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.com
Helium-Oxygen Blender
CONTENTS
SECTION 1: SAFETY INFORMATION - WARNINGS AND CAUTIONS ......................................................................................... 1
EXPLANATION OF ABBREVIATIONS ..................................................................................................................................... 2
Blender Diagrams ................................................................................................................................................................ 2
COMPONENT DESCRIPTIONS in Blender Diagrams ............................................................................................................. 3
SECTION 2: TECHNICAL DESCRIPTION ..................................................................................................................................... 5
HELIOX / OXYGEN FLOW PATH INDICATION DIAGRAM ...................................................................................................... 6
SECTION 3: MAINTENANCE PROCEDURES, REPAIR AND CALIBRATION ................................................................................. 7
I. LOW FLOW (PM5400 Model) ........................................................................................................................................... 7
Step 1: DISASSEMBLY ...................................................................................................................................................... 7
Step 2: CLEANING ............................................................................................................................................................ 9
Step 3: LOW FLOW ASSEMBLY ...................................................................................................................................... 10
Step 4: TEST ................................................................................................................................................................... 12
Typical Test Configuration Diagram .................................................................................................................................. 12
LOW Flow Operation Verification Procedure ................................................................................................................... 15
II. HIGH FLOW (PM5500 Model) ....................................................................................................................................... 16
Step 1: DISASSEMBLY .................................................................................................................................................... 16
Step 2: CLEANING .......................................................................................................................................................... 18
Step 3: LOW FLOW ASSEMBLY ...................................................................................................................................... 19
Step 4: TEST ................................................................................................................................................................... 21
Typical Test Configuration Diagram .................................................................................................................................. 21
High Flow Operation Verification Procedure .................................................................................................................... 24
III. INTERNATIONAL LOW / HIGH Flow Operation Verification Procedure ....................................................................... 25
SECTION 4: TROUBLESHOOTING ........................................................................................................................................... 26
SECTION 5: BLENDER PARTS LIST .......................................................................................................................................... 27
Label information .............................................................................................................................................................. 28
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.
The Heliox-Oxygen Blender should be serviced by a qualified service technician.
An Oxygen Analyzer/Monitor must be used to verify Oxygen concentrations.
When reassembling the Blender, do not pressurize the system until the retaining screw of the
Proportioning Module has been fully tightened. The Proportioning Module can be forcefully ejected
by gas pressure if not sufficiently tightened.
Always follow ANSI and CGA standards for Medical Gas Products, Flowmeters and Oxygen Handling.
When servicing requirements of Directive 93/42/EEC concerning medical devices and all
International Standards apply. (On CE marked devices ONLY)
DO NOT obstruct the alarm.
Oxygen Concentration Dial does not rotate 360 degrees. Rotating the dial less than 21% or over
100% Oxygen will damage the Blender.
Service Warning
This Service Manual is provided for your safety and to prevent damage to the Heliox-Oxygen
Blender.
It is essential to read and understand this entire manual before attempting to service the Heliox-
Oxygen Blender.
If you have any questions regarding the installation, setup, operation, and/or maintenance of the
Heliox-Oxygen Blender, contact Precision Medical, Inc.
CAUTION
Use recommended lubricants sparingly as lubricant may migrate to other areas and cause the
Blender to malfunction.
When pressurizing the Blender inlets, avoid pressure surges greater than 100 psi (6.9 bar) .
Ensure all connections are tight and leak free before returning to service.
Store Blender in a clean, dry area when not in use.
DO NOT steam autoclave.
DO NOT gas sterilize with (ETO) Ethylene Oxide.
DO NOT immerse Heliox-Oxygen Blender into any liquid.
DO NOT use if dirt or contaminants are present on or around the Blender or connecting devices.
DO NOT clean with aromatic hydrocarbons.
Heliox / Oxygen Blender Service Manual
Page 1
Blender Diagrams
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
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.
B
Oxygen Inlet Fitting
A female DISS or NIST Oxygen fitting with one way valve that is used to connect an Oxygen supply
hose.
C
Heliox Inlet Fitting
A male DISS or NIST Heliox fitting with one way valve that is used to connect a Heliox supply hose.
D
Oxygen Concentration Dial
A dial used for selecting Oxygen concentrations between 20%-100% or 30%-100%. The FIO2 scale
is used for reference only. The actual FIO2 must be verified with an Oxygen Monitor.
The Dial does not rotate 360°. The dial starts at 20% or 30% and ends at 100%.
E
Rear Slide Mount with dove tail.
F
Auxiliary Bleed Collar
The collar is used to engage and disengage the bleed. The bleed is necessary to maintain accurate
FIO2 Concentration below 15 lpm for the High Flow and 3 lpm for the Low Flow. To activate the
bleed, slide and rotate (if applicable) the knurled collar back until it contacts the cover. To
deactivate the bleed, pull and rotate (if applicable) collar away from cover until it reaches a
positive stop.
G
Auxiliary Outlet Port
A male DISS Oxygen fitting with check valve that delivers flow when engaged to any controlling
device, such as a flowmeter. This outlet is equipped with a bleed valve that allows the user to
control if the bleed is ON or OFF. With the bleed in the ON position, this outlet delivers accurate
Oxygen concentrations in the following flows:
Model Flow Range
High Flow 2 – 100 lpm
Low Flow 0 – 30 lpm
H
Alarm
An audible alarm that sounds due to an excessive pressure drop or deletion of either gas supply.
Heliox / Oxygen Blender Service Manual
Page 3
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.
Heliox / Oxygen Blender Service Manual
Page 4
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. The dial settings range
from 20-100% on the PM5480 & PM5580 models and 30-100% on the PM5470 & PM5570 models.
The Path of the Gases
The supply enters through the Heliox and Oxygen inlet connectors located on the bottom of the Blender. Each
inlet connector contains a particulate filter and duckbill check valves which prevent possible reverse gas flow.
Diaphragm Housing Module
The two gases then enter the two-stage pressure Diaphragm Housing Module. In this module, the pressures of
both gas sources are equalized prior to entering the Proportioning Module. The pressure is equalized at the
lower pressure. The diaphragm within the module responds to the difference in pressure and directs the
movement of each check valve assembly contained within the Heliox and Oxygen chambers. The movement of
each ball adjusts the amount of gas flowing through the Diaphragm Housing Module, equalizing the Heliox and
Oxygen pressures to the lower pressure.
Proportioning Module
From the Diaphragm Housing Module the gases flow into the Proportioning Module and are mixed according
to the Oxygen percentage selected on the Oxygen Concentration Dial. The Proportioning Module consists of a
double ended valve positioned between two valve seats. One seat controls the passage of Heliox and the
other valve seat controls the passage of Oxygen into the outlet. At this point, the two gases have been
blended according to the Oxygen percentage selected on the Oxygen Concentration Dial.
With the Oxygen Concentration Dial at the full counterclockwise position (20/30%), the double ended valve
will completely close off the flow of Oxygen, allowing only the Heliox to flow. By adjusting the Oxygen
Concentration Dial to the full clockwise position (100%), the flow of Heliox is blocked, permitting only the flow
of Oxygen through the Blender outlet.
Alarm and Alarm Bypass
An audible alarm located on the bottom of the Blender signals when the difference in pressure between the
two inlet gases is ≥ 18 psi for Low Flow and ≥ 13 psi for High Flow. When the source gases are near equal
pressure, the alarm bypass poppet will remain seated over the alarm channel and the alarm does not sound.
When the gas pressures become unbalanced the higher pressure gas will unseat the poppet by overcoming
the spring force causing gas to flow through the alarm channel and the alarm sounds. The oxygen
concentration from the Blender will be that of the higher gas pressure. The Blender in the alarm/bypass mode
will deliver the oxygen (100%) or Heliox until the bypass mechanism resets when the source gas pressure is
restored to a differential of approximately 6 psi (0.42 kg/cm2). If the Blender is set at 20 or 30% (depending
on model), the OXYGEN source pressure is reduced or lost, the unit will not alarm because it will continue to
deliver 20 or 30% concentration according to the setting. If the control is moved slightly from the 20 or 30%
setting, the alarm will sound. Similarly, if the Blender is set to deliver 100% oxygen concentration and Heliox
source pressure is reduced or lost, the unit will not alarm because it will continue to deliver the selected 100%
concentration. The alarm will not function when there is no flow to the blender.
Heliox / Oxygen Blender Service Manual
Page 5
Gas Outlets
The Primary and Auxiliary Outlets are DISS male adapters with check valves.
HELIOX / OXYGEN FLOW PATH INDICATION DIAGRAM
Heliox / Oxygen Blender Service Manual
Page 6
SECTION 3: MAINTENANCE PROCEDURES, REPAIR AND CALIBRATION
I. LOW FLOW (PM5400 Model)
Step 1: DISASSEMBLY
Tools Required
#2 Phillips Screwdriver 11/32 in. Nut Driver
#3 Phillips Screwdriver 5/32 in. Long Hex Key
1/2 in. Open End Wrench 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. open end wrench to unscrew and remove the
Heliox [5] and Oxygen [4] inlet assemblies from bottom of the
Blender.
Oxygen inlet has left hand threads.
5. If manifold outlet assembly is present, unscrew the stem using
a 5/32 hex key and holding the manifold outlet assembly to
the bottom of the Blender.
6. Remove the four flat head screws [2] from bottom cover [6].
7. Remove bottom cover.
Heliox / Oxygen Blender Service Manual
Page 7
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].
Push the alarm assembly through to remove the
assembly from manifold block.
LOW FLOW
Figure E
12. Using a 11/32 in. nut driver or socket, loosen
the nut [14] (ONLY two turns) holding the
knob guide [15] on the proportioning valve
assembly [16]. Slide knob guide assembly
from proportioning valve assembly shaft.
Slide resistance ring [17] from proportioning
valve assembly.
13. Remove phillips head screw [18] and washer
[19] from side of proportioning valve
assembly.
14. Replace knob guide assembly and tighten the
nut.
15. Pull knob guide assembly to remove
proportioning valve assembly from manifold
block. Again, loosen the nut (ONLY two turns) holding the knob guide to the proportioning valve
assembly, remove knob guide from proportioning valve assembly shaft.
Heliox / Oxygen Blender Service Manual
Page 8
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].
Step 2: CLEANING
Precision Medical, Inc. recommends using an ultrasonic cleaner for cleaning all non-elastomeric and nonmetallic components. However, cleaning with an all-purpose liquid cleaner and rinsing with clean, warm water
may be substituted. Both methods require thoroughly blow drying all passages before reassembly. Follow the
ultrasonic cleaner manufacturer instruction.
Heliox / Oxygen Blender Service Manual
Page 9
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. The large
holes opposite the mounting locations of the diaphragm housing assemblies are
facing you.
2. Cover the alarm assembly thread location with thumb. Drop spring [25] then
ball [24] into alarm bypass orifice.
3. Place alarm bypass body [23] onto long shaft of 5/32 hex key. Guide the alarm
bypass body, threads first into the alarm bypass orifice, and screw into cavity.
Tighten until alarm bypass body is flush with bottom of center hole. Tighten
enough to clear center threads ONLY.
4. Replace O-ring [32] on plug [22]. Insert plug and tighten.
Figure I
5. Lubricate alarm bypass assembly bore on manifold block with Krytox GPL
106.
6. Using retaining ring pliers install retaining ring [12] in one side of alarm
assembly bore.
7. Insert alarm assembly [13] into bore of manifold block.
8. Install remaining retaining ring.
9. For Models without manifold block assembly:
Replace O-ring [32] on plug [22] then install plug [22] into bottom hole of
manifold block.
10. Thread auxiliary outlet assembly [10] to manifold block, torque to 10 ft-
lbs (13.6 Nm).
Heliox / Oxygen Blender Service Manual
Page 10
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. Lubricate proportioning valve bore with Krytox
GPL 106.
17. Align the (3) holes on the proportioning valve
assembly [16] equal distance between the (2)
plugs and push in. *Reference drawing below.
18. Replace washer [19] and phillips head screw
[18].
19. Place new resistance ring [17] in its place on the
proportioning valve assembly.
*Proportional valve assembly inserted, with
the “L” stamped on back for Low Flow Model.
Heliox / Oxygen Blender Service Manual
Page 11
Equipment 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
Tools Required
Phillips Screwdriver
Torque Driver capable of 10 in-lbs
Adjustable Wrench
Retaining Ring Pliers
Nut Driver
Step 4: TEST
Typical Test Configuration Diagram
Instructions for Testing
A. Heliox and Oxygen Supply Setup
Both gas supplies must be clean and dry per the specifications outlined in this manual and have the ability to
generate up to 100 psi (6.89 bar) for both the Heliox and Oxygen inlet pressures. Verify Heliox and Oxygen
supply concentrations with an analyzer/monitor.
Heliox / Oxygen Blender Service Manual
Page 12
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.
7. Attach a calibrated Heliox or Oxygen Flow Monitor capable of 0-70 lpm or greater to the other outlet
on the t-fitting.
8. The system is now ready for an initial performance test.
C. Initial Performance Test
NOTE: Before pressurizing make sure proportioning valve assembly is secure and screw is tightened.
1. Perform calibration on Oxygen Analyzer/Monitor per the manufacturer’s instructions prior to testing
the Blender.
2. Set Heliox & Oxygen pressures to 50 psi (3.45 bar) each.
NOTE: Turn OFF and check for leak by watching for pressure drops on pressure gauges.
3. An initial pressure drop may occur, no further drop in pressure should occur.
4. If continued pressure drop is observed, troubleshoot by using a commercial leak detector to find
source of leak and refer to Section 4: TROUBLESHOOTING for further instructions.
5. Use a lint free dry cloth to wipe Blender clean of commercial leak detector.
6. Ensure both inlet pressures are at 50 psi.
7. Replace the top cover.
NOTE: DO NOT install the (4) mounting screws until the end of the Final Test, or after satisfactory
completion of the Performance Check. Refer to the “OPERATING INSTRUCTIONS” in Users Manual.
8. Set flowmeter to 3-3.5 lpm.
9. Set the Blender to 60% FIO2 with Oxygen Analyzer/Monitor, this value should remain within 3.0% of
original reading throughout the following test.
a. Set flowmeter to 30-30.5 lpm, check concentration reading.
b. Set flowmeter back to 3-3.5 lpm.
c. Set Heliox inlet pressure to 50 psi (3.45 bar) and the Oxygen inlet pressure to 43 psi (2.96 bar)
adjust flow to 3-3.5 lpm, check concentration reading.
d. Set Heliox inlet pressure to 43 psi (2.96 bar) and the Oxygen inlet pressure to 50 psi (3.45 bar)
adjust flow to 3-3.5 lpm, check concentration reading.
e. If the Oxygen Analyzer/Monitor setting does not remain within 3.0% of the original reading, then
replace one or both of the diaphragm block assemblies.
Heliox / Oxygen Blender Service Manual
Page 13
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. Replace the Duckbill Check Valve in the Oxygen inlet if bubbles indicate leakage.
4. Repeat steps 1-3 to check for leakage past the Heliox inlet check valve.
5. Reconnect the Heliox inlet hose and adjust both supply pressures back to standard inlet pressure.
E. Setup of PROPORTIONING VALVE ASSEMBLY CALIBRATION
1. Set Heliox and Oxygen inlet pressures to 50 psi.
2. Set flow to 9 lpm.
3. Turn Adjustment Shaft counterclockwise until the Oxygen Analyzer/Monitor displays a concentration
equal to that of the source Heliox (±0.3), reference Part A in Setup.
4. Attach knob guide assembly onto adjustment shaft of proportioning valve assembly so that the knob
stop rests on top of the screw. Ensure knob stop aligns with the slot in the resistance ring.
5. While applying downward pressure to the 2 screws on the knob guide assembly, attach nut to
adjustment shaft using nut driver.
6. Turn knob guide fully clockwise, Oxygen Analyzer/Monitor display should be equal to concentration of
the source Oxygen (±0.3).
7. Turn knob guide back to 21% position to ensure no drift from original reading (±0.3).
8. Re-attach knob guide, torque nut to adjustment shaft and tighten to 10 in-lbs using a torque driver.
9. Snap in knob back into knob guide, pay close attention to the key location of the knob.
10. Set knob to the 60 graduation.
11. Replace the top cover.
NOTE: DO NOT install the four (4) mounting screws until the end of the Final Test.
F. Final Test
Complete Operation Verification Procedure as per the test table, page 15 or 25.
Record test results in the test table.
When Final Test is complete replace top cover and install the four (4) mounting screws into cover.
NOTE: Operation Verification Procedure should be performed at least once a year.
Heliox / Oxygen Blender Service Manual
Page 14
S E Q #
DIAL
SET
O2%
OXYGEN PRESS ±1.0
HELIOX PRESS ±1.0
FLOWMETER
SET TO
lpm ±0.2
AUXILIARY
BLEED
FUNCTION
TARGET VALUE
ACTUAL
VALUE
psi
bar
psi
bar
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
3.45 3 open
set point
37.0%-43.0%
6
60
50
3.45
50
3.45 3 open
set point
57.0%-63.0%
7
80
50
3.45
50
3.45 3 open
set point
77.0%-83.0%
8
100
50
3.45
50
3.45 3 open
end point
(±0.3) Source Value
9
60
50
3.45
50
3.45 1 open
set point
57.0%-63.0%
10
60
60
4.14
67
4.62 1 open
set point
57.0%-63.0%
11
60
60
4.14
50
3.45 1 open
set point
57.0%-63.0%
12
60
50
3.45
Slowly
reduce to
30
Slowly
reduce to
2.07
3
closed
Alarm ON
30.0 ± 2.0 psi
13
60
50
3.45
Slowly Increase until
alarm shuts off
3
closed
Alarm OFF
45.0 psi MAX
14
60
Slowly
Reduce to
30
Slowly
Reduce to
2.07
50
3.45 3 closed
Alarm ON
30.0 ± 2.0 psi
15
60
Slowly Increase until
alarm shuts off
50
3.45 3 closed
Alarm OFF
45.0 psi MAX
16
60
50
3.45
50
3.45
MAX
closed
flow rate
30.0 lpm MIN
17
60
50
3.45 0 MAX
closed
flow rate
30.0 lpm MIN
18
60 0 50
3.45
MAX
closed
flow rate
30.0 lpm MIN
19
60
50
3.45
50
3.45
MAX
open
flow rate
30.0 lpm MIN
LOW Flow Operation Verification Procedure
USA and CANADA ONLY
(50 psi / 3.45 bar MODELS)
* Reference, Letter D. (Reverse Gas Flow Procedure)
Heliox / Oxygen Blender Service Manual
Page 15
II. HIGH FLOW (PM5500 Model)
Step 1: DISASSEMBLY
Tools Required
#2 Phillips Screwdriver 11/32 in. Nut Driver
#3 Phillips Screwdriver 5/32 in. Long Hex Key
1/2 in. Open End Wrench 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. open end wrench to unscrew and remove the
Heliox [4] and Oxygen [5] inlet assemblies and primary [9]
from bottom of the Blender.
Oxygen inlet has left hand threads.
5. If manifold outlet assembly is present, unscrew the stem
using a 5/32 hex key and holding the manifold outlet
assembly to the bottom of the Blender.
6. Remove the four flat head screws [2] from bottom cover
[6].
7. Remove bottom cover.
Heliox / Oxygen Blender Service Manual
Page 16
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]. Push the alarm assembly through to remove
the assembly from manifold block.
HIGH FLOW
Figure E
12. Using a 11/32 in. nut driver or socket, loosen
the nut [14] (ONLY two turns) holding the
knob guide [15] on the proportioning valve
assembly [16]. Slide knob guide assembly
from proportioning valve assembly shaft.
Slide resistance ring [17] from proportioning
valve assembly.
13. Remove phillips head screw [18] and washer
[19] from side of proportioning valve
assembly.
14. Replace knob guide assembly and tighten the
nut.
15. Pull knob guide assembly to remove
proportioning valve assembly from manifold
block. Again, loosen the nut (ONLY two turns) holding the knob guide to the proportioning valve
assembly, remove knob guide from proportioning valve assembly shaft.
Heliox / Oxygen Blender Service Manual
Page 17
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].
Step 2: CLEANING
Precision Medical, Inc. recommends using an ultrasonic cleaner for cleaning all non-elastomeric and nonmetallic components. However, cleaning with an all-purpose liquid cleaner and rinsing with clean, warm water
may be substituted. Both methods require thoroughly blow drying all passages before reassembly. Follow the
ultrasonic cleaner manufacturer instruction.
Heliox / Oxygen Blender Service Manual
Page 18
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. The large
holes opposite the mounting locations of the diaphragm housing assemblies
are facing you.
2. Cover the alarm assembly thread location with thumb. Drop spring [25] then
ball [24] into alarm bypass orifice.
3. Place alarm bypass body [23] onto long shaft of 5/32 hex key. Guide the alarm
bypass body, threads first into the alarm bypass orifice, and screw into cavity.
Tighten until alarm bypass body is flush with bottom of center hole. Tighten
enough to clear center threads ONLY.
4. Replace O-ring [32] on plug [22]. Insert plug and tighten.
Figure I
5. Lubricate alarm bypass assembly bore on manifold block with Krytox
GPL 106.
6. Using retaining ring pliers install retaining ring [12] in one side of alarm
assembly bore.
7. Insert alarm assembly [13] into bore of manifold block.
8. Install remaining retaining ring.
9. Thread auxiliary outlet assembly [10] to manifold block, torque to 10 ft-
lbs (13.6 Nm).
Heliox / Oxygen Blender Service Manual
Page 19
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. Install new Heliox inlet assembly [4], torque to
10 ft-lbs (13.6 Nm).
Figure L
16. Lubricate proportioning valve bore with Krytox
GPL 106.
17. Align the (3) holes on the proportioning valve
assembly [16] equal distance between the (2)
plugs and push in. *Reference drawing below.
18. Replace washer [19] and phillips head screw [18].
19. Place new resistance ring [17] in its place on the
proportioning valve assembly.
*Proportional valve assembly inserted, with the
“H” stamped on back for High Flow Model.
Heliox / Oxygen Blender Service Manual
Page 20
Equipment 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
Tools Required
Phillips Screwdriver
Torque Driver capable of 10 in-lbs
Adjustable Wrench
Retaining Ring Pliers
Nut Driver
Step 4: TEST
Typical Test Configuration Diagram
Instructions for Testing
A. Heliox and Oxygen Supply Setup
Both gas supplies must be clean and dry per the specifications outlined in this manual and have the ability to
generate up to 100 psi (6.89 bar) for both the Heliox and Oxygen inlet pressures. Verify Heliox and Oxygen
supply concentrations with an analyzer/monitor.
Heliox / Oxygen Blender Service Manual
Page 21
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. Attach an Oxygen Analyzer/Monitor to the one outlet on the t-fitting.
7. Attach a calibrated Heliox or Oxygen Flow Monitor capable of 0-120 lpm or greater to the other outlet
on the t-fitting.
8. The system is now ready for an initial performance test.
C. Initial Performance Test
NOTE: Before pressurizing make sure proportioning valve assembly is secure and screw is tightened.
1. Perform calibration on Oxygen Analyzer/Monitor per the manufacturer’s instructions prior to testing
the Blender.
2. Set Heliox & Oxygen pressures to 50 psi (3.45 bar) each.
NOTE: Turn OFF and check for leak by watching for pressure drops on pressure gauges.
3. An initial pressure drop may occur, no further drop in pressure should occur.
4. If continued pressure drop is observed, troubleshoot by using a commercial leak detector to find
source of leak and refer to Section 4: TROUBLESHOOTING for further instructions.
5. Use a lint free dry cloth to wipe Blender clean of commercial leak detector.
6. Ensure both inlet pressures are at 50 psi.
7. Replace the top cover.
NOTE: DO NOT install the (4) mounting screws until the end of the Final Test, or after satisfactory
completion of the Performance Check. Refer to the “OPERATING INSTRUCTIONS” in Users Manual.
8. Set flowmeter to 3-3.5 lpm.
9. Set the Blender to 60% FIO2 with Oxygen Analyzer/Monitor, this value should remain within 3.0% of
original reading throughout the following test.
a. Set flowmeter to 30-30.5 lpm, check concentration reading.
b. Set flowmeter back to 3-3.5 lpm.
c. Set Heliox inlet pressure to 50 psi (3.45 bar) and the Oxygen inlet pressure to 43 psi (2.96 bar)
adjust flow to 3-3.5 lpm, check concentration reading.
d. Set Heliox inlet pressure to 43 psi (2.96 bar) and the Oxygen inlet pressure to 50 psi (3.45 bar)
adjust flow to 3-3.5 lpm, check concentration reading.
e. If the Oxygen Analyzer/Monitor setting does not remain within 3.0% of the original reading, then
replace one or both of the diaphragm block assemblies.
Heliox / Oxygen Blender Service Manual
Page 22
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. Replace the Duckbill Check Valve in the Oxygen inlet if bubbles indicate leakage.
4. Repeat steps 1-3 to check for leakage past the Heliox inlet check valve.
5. Reconnect the Heliox inlet hose and adjust both supply pressures back to standard inlet pressure.
E. Setup of PROPORTIONING VALVE ASSEMBLY CALIBRATION
1. Set Heliox and Oxygen inlet pressures to 50 psi.
2. Set flow to 9 lpm.
3. Turn Adjustment Shaft counterclockwise until the Oxygen Analyzer/Monitor displays a concentration
equal to that of the source Heliox (±0.3), reference Part A in Setup.
4. Attach knob guide assembly onto adjustment shaft of proportioning valve assembly so that the knob
stop rests on top of the screw. Ensure knob stop aligns with the slot in the resistance ring.
5. While applying downward pressure to the 2 screws on the knob guide assembly, attach nut to
adjustment shaft using nut driver.
6. Turn knob guide fully clockwise, Oxygen Analyzer/Monitor display should be equal to concentration of
the source Oxygen (±0.3).
7. Turn knob guide back to 21% position to ensure no drift from original reading (±0.3).
8. Re-attach knob guide, torque nut to adjustment shaft and tighten to 10 in-lbs using a torque driver.
9. Snap in knob back into knob guide, pay close attention to the key location of the knob.
10. Set knob to 60 graduation.
11. Replace the top cover.
NOTE: DO NOT install the four (4) mounting screws until the end of the Final Test.
F. Final Test
Complete Operation Verification Procedure as per the test table, page 24 or 25.
Record test results in the test table.
When Final Test is complete replace top cover and install the four (4) mounting screws into cover.
NOTE: Operation Verification Procedure should be performed at least once a year.
Heliox / Oxygen Blender Service Manual
Page 23
High Flow Operation Verification Procedure
S E Q #
DIAL
SET
O2%
OXYGEN PRESS ±1.0
HELIOX PRESS ±1.0
FLOWMETER
SET TO
lpm ±0.2
AUXILIARY
BLEED
FUNCTION
TARGET VALUE
ACTUAL
VALUE
psi
bar
psi
bar
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
3.45 3 open
set point
37.0%-43.0%
6
60
50
3.45
50
3.45 3 open
set point
57.0%-63.0%
7
80
50
3.45
50
3.45 3 open
set point
77.0%-83.0%
8
100
50
3.45
50
3.45 3 open
end point
(±0.3) Source Value
9
60
50
3.45
50
3.45 1 open
set point
57.0%-63.0%
10
60
60
4.14
67
4.62 1 open
set point
57.0%-63.0%
11
60
60
4.14
50
3.45 1 open
set point
57.0%-63.0%
12
60
50
3.45
Slowly
reduce to
31
Slowly
reduce to
2.14
3
closed
Alarm ON
31.0 ± 6.0 psi
13
60
50
3.45
Slowly Increase until
alarm shuts off
3
closed
Alarm OFF
45.0 psi MAX
14
60
Slowly
Reduce to
31
Slowly
Reduce to
2.14
50
3.45 3 closed
Alarm ON
31.0 ± 6.0 psi
15
60
Slowly Increase until
alarm shuts off
50
3.45 3 closed
Alarm OFF
45.0 psi MAX
16
60
50
3.45
50
3.45
MAX
closed
flow rate
120.0 lpm MIN
17
60
50
3.45 0 MAX
closed
flow rate
85.0 lpm MIN
18
60 0 50
3.45
MAX
closed
flow rate
85.0 lpm MIN
19
60
50
3.45
50
3.45
MAX
open
flow rate
120.0 lpm MIN
USA and CANADA ONLY
(50 psi / 3.45 bar MODELS)
* Reference, Letter D. (Reverse Gas Flow Procedure)
Heliox / Oxygen Blender Service Manual
Page 24
III. INTERNATIONAL LOW / HIGH Flow Operation Verification Procedure
S E Q #
DIAL
SET
O2%
OXYGEN PRESS ±1.0
HELIOX PRESS ±1.0
FLOWMETER
SET TO
lpm ±0.2
AUXILIARY
BLEED
FUNCTION
TARGET VALUE
ACTUAL
VALUE
psi
bar
psi
bar
Low
Flow
High
Flow
Low
Flow
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
4.14
3
15
open
closed
end point
(±0.3) Source Value
5
40
60
4.14
60
3.45
3
15
open
closed
set point
37.0%-43.0%
6
60
60
4.14
60
3.45
3
15
open
closed
set point
57.0%-63.0%
7
80
60
4.14
60
3.45
3
15
open
closed
set point
77.0%-83.0%
8
100
60
4.14
60
3.45
3
15
open
closed
end point
(±0.3) Source Value
9
60
60
4.14
60
3.45
1
1.5
open
set point
57.0%-63.0%
10
60
60
4.14
70
4.83
1
1.5
open
set point
57.0%-63.0%
11
60
60
4.14
53
3.65
1
1.5
open
set point
57.0%-63.0%
12
60
60
4.14
Slowly
reduce
to 40
Slowly
reduce to
2.76
3
15
closed
Alarm ON
42.0 ±
2.0 psi
31.0 ±
6.0 psi
13
60
60
4.14
Slowly
Increase
to 60
Slowly
Increase
to 4.14
3
15
closed
Alarm OFF
45.0 psi MAX
14
60
Slowly
Reduce to
40
Slowly
Reduce to
2.76
60
4.14
3
15
closed
Alarm ON
42.0 ±
2.0 psi
31.0 ±
6.0 psi
15
60
Slowly
Increase
to 60
Slowly
Increase
to 4.14
60
4.14
3
15
closed
Alarm OFF
55.0 psi MAX
16
60
60
4.14
60
4.14
MAX
closed
flow rate
30.0
lpm
MIN
120.0
lpm
MIN
17
60
60
4.14 0 MAX
closed
flow rate
30.0
lpm
MIN
85.0
lpm
MIN
18
60 0 60
4.14
MAX
closed
flow rate
30.0
lpm
MIN
85.0
lpm
MIN
19
60
60
4.14
60
4.14
MAX
open
flow rate
30.0
lpm
MIN
120.0
lpm
MIN
(60 psi / 4.14 bar MODELS)
* Reference, Letter D. (Reverse Gas Flow Procedure)
Heliox / Oxygen Blender Service Manual
Page 25
SECTION 4: TROUBLESHOOTING
Test #’s
Problem
Probable Cause
Remedy
1
Pressure drop greater
than 2 psi in two
minutes
Leakage from manifold caused by cut or
missing o-ring or due to particulates.
Check ALL manifold connections (inlets, outlets,
plugs, proportioning valve, alarm poppet, etc.) with
Oxygen leak detector to find source of leakage; if
leak is found, remove appropriate parts and clean
seal area and o-rings and/or replace appropriate
o-ring.
Ball not sealing in the alarm bypass.
Replace spring and ball in alarm bypass; ensure
seal surface is clean.
Auxiliary bleed is open.
Close auxiliary bleed by turning and pulling
knurled collar away from cover until bleed is
closed.
Leakage from one of the outlets.
Replace outlet.
2 and 3
Back flow leak
Faulty inlet.
Replace duckbill valve or entire inlet assembly.
4 thru 8
Measured FIO2 values
do not meet target
values
Outlet flow is less than 3 lpm.
Adjust flowmeter to 3 lpm (Note: flow must be
adjusted after each change in FIO2 setting).
Proportioning valve endpoints are not
set correctly.
Set proportioning valve endpoints (See setup
procedure in Section E).
Diaphragm blocks not balancing
properly.
Replace Diaphragm Blocks.
Internal leakage in proportion valve.
Remove proportioning valve; clean seal areas
and/ or replace the two rear o-rings. If necessary,
replace proportioning valve assembly.
9 thru 11
Measured FIO2 values
do not meet target
values
Bleed not open.
Open bleed by turning and pushing the knurled
collar until it contacts the cover.
Blockage in bleed holes.
Replace auxiliary outlet.
Internal leak in proportioning valve.
Remove proportioning valve; clean seal areas
and/ or replace the two rear o-rings. If necessary,
replace proportioning valve assembly.
Flow not set to 1 lpm.
Adjust flow to 1 lpm.
Diaphragm blocks not balancing
properly.
Replace diaphragm block.
12
And
14
Alarm not audible and
gas is not exiting the
alarm vent
Pressure differential not sufficient to
trigger alarm.
Ensure supply pressures are set properly to
achieve differential (Low Flow: 18 to 22; High
Flow: 13 to 25).
Alarm not audible and
gas is exiting the
alarm vent
Faulty alarm.
Replace alarm. (See Figure C & K)
13
And
15
Alarm does not turn
off after balancing
supply pressures
Faulty alarm assembly.
Replace alarm assembly. (See Figure C & K)
Ball not sealing in the alarm bypass.
Replace spring and ball in alarm bypass; ensure
seal surface is clean.
16
Thru
19
Measured flow values
do not meet minimum
target values
Gas inlets are restricted.
Check appropriate gas inlet(s) for restriction in gas
pathway; replace duckbill or entire inlet as
necessary.
High flow model only: low flow inlets
installed in place of high-flow inlets.
Confirm that high-flow inlets are installed; replace
as necessary.
Alarm bypass is threaded too far into
manifold block (only applicable to tests
17 and 18).
Replace ball and spring (see Figure I for proper
assembly method).
High flow models only: wrong ball in
alarm bypass block (only applicable to
tests 17 and 18).
Confirm that correct ball is installed in alarm
bypass; replace as necessary.
Heliox / Oxygen Blender Service Manual
Page 26
SECTION 5: BLENDER PARTS LIST
PART #
DESCRIPTION
LOW FLOW
PM5400
HIGH
FLOW
PM5500
504562
CONTROL KNOB (Dial)
504720
FLAT HEAD SCREW
504718
TOP COVER
504719
BOTTOM COVER
505989
HELIOX INLET ASSEMBLY
505046
OXYGEN INLET ASSEMBLY
504605
MANIFOLD BLOCK ASSEMBLY
504546
PRIMARY OUTLET ASSEMBLY
504741
506084
EASYOFF AUXILIARY ASSEMBLY
505994
504566
AUDIO ALARM ASSEMBLY
504536
RING RETAINING
504530 set
MAIN ALARM ASSEMBLY
504938
GUIDE KNOB ASSEMBLY
504664 set HE
PROPORTIONING VALVE ASSEMBLY
504557 set HE
505009
RESISTANCE RING
504561
PAN HEAD SCREW
504684
FLAT WASHER
506327
MOLDED DIAPHRAGM HOUSING ASSEMBLY
504526
HEX SOCKET HEAD SCREW
506748
BYPASS ALARM SERVICE KIT
504122
O-RING, #008,SILICONE,70 DUROMETER
504686
O-RING, #013,SILICONE,70 DUROMETER
504744
OUTLET CAP
506743
FLOW PATH PLUG ASSEMBLY
506744
BYPASS ALARM BODY ASSEMBLY (Included in 506748 and 506745:
Bypass Alarm Service Kit)
506212
SERVICE KIT
506125
NIST BLENDERS ONLY
506864
SERVICE KIT - PM5500NIST
506863
SERVICE KIT - PM5400NIST
506136
NIST HELIOX INLET ASSEMBLY
505495
NIST OXYGEN INLET ASSEMBLY
Reference Diagram on page 29
Heliox / Oxygen Blender Service Manual
Page 27
Label information
Part #
Label Description
Low Flow
PM5400
High Flow
PM5500
Location
(Blender / dial facing you)
506122
Primary Outlet
Left Side on top cover
606019
506008
Side Labels
Left & Right Side on top cover
506013
505961
Scale 20-100
Bottom Front on top cover
505960
505974
Scale 30-100
Bottom Front on top cover
505973
506004
Face
Top Front on top cover
506003
Auxiliary Outlet
Right Side on top cover
506020
506018
Bottom
Bottom Cover
507043
Warning, Inlet Pressure
Top Back of top cover
504879
Year of Mfg / CE
Bottom Back of top cover
Under Model#, Caution
Label (CE Models Only)
Heliox / Oxygen Blender Service Manual
Page 28
Heliox / Oxygen Blender Service Manual
Page 29
Precision Medical, Inc.
300 Held Drive
Northampton, Pa 18067 USA
Toll Free Tel: 800-272-7285
Toll Free Fax: 800-353-1240
Tel:(+001) 610-262-6090
Fax:(+001) 610-262-6080
Heliox / Oxygen Blender Service Manual 506124 Rev3 032014 (WD) Printed in USA
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