwards. The cover will not come off unless the dial is at the 60 graduation Figure B 4.
LOW FLOW Figure C 8. Remove dial [1] by pulling dial away from manifold block [8]. 9. Remove the primary [9] and auxiliary [10] outlets (auxiliary contains Blue Muffler [38]) by using a ½ in. open end wrench to unscrew. 10. Use Retaining Ring Pliers to unscrew and remove audio alarm assembly [11] from the bottom of the manifold block. Figure D 11. Use small retaining ring pliers to remove retaining rings [12] from each side of the alarm assembly [13].
LOW FLOW Figure F 16. Remove each diaphragm housing assembly [20] from the manifold by removing the two hex socket head screws [21] on the top of each diaphragm housing with 5/32 hex key. Figure G 17. Using 5/32 in. long hex wrench, unscrew and remove plug [22] from the bottom of the manifold block. 18. Remove rear plug [22] from the back of the manifold block. Insert a long 5/32 hex key through rear plug opening, unscrew and remove the alarm bypass body [23], ball [24] and spring [25].
LOW FLOW Step 3: LOW FLOW ASSEMBLY Tools Required Lint Free Swab (optional) Pointed instrument for removing O-rings Krytox GPL 106 or equivalent Oxygen safe lubricant #2 Phillips Screwdriver 1/2 in. Open End Torque Wrench (Torque wrench(s) capable of 60 in-lbs and 10 ft-lbs) 11/32 in. Nut Driver 5/32 in. Long Hex Key Small Retaining Ring Pliers Figure H 1. Position manifold block so that the mounting bracket is facing up.
LOW FLOW Figure J 11. Thread new primary outlet assembly [37] to Manifold Block torque to 10 ft-lbs (13.6 Nm). Figure K 12. Start threads of new alarm assembly [11] by hand, tighten with Retaining Ring Pliers, ensure not to bend reed. 13. Attach bottom cover [6] using four flat head screws [2]. 14. Install new Oxygen inlet assembly [5] torque to 10 ft-lbs (13.6 Nm). Oxygen inlet assembly has left handed threads. 15. Install new Heliox inlet assembly [4], torque to 10 ft-lbs (13.6 Nm). Figure L 16.
Step 4: TEST Equipment Required Tools Required Medical Heliox Supply Medical Oxygen Supply Calibrated Oxygen Analyzer/Monitor Calibrated Heliox or Oxygen flow monitor 0 to 70 lpm or greater Flowmeter 0 to 70 lpm or greater Calibrated Pressure Gauges 0 to 100 psi Regulators Tubing / Hoses Phillips Screwdriver Torque Driver capable of 10 in-lbs Adjustable Wrench Retaining Ring Pliers Nut Driver Typical Test Configuration Diagram Instructions for Testing A.
B. Blender Setup 1. Mount the Blender into a secured mating wall or pole bracket in an upright position. 2. Secure the Heliox and Oxygen hoses to the corresponding Blender inlets. 3. It is recommended that a condensation trap be installed in the Heliox supply line just before the Blender Heliox inlet. 4. Attach a flowmeter capable of 0-70 lpm to the auxiliary outlet on the Blender. 5. Attach a t-fitting to the outlet of the flowmeter. 6. Attach an Oxygen Analyzer/Monitor to the one outlet on the t-fitting.
D. Reverse Gas Flow Procedure (Reference Operational Verification Procedure #’s 2 & 3 in Table, page 15 or 25.) 1. Disconnect the Oxygen hose from the gas source. Remove all outlet connections from the Blender to ensure that there is no outlet flow. 2. Place the free end of the Oxygen supply hose under water. Gradually increase the Heliox supply pressure from 30 - 75 psi (2.07 - 5.17 bar), check for leakage past the Oxygen inlet check valve. 3.
LOW Flow Operation Verification Procedure USA and CANADA ONLY (50 psi / 3.45 bar MODELS) SEQ# DIAL SET O2% OXYGEN PRESS ±1.0 HELIOX PRESS ±1.0 psi bar psi bar FLOWMETER SET TO lpm ±0.2 AUXILIARY BLEED FUNCTION TARGET VALUE 1 ANY 50 3.45 50 3.45 closed closed leak <2 psi / 2 MIN *2 60 75 5.17 0 0 0 closed back flow <100 ml/min *3 60 0 0 75 5.17 0 closed back flow <100 ml/min 4 21 50 3.45 50 3.45 3 open end point (±0.3) Source Value 5 40 50 3.45 50 3.
II. HIGH FLOW (PM5500 Model) Step 1: DISASSEMBLY Tools Required #2 Phillips Screwdriver #3 Phillips Screwdriver 1/2 in. Open End Wrench 11/32 in. Nut Driver 5/32 in. Long Hex Key Small Retaining Ring Pliers Figure A 1. Rotate dial [1] to the 60 graduation. 2. Remove the two flat head screws [2] on each side of the top cover [3]. 3. Remove top cover by pulling upwards. The cover will not come off unless the dial is at the 60 graduation Figure B 4. Use a ½ in.
HIGH FLOW Figure C 8. Remove dial [1] by pulling dial away from manifold block [8]. 9. Remove the primary [9] and auxiliary [10] outlets (auxiliary contains Blue Muffler [38]) by using a ½ in. open end wrench to unscrew. 10. Use Retaining Ring Pliers to unscrew and remove audio alarm assembly [11] from the bottom of the manifold block. Figure D 11. Use small retaining ring pliers to remove retaining rings [12] from each side of the alarm assembly [13].
HIGH FLOW Figure F 16. Remove each diaphragm housing assembly [20] from the manifold by removing the two hex socket head screws [21] on the top of each diaphragm housing with 5/32 hex key. Figure G 17. Using 5/32 in. long hex wrench, unscrew and remove plug [22] from the bottom of the manifold block. 18. Remove rear plug [22] from the back of the manifold block. Insert a long 5/32 hex key through rear plug opening, unscrew and remove the alarm bypass body [23], ball [24] and spring [25].
HIGH FLOW Step 3: LOW FLOW ASSEMBLY Tools Required Lint Free Swab (optional) Pointed instrument for removing O-rings Krytox GPL 106 or equivalent Oxygen safe lubricant #2 Phillips Screwdriver 1/2 in. Open End Torque Wrench (Torque wrench(s) capable of 60 in-lbs and 10 ft-lbs) 11/32 in. Nut Driver 5/32 in. Long Hex Key Small Retaining Ring Pliers Figure H 1. Position manifold block so that the mounting bracket is facing up.
HIGH FLOW Figure J 10. Replace O-ring [32] on plug [22]. Install plug and tighten. Figure K 11. Start threads of new alarm assembly [11] by hand, tighten with Retaining Ring Pliers, ensure not to bend reed. 12. Attach bottom cover [6] using four flat head screws [2]. 13. Install new Heliox inlet assembly [4], torque to 10 ft-lbs (13.6 Nm). 14. Install new Oxygen inlet assembly [5] torque to 10 ft-lbs (13.6 Nm). Oxygen inlet assembly has left handed threads. 15.
Step 4: TEST Equipment Required Tools Required Medical Heliox Supply Medical Oxygen Supply Calibrated Oxygen Analyzer/Monitor Calibrated Heliox or Oxygen flow monitor 0 to 120 lpm or greater Flowmeter 0 to 120 lpm or greater Calibrated Pressure Gauges 0 to 100 psi Regulators Tubing / Hoses Phillips Screwdriver Torque Driver capable of 10 in-lbs Adjustable Wrench Retaining Ring Pliers Nut Driver Typical Test Configuration Diagram Instructions for Testing A.
B. Blender Setup 1. Mount the Blender into a secured mating wall or pole bracket in an upright position. 2. Secure the Heliox and Oxygen hoses to the corresponding Blender inlets. 3. It is recommended that a condensation trap be installed in the Heliox supply line just before the Blender Heliox inlet. 4. Attach a flowmeter capable of 0-120 lpm to the auxiliary outlet on the Blender. 5. Attach a t-fitting to the outlet of the flowmeter. 6.
D. Reverse Gas Flow Procedure (Reference Operational Verification Procedure #’s 2 & 3 in Table, page 24 or 25) 1. Disconnect the Oxygen hose from the gas source. Remove all outlet connections from the Blender to ensure that there is no outlet flow. 2. Place the free end of the Oxygen supply hose under water. Gradually increase the Heliox supply pressure from 30 - 75 psi (2.07 - 5.17 bar), check for leakage past the Oxygen inlet check valve. 3.
High Flow Operation Verification Procedure USA and CANADA ONLY (50 psi / 3.45 bar MODELS) SEQ# DIAL SET O2% OXYGEN PRESS ±1.0 HELIOX PRESS ±1.0 psi bar psi bar FLOWMETER SET TO lpm ±0.2 AUXILIARY BLEED FUNCTION TARGET VALUE 1 ANY 50 3.45 50 3.45 closed closed leak <2 psi / 2 MIN *2 60 75 5.17 0 0 0 closed back flow <100 ml/min *3 60 0 0 75 5.17 0 closed back flow <100 ml/min 4 21 50 3.45 50 3.45 3 open end point (±0.3) Source Value 5 40 50 3.
III. INTERNATIONAL LOW / HIGH Flow Operation Verification Procedure (60 psi / 4.14 bar MODELS) SEQ# DIAL SET O2% OXYGEN PRESS ±1.0 HELIOX PRESS ±1.0 psi bar psi bar FLOWMETER SET TO lpm ±0.2 Low Flow High Flow AUXILIARY BLEED Low Flow TARGET VALUE FUNCTION High Flow Low Flow High Flow 1 ANY 60 4.14 60 4.14 closed closed leak <2 psi / 2 MIN *2 60 75 5.17 0 0 0 closed back flow <100 ml/min *3 60 0 0 75 5.17 0 closed back flow <100 ml/min 4 21 60 4.14 60 4.
SECTION 4: TROUBLESHOOTING Test #’s Problem Probable Cause Remedy Leakage from manifold caused by cut or missing o-ring or due to particulates. 1 Pressure drop greater than 2 psi in two minutes Ball not sealing in the alarm bypass. Auxiliary bleed is open. 2 and 3 Back flow leak Leakage from one of the outlets. Faulty inlet. Outlet flow is less than 3 lpm. 4 thru 8 Measured FIO2 values do not meet target values Proportioning valve endpoints are not set correctly.
SECTION 5: BLENDER PARTS LIST Reference Diagram on page 29 PART # 504562 504720 504718 504719 505989 505046 504605 504546 504741 506084 505994 504566 504536 504530 set 504938 504664 set HE 504557 set HE 505009 504561 504684 506327 504526 506748 504122 504686 504744 506743 506744 506212 506125 DESCRIPTION LOW FLOW PM5400 CONTROL KNOB (Dial) FLAT HEAD SCREW TOP COVER BOTTOM COVER HELIOX INLET ASSEMBLY OXYGEN INLET ASSEMBLY MANIFOLD BLOCK ASSEMBLY PRIMARY OUTLET ASSEMBLY HIGH FLOW PM
Label information Part # 506122 606019 506008 506013 505961 505960 505974 505973 506004 506003 506020 506018 507043 504879 Label Description Primary Outlet Side Labels Scale 20-100 Scale 30-100 Face Auxiliary Outlet Bottom Warning, Inlet Pressure Year of Mfg / CE Low Flow PM5400 High Flow PM5500 Location (Blender / dial facing you) Left Side on top cover Left & Right Side on top cover Bottom Front on top cover Bottom Front on top cover Top Front on top cover
Heliox / Oxygen Blender Service Manual Page 29
Precision Medical, Inc.
