CAIRE Inc. HELiOS Universal U-46EU, U-36EU, U-46SW Liquid Oxygen Reservoirs Service Manual

CAIRE Inc.
Service Manual
HELiOSLVDtrademarkof &$,5(,QF
To obtain information about a warranty, if any, contact &$,5(,QF Technical
Services Department, or your local representative.
Covered by one or more of the following U.S. Patents and foreign equivalents:
6,742,517 and 6,575,159.
Caution: Federal law (U.S.) restricts this device to sale by or on the order of a
physician.
To contact a Puritan Bennett representative, call your local Puritan Bennett sales
representative.
Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Information ................................................................................................. 1
Warnings . ................................................................................................... 1
Cautions .. ................................................................................................... 2
Notes . ......................................................................................................... 3
Safety Precautions ................................................................................................3
Cold Safety ................................................................................................. 3
Recommended Protective Clothing ............................................ 3
Important Facts ........................................................................... 4
Expansion Safety ....................................................................................... 4
Important Facts ........................................................................... 4
Fire Safety .................................................................................................. 4
Important Facts ........................................................................... 5
Liquid Oxygen Saturation Principles ..................................................................... 6
Pressure Fittings and Connections ....................................................................... 9
Compression Fitting Makeup ...................................................................... 9
Compression Fitting Remake ................................................................... 10
Compression Fitting Troubleshooting ....................................................... 10
Tapered Pipe Thread (NPT) Makeup ....................................................... 11
Tapered Pipe Thread Troubleshooting ..................................................... 12
Flexible Tube Barbed Fitting Makeup ....................................................... 12
Flexible Tube Removal from Barbed Fitting ... .......................................... 12
Recommended Tools, Test Equipment, and Service Materials .......................... 13
Test Equipment Calibration ...................................................................... 16
Accessories . .............................................................................................17
Product Description ............................................................................................ 20
Controls, Indicators, and Connectors .... ................................................... 21
Serial Number Identification ..................................................................... 22
Filling Instructions ............................................................................................... 23
Oxygen Source Requirements .................................................................23
Transfer Line ............................................................................................ 25
Pre-Fill Inspection ..................................................................................... 25
Filling Procedure ...................................................................................... 27
Post-Fill Inspection ................................................................................... 29
Checking Saturation Pressure .................................................................. 29
Resaturating Liquid Oxygen .................................................................... 30
Operating Procedures .............................................................................. 30
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Performance Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Equipment Required ........................................................................................... 33
Leak Tests .......................................................................................................... 34
Liquid Leak Detector Test ........................................................................ 34
Pressure Hold Test (Alternate Leak Test) ... ............................................. 37
Gaseous Oxygen Functional Tests ..................................................................... 38
Primary Relief Valve Test ......................................................................... 38
Secondary Relief Valve Test .... ................................................................ 39
Pressure Indicator Test ............................................................................ 39
Liquid Oxygen Functional Tests ......................................................................... 40
Universal Reservoir Service Manual
iii
Contents
Contents Indicator Test ............................................................................ 40
Normal Evaporation Rate (NER) Test ...................................................... 41
Economizer Test ...................................................................................... 42
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Service And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Emptying a Reservoir ......................................................................................... 47
Shroud Assembly ................................................................................................ 49
Upper Shroud Removal ............................................................................ 49
Upper Shroud Service .............................................................................. 49
Upper Shroud Installation ......................................................................... 49
Lower Shroud Removal ............................................................................ 49
Lower Shroud Installation ......................................................................... 50
Contents Indicator ............................................................................................... 51
Removal .. ................................................................................................. 51
Service . .................................................................................................... 52
Installation ... ............................................................................................. 53
Fill Connector Release Assembly ....................................................................... 54
Removal .. ................................................................................................. 54
Installation ... ............................................................................................. 54
Male Fill Connector ............................................................................................. 54
Removal .. ................................................................................................. 54
Inspection .... ............................................................................................. 54
Service . .................................................................................................... 55
Disassembly ... .......................................................................................... 55
Reassembly ..............................................................................................56
Installation ... ............................................................................................. 56
Vent Valve .......................................................................................................... 57
Removal .. ................................................................................................. 57
Inspection .... ............................................................................................. 57
Service . .................................................................................................... 57
Installation ... ............................................................................................. 59
Relief/Economizer (R/E) Valve ........................................................................... 60
Removal .. ................................................................................................. 60
Installation ... ............................................................................................. 60
R/E Valve Adjustment .............................................................................. 61
Adjusting the Economizer Valve ............................................................... 62
Secondary Relief Valve ...................................................................................... 63
Removal .. ................................................................................................. 63
Installation ... ............................................................................................. 63
Warming Coil ...................................................................................................... 63
Removal .. ................................................................................................. 63
Installation ... ............................................................................................. 64
Economizer Tube Assembly ............................................................................... 64
Removal .. ................................................................................................. 64
Installation ... ............................................................................................. 65
Oxygen Outlet Block ........................................................................................... 65
Removal .. ................................................................................................. 65
Installation ... ............................................................................................. 65
Cryogenic Container ........................................................................................... 66
Removal .. ................................................................................................. 66
Installation ... ............................................................................................. 66
Purging the Container Liquid Sense Tube .......................................................... 67
iv
Contents
Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Expanded View, U-46EU .................................................................................... 69
Expanded View, U-36EU .................................................................................... 72
Expanded View, U-46SW ................................................................................... 75
Unpacking, Installation, and Repacking . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Unpacking ...........................................................................................................79
Installation ...........................................................................................................79
Repacking for Return .......................................................................................... 80
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Reservoir Components ....................................................................................... 83
Cryogenic Container ................................................................................. 83
Fill Connector/Quick Connect ................................................................... 84
Vent Valve ................................................................................................ 85
Relief/Economizer Valve .......................................................................... 86
Secondary Relief Valve ............................................................................ 87
Warming Coil ............................................................................................ 88
Oxygen Outlet with Poppet Valve ............................................................. 88
Pressure Indicator .................................................................................... 89
Contents Indicator .................................................................................... 89
Reservoir Operation ............................................................................................ 90
Filling the Reservoir .................................................................................. 90
Fill Termination ......................................................................................... 92
Standby ... ................................................................................................. 93
Gaseous Oxygen Use .............................................................................. 94
Universal Reservoir Service Manual
v
Contents
Figures
Figure 1:
Figure 2:
Figure 3:
Figure 4:
Figure 5:
Figure 6:
Figure 7:
Figure 8:
Figure 9:
Figure 10:
Figure 11:
Figure 12:
Figure 13:
Figure 14:
Figure 15:
Figure 16:
Figure 17:
Figure 18:
Figure 19:
Figure 20:
Figure 21:
Figure 22:
Figure 23:
Figure 24:
Figure 25:
Figure 26:
Figure 27:
Figure 28:
Figure 29:
Figure 30:
Figure 31:
Figure 32:
Figure 33:
Figure 34:
Figure 35:
Figure 36:
Figure 37:
Figure 38:
Figure 39:
Figure 40:
Figure 41:
vi
Liquid Oxygen Expansion Ratio .................................................... 4
Combustion Triangle ..................................................................... 6
Saturated (Boiling) Water at Sea Level .... ..................................... 7
Saturated (Boiling) Water at Higher Pressure ............................... 7
Saturated (Boiling) Water at Lower Pressure ................................ 8
Liquid Oxygen Saturation Curve . .................................................. 8
Compression Fitting ...................................................................... 9
Compression Fitting Makeup ....................................................... 10
NPT Fittings (National Pipe Tapered) ......................................... 11
Applying Teflon Tape .................................................................. 11
Vent Wrench
B-775182-00 ................................................................................ 15
Fill Connector Cartridge Installation Tools,
B-775392-00 (I), B-775393-00 (M), B-775394-00 (F) .................. 15
Reservoir Pressurizing Fixture
B-701731-00 ................................................................................ 15
Van Companion Delivery Cart ..................................................... 18
Roller Base .................................................................................. 18
Transfer Line Assembly ............................................................... 18
Universal Adapter Kit ................................................................... 19
Oxygen Supply Line .................................................................... 19
Reservoir Fill Connector Cover ... ................................................ 19
Controls, Indicators, and Connectors .......................................... 21
Serial Number Scheme (a) and Location (b) ............................... 22
Vapor Release from Depressurized Liquid Oxygen . ................... 24
Standard Transfer Line Assembly .. ............................................. 25
Reservoir Labels ......................................................................... 26
Indicator Needle “Hovering” ........................................................ 29
Securing Pressurizing Fixture to Reservoir ................................. 35
Gaseous Oxygen Connected to Pressurizing Fixture ................. 35
Leak Testing the Fill Connector ................................................... 36
Pressurizing Reservoir ... ............................................................. 37
Check Pressure ........................................................................... 37
Primary RV Test Setup ................................................................ 38
Blocking R/E Valve Vent Port ...................................................... 39
Transfer Line Configuration for Emptying
a Universal Reservoir .................................................................. 48
9-volt Battery Installation ... .......................................................... 52
Contents Indicator Pressure Sense Tube Routing ...................... 53
Removing the Retainer Ring ....................................................... 55
Removing Cartridge Assembly and Retainer Ring ...................... 55
Inserting Retainer Ring into Male Installation Sleeve .................. 56
Installing the Retainer Ring ......................................................... 56
Vent Valve Inspection .................................................................. 57
Wrench Adapter Inspection ......................................................... 57
Contents
Figure 42:
Figure 43:
Figure 44:
Figure 45:
Figure 46:
Figure 47:
Figure 48:
Figure 49:
Figure 50:
Figure 51:
Figure 52:
Figure 53:
Figure 54:
Figure 55:
Figure 56:
Figure 57:
Figure 58:
Figure 59:
Figure 60:
Figure 61:
Figure 62:
Figure 63:
Figure 64:
Figure 65:
Figure 66:
Figure 67:
Figure 68:
Figure 69:
Universal Reservoir Service Manual
Positioning the Flat On the Vent Valve Shaft .............................. 58
Installing the Wrench Adapter .. ................................................... 58
Seat the Vent Valve ..................................................................... 58
Check the Gap ............................................................................ 58
Tighten Set Screw ....................................................................... 59
Verify Vent Valve Operation ........................................................ 59
Primary Relief Valve Test Setup . ................................................ 61
Primary Relief Valve and Economizer Adjustment ...................... 62
Removing the Warming Coil ........................................................ 64
U-46EU Reservoir ....................................................................... 71
U-36EU Reservoir ....................................................................... 74
U-46SW Reservoir ...................................................................... 77
Cryogenic Container .................................................................... 83
Fill Connector/Quick Connect ...................................................... 85
Male/Female Fill Connectors Fully Engaged ............................... 85
Vent Valve ................................................................................... 85
Relief/Economizer Valve ............................................................. 87
Secondary Relief Valve ............................................................... 87
Warming Coil ............................................................................... 88
Oxygen Outlet w/Poppet Valve ... ................................................ 88
Pressure Indicator ... .................................................................... 89
Contents Indicator ....................................................................... 90
Filling the Reservoir ..................................................................... 91
Fill Termination ............................................................................ 92
Standby ....................................................................................... 93
Oxygen Flow Through Economizer Circuit .................................. 94
Oxygen Flow Through Liquid Withdrawal Circuit ........................ 95
Universal Reservoir Pressure Over 24 Hours ............................. 96
vii
Blank Page
General Information
This section provides information on the HELiOS™ Universal™ Reservoir,
including: Safety Information, Product Description, Filling Instructions, and
Operating Procedures.
Safety Information
The following paragraphs contain important safety information related to general
use of the Universal Reservoir.
Other important safety information appears throughout the manual in sections that
relate specifically to the precautionary information. Be sure to read all text
surrounding all precautionary information.
Before use, carefully read this manual and all precautionary information in
boldface type, and product specifications.
Warnings
Warnings are identified by the WARNING symbol shown above or other relevant
symbols, as shown.
Warnings alert the user to potential serious outcomes (death, injury, or adverse
events) to the patient or user.
WARNING: 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 the oxygen
supply.
WARNING: Do not smoke near this equipment. Keep cigarettes or burning
tobacco away from the area where equipment is operated.
WARNING: Keep flammable materials away from this equipment. Oils,
grease, including facial creams and petroleum jelly, ignite easily and may
burn rapidly in the presence of oxygen. Never lubricate any part of this
equipment.
Universal Reservoir Service Manual
1
General Information
WARNING: Do not touch liquid oxygen or parts that have been in contact
with liquid oxygen. Liquid oxygen is extremely cold (-297 °F / -183 °C). When
touched, liquid oxygen, or parts of the equipment that have been carrying
liquid oxygen, can freeze skin and body tissue.
WARNING: Always keep the Reservoir in an upright position.
WARNING: Keep this equipment away from electrical appliances. Use and
store the Reservoir at least five feet from electrical appliances that may cause
heat or sparks.
WARNING: Keep oxygen equipment away from open flames. Use and store
the Reservoir at least five feet away from equipment such as furnaces, water
heaters, and stoves that may contain open flames.
WARNING: Keep equipment in a well-ventilated area at all times. The
Reservoir periodically releases small amounts of oxygen gas that must be
ventilated to prevent buildup. Do not store liquid oxygen equipment in a
closet, car trunk, or other confined area. Do not place blankets, draperies, or
other fabrics over equipment.
WARNING: Never tamper with the equipment. Doing so could create a
hazardous condition and possibly cause the equipment to work improperly.
WARNING: Always keep tubing or oxygen supply line away from path of
walking to avoid potential trip or fall.
Cautions
Cautions are identified by the CAUTION symbol shown above.
Cautions alert the user to exercise care necessary for the safe and effective use of
the Universal Reservoir.
CAUTION: Although there are no risks associated with the disposal of any
components within this device, in the interests of environmental protection, it
is recommended that all faulty components that are under warranty, or used
componets, be returned to the manufacturer.
CAUTION: When replacing the 9-volt battery from the Reservoir contents
indicator (see manual section Low Battery Level), carefully dispose of the old
battery with due regard for the environment.
2
General Information
Notes
Notes are identified by the NOTE symbol shown above.
Notes are listed before or after procedural steps or information and provide
additional guidelines or information on the subject being described.
Safety Precautions
This section covers precautions and safe practices as they apply to facilities and
personnel involved in servicing medical oxygen equipment. These precautions are
divided into three main areas: cold safety, expansion safety, and fire safety. To
ensure reliability and safety, the service techniques, work area, and equipment
used in the storage, service, and handling of this system must be of the highest
standard. Refer to the HELiOS Universal Home Use Guide for additional safety
precautions regarding the use of this equipment.
Cold Safety
ARNING
WARNING
WARNING: Extreme cold hazard. Liquid oxygen is extremely cold (-297°F/183°C) and will freeze skin on contact. Never touch liquid oxygen or frosted
parts.
WARNING: Extreme cold hazard. Liquid oxygen can spill if the Reservoir is
tipped over. Keep the Reservoir upright at all times. Secure the Reservoir
when transporting to prevent accidental tip-over.
WARNING: Extreme cold hazard. Forceful discharge of liquid oxygen
possible if fill connector freezes open upon disengagement. Always dry fill
connectors with clean, dry lint free cloth before fill.
Recommended Protective Clothing
• Heavily insulated gloves (for example, cryogenic or welding gloves). Never
use gloves that are contaminated with grease or oil when working with liquid
oxygen.
• Protective face shield and goggles.
• Long sleeve shirt. Wear natural fibers such as cotton or wool. Avoid synthetic
materials such as polyester or rayon.
Universal Reservoir Service Manual
3
General Information
• Long pants. Never wear pants with cuffs. Liquid oxygen may become trapped
and cause serious burns to skin. Wear natural fibers such as cotton or wool.
Avoid synthetic materials such as polyester or rayon.
• Protective cryogenic or welding apron.
Important Facts
• Direct exposure to liquid oxygen or exposure to its vented gas or components
cooled by liquid oxygen can result in frostbite. If frostbite occurs, seek medical
attention immediately.
Expansion Safety
WARNING: Explosive hazard. Extreme high pressure can rupture container
or plumbing components. Be sure specified pressure relief devices are
present, in the proper location, and functioning properly.
Important Facts
• Liquid oxygen at atmospheric pressure expands at a ratio of approximately
860:1 (at 0 psig) when vaporizing into a gas (Figure 1). This can occur very
rapidly when exposed to the heat in the atmosphere.
• Ensure that the specified pressure relief devices are present and functioning
properly in any device that will contain liquid oxygen. This includes transfer
hose assemblies.
Figure 1: Liquid Oxygen Expansion Ratio
Fire Safety
WARNING: Concentrated oxygen. Increased risk of fire.
WARNING: Do not smoke or keep burning tobacco near this equipment.
Death or injury may occur.
4
General Information
WARNING: Keep flammable materials away from this equipment. Oils,
grease, including facial creams and petroleum jelly, asphalt, and synthetic
fibers ignite easily and burn rapidly in the presence of concentrated oxygen.
If needed, use only specified oxygen compatible lubricants as directed.
WARNING: Keep oxygen equipment away from open flames. Keep
Reservoir and Portable units at least five feet away from equipment such as
furnaces, water heaters, and stoves that may contain open flames.
WARNING: Keep oxygen equipment away from electrical appliances. Keep
Reservoir and Portable units at least five feet from electrical appliances that
may cause heat or sparks.
WARNING: 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.
Important Facts
The possibility of fire exists when the combination of a fuel, source of ignition,
and oxygen is present (Figure 2). 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 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.
Universal Reservoir Service Manual
5
General Information
Figure 2: Combustion Triangle
Liquid Oxygen Saturation Principles
Oxygen, in its normal state, is a colorless, tasteless, and odorless gas that is nonflammable, although it greatly accelerates combustion in high concentrations. It
constitutes about 21% of the Earth’s atmosphere by volume. Oxygen in higher
concentrations is medically beneficial to patients suffering from certain
respiratory diseases.
Oxygen, like most gases, will condense into a liquid with an increase in pressure
or decrease in temperature. As a liquid, oxygen is pale blue in color and is about
860 times as dense as its gaseous form. At atmospheric pressure (14.7 psia),
oxygen condenses into its liquid form at a temperature of about -297°F (-184°C).
Liquid oxygen (LOX) is an efficient form of oxygen to meet a patient’s portable,
ambulatory oxygen needs. A volume of liquid oxygen, when vaporized, yields
about 860 volumes of gaseous oxygen (Figure 1). As you can see, a relatively
small volume of liquid oxygen provides a much larger volume of gaseous oxygen
for a patient to use.
In medical liquid oxygen systems, liquid oxygen, and the gaseous oxygen
resulting from its vaporization or boiling, is stored under pressure. The elevated
pressure, typically 22 psig (152 kPa), enables oxygen to flow to the patient at a
selected, prescribed rate. To sustain this oxygen flow to the patient, the liquid
oxygen must be in a state that allows vaporization to readily occur. In other words,
the liquid oxygen must be in a state of saturation. Let’s take a look at what liquid
saturation is all about.
A saturated liquid is one that absorbs the maximum amount of heat possible at a
given pressure without vaporizing into a gas. If additional heat is added, the
saturated liquid begins to vaporize (boil) while remaining at a constant
temperature until all of the liquid is vaporized.
6
General Information
A common example of a saturated liquid is water at its boiling point of 212°F
(100°C) at sea level. The constant addition of heat to the boiling water does not
cause it to become hotter, but instead causes part of the liquid water to turn to
water vapor (Figure 3).
8JUIBUNPTQIFSJDQSFTTVSFBUTFBMFWFM
CFJOH14*" #BS XBUFSCPJMT
BU¡' ¡$
Figure 3: Saturated (Boiling) Water at Sea Level
The saturation (boiling) point of a liquid depends not only on temperature but also
on pressure. If the pressure in a container of saturated liquid increases, the
temperature required for saturation to occur will also increase. This leaves the
liquid unsaturated, that is, capable of accepting more heat before it will boil
(Figure 4).
8JUIBUNPTQIFSJDQSFTTVSFBU14*"
BOEUIFQSTTVSFDPPLFSBU14*(
14*" #BS XBUFSCPJMT
BU¡' ¡$
Figure 4: Saturated (Boiling) Water at Higher Pressure
If the pressure in a container of saturated liquid decreases, the temperature
required for saturation to occur will decrease. This leaves the liquid “super
saturated” or too warm. When this occurs, rapid boiling and vaporizing of some of
the liquid occurs. The rapid boiling and evaporation of the liquid dissipates the
excessive heat until the remaining liquid cools down to the new saturation
temperature associated with the decreased pressure (Figure 5).
Universal Reservoir Service Manual
7
General Information
8JUIBUNPTQIFSJDQSFTTVSF
BU14*" #BS XBUFSCPJMT
BU¡' ¡$
Figure 5: Saturated (Boiling) Water at Lower Pressure
Oxygen, which is normally a gas at atmospheric pressure, changes into liquid
form when it is cooled to about -297°F (-183°C) at atmospheric pressure. It is
saturated at this temperature (and pressure) which means it will remain a liquid as
long as no additional heat is added. However, the large quantity of heat present in
the atmosphere constantly enters the liquid oxygen and causes it to boil and
vaporize back into a gas. Since it is virtually impossible to keep all of the heat in
the atmosphere from entering the liquid oxygen, constant boiling and vaporization
occurs.
Now when liquid oxygen is placed in a closed container, the vaporizing gas is
trapped and begins to build pressure. As pressure increases above atmospheric
pressure, more heat is needed for boiling to occur at the higher pressure. The heat
that is constantly available from the atmosphere warms the liquid to a higher
temperature where boiling again occurs. The vaporizing gas builds pressure and
the process continues. As the pressure on liquid oxygen builds, the related
saturation temperature of the liquid increases proportionally (Figure 6).
Figure 6: Liquid Oxygen Saturation Curve
8
General Information
It is important to maintain liquid oxygen saturation (boiling) at the specified
operating pressure of the HELiOS system. As an oxygen flow demand is put on
the system, a slight decrease in pressure occurs due to oxygen withdrawal. The
saturated liquid oxygen in the system vaporizes enough gaseous oxygen to
maintain system operating pressure. This ensures proper oxygen flow to the
patient. If the liquid oxygen saturation temperature is too low, the corresponding
lower saturation pressure causes low oxygen flows to the patient.
Pressure Fittings and Connections
The HELiOS liquid oxygen system uses aluminum tubing compression fittings,
tapered pipe thread (NPT) fittings, and flexible tube barbed fittings. Proper makeup and service of these pressure fittings is essential to leak-free operation.
Compression Fitting Makeup
The compression fittings used in the HELiOS system consist of a fitting body,
tube, ferrule, and nut (Figure 7). These fittings typically connect the aluminum
tubing to other components in the system. In a properly made-up compression
fitting, sealing occurs at two points: between the ferrule and the fitting body; and
between the ferrule and the tube.
Figure 7: Compression Fitting
Perform the following steps to make up a new compression fitting:
1. Inspect the tube end. The tube end should be cut square and the outside
surface of the tube should be free of scratches or other marks at least one inch
(25 mm) back from the tube end. Lightly buff the tube end with Scotch-Brite
or fine emery paper to remove any surface marks.
2. Insert the tube and make sure it is aligned squarely in the fitting body.
3. Make sure the tube end is bottomed against the tube stop in the fitting body.
This is necessary to prevent movement of the tube while the nut forces the
ferrule to grip the tube and create a seal.
4. Never permit the fitting body to rotate during make-up; use two wrenches.
Always hold the fitting body with a wrench while tightening the tube nut.
Universal Reservoir Service Manual
9
General Information
5. Always turn the tube nut the prescribed amount. With the tube against the
tube stop in the fitting body, tighten the tube nut finger-tight (Figure 8). For
¼-in. diameter tubing, tighten the nut an additional 1¼ turns from finger-tight
with a wrench. For 1/8-in. diameter tubing, tighten the nut an additional ¾
turn from finger-tight with a wrench.
Figure 8: Compression Fitting Makeup
Compression Fitting Remake
When disassembling a compression fitting, mark the tube nut and the fitting body
before disassembly. To remake the connection, tighten the tube nut until the
marks realign. A slight torque increase indicates the ferrule is being re-sprung into
sealing position. After several remakes, it may become necessary to advance the
tube nut slightly past the original position. This advance need only be 15° to 20°
(¼ to 1/3 of a hex flat). In situations where the existing tube with seated ferrule is
to be used with a replacement fitting body, tighten the tube nut until a slight
torque increase indicates the ferrule is being resprung into sealing position.
Advance the nut an additional 15° to 20°.
Compression Fitting Troubleshooting
Most leaks in compression fittings are the result of improper connections.
Typically the tube is either not aligned squarely in the fitting body before
connection or the tube is not secured against the stop during connection. In
addition, overtightening may also result in a cracked fitting body that will leak.
To check for leaks, pressurize the system and use an oxygen-compatible leak
detector (such as SNOOP) on the fitting. If bubbles form at the back of the nut
between the nut and the tube, you probably did not get a seal between the ferrule
and the tube; misalignment may be the cause. However, check the tube itself for a
scratch or seam running along the tube, allowing a leak to occur.
If the leak detector forms bubbles at the front of the nut, between it and the fitting
body, then the leak is probably between the ferrule and the fitting’s tapered seat.
Check this area for imbedded dirt or cracks.
10
General Information
Tapered Pipe Thread (NPT) Makeup
Some components used in the HELiOS system have tapered pipe (NPT) threads
(Figure 9). NPT threads create leak-tight connections provided a thread sealant
(such as Teflon tape) is used on the threads.
Figure 9: NPT Fittings (National Pipe Tapered)
Perform the following steps when making up a NPT fitting:
1. Remove old thread sealant if present. Use a wire brush to remove sealant or
dirt from male and female threads of NPT fittings. Make sure contaminants do
not drop into the fittings during the cleaning process.
2. Apply thread sealant to the male threads. Apply two to three layers of Teflon
tape to the male threads starting two threads back from the end (Figure 10).
Wrap the Teflon tape clockwise (as viewed from thread end of fitting) to
prevent unraveling when installing the fitting.
Figure 10: Applying Teflon Tape
1. Assemble the fittings and tighten until snug. Since NPT fittings have tapered
threads, torque requirements increase as the fittings are tightened. Tighten
NPT fittings until you achieve a good seal (usually a minimum of three turns).
Do not overtighten NPT fittings. Overtightening may result in cracked
fittings.
Note: Some NPT connections require alignment of one of the fittings in a certain
orientation. Do not back out the fitting if you are unable to achieve the
proper orientation as you tighten the fitting. This will typically result in a
leak. Disassemble and remake the fittings instead.
Universal Reservoir Service Manual
11
General Information
Tapered Pipe Thread Troubleshooting
Leaks at NPT fittings are usually the result of improper application of thread
sealant or loosening of the fittings. To check for leaks, pressurize the system and
use an oxygen compatible leak detector (such as SNOOP) on the fitting threads. If
bubbles appear, disassemble the fittings and remake (see Tapered Pipe Thread
Makeup on the preceding page).
Flexible Tube Barbed Fitting Makeup
Flexible tube barbed fittings are used in the HELiOS system to create leak-tight
pressure connections where flexible tubes connect to components. The outside
diameter of the barb is slightly larger than the inside diameter of the flexible
tubing. This creates an interference fit sufficient to seal and secure the connection.
Perform the following steps to install a flexible tube on a barbed fitting:
1. Inspect the tube end. The tube end should be cut square and should be free of
cuts or tears. If there is an impression of the barb in the tube, cut the end of the
tube off (if the tube length is sufficient) or replace the tube.
2. Where required, install a brass collar on the tube so that the large end of the
collar is toward the barbed fitting.
3. Push the tube squarely onto the barb as far as possible.
4. Push the brass collar (if present) onto the tube end connected to the barbed
fitting.
Flexible Tube Removal from Barbed Fitting
Perform the following steps to remove the flexible tube from a barbed fitting:
1. Use a small flat-blade screwdriver to carefully back the brass collar (when
used) off of the barbed fitting.
2. Work the screwdriver between the end of the tube and the fitting body.
3. Simultaneously pull on the tube and pry the end of the tube back from the
barb. Use care to prevent damage to the barbed fittings.
12
General Information
Recommended Tools, Test Equipment, and Service Materials
Hand tools, test equipment, and materials used to properly service the HELiOS
system and maintain it in operable condition are listed in Table 1. If hand tools,
test equipment, and materials other than those specified in Table 1 are used, their
functional characteristics such as quality and accuracy must be equal to, or better
than, those specified in the table. Tools, test equipment, and materials should be
cleaned for oxygen service.
Table 1: Recommended Tools, Test Equipment & Service Materials
Tools
Hex Key (Allen) Wrench – 3/32 in., 7/64
in., 5/32 in.
Local Source
Open End Wrenches – ¼ in., ½ in., 9/16
in., 5/8 in., ¾ in., 7/8 in., 1 in.
Local Source
Adjustable Wrench – 10 in.
Local Source
Pliers – 10 in. arc-joint, needlenose
Local Source
Screwdrivers – medium flat blade, small
flat blade,medium Phillips blade, Torx T
10
Local Source
Side Cutters
Local Source
Vent Wrench (Figure 11)
CAIRE Inc. No. B-775182-00
CAIRE Inc. Fill Connector Cartridge
Installation Tools (Figure 12)
• Inner Plunger
• Male Connector Sleeve
• Female Connector Sleeve
CAIRE Inc. No. B-775392-00
CAIRE Inc. No. B-775393-00
CAIRE Inc. No. B-775394-00
Micro Bar Clamp
American Tool 6-in.
Quick-Grip #53006
Clamp or Hemostat for 1/16 in. Flexible
Tubing
Local Source
Dental Pick
Local Source
Universal Reservoir Service Manual
13
General Information
Test Equipment
Reservoir Pressurizing Fixture –
0-100 psig/0-690 kPa (Figure 14)
Adjustable 0-100 psig (0-690 kPa)
gaseous oxygen source
CAIRE Inc. No. B-701731-00
Local Source
Oxygen Compatible Leak Detector
(Snoop)
CAIRE Inc. No. B-775272-00
Calibrated Weight Scale – 0-200 lbs
(0-91 kg)with .02 lb (9.1 g) maximum
graduation, accuracy, and repeatability
A&D Engineering Model FW
100-KA1 (or equivalent)
Calibrated Test Flowmeters
• 0-3 L/min oxygen, 1% full scale
• 0-40 L/min oxygen, 1% full scale
Brooks Instrument Division,
Emerson Electric Co.,
Hatfield, PA
0-10 L/min, 22 psig external flow control
valve
CAIRE Inc. No. B-701655-00
Service Materials
14
Oxygen DISS Wye Outlet Adapter w/
Demand Check Valve Outlets
Bay Corp., Westlake, OH-Part
No. YO-124DV; Precision
Medical, Inc., Northhampton, PA
Part No. 7211
Tie Wrap, 4-in./10 cm
CAIRE Inc. No. B-775091-00
Lubricant - Krytox 240 AC Fluorinated
Grease (DuPont)
CAIRE Inc. No. B-775239-00
Isopropyl Alcohol
Local Source
Thread Sealant – 3/16 in. Teflon Tape
Local Source
Cloth – Lint Free
Local Source
General Information
Figure 11: Vent Wrench
B-775182-00
Figure 12: Fill Connector Cartridge Installation Tools,
B-775392-00 (I), B-775393-00 (M), B-775394-00 (F)
Figure 13: Reservoir Pressurizing Fixture
B-701731-00
Universal Reservoir Service Manual
15
General Information
Test Equipment Calibration
Periodically calibrate test equipment (pressure gauges, weight scales, flowmeters,
etc.) to ensure the reliable operation of the HELiOS liquid oxygen system. 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.
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 HELiOS equipment 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 directory under Calibration for the location of
an accredited calibration lab.
Refer to ISO 10012-1 (Quality Assurance Requirements for Measuring
Equipment) for additional information.
16
General Information
Accessories
Accessories for the HELiOS Reservoir are listed in Table 2.
Table 2: HELiOS Accessories
Description
Part Number
Location
1.Van Companion Assembly (Delivery Cart)
B-775462-00
Figure 15
•
•
•
•
B-775477-00
B-775478-00
B-775476-00
B-776169-00
Figure 15, #1
Figure 15, #2
Figure 15, #3
Figure 15, #4
2.Rollerbase Assembly
B-701537-00
Figure 16
• Caster (5 Required)
B-701536-00
Figure 16, #1
3.Transfer Line Assembly (6 ft./1.8 m)
B-775288-00
Figure 17
Transfer Line Assembly (10 ft./3 m)
• Transfer Hose (6 ft./1.8 m)
• Transfer Hose (10 ft./3 m)
• Source Adapter Assembly
• Relief Valve (150 psi/1035 kPa)
• Source Adapter
• Fill Adapter Assembly
• Fill Adapter
• Fill Adapter Seal
• Female Fill Connector
• Union, 5/8-in. Flare (2/Transfer Line)
B-775289-00
B-775280-00
B-775281-00
B-775279-00
B-775273-00
B-775313-00
B-775278-00
B-775312-00
B-775262-00
B-775264-00
B-775277-00
Figure 17
Figure 17, #1
Figure 17, #1
Figure 17, #2
Figure 17, #3
Figure 17, #4
Figure 17, #5
Figure 17, #6
Figure 17, #7
Figure 17, #8
Figure 17, #9
4.Universal Adapter Kit
B-775461-00
Figure 18
• Male Flare Adapter
• Female Flare Adapter
• PB Fill Connector/Tee Assembly
B-775342-00
B-775418-00
B-775276-00
Figure 18, #1
Figure 18, #2
Figure 18, #3
5.Shipping Carton, U-36EU
B-701690-00
Not Shown
• Corner Post (4 Required)
B-702011-00
Not Shown
6.Shipping Carton, U-46EU, U-46SW
B-701691-00
Not Shown
• Corner Post (4 Required)
B-702011-00
Not Shown
7.Oxygen Supply Tube Assy. (50 ft./15.2 m)
B-701656-00
Figure 19
8.Oxygen Supply Extension Tube
(50 ft./15.2 m)
B-701432-00
Not Shown
9.Reservoir Fill Connector Cover
B-777095-00
Figure 20
Strap and Buckle Assembly
Faspin
Pads (2 Required)
Wear Strips (2 Required)
Not Shown
10.Universal Reservior Home Use Guide
•
•
•
•
English, Greek, Portuguese, Spanish
Dutch, French, German, Italian
Danish, Finnish, Norwegian, Swedish
Czech, Hungarian, Polish, Russian, Turkish
11.Valve, Flow Control, 0.5-10 L/min, Universal Reservoir
Universal Reservoir Service Manual
10005502
10005505
10005506
10005507
10000554
Not Shown
17
General Information
3
4
2
1
Figure 14: Van Companion Delivery Cart
1
Figure 15: Roller Base
2
Figure 16: Transfer Line Assembly
18
General Information
Note: Install the universal adapter kit on the transfer line assembly to allow the
filling of both CAIRE Inc. and liquid oxygen units with side-fill
connectors with the same transfer line. (Installs between the side-fill
adapter and the transfer hose.)
Figure 17: Universal Adapter Kit
Figure 18: Oxygen Supply Line
Figure 19: Reservoir Fill Connector Cover
Universal Reservoir Service Manual
19
General Information
Product Description
The Universal Reservoir is designed to store liquid oxygen. The Universal
Reservoir is available in three models: the U-46EU and U-46SW hold 110 pounds
(49.9 kg) of liquid oxygen. And, the U-36EU holds 85 pounds (38.56 kg) of liquid
oxygen.
The Universal Reservoir can be used to fill both HELiOS Portable models H300
and H850, and Companion Portable models C1000, C1000 Transport, C550 and
C500.
The Reservoir uses the CAIRE Inc. top fill connector and is compatible with
Puritan Bennett Companion filling equipment (vent wrench, transfer hose
assembly, source tank). The Reservoir requires a minimum 22 psig (152 kPa)
saturated liquid oxygen to operate and may be filled using standard or fast fill
techniques. An electronic contents indicator uses reliable, differential pressure
based level sensing technology to provide accurate and easy to read liquid oxygen
contents indication. The 9-volt battery powered contents indicator incorporates
high visibility LEDs for indicating liquid oxygen contents. LEDs also warn of low
battery and low contents conditions.
The Universal Reservoir oxygen outlet pressure is maintained at 22 psig (152 kPa)
when a flow is delivered but climbs to 26 psig (179 kPa) when in standby mode. A
manufacturer-specified flow control valve (FCV), attached to the Reservoir
oxygen outlet connector provides gaseous oxygen at up to 10 L/min continuous
flow. A flexible oxygen supply line attached to the FCV which is set at 10 L/min,
provides gaseous oxygen to power the H300 and the H850 (in demand mode
only).
To fill a HELiOS or Companion portable with liquid oxygen, the patient engages
the quick connect couplings on the portable and Reservoir. The patient then opens
the portable vent valve to begin filling and closes the vent valve a short time later
to terminate the fill. Depressing a release button disengages the portable from the
Reservoir.
20
General Information
Controls, Indicators, and Connectors
The controls, indicators, and connectors that are used on the Universal Reservoir
are shown in Figure 20. Their functions are described below.
Figure 20: Controls, Indicators, and Connectors
(1)
Liquid Oxygen Fill
Connector
The Reservoir uses the top fill CAIRE Inc. fill
connector to transfer liquid oxygen to and from the unit. It
is the male half of a cryogenic quick connect coupling
system. A spring loaded poppet automatically opens when
the connector is engaged and automatically closes when
the connector is disengaged.
(2)
Release Button
Pressing the release button on the Reservoir activates the
fill connector release lever mechanism. This disengages
either a portable oxygen unit or a liquid oxygen transfer
line from the Reservoir.
(3)
Pressure Gauge
The pressure gauge displays the status of the pressure
inside the Reservoir. A filling technician monitors the
pressure indicator to help maintain 22-24 psig (152-166
kPa) liquid oxygen saturation pressure in the Reservoir
during a fill. Under normal operating conditions, the
indicator pointer typically indicates a pressure between 22
psig (152 kPa) and 26 psig (179 kPa).
(4)
Moisture Container
The moisture container is part of the Reservoir shroud
assembly that collects condensed water run-off from the
warming coils. The lower shroud channels the water runoff into the moisture container. The moisture container
slides easily out of the lower shroud assembly to be
emptied.
(5)
External Flow
Control Valve,
Manufacturerspecified
The manufacturer-specified external flow control valve
(FCV) attached to the Reservoir oxygen outlet connector
provides gaseous oxygen at up to 10 L/min continuous
flow. A flexible oxygen line attached to the FCV set at 10
L/min flow rate, provides gaseous oxygen to the H300 and
H850 Portables (demand mode only for the H850).
Universal Reservoir Service Manual
21
General Information
(6)
Oxygen Outlet
Connector
The Reservoir oxygen outlet connector provides a source
of 22 psig (152 kPa) oxygen. A spring activated poppet in
the oxygen outlet connector prevents oxygen flow when
not using the manufacturer-specified external flow control
valve (FCV). Only when the manufacturer-specified
external FCV is attached to the outlet will the poppet open
to allow oxygen flow. The HELiOS Portable oxygen
supply line or a single-lumen cannula must be connected
to the external FCV outlet fitting in order to allow the
patient to breathe from the Reservoir. The external FCV
must be set to 10 L/min when tethered to a HELiOS
Protable.
(7)
Contents Indicator
The contents indicator displays the amount of liquid
oxygen in the Reservoir. Depressing the button on the
contents indicator turns on from one to eight green light
emitting diodes (LEDs) that represent the empty to full
range of the Reservoir. A yellow “low contents” LED
comes on when about 8.5 lbs. (3.9 kg) or less of liquid
oxygen remain. A 9-volt battery powers the contents
indicator. A low battery yellow LED comes on when
battery voltage drops below a predetermined level.
(8)
Vent Valve
The vent valve is a quarter-turn ball valve that is
accessible with a separate vent wrench through a hole in
the Reservoir top cover. The filling technician opens the
vent valve to vent the inner container during the Reservoir
unit filling process. The technician closes the valve upon
terminating the filling process.
Serial Number Identification
Each Universal Reservoir is identified by a unique eight-digit serial number. The
number contains the year and calendar day of manufacture, as well as the unit’s
production number for that day (Figure 21). The Universal Reservoir serial
number is etched into a Reservoir handle bracket.
SN
{
{
{
05 300 032
Designates
Year
Designates
Sequential Day of
Year (Ja n 1 = 001,
Dec 31 = 365)
(a)
Designates
Number of Specific
Unit Produced
that day
Handle
(b)
Figure 21: Serial Number Scheme (a) and Location (b)
22
General Information
Filling Instructions
The Reservoir must be filled with liquid oxygen saturated at 22-24 psig (152-166
kPa) to ensure proper operation. The information in this section will help you fill
the Reservoir with liquid oxygen in a proper, safe, and efficient manner.
Oxygen Source Requirements
The HELiOS Reservoir must be filled with only Medical Grade Oxygen. The
liquid oxygen used for filling the Reservoir must have no moisture content. Liquid
oxygen entering the Reservoir during the filling operation must be saturated at 2224 psig (152-166 kPa) for proper operation to occur. In order to achieve 22-24
psig (152-166 kPa) saturation in the Reservoir during the fill, the saturation
pressure of the liquid oxygen filling source must be carefully considered.
The filling source saturation pressure requirement mainly depends on the type of
filling technique used. The Standard Fill technique requires a liquid oxygen
source saturation pressure of 40-50 psig (276-345 kPa). The Fast Fill filling
technique requires a liquid oxygen source saturation pressure of 24-28 psig (166193 kPa). Following is a brief description of each filling technique and
corresponding liquid oxygen source requirement.
Both Reservoir filling techniques use pressure in the source tank as the force to
drive the liquid oxygen into the Reservoir. In order to transfer liquid oxygen from
the source tank to the Reservoir, a pressure differential must exist so that the
source tank pressure remains greater than the Reservoir pressure during the fill.
The Standard Fill technique requires the source saturation pressure to be greater
than the saturation pressure needed in the Reservoir. With the filling source
saturated at 40-50 psig (276-345 kPa), the boiling action of the liquid oxygen
maintains the pressure differential as the Reservoir pressure is lowered by opening
its vent valve. The filling technician adjusts the opening of the Reservoir vent
valve and/or source tank liquid valve to maintain 22-24 psig (152-166 kPa) on the
Reservoir pressure gauge. However, liquid oxygen saturated at 40-50 psig (276345 kPa) is at a higher temperature than liquid oxygen saturated at 24 psig (166
kPa).
During the fill, liquid oxygen saturated at 40-50 psig (276-345 kPa) in the source
tank boils rapidly to release heat and cool down to the lower temperature required
for 22-24 psig (152-166 kPa) saturation in the Reservoir. The rapid boiling
(desaturation) of the liquid oxygen creates a large volume of gaseous oxygen that
is vented out the Reservoir vent valve during the fill. With the source saturated at
50 psig (345 kPa), a volume of liquid oxygen equal to about 14% of the liquid
oxygen transferred into the Reservoir boils off into gas and is expelled through the
vent valve as a result of the depressurization (Figure 22). Consequently, longer fill
times and greater filling losses occur with the Standard Fill technique.
Universal Reservoir Service Manual
23
General Information
Percent - %
20
15
Liquid Oxygen Vaporized
During Fill as Percent of
Liquid Oxygen Transferred
Into Reservoir
10
14%
5
0
10
20
30
40
50
60
70
80
(69) (138) (207) (276) (345) (414) (483) (552)
Saturation Pressure in Source Tank - PSIG (kPa)
Figure 22: Vapor Release from Depressurized Liquid Oxygen
The Fast Fill technique requires the liquid oxygen saturation pressure in the
source tank to be about 24-28 psig (166-193 kPa), close to the saturation pressure
needed in the Reservoir. With the source saturated at 24-28 psig (166-193 kPa),
rapid boiling (desaturation) of the liquid oxygen is minimal as it moves from the
source tank into the Reservoir during a fill.
However, in order to drive the liquid oxygen from the source tank to the
Reservoir, a pressure differential must exist so that the source tank pressure
remains greater than the Reservoir pressure during the fill. Consequently, a source
tank equipped with a pressure building circuit must be used with the Fast Fill
technique.
By turning on the pressure building system in the source tank, a small amount of
the liquid oxygen in the tank vaporizes in a heat exchanger and builds pressure
above the surface of the liquid oxygen. This provides the head pressure (40-50
psig/276-345 kPa) needed to drive the liquid oxygen saturated at 24-28 psig (166193 kPa) into the Reservoir. While monitoring the internal pressure gauge, the
filling technician adjusts the opening of the Reservoir vent valve and/or source
tank liquid valve to maintain 22-24 psig (152-166 kPa) saturation in the Reservoir
during the fill. Faster fill times and less filling losses are the end results. The Fast
Fill technique requires a source tank that meets the following conditions:
1. The source tank must be filled with liquid oxygen saturated at 24-28 psig
(166-193 kPa).
2. The source tank must be equipped with a 24-28 psig (166-193 kPa) road relief
valve, a 40-50 psig (276-345 kPa) pressure building relief valve, and a means
to switch between the two relief valves. The 24-28 psig (166-193 kPa) relief
valve maintains saturation pressure between fills. The 40-50 psig (276-345
kPa) relief valve enables pressure building to occur during a fill.
3. The source tank must have a pressure building system capable of maintaining
40-50 psig (276-345 kPa) head pressure during each fill.
Since a variety of source tank configurations and filling pressures are possible,
contact CAIRE Inc. Technical Support for advice when considering a liquid
oxygen source and filling technique to best meet your needs.
24
General Information
Transfer Line
The standard CAIRE Inc. transfer line assembly (Figure 23) is used to transfer
liquid oxygen from the source tank to the Reservoir. The 5/8-in. flared connection
on the transfer line source adapter connects to a mating fitting on the source tank
liquid withdrawal valve. See Accessories section for individual component
descriptions.
WARNING: Explosive hazard. Extreme high pressure can rupture a
transfer line. Make sure the specified pressure relief valve is present, in the
proper location, and functioning properly.
Source
Adapter
150 PSI (1035 kPa)
Relief Valve
Puritan Bennett
Fill Adapter
Transfer Line
Lip Seal
Transfer Hose
Figure 23: Standard Transfer Line Assembly
Pre-Fill Inspection
Perform the following procedure to visually inspect the Reservoir and determine
its operational status before filling. Correct observed problems before proceeding
to fill the Reservoir.
1. Ask the patient (where applicable) if there are any questions or concerns
regarding the equipment since your last visit.
2. Visually inspect the Reservoir unit for overall product integrity (for example,
cracked or damaged components).
3. Verify that all labels are present and legible on the unit (Figure 24).
4. Verify that no frost or heavy condensation is present on the container below
the shroud and that there is no excessive venting from the relief valve. (Some
venting from the relief valve is normal.)
5. Verify that the liquid oxygen contents level is consistent with the delivery
schedule and expected patient usage.
6. Verify that the fill connector is not worn, leaking, or damaged.
7. Verify that the vent valve stops are not bent or broken.
Universal Reservoir Service Manual
25
General Information
8. Verify that the contents indicator is operational and at least one green LED
lights when the button is depressed. The yellow low contents LED may light
if the Reservoir is low or empty. Replace the 9-volt battery if the yellow low
battery LED is on.
9. Verify that the moisture container is in place and empty.
10. Verify that the transfer line lip seal, located on the inside of the female
connector, is not worn, broken or missing.
11. If the Reservoir contains liquid oxygen, verify that the pressure displayed on
the Reservoir’s pressure gauge is 20-28 psi (138-193kPa).
12. If the Reservoir is being returned to service after storage, verify that the
operating pressure range is 20.5-23.5 psig (141-162 kPa). (See the
Economizer Test under the Performance Verification section of this manual.)
Figure 24: Reservoir Labels
26
General Information
Filling Procedure
Perform the following procedure to fill a HELiOS Reservoir with liquid oxygen.
WARNING: Fire hazard. Liquid oxygen spilled on asphalt or any other
combustible surface will increase the possibility of fire if an ignition source is
present. Always fill the unit on a non-combustible surface, such as concrete
or a steel drip pan.
WARNING: Explosive hazard. Extreme high pressure can rupture a
transfer line. Make sure the specified pressure relief valve is present, in the
proper location, and functioning properly on the transfer line assembly.
WARNING: Fire hazard. Liquid oxygen spillage will occur if the Reservoir is
tipped over. Before transporting, secure Reservoir units containing liquid
oxygen in an upright position.
WARNING: Fire hazard. Oxygen can accumulate in a delivery vehicle.
Exhaust vent gases to outside of vehicle. (See CGA Safety Bulletin SB-9.)
1. Wear the proper protective clothing (see Safety Precautions).
2. Verify that the liquid oxygen saturation pressure in the source tank is 40-50
psig (276-345 kPa) if using the Standard Fill technique. Verify that the liquid
oxygen saturation pressure in the source tank is 24-28 psig (166-193 kPa) if
using the Fast Fill technique.
Note: If you experience difficulty obtaining properly saturated oxygen, consult
the Technical Service Department for alternatives.
3. Attach the 5/8-in. female end of the transfer line source adapter to the liquid
withdrawal valve of the source tank. Position the source adapter relief valve
straight up.
4. If the Reservoir contains some liquid oxygen, verify that the Reservoir’s
pressure gauge reads 20-28 psig (138-193kPa). A pressure reading outside of
this range may indicate a problem. If the unit is empty, continue with step 5
without verifying the pressure at this point.
5. Remove the fill connector cover from the fill connector, if present. (Available
as an option.)
6. Check the fill connectors on both the Reservoir unit and the fill adapter to
ensure that they are clean and dry. Wipe the connectors with a clean, lint-free
cloth or blow-dry with gaseous oxygen or nitrogen as needed.
7. Use the vent wrench to open the vent valve on the Reservoir unit by rotating
the wrench a quarter-turn counterclockwise.
Universal Reservoir Service Manual
27
General Information
Note: At this point you may hear a venting noise if the Reservoir unit is
pressurized.
8. Engage the transfer line to the fill connector on the Reservoir unit by aligning
the fill connector on the transfer line directly over the fill connector on the
Reservoir. Apply about 20 lbs (89 N) of downward force.
9. Maintain a downward force on the transfer line fill adapter while slowly
opening the liquid valve on the source tank. At this point a vigorous audible
venting noise will confirm that the filling process has started. Adjust the
source tank liquid valve as needed to keep the pointer on the pressure gauge
at 22-24 psig (152-166 kPa).
Note: It may be necessary to open the source tank liquid valve completely and
throttle the Reservoir vent valve to maintain the proper pressure during the
fill.
10. Close and reopen the vent valve on the Reservoir after 45 to 60 seconds have
passed. This will minimize the possibility of the vent valve freezing in the
open position.
Note: As the level of liquid oxygen nears the top of the Reservoir inner container,
the sound and appearance of vapors escaping through the vent valve will
change. The vapor will become denser, and as liquid oxygen reaches the
vent valve, a discharge of liquid oxygen will be visible and audible.
WARNING: Extreme cold hazard. Liquid oxygen discharge from the fill
connector can occur. When disconnecting the transfer line, never stand
directly over the Reservoir fill connector. If the Reservoir fill connector stays
open and minor liquid oxygen discharge occurs, carefully re-engage and
disengage the transfer line to help dislodge any ice or other obstruction. If
major liquid oxygen discharge (steady stream) occurs, open the vent valve (if
safely possible) to vent pressure and stop the release of liquid oxygen. Open
windows and doors to ventilate room and do not walk on areas exposed to
liquid oxygen for 60 minutes after frost disappears.
11. When you observe the first steady discharge (greater than 1 second) of liquid
oxygen from the vent valve, disconnect the transfer line from the Reservoir
by depressing the portable release button and lifting the fill adapter straight
up. Allow the Reservoir to vent for a few seconds and then close the vent
valve by rotating the vent wrench a quarter-turn clockwise. If the Reservoir
pressure begins to climb past 24 psig (166 kPa), open the vent valve for a few
more seconds to bring the pressure back down to 24 psig (166 kPa).
CAUTION: If the vent valve freezes in the open position, terminate the fill by
disconnecting the transfer line and then allow the vent valve to warm until it
closes easily. If the vent valve remains open for a period of time, the liquid
oxygen in the unit will desaturate to a pressure lower than required. If this
occurs, refer to Checking Saturation Pressure.
12. Replace the fill connector cover, if present, on the Reservoir unit. Close the
source tank liquid valve when the frost melts from the transfer line assembly.
28
General Information
WARNING: Extreme cold hazard. Liquid oxygen discharge from the
transfer line relief valve can occur. Closing the source tank liquid valve
before the frost on the transfer line melts may trap liquid oxygen in the
transfer line. This may cause the relief valve to open forcefully. Never place
hands, arms, or face directly over the relief valve.
Post-Fill Inspection
Perform the following procedure to inspect the Reservoir and determine its
operational status after filling it with liquid oxygen. Correct observed problems
before placing the unit in service.
1. Verify that the Reservoir fill connector poppet is closed and not leaking.
2. Verify that the vent valve is completely closed and not leaking.
3. Verify that the Reservoir pressure gauge reads at least 22 psig (152 kPa)
within five minutes after terminating the fill.
4. Verify that there is no frost or heavy condensation on the container below the
shroud.
5. Verify that all green LEDs light when the contents indicator button is
depressed.
Checking Saturation Pressure
Perform the following procedure as needed to determine the saturation pressure
of the liquid oxygen in the Reservoir.
1. Note the pressure indicated on the Reservoir pressure gauge.
2. Momentarily open the vent valve on the Reservoir and observe the pressure
gauge pointer as it drops.
3. Note the pressure value where the gauge pointer hovers (Figure 25) and then
close the vent valve. This is the approximate saturation pressure of the
Reservoir. Saturation pressure readings between 20 and 28 psig (138 and 193
kPa) are in the acceptable pressure range of the unit.
Figure 25: Indicator Needle “Hovering”
Universal Reservoir Service Manual
29
General Information
Resaturating Liquid Oxygen
If the Reservoir looses its saturation pressure and you correct the cause of this
condition without emptying the liquid oxygen contents, saturation pressure can be
restored by simply allowing the unit to stand in normal room conditions. The
entire volume of liquid will usually regain proper saturation within several days.
If, however, this is not a reasonable option, perform the following procedure:
1. Attach the source adapter of the transfer line assembly to either the gas
withdrawal valve or vent valve of the source tank.
2. Connect the transfer line fill adapter to the Reservoir fill connector and
depress to engage the fill connectors.
3. Slowly open the vent valve or gas withdraw valve on the source tank and
monitor the Reservoir pressure gauge. Open the source tank valve just enough
to see a slow, steady rise in the pressure gauge pointer. Be sure to leave the
Reservoir vent valve closed.
4. Observe the pressure gauge. When the pressure gauge pointer reaches 24 psig
(166 kPa), close the source tank valve.
5. Recheck the saturation pressure. Repeat the resaturation procedure, if
necessary, until the liquid oxygen is saturated at 24 psig (166kPa). Be sure to
reconnect the transfer line to the source tank liquid valve after completing this
procedure.
Operating Procedures
The patient typically uses the Reservoir in two different ways.
1. The Reservoir provides the patient with a liquid oxygen filling source for a
portable unit.
2. The Reservoir provides gaseous oxygen for the patient to breathe when at
home.
Refer to the Universal Reservoir Home Use Guide for information on how to use
the Reservoir with your particular Portable model.
30
Maintenance
The Pre-Fill Inspection and Post-Fill Inspection conducted as part of the Reservoir
filling procedure provide routine assessment of the functional status of the
Reservoir. Functional problems observed during these inspections must be
corrected before placing the unit in service.
Use the information in Table 3 as a guide to clean, inspect, and test the Reservoir
when functional problems are observed or as needed.
Note: The following cleaning and disinfecting solutions are acceptable for use
with the HELiOS Reservoir:
Cleaning
• Sporicidin Disinfectant Solution
• Mild dish washing detergent/warm water solution
Disinfecting
• Sporicidin Disinfectant Solution
• Household Bleach (1:10 dilution with water, freshly made within 24
hours)
Table 3: Reservoir Maintenance Guide
Item
Cleaning
Action
• Remove the upper shroud and clean the interior and exterior
with a mild detergent and water. Wipe dry with a towel. Use
cotton swabs in tight places. Use Scotch-Brite pad lightly with
detergent to remove scuff marks.
• Clean the contents indicator with a towel moistened with
detergent and water. Wipe dry.
• Clean the Reservoir plumbing and lower shroud with detergent and water. Dry with a towel and oil-free compressed gas.
Note: Make sure that the fill connector and vent valve
shaft are thoroughly dry before proceeding.
• Remove the moisture container and thoroughly clean and dry
it. Verify that the condensate drain hole in the lower shroud is
open.
• Clean the stainless steel container with oil-free cleaner and
Scotch-Brite abrasive pad to remove scuff marks.
Universal Reservoir Service Manual
31
Maintenance
Table 3: Reservoir Maintenance Guide
Item
32
Action
Inspection
• Inspect the upper and lower shrouds for cracks, warpage, and
discoloration.
• Inspect the umbrella seal for cracks.
• Verify that the warning labels are present and legible on the
upper shroud.
• Verify that the Portable release mechanism moves freely and
is not worn. Verify that the release button is secure on the
lever and is not cracked.
• Verify that the fill connector is not worn or damaged and that
the poppet is not broken.
• Verify that the vent valve works properly and that the valve
stops are not bent or broken.
• Verify that the yellow “low contents” LED lights when the
contents indicator button is depressed (empty unit). Replace
the 9-volt battery if the low battery LED lights.
• Verify that the aluminum tubing is not bent or kinked and that
a uniform air gap exists between each coil.
Testing
• Perform Leak Test .
• Perform Gaseous Oxygen Functional Tests.
• Perform Liquid Oxygen Functional Tests.
P e r f o r m a n c e Ve r i f i c a t i o n
This section provides testing information to verify Reservoir performance for any
of the following reasons:
• To determine the cause of operational failure.
• To check the unit’s overall system operation after the repair or replacement
of a component.
• To verify that the unit operates within specifications as a function of
routine maintenance.
Note: Remove the Reservoir upper shroud to conduct the performance
verification tests.
Equipment Required
The following equipment is required to complete the performance verification
tests in this section:
1. Medium flat-blade screwdriver
2. Vent valve wrench (P/N B-775182-00).
3. Source of liquid oxygen saturated at 40 to 50 psig (276 to 311 kPa).
4. Pressurizing fixture (P/N B-701731-00).
5. Adjustable 0 to 100 psig (0 to 690 kPa) gaseous oxygen source.
6. Calibrated 0 to 200 lb. (0 to 91 kg) weight scale.
7. Liquid leak detector – SNOOP (P/N B-775272-00).
8. Micro bar clamp (American Tool 6 in. Quick-Grip).
9. 0-100 psig test pressure gauge w/ tubing adapter (P/N B-701732-00).
10. Test flowmeter, 0-40 L/min (optional).
11. 0-10 L/min, 22 psig external flow control valve (P/N 10000554).
Note: It is important to use a calibration schedule for test equipment used for
Reservoir performance testing. Follow recommendations in Test Equipment
Calibration section to ensure accurate test results.
Note: Do not use pressure gauges or flowmeters that have been dropped or
mishandled. They must be calibrated before placing them back into service.
Universal Reservoir Service Manual
33
Performance Verification
Leak Tests
Liquid oxygen leakage from the Reservoir in any amount is unacceptable and
calls for the immediate removal from service of any such leaking Reservoir.
Minor gas leaks in connections and fittings will not affect system operation
provided they do not exceed the Normal Evaporation Rate (NER) of the
Reservoir. Either of the following leak test procedures will determine the presence
of external leaks. Use the Liquid Leak Detector Test to determine the presence and
location of any substantial leaks. Use the Pressure Hold Test to determine if the
total system leak rate is acceptable.
Liquid Leak Detector Test
The liquid leak detector test may be performed on Reservoirs that contain
pressurized liquid or gaseous oxygen.
1. Attach the pressurized fixture (Figure 13) to the fill connector on the Reservoir and secure it with the attached strap (Figure 26). If the Reservoir contains
liquid oxygen, verify that it is pressurized between 20.5 and 28 psig (141 and
193 kPa). If the pressure is out of range, refer to Reservoir Troubleshooting. If
the Reservoir does not contain liquid oxygen, connect an adjustable 0-100
psig (0 to 690 kPa) source of gaseous oxygen to the DISS oxygen inlet on the
pressurizing fixture (Figure 27). Pressurize the Reservoir with gaseous oxygen to 22 psig (152 kPa).
34
Performance Verification
(a) Place coated strap end between contents
(b) Route strap between contents indicator
indicator and R/E valve.
bracket and container flange.
(c) Adjust strap to its longest length and snap
(d) Push fixture down and pull up on loose
together connectors.
end of strap to secure.
Figure 26: Securing Pressurizing Fixture to Reservoir
(a) Hose connected to DISS inlet on
Reservoir pressurizing fixture.
(b) Adjustable pressure source.
Figure 27: Gaseous Oxygen Connected to Pressurizing Fixture
WARNING: Extreme cold hazard. Rapid discharge of liquid oxygen and/or
system malfunction can occur. Use only Snoop liquid leak detector on the
Reservoir fill connector. When finished with leak test, rinse the fill connector
with clean water and blow dry completely with gaseous oxygen or nitrogen.
Note: When using Snoop on the stem of the vent valve, be sure to blow it dry with
gaseous oxygen or nitrogen.
Universal Reservoir Service Manual
35
Performance Verification
2. Use liquid leak detector to test all Reservoir fittings and connections. Be sure
to test the fill connector compression fitting (large brass nut). Place a finger
wetted with Snoop lightly against the vent valve outlet to test for leakage.
Place a finger wetted with Snoop lightly against the DISS oxygen outlet to
test for leakage.
3. Disconnect and remove the pressurizing fixture from the Reservoir fill connector. Apply Snoop to the fill connector poppet and check for leakage.
Note: A small amount of leakage around the poppet of the male fill connector is
acceptable. Acceptable leaks appear as white, foam-like bubbles in the
liquid leak detector. If the bubbles created by the leak detector are, after 30
seconds, considerably larger than those shown in Figure 28, make
necessary repairs to the male fill connector according to the Service and
Repair section of this manual.
(a)
(b)
Figure 28: Leak Testing the Fill Connector
4. Make repairs to leaking fittings or connections per the Service and Repair
section.
5. If the Reservoir continues to experience pressure related problems, perform
the Pressure Hold Test to determine if an external leak is the source of the
problem.
36
Performance Verification
Pressure Hold Test (Alternate Leak Test)
Note: Conduct the Pressure Hold Test on Reservoirs with empty, warm inner
containers only. Performing this test on units that contain liquid oxygen
yields inaccurate results. If the Reservoir contains liquid oxygen, remove
the liquid oxygen from the unit per the Service and Repair section. Then
warm the container by connecting gaseous oxygen to the fill connector and
opening the vent valve. Allow gaseous oxygen to purge the container for
about 45 minutes.
1. Attach an adjustable 0 to 100 psig (0 to 690 kPa) source of gaseous oxygen to
the DISS oxygen inlet on the pressurizing fixture. Momentarily engage the
pressurizing fixture to the Reservoir fill connector and pressurize the unit to
24 psig (166 kPa) (Figure 29). Remove the pressurizing fixture. Let the unit
stand for 10 minutes to allow the pressure inside the Reservoir to stabilize.
Figure 29: Pressurizing Reservoir
Figure 30: Check Pressure
2. Disconnect the gaseous oxygen source from the pressurizing fixture and
momentarily engage the pressurizing fixture to the fill connector (Figure 30).
Record the initial time and pressure. Lightly tap the pressure gauge with your
finger to assure that the needle is reading properly. Verify that the pressure is
22-24 psig (152-166 kPa). Remove the pressurizing fixture. Repeat step 1 if
the pressure is not within tolerance.
3. After 14 to 15 hours, engage the pressurizing fixture (without the gaseous
oxygen source) and take a final reading. Verify that the pressure is greater
than 18 psig (124 kPa) for a U-46 or greater than 17 psig (117 kPa) for a U-36.
If the pressure is out of specification, perform the Liquid Leak Detector Test
to determine the source of the leak.
Universal Reservoir Service Manual
37
Performance Verification
Gaseous Oxygen Functional Tests
Conduct the following tests on an empty Reservoir that has warmed to room
temperature.
Primary Relief Valve Test
The primary relief valve maintains system pressure at a preset value when the
Reservoir contains liquid oxygen and is in the standby mode. The primary relief
valve is part of the relief/economizer (R/E) valve. This test uses only gaseous
oxygen to determine if the primary relief valve opens within its acceptable range.
1. Engage the pressurizing fixture (Figure 13) to the fill connector on the Reservoir and secure it with the attached strap (Figure 26). Attach an adjustable 0 to
100 psig (0 to 690 kPa) source of gaseous oxygen to the Diameter Index
Safety System (DISS) oxygen inlet on the pressurizing fixture (Figure 27).
2. The primary relief valve vents through the barbed fitting in the side of the R/E
valve. Attach one end of a 1/8-inch I.D. flexible tube to the barbed fitting.
Insert the other end of the tube into a clean jar of water (Figure 31).
(a)
(b)
Figure 31: Primary RV Test Setup
3. Slowly pressurize the Reservoir until a continuous stream of small bubbles
first appears in the jar of water.
4. Verify that the primary relief valve opens (bubbles) at 24-28 psig (166-193
kPa). If the opening pressure is not within the acceptable range, adjust the primary relief valve per the instructions in the Service and Repair section.
Replace the R/E valve if unable to maintain primary relief valve pressure.
38
Performance Verification
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 at a specified pressure greater than the opening pressure of
the primary relief valve. This test uses only gaseous oxygen to determine if the
secondary relief valve opens within its acceptable range.
1. Engage the pressurizing fixture (Figure 13) to the fill connector on the
Reservoir and secure it with the attached strap (Figure 26). Attach an
adjustable 0 to 100 psig (0 to 690 kPa) source of gaseous oxygen to the
Diameter Index Safety System (DISS) oxygen inlet on the pressurizing fixture
(Figure 28).
2. Obtain a 6 in. Quick-Grip micro bar clamp (Figure 32 (a)). Position the
movable bar clamp arm over the R/E valve vent barbed fitting. Position the
fixed bar clamp arm on the edge of the mounting bracket window cutout
(Figure 32 (b)). Tighten the clamp to seal the vent port.
(a)
(b)
Figure 32: Blocking R/E Valve Vent Port
3. Slowly pressurize the Reservoir by adjusting the oxygen source regulator.
Verify that the secondary relief valve opens (audible hiss) at 25-37 psig (173255 kPa).
Note: If the secondary relief valve does not open within this range the first time,
reduce the pressure in the Reservoir and repeat the test a second time. If it
fails to open within the acceptable range the second time, replace the valve
per the Service and Repair section.
4. Disconnect the pressurizing fixture and open the Reservoir vent valve to
reduce the pressure below 20 psig (138 kPa). Remove the clamp blocking
the R/E valve vent port.
Pressure Indicator Test
The Reservoir pressure indicator is a bourdon tube pressure gauge that indicates
the status of the pressure in the system upstream. This test determines the
accuracy of the pressure indicator.
Universal Reservoir Service Manual
39
Performance Verification
1. Engage the pressurizing fixture (Figure 13) to the fill connector on the
Reservoir and secure it with the attached strap (Figure 26). Attach an
adjustable 0 to 100 psig (0 to 690 kPa) source of gaseous oxygen to the
Diameter Index Safety System (DISS) oxygen inlet on the pressurizing fixture
(Figure 29).
2. Slowly pressurize the Reservoir until the needle of the Reservoir pressure
indicator lines up with the 20 psig mark. It may be necessary to tap on top of
the indicator with your finger to assure that the indicator is operating properly.
Verify that the reading on the pressurizing fixture gauge is 18-22 psig (124152 kPa).
Note: If the pressure indicator readings are not within the acceptable range, verify
the accuracy of the test gauge. Replace the indicator, if required, per the
Service and Repair Section.
Liquid Oxygen Functional Tests
Conduct the following tests on a Reservoir that contains properly saturated liquid
oxygen.
Contents Indicator Test
The contents indicator is an electronic, battery operated device that measures and
displays the approximate amount of liquid oxygen in the Reservoir. It determines
liquid oxygen contents by sensing the pressure created by the weight of the liquid
oxygen in the container. Functional components include an 8-LED display panel,
a low contents LED, and a low battery LED. This test verifies that the electronic
circuit is operational and that the pressure sense tubes are clear.
1. Verify that the yellow, low battery LED is off. Replace the 9-volt battery if
needed.
2. Press the blue button on the contents indicator and verify that the yellow, low
contents LED lights when the liquid oxygen contents is 8.5 lbs (3.9 kg) or less
3. Fill the Reservoir so that it contains 20 to 25 lbs (9 to 11 kg) of liquid oxygen.
4. After five minutes, press the blue button and verify that the number of green
LEDs lit on the the display correspond to the information in Table 4. The
yellow, low contents LED should be off.
40
Performance Verification
Note: If step 4 fails, purge the container liquid sense tube per the Service and
Repair section. If step 4 fails after purging the container liquid sense tube,
replace the contents indicator per the Service and Repair section.
Table 4: Contents Indicator Display States
Contents Indicator
No. of Green LEDs On
U-36/U-46 Reservoir
Yellow LED Status
Weight of LOX Lb. (kg)
0
On
0.0-8.5 (0.0-3.9)
1
Off
8.5-18.2 (3.9-8.3)
2
Off
18.2-28.0 (8.3-12.7)
3
Off
28.0-37.6 (12.7-17.1)
4
Off
37.6-47.4 (17.1-21.5)
5
Off
47.4-57.1 (21.5-25.9)
6
Off
57.1-66.8 (25.9-30.0)
7
Off
66.8-76.5 (30.3-34.7)
8
Off
> 76.5 (34.7)
Note: Table 4 presents nominal values. There is a ±5% error of full scale values.
Normal Evaporation Rate (NER) Test
The NER test measures the insulation efficiency of the HELiOS Reservoir liquid
oxygen container. The test results express in pounds (kilograms) the amount of
liquid oxygen lost (converted into gaseous oxygen and vented through the relief
valve) in a 24-hour period. Perform this test when one or more of the following
symptoms exist:
a. Rapid loss of liquid oxygen contents from the container.
b. Heavy condensation or frost on the container.
c. Excessive venting of gaseous oxygen through the relief valve.
Note: Some venting of gaseous oxygen through the relief valve is normal.
1. Perform a leak test on the unit and verify that the results are acceptable.
2. Fill the unit with 20 to 25 lbs (9 to 11 kg) of liquid oxygen. Before continuing,
allow the unit to sit undisturbed and stabilize for a minimum of 24 hours.
Note: The 24-hour stabilization period is critical to the NER test. Failure to allow
for the stabilization period will yield inaccurate test results.
Note: The primary relief valve must be venting within the acceptable pressure
range of 24 to 28 psig (166-193 kPa) before starting NER test
measurements.
Universal Reservoir Service Manual
41
Performance Verification
3. After the stabilization period, start the test by recording the initial weight,
pressure and time.
4. After an additional, minimum time of 24 hours, stop the test by recording the
final weight, pressure, and time.
5. Calculate the NER using the following formula:
6. Verify that the NER is 1.5 lb./day (0.68 kg/day) or less.
Note: If the NER is not within specification, allow the unit to stand for an
additional 24 hours and recalculate the NER for this longer period of time
before returning the unit for repair.
Economizer Test
The economizer valve establishes an operating pressure that allows a patient to
breathe gas that would otherwise vent to atmosphere through the primary relief
valve. Oxygen flow through the oxygen outlet must occur to establish the
economizer operating pressure. The economizer valve is part of the relief/
economizer (R/E) valve. This test verifies that the economizer valve maintains
Reservoir operating pressure within the acceptable range.
1. Verify that the Reservoir contains at least 20 lbs (9 kg) of liquid oxygen. If
not, fill the unit with 20 to 25 lbs (9 to 11 kg) of liquid oxygen.
2. Engage the pressurizing fixture (Figure 14) to the fill connector on the
Reservoir and secure it with the attached strap (Figure 27).
3. To begin the test, the pressurizing fixture gauge should read 24-28 psig (166193 kPa). If the gauge reading is lower, allow time for the saturation pressure
to increase to 24-28 psig (166-193 kPa).
4. Attach the22 psig (152 kPa) manufacturer-specified external flow control
valve (P/N 10000554) to the Reservoir oxygen outlet and set a continuous
flow of 4 L/min.
Note: To test the economizer valve function, the Reservoir must be delivering a
flow.
5. With the unit delivering an oxygen flow, record the pressure readings on the
pressurizing fixture gauge every hour until the pressure stabilizes.
Stabilization occurs when two consecutive readings are within 1 psig (7 kPa)
of each other.
The acceptable operating range for the economizer valve is 20.5-23.5 psig
(141-162 kPa). If the pressure reading is not within this range, adjust the
economizer valve per the Service and Repair section.
42
Tro u b l e s h o o t i n g
Table 5 provides troubleshooting procedures for the HELiOS Universal
Reservoir. This guide is not all-inclusive but is intended to serve as a general
outline for solving operational problems. The table describes symptoms, identifies
probable causes, and suggests corrective actions.
When more than one probable cause is identified, the causes are listed in order of
most likely to least likely reasons for the problem.
Table 5: Troubleshooting the Universal Reservoir
Symptom
1. Liquid oxygen leaks from
fill connector
after fill.
Probable Cause
Corrective Action
a. Ice crystal preventing proper
closure of poppet.
a. If minor leak, engage and
disengage mating fill connectors
several times to dislodge ice
crystal. If this fails, or if major
leak, vent pressure in Reservoir to
stop leak.
b. Damaged poppet or fill
connector.
b. Examine poppet and fill
connector. If damaged, replace
cartridge assembly or fill connector
per Service and Repair section.
2. Liquid oxygen leaks from
engaged fill
connectors during fill.
a. Teflon lip seal in female fill
connector cracked or damaged.
a. Replace lip seal.
3. Unable to disconnect transfer
line (or Portable) from Reservoir after fill.
a. Fill connectors frozen together
due to presence of moisture.
a. Close liquid valve on source tank
(or vent valve on Portable) and
allow transfer line (or Portable) to
sit until fill connectors are warm
enough to disconnect. (Fill
connectors should be dried with
lint-free cloth before filling.)
4. Excessively
long fill time for
fill technique
used (standard
or fast-fill).
a. Vent valve not fully open.
a. Rotate vent wrench
counterclockwise until it stops.
b. Liquid oxygen in source tank not
at 40-50 psig (276-345 kPa)
saturation pressure (standard fill);
24-28 psig (166-193 kPa)
saturation pressure w/50 psig (345
kPa) pressure builder head (fastfill).
b. Allow liquid oxygen to saturate
to proper pressure; verify pressure
builder working properly.
c. Fill connector not opening
properly.
c. Check fill connector and
cartridge assembly for damage;
make sure fill conectors fully
engage.
Universal Reservoir Service Manual
43
Troubleshooting
Table 5: Troubleshooting the Universal Reservoir
Symptom
Probable Cause
Corrective Action
5. Low pressure
reading on Reservoir pressure
indicator (pressure reads less
than 20 psig
(138 kPa)).
a. Vent valve not completely closed
or leaking.
a. Close vent valve. Leak test valve
outlet and stem. Replace or repair.
b. Reservoir filled with liquid
oxygen at incorrect saturation
pressure.
b. Perform Resaturating Liquid
Oxygen procedure.
c. Leak at plumbing connection.
c. Perform leak test.
d. Damaged pressure indicator.
d. Perform Pressure Indicator Test.
e. Economizer valve stuck in open
state (problem noticeable only
during oxygen flow demand).
e. Perform economizer test.
a. Primary relief valve setting too
high or relief valve operating
improperly.
a. Perform primary relief valve test.
Adjust or replace R/E valve.
b. Container vacuum loss.
b. Perform NER test.
c. Damaged pressure indicator.
c. Perform Pressure Indicator Test.
d. Reservoir economizer valve
stuck in closed state (problem
noticeable only during oxygen flow
demand).
d. Perform economizer test.
a. Low pressure at oxygen outlet.
a. See Symptom 5.
b. Partial obstruction in liquid
withdrawal tube or warming coil.
b. Check liquid withdrawal tube
and warming coil for blockage.
Clean or replace as needed.
6. High pressure reading on
Reservoir pressure indicator
(pressure is
greater than 28
psig (193 kPa)).
7. Low flow at
oxygen outlet.
Note: Be aware of a nonremovable twisted copper wire
inserted into warming coil near its
inlet.
8. No flow at
oxygen outlet.
9. Contents indicator reads
incorrectly.
44
a. Reservoir is empty.
a. Fill unit with liquid oxygen
saturated at 22 psig (152 kPa).
b. Zero head pressure caused by
major leak (vent valve open, relief
valve malfunction, etc.)
b. Locate leak and repair as needed.
c. Total obstruction in liquid
withdrawal tube, warming coil, or
flow restrictor connector.
c. Locate obstruction and clean or
replace components as needed.
a. Battery voltage low.
a. Replace 9-volt battery.
b. Leak in sensing tubes or fittings.
b. Perform leak test. Repair as
needed.
c. Flexible contents indicator
pressure sense tube pinched.
c. Visually inspect flexible
pressure sense tubes and remove
pinching condition.
d. Ice blockage in contents
indicator (liquid) pressure sense
tube.
d. Perform contents indicator
liquid sense tube purge procedure
in Service and Repair section.
e. Contents indicator electronics
malfunction.
e. Replace contents indicator
module.
Troubleshooting
Table 5: Troubleshooting the Universal Reservoir
Symptom
10.High product loss rate.
Universal Reservoir Service Manual
Probable Cause
Corrective Action
a. Container vacuum loss.
a. Perform NER test.
b. Leak in tubing or connections.
b. Perform leak test. Repair as
needed.
45
Blank Page
Service And Repair
This section provides procedures for servicing the individual components of the
Reservoir. Included are instructions, where applicable, for removal, disassembly,
operational check, cleaning, inspection, adjustment, reassembly, and installation.
WARNING: Personal injury can occur from the uncontrolled release of
pressurized gaseous and liquid oxygen. Empty liquid oxygen contents and
vent system pressure before servicing.
WARNING: Injury to eyes from flying objects possible. Wear eye protection
when servicing the Reservoir.
After removing a component, visually inspect for damage or any other indication
that the part should be replaced. Unless otherwise specified, replace as needed
with a new part. Refer to the Illustrated Parts List section.
Note: After making repairs, always verify proper system operation by performing
the Reservoir functional tests in the Performance Verification section.
Emptying a Reservoir
The liquid oxygen in a Reservoir must be removed and the pressure vented to
atmosphere before disassembling the unit for service. Also, the Reservoir oxygen
contents must be removed before packaging and shipping the unit.
If time allows, empty the Reservoir by attaching a 22 psig (152 kPa) external flow
control device that can deliver flows not exceeding 10 L/min. Place the Reservoir
in a well ventilated location away from sources of ignition and pedestrian traffic.
Set a flow and let the Reservoir run until it is empty. Remove the flow control
device as soon as the Reservoir is empty.
You can empty the Reservoir more rapidly by transferring its liquid oxygen into
an empty HELiOS or Companion Reservoir unit of equal or larger size. To empty
a Reservoir in this way, perform the following procedure.
Note: Reservoir pressure should be at least 15 psig (104 kPa) to perform this
procedure.
WARNING: Explosive hazard. Extremely high pressure can rupture the
transfer line. Make sure the specified pressure relief valve is present, in the
proper location, and functioning properly. After use, position the transfer
line relief valve so that any liquid oxygen trapped in the line discharges in a
safe direction as the line warms.
1. Attach an extra fill adapter assembly to the source adapter of the transfer line
assembly (Figure 33).
Universal Reservoir Service Manual
47
Service And Repair
2. Put on the personal protective gear (heavy gloves, face shield, etc.) used when
filling the Reservoir with liquid oxygen.
3. Engage one fill adapter assembly to the Reservoir unit to be emptied (source).
Engage the second fill adapter assembly to an empty Reservoir (receiver).
4. Open the vent valve on the receiver unit to begin the transfer process.
5. When the source unit is empty, venting from the receiver unit will diminish
and eventually stop. Detach the transfer line assembly from each unit once the
frost on the transfer line hose begins to melt.
Note: A small amount of liquid oxygen will remain in the Reservoir since the fill
tube does not go all the way to the bottom of the container. This liquid
oxygen will evaporate and build pressure. Open the Reservoir vent valve to
vent the pressure.
Extra Fill
Adapter Assy.
5/8 Male
Flare Union
Source
Adapter
150 PSI (1035 kPa)
Relief Valve
Figure 33: Transfer Line Configuration for Emptying
a Universal Reservoir
48
Service And Repair
Shroud Assembly
The Reservoir unit’s shroud assembly includes an upper shroud and a lower
shroud. Both components are molded from an impact resistant plastic and protect
the plumbing components on top of the unit.
Upper Shroud Removal
1. Remove the two pan head screw from the topside of the upper shroud.
2. Carefully remove the upper shroud by lifting it up and over the plumbing
components.
Upper Shroud Service
Service to the upper shroud consists only of replacing the front warning label, the
fill connector label, the oxygen diamond label, and the oxygen outlet warning
label.
Note: New labels must be installed any time the upper shroud is replaced. Make
sure that the front warning label is the correct one for the model of
Reservoir it is to be used on.
Upper Shroud Installation
Install the upper shroud by reversing the removal procedure.
Note: Be sure to align the upper shroud so that the access holes are positioned
directly over the corresponding Reservoir plumbing components. Also, be
sure that the upper shroud is seated uniformly on the lower shroud lip.
Lower Shroud Removal
1. Before servicing the unit, empty the liquid oxygen contents from the
Reservoir.
2. Use the vent wrench to open the vent valve on the Reservoir.
3. Remove the upper shroud.
4. Slide the press-on tubing clamp back and disconnect the flexible black (gas)
pressure sense tube from the barbed fitting on the R/E valve. Refer to the
Contents Indicator section in Service and Repair, and note the warnings and
cautions. Disconnect the flexible red (liquid) pressure sense tube from the
“liquid” pressure sense barbed fitting (marked “HI”) on the contents indicator.
5. While using a 9/16-in. open end wrench to hold the liquid withdrawal tee
stationary, use a second 9/16-in. open end wrench to remove the warming coil
compression nut from the tee. Pull the aluminum warming coil tube away
from the tee and carefully guide the small Teflon liquid withdrawal tube out
of the aluminum tube.
Universal Reservoir Service Manual
49
Service And Repair
6. Use a 5/32-in. hex key wrench to remove the four socket head cap screws that
secure the mounting bracket to the manifold flange. Remove the mounting
bracket and attached components.
7. Use an adjustable wrench to remove the vent valve from the threaded
manifold extension tube. Place the wrench on the valve hex flats closest to the
manifold extension tube to prevent disassembly of the valve.
8. Use a 9/16-in. open end wrench to remove the economizer tube compression
nut from the liquid withdrawal tee. Use a ½-in. open end wrench to remove
the economizer tube inverted compression nut from the R/E valve. Remove
the economizer tube.
9. Use a ¾-in. open-end wrench to remove the R/E valve assembly from the
threaded manifold extension tube.
10. Remove the umbrella seal by carefully working it up over the manifold flange
and tubes.
11. Remove the lower shroud by carefully working it up over the manifold flange
and tubes.
Lower Shroud Installation
1. Install the lower shroud over the manifold flange and tubes. Pull the red
flexible contents indicator tube up through the 3/16 in. (0.5 cm) diameter hole
in the lower shroud tray (not the larger moisture drain hole).
2. Position the embossed 1-in. (2.5-cm) circular index mark on the top of the
lower shroud directly over the vacuum port on the container. Ensure that the
container vacuum port is captured between two parallel vertical ribs on the
bottom of the lower shroud. Use a flashlight and look to the right through the
moisture container opening to verify capture of the vacuum port.
3. Install the umbrella shield over the manifold flange and tubes. Pull it down the
neck of the container until it sits snugly over the oval opening in the center of
the lower shroud.
4. Apply Teflon tape sealant to the threaded manifold tube facing the embossed
circular index mark on the top of the lower shroud. Install the R/E valve
assembly on the manifold tube and tighten so that the secondary relief valve is
in a vertical, up position.
5. Install the end of the economizer tube with the inverted compression nut in
the bottom port of the R/E valve. Install the opposite end of the economizer
tube in the side port of the liquid withdrawal tee. Make sure both tube ends are
aligned properly and then tighten both compression nuts.
6. Apply Teflon tape sealant to the threaded manifold tube opposite the R/E
valve. Install the vent valve on the manifold tube with the valve flow direction
arrow pointing away from the manifold. Tighten so that the valve stem is in a
vertical, up position.
50
Service And Repair
7. Position the mounting bracket with attached components over the manifold so
that the release lever is over the R/E valve. Carefully insert the Teflon liquid
withdrawal tube into the open end of the aluminum warming coil tube. Be
careful not to kink or scrape the Teflon tube. Align the warming coil tube in
the liquid withdrawal tee port and finger tighten the compression nut.
8. Align the mounting bracket on the manifold flange. Install the four socket
head cap screws and tighten with a 5/32-in. hex key wrench. Tighten the
warming coil compression nut using two 9/16-in. open-end wrenches.
9. Connect the flexible black (gas) pressure sense tube from the contents
indicator “LO” circuit to the barbed fitting on the R/E valve. Slide the presson tubing clamp onto the barbed fitting. Connect the flexible red (liquid)
pressure sense tube from the container sense line to the “liquid” pressure
sense fitting on the contents indicator. The “liquid” pressure sense fitting is
marked “HI” and is located closest to the rear of the contents indicator
module.
10. Install the upper shroud.
Contents Indicator
The contents indicator measures the amount of liquid oxygen in the Reservoir. An
electronic transducer senses a differential pressure proportional to the height of
the liquid oxygen in the container. A panel of eight LEDs provide liquid oxygen
level indication.
Removal
WARNING: Extreme cold hazard. Liquid oxygen discharge can occur from
the contents indicator red (liquid) pressure sense tube. Remove all liquid
oxygen contents and vent system pressure before servicing.
1. Remove the upper shroud.
2. Lift the contents indicator module off of the mounting bracket and carefully
turn it over.
CAUTION: Damage to contents indicator or barbed fittings can occur. Vent
Reservoir pressure before removing either contents indicator tube. Use care when
removing flexible tubes from barbed fittings on contents indicator. To remove,
carefully cut tubes as close to end of barbed fittings as possible. Use razor blade to
cut away tubing remnants remaining on barbed fittings.
3. Remove the flexible black (gas) pressure sense tube from the barbed fitting
(“LO”) on the contents indicator.
4. Remove the flexible red (liquid) pressure sense tube from the barbed fitting
(“HI”) on the contents indicator.
Universal Reservoir Service Manual
51
Service And Repair
Service
The contents indicator is not field serviceable except for replacement of the 9-volt
battery. To replace the battery, perform the following steps.
1. Insert a coin into the battery door slot at the rear of the contents indicator
module.
2. Lift the coin up to remove the door.
3. Carefully disengage the battery from the battery clip.
4. Install a new 9-volt alkaline battery, taking care to observe proper battery
polarity (Figure 34).
5. Make sure the battery wires are positioned in the bottom of the battery
compartment. Position the battery door over the battery and push down until it
snaps in place.
Figure 34: 9-volt Battery Installation
52
Service And Repair
Installation
CAUTION: The contents indicator can read incorrectly. Do not pinch or
kink the pressure sense tubes when installing the contents indicator. Do not
cross-connect the pressure sense tubes. The red (liquid) pressure sense
tube connects the barbed fitting nearest the rear of the contents indicator
(marked “HI”) to the barbed fitting on the container stainless steel sensor
tube. The black (gas) pressure sense tube connects the barbed fitting
nearest the front of the contents indicator (marked “LO”) to the tee
connecting the pressure indicator and the R/E valve (Figure 35).
Install the contents indicator by reversing the removal procedure.
Figure 35: Contents Indicator Pressure Sense Tube Routing
Universal Reservoir Service Manual
53
Service And Repair
Fill Connector Release Assembly
The fill connector release assembly disengages the female fill connector from the
male fill connector upon completion of a fill. It consists of a release button and
lever assembly.
Removal
1. Remove the upper shroud.
2. Use a needlenose pliers to remove one E-clip from the release lever pivot pin.
Remove the pin from the release lever. Remove the lever from the mounting
bracket.
3. Use a No. T10 Torx driver to remove two Torx screws from the release
button. Remove the button from the lever.
Installation
Install the fill connector release assembly by reversing the removal procedure.
Male Fill Connector
The male fill connector is the male half of a fluid coupling system. The male
connector, when engaged with a female connector, provides a means of
transferring liquid oxygen to and from the Reservoir. The male connector consists
of an anodized aluminum body, poppet cartridge assembly, and retainer ring.
CAUTION: Use care to prevent contaminants from entering container when
removing fill connector. Do not nick or scratch tapered sealing surfaces of fill
connector or ferrule.
Removal
1. Before servicing the unit, empty the liquid oxygen contents from the
Reservoir.
2. Use the vent wrench to open the vent valve on the Reservoir.
3. Remove the upper shroud.
4. Use a 7/8-in. open-end wrench to hold the body of the fill connector
stationary. Use a 10-in. adjustable wrench to loosen the compression nut on
the fill connector. Remove the fill connector.
Inspection
1. Inspect the Kel-F poppet on the cartridge assembly for wear, damage, or
embedded contaminants.
54
Service And Repair
2. Inspect the fill connector body for wear or damage. Inspect the tapered sealing
surface for embedded debris or scratches.
Service
Service to the male fill connector consists of replacing the fill connector assembly
or replacing the cartridge assembly. To replace the cartridge assembly, follow the
Disassembly procedure.
Disassembly
1. Use a small screwdriver or awl to remove the spiral retainer ring by first
carefully lifting the beveled edge of the retainer over the lip of the retaining
ring groove (Figure 36).
Figure 36: Removing the Retainer Ring
2. Carefully pry the rest of the ring over the lip until the entire ring pops out.
3. Remove the cartridge assembly (Figure 37).
Figure 37: Removing Cartridge Assembly and Retainer Ring
Universal Reservoir Service Manual
55
Service And Repair
Reassembly
1. Insert the cartridge assembly into the fill connector body.
2. Insert the small opening end of the male installation sleeve (marked “M”,
P/N B-775393-00) into the threaded end of the fill connector body.
3. Place the spiral retainer ring into the open end of the male installation sleeve
(Figure 38).
Figure 38: Inserting Retainer Ring into Male Installation Sleeve
4. Hold the male installation sleeve firmly against the body of the fill connector.
Insert the rounded end of the inner installation tool (marked “I”, P/N B775392-00) into the male sleeve and push the retainer ring down until you feel
it “click” into place (Figure 39).
Figure 39: Installing the Retainer Ring
Installation
Install the male fill connector on the Reservoir fill tube by reversing the removal
procedure. Be sure to hold the fill connector stationary while tightening the
compression nut.
Note: To ease the installation process, use a small amount of Krytox 240 AC on
the threads of the fill connector. This helps lubricate the threads and makes
tightening the connector easier.
56
Service And Repair
Vent Valve
The vent valve is a quarter turn ball valve that, when open, vents the Reservoir
container to begin a fill. Closing the vent valve terminates the fill.
Removal
1. Before servicing the unit, empty the liquid oxygen contents from the
Reservoir.
2. Use the vent wrench to open the vent valve on the Reservoir.
3. Remove the upper shroud.
4. Use an adjustable wrench to remove the vent valve. Place the wrench on the
valve hex flats closest to the manifold to prevent disassembly of the valve as
you remove it.
Inspection
Verify that the black vent valve orifice is present in the valve outlet. Inspect the
vent valve wrench adapter for wear or damage. Verify that the wrench adapter set
screw is tight and that the adapter stop tab is not damaged (Figure 40). Inspect the
wrench adapter stops on the valve body for wear or damage (Figure 41).
Set Screw
Stop
Tab
Figure 40: Vent Valve
Inspection
Wrench
Adapter
Valve Stops
Figure 41: Wrench Adapter
Inspection
Service
Service to the Reservoir vent valve consists of replacing the vent valve adapter.
1. Use a 5/64-inch hex key wrench to loosen the set screw in the wrench adapter.
2. Pull the wrench adapter up and off of the vent valve shaft.
3. Position the flat on the vent valve shaft so it is facing the valve outlet. Position
the new wrench adapter over the valve shaft with the adapter set screw facing
the valve outlet (Figure 42).
Universal Reservoir Service Manual
57
Service And Repair
4. Install the wrench adapter on the valve shaft, making sure that the stop tab on
the bottom of the wrench adapter is behind the valve stop (Figure 43).
Set Screw
Flat
Figure 42: Positioning the Flat
On the Vent Valve Shaft
Valve
Stop
Stop
Tab
Figure 43: Installing the
Wrench Adapter
5. Place a block of wood between the bottom of the vent valve and the top of the
lower shroud to support the valve. Place a vent wrench on the wrench adaper.
Using a small hammer, lightly strike the end of the vent wrench three or four
times to seat the wrench adapter squarely on the valve shaft (Figure 44).
6. Check that the wrench adapter is seated squarely on the valve shaft. There
should be about a 1/16-inch gap between the bottom of the adapter and the
valve body (Figure 45).
1/16-inch
gap
Figure 44: Seat the Vent Valve
Figure 45: Check the Gap
7. Use a 5/64-inch hex key wrench to tighten the set screw in the wrench
adapter. Ensure that the adapter is tight on the valve shaft (Figure 46).
58
Service And Repair
8. Place the vent wrench on the wrench adapter and verify that you can turn the
vent wrench 90° counterclockwise from the valve’s full closed position to the
full open position (Figure 47).
Closed
Figure 46: Tighten Set Screw
Open
Figure 47: Verify Vent Valve
Operation
Installation
Note: Before installing the vent valve, wrap the threaded manifold extension tube
with Teflon tape starting two threads back from the end. Verify that the
arrow on the vent valve body points away from the manifold.
Install the vent valve by reversing the removal procedure.
Universal Reservoir Service Manual
59
Service And Repair
Relief/Economizer (R/E) Valve
The relief/economizer (R/E) valve is a pressure regulating device that combines
the function of a primary relief valve and an economizer valve into one
component. The primary relief valve establishes the maximum operating pressure
achievable in the Reservoir. The economizer valve establishes an operating
pressure that allows a patient to breathe gas that would otherwise vent to
atmosphere through the primary relief valve. The R/E valve is not field repairable.
However, the R/E valve pressure settings may be adjusted if they are out of range.
Removal
1. Before servicing the unit, empty the liquid oxygen contents from the
Reservoir.
2. Use the vent wrench to open the vent valve on the Reservoir.
3. Remove the upper shroud.
4. Use a 5/8-in. open-end wrench to remove the secondary relief valve from the
R/E valve.
5. Slide the press-on tubing clamp back and disconnect the flexible black (gas)
pressure sense tube from the 1/16-in. barbed fitting on the R/E valve. Use a 1/
4-in. open-end wrench to remove the 1/16-in. barbed fitting.
6. Use a ½-in. open-end wrench to remove the economizer tube assembly
inverted compression nut from the R/E valve. Carefully pull the economizer
tube down until it clears the R/E valve.
7. Use a ¾-in. open-end wrench to remove the R/E valve from the threaded
manifold extension tube.
Installation
1. Apply Teflon tape sealant to the threaded manifold tube facing the embossed
circular index mark on the top of the lower shroud. Install the R/E valve on
the threaded manifold tube and tighten so that the secondary relief valve port
is in a vertical, up position.
2. Install the end of the economizer tube with the inverted compression nut in
the bottom port of the R/E valve. Make sure the tube end is aligned properly
in the port and then tighten the inverted compression nut.
3. Install the 1/16-in. barbed fitting in the R/E valve port that faces the center of
the Reservoir. Connect the flexible black tube and the tubing clamp to the
barbed fitting.
CAUTION: High pressure hazard. Over tightening the secondary relief valve
can cause it to operate improperly. Do not over tighten the valve. Perform
Secondary Relief Valve Test.
60
Service And Repair
4. Apply Teflon tape sealant to the secondary relief valve threads. Install the
secondary relief valve in the R/E valve port and tighten until snug.
5. Install the upper shroud.
R/E Valve Adjustment
If the primary relief valve or the economizer valve is operating at a pressure out of
its acceptable range, it may be possible to adjust the setting of the valve. Carefully
perform the following steps to adjust the pressure setting for the appropriate
valve.
Note: Before making any R/E valve adjustments, verify that perceived pressure
problems are not the result of other Reservoir functional problems.
Adjusting the Primary Relief Valve
1. Attach one end of a 1/8-in. I.D. flexible tube to the 1/8-in. barbed fitting at the
R/E valve vent port (Figure 48 (a)). Insert the other end of the flexible tube
into a clean jar of water (Figure 48 (b)).
(a)
(b)
Figure 48: Primary Relief Valve Test Setup
2. Connect a pressurizing fixture (P/N B-701731-00, Figure 13) to the fill
connector on the empty Reservoir. Attach an adjustable 0-100 psig (0-690
kPa) source of gaseous oxygen to the DISS oxygen inlet on the pressurizing
fixture.
3. Slowly pressurize the Reservoir with gaseous oxygen by adjusting the oxygen
source pressure regulator.
4. The pressurizing fixture gauge should read 24-28 psig (166-193 kPa) when a
continuous stream of bubbles first appears in the jar of water.
5. If the primary relief valve pressure is low, use a 5/16-inch open end wrench
and loosen the primary relief valve adjustment screw lock nut. Use a 1/16inch hex key wrench to turn the primary relief valve adjustment screw a
quarter turn clockwise (in), and repeat steps 3, 4, and 5. The primary relief
valve adjustment screw is located on the contents indicator side of the R/E
valve (Figure 49).
Universal Reservoir Service Manual
61
Service And Repair
6. If the primary relief valve pressure is high, reduce the pressure in the
Reservoir to 22 psig (152 kPa).Turn the primary relief valve adjustment screw
a quarter turn counterclockwise (out) and repeat steps 3 through 6.
Liquid
Withdrawal
Tee
Primary
Relief
Valve
Economizer
Valve
Figure 49: Primary Relief Valve and Economizer Adjustment
Adjusting the Economizer Valve
1. Fill the Reservoir with about 20 lbs (9 kg) of liquid oxygen. Allow enough
time for the liquid oxygen to reach a saturation pressure of 24-28 psig (166193 kPa) or refer to Resaturating Liquid Oxygen.
2. Attach a 22 psi (152 kPa) external flow control (P/N B-701655-00) to the
Reservoir oxygen outlet and set a continuous flow of 4 L/min.
Note: To check the economizer adjustment the Reservoir must be delivering a
flow.
3. Momentarily connect the pressurizing fixture to the Reservoir fill connector
to take a pressure reading. Record the reading.
4. With the Reservoir delivering a flow, record pressure readings every hour
until the pressure stabilizes. Stabilization has occurred when two consecutive
readings are within 1 psig (6.9 kPa) of each other.
The acceptable operating range for the economizer valve is 20.5-23.5 psig
(141-162 kPa).
5. If the economizer pressure is low, use a 5/16-inch open end wrench and
loosen the economizer valve adjustment screw lock nut. Use a 1/16-inch hex
key wrench to turn the economizer valve adjustment screw a quarter turn
clockwise (in). If the economizer valve pressure is high, turn the economizer
valve adjustment screw a quarter turn counterclockwise (out). The
economizer valve adjustment screw is located on the liquid withdrawal tee
side of the R/E valve (Figure 49).
62
Service And Repair
Note: The Reservoir must continue to deliver flow when making economizer
valve adjustments. After making an adjustment, record pressure readings
every hour until the pressure stabilizes at the new economizer pressure
setting. Repeat this step as needed to bring the economizer pressure within
specifications.
Secondary Relief Valve
The secondary relief valve is a poppet-type pressure control valve that acts as a
safety backup in the event that the primary relief valve fails to limit system
pressure to an acceptable range. Under normal operating conditions, the
secondary relief valve remains closed. The secondary relief valve is not field
serviceable or adjustable.
Removal
1. Before servicing the unit, empty the liquid oxygen contents from the
Reservoir.
2. Use the vent wrench to open the vent valve on the Reservoir.
3. Remove the upper shroud.
4. Use a 5/8-in. open-end wrench to remove the secondary relief valve from the
R/E valve.
Installation
CAUTION: High pressure hazard. Over tightening the secondary relief valve
can cause it to operate improperly. Do not over tighten the valve. Perform
Secondary Relief Valve Test.
5. Apply Teflon tape sealant to the secondary relief valve threads. Install the
secondary relief valve in the R/E valve port and tighten until snug.
6. Install the upper shroud.
Warming Coil
The Reservoir warming coil is a heat exchanger consisting of a loosely wound coil
of ¼-in. aluminum tubing over 20 feet (6 meters) long. A non-serviceable internal
copper twist wire improves the efficiency of the heat exchange process. The
warming coil connects the liquid withdrawal tee to the outlet mounting block.
Removal
1. Remove the upper shroud.
2. Use a 9/16-inch open-end wrench to hold the flow restrictor connector
stationary at the outlet block inlet. Use a second 9/16-inch open-end wrench
Universal Reservoir Service Manual
63
Service And Repair
to remove the warming coil compression nut from the flow restrictor
connector (Figure 50 (a)). Carefully pull the warming coil tube out of the
connector.
3. Use a 1/2-in. open-end wrench to hold the liquid withdrawal tee stationary.
Use a 9/16-in. open-end wrench to remove the warming coil compression nut
from the tee. Pull the aluminum warming coil tube away from the tee and
carefully guide the small Teflon liquid withdrawal tube out of the aluminum
tube (Figure 50 (b)).
4. Pull the warming coil assembly away from the Reservoir.
(a)
(b)
Figure 50: Removing the Warming Coil
Installation
Install the warming coil by reversing the removal procedure.
CAUTION: Be careful not to kink or scrape the Teflon liquid withdrawal
tube when inserting it into the warming coil.
Economizer Tube Assembly
The economizer tube assembly connects the R/E valve outlet to the liquid
withdrawal tee. When a flow demand is present at the oxygen outlet and the
economizer valve is open, gaseous oxygen from the Reservoir headspace flows
through the economizer tube. As outlet flow demand continues, and headspace
pressure decreases to the economizer valve setting, flow through the economizer
tube drops to less than 1 L/min. Vaporized oxygen from the liquid withdrawal
circuit makes up the balance of the flow demand.
Removal
1. Before servicing the unit, empty the liquid oxygen contents from the
Reservoir.
2. Use the vent wrench to open the vent valve on the Reservoir.
64
Service And Repair
3. Remove the upper shroud.
4. Use a 9/16-in. open end wrench to remove the economizer tube assembly
compression nut from the liquid withdrawal tee. Use a ½-in. open end wrench
to remove the economizer tube assembly inverted compression nut from the
R/E valve. Remove the economizer tube assembly.
Installation
Note: Before installing the economizer tube assembly, make sure a sintered
element is present in the end of the tube that connects to the liquid
withdrawal tee.
Install the economizer tube assembly by reversing the removal procedure.
Oxygen Outlet Block
WARNING: Do not tamper with or replace oxygen outlet fitting (p/n:
10009690) with a standard DISS fitting. Serious patient injury may occur.
Note: The oxygen outlet fitting poppet is inset deeper than the standard DISS
fitting. This prevents breathing or tethering to a Portable without the use of
the manufacturer-specified external flow control valve (p/n: 10000554)
Removal
1. Before servicing the unit, empty the liquid oxygen contents from the
Reservoir.
2. Use the vent wrench to open the vent valve on the Reservoir.
3. Remove the upper shroud.
4. Use a 5/8-in. open-end wrench to remove the demand check valve fitting from
the outlet block.
5. Use a 9/16-in. open-end wrench to hold the male connector stationary at the
oxygen outlet block inlet. Use a second 9/16-in. open-end wrench to remove
the warming coil compression nut from the male connector. Carefully pull the
warming coil tube out of the connector.
6. Use a 9/16-in. open-end wrench to remove the male connector from the
oxygen outlet block.
7. Lift the contents indicator off of the mounting plate and use a 5/32 in. hex key
wrench to remove the flat head screw that fastens the oxygen outlet block to
the mounting plate. Remove the oxygen outlet block.
Universal Reservoir Service Manual
65
Service And Repair
Installation
Install the oxygen outlet block by reversing the removal procedure.
Note: Apply Teflon tape sealant to the NPT threads of the male connector and the
demand check valve fitting before installing onto the oxygen outlet block.
Cryogenic Container
The Reservoir cryogenic container is a stainless steel, double-walled, vacuuminsulated container that holds liquid oxygen. The container’s main function is to
limit the amount of heat that leaks into the container from the surrounding
atmosphere. The container is not field serviceable. Contact CAIRE Inc.
Technical Support if you suspect a problem with the cryogenic container.
Removal
1. Before servicing the unit, empty the liquid oxygen contents from the
Reservoir.
2. Use the vent wrench to open the vent valve on the Reservoir.
3. Remove the upper shroud and lower shroud.
4. Remove the male fill connector.
5. Use a 9/16-in. open-end wrench to remove the liquid withdrawal tee from the
threaded manifold extension tube.
6. Carefully slide the tubing clamp away from the barbed fitting that connects
the steel container sense tube to the flexible red (liquid) pressure sense tube.
Disconnect the flexible red (liquid) pressure sense tube from the barbed
fitting.
7. To prevent contaminants from entering the cryogenic container, place a clean
plastic bag over the open manifold ports and seal tightly.
Installation
Install the cryogenic container by reversing the removal procedure.
Note: Apply Teflon tape sealant to the NPT threads on the manifold ports before
installing components.
66
Service And Repair
Purging the Container Liquid Sense Tube
If the contents indicator is reading empty or low when the Reservoir unit is full,
and there are no leaking fittings or connections, there may be an obstruction in the
container liquid sense tube. The most common obstruction is the formation of ice
crystals. Over a period of time, water may enter the system during the filling
process. Once in the system, the water may become trapped in the container liquid
sense tube. When the inner container cools to cryogenic temperatures, the water
freezes and blocks the tube, causing the contents indicator to operate improperly.
If this happens, follow the purging procedure listed below.
Procedure
1. Before servicing the unit, empty the liquid oxygen contents from the
Reservoir.
2. Use the vent wrench to open the vent valve on the Reservoir.
3. Remove the upper shroud.
4. Connect the pressurizing fixture (P/N B-701731-00, Figure 14) to the fill
connector on the Reservoir unit. Attach an adjustable 0 to 100 psig (0 to 690
kPa) source of gaseous oxygen to the DISS oxygen inlet on the fixture (Figure
28).
5. Adjust the regulator until the gauge on the pressurizing fixture reads
approximately 15 psig (103 kPa). With only the vent valve open, allow the
system to purge for about 45 minutes.
6. Disconnect the pressurizing fixture.
7. With no pressure in the unit, disconnect both the flexible black (gas) pressure
sense tube and the flexible red (liquid) pressure sense tube from the contents
indicator. Using a wire tie, lightly secure the tubes to the vent valve to prevent
them from moving around.
CAUTION: Damage to the contents indicator can occur. Disconnect both
contents indicator tubes before pressurizing the Reservoir. Vent the
Reservoir before connecting or disconnecting indicator tubes.
8. Close the vent valve. Reconnect the pressurizing fixture and adjust the
regulator until the pressurizing fixture reads approximately 15 psig (103 kPa).
Allow an additional 15 minutes for gas to flow through and purge the contents
indicator tubes.
9. Disconnect the pressurizing fixture and open the Reservoir vent valve.
Reconnect both pressure sense tubes to the contents indicator. Perform the
contents indicator test.
Universal Reservoir Service Manual
67
Blank Page
Illustrated Parts List
This section contains expanded views of the three available reservoirs, along with
corresponding parts lists.
Expanded View, U-46EU
Item
Part
Number
Description
1
Reference
Assembly, Bottle, Welded
1
2
10005531
Label, U-46EU
1
3
10005527
Label, Cleaning Instructions
1
4
10005523
Label, O2, Non-flammable
1
5
10005349
Label, Contents
1
6
10005525
Label, Flow Control
1
Male Fill Connector
1
7
B-775322-00
Qty.
8
10003033
Shroud, Upper
1
9
10009690
Fitting, Demand Check Valve, Oxygen Outlet
1
10
B-701543-00
Shroud, Lower
1
11
B-701626-00
Seal, Umbrella
1
12
B-701622-00
Tee Fitting, LOX withdrawal
1
13
B-702105-00
R/E Valve
1
14
10002910
Warming Coil
1
15
B-701631-00
Inverted Tube Nut, 1/4-in. O.D. Tube
1
16
B-778167-00
Barbed Hose Fitting
1
17
B-775139-00
Relief Valve, 30 psi
1
18
B-775479-00
Assembly, Vent to Fill, w/Wrench Adapter
1
19
B-701699-00
Vent Valve Orifice, Black
1
20
10003034
Reservoir Bracket
1
21
B-701635-00
Socket HD Cap Screw, 10-24 X 3/8-inch
4
22
B-702106-00
Lever, Release
1
23
B-701545-00
Button, Release
1
Universal Reservoir Service Manual
69
Illustrated Parts List
Part
Number
Description
24
B-701634-00
Shaft, Pivot
1
25
B-777505-00
E-Ring
2
26
B-701524-00
Screw, 8-16 X .75, Large Plastic
2
27
B-775794-00
Hose Clamp, Brass
2
28
B-701629-00
Connector, Male
1
29
B-702145-00
Pipe Nipple
2
30
B-702225-00
Adaptor, Vent Valve
1
31
B-702226-00
Screw, Set, Flat Point, 8-32
1
32
B-702207-00
Contents Indicator
1
33
B-701002-00
Screw, Pan Head, 1/4-28 X 1 1/4
2
34
B-701546-00
Collector, Condensation
1
35
B-702108-00
Oxygen Outlet Block
1
36
B-702109-00
Screw, SFHC, 1/4-20 X 1/2 long
1
38
B-730040-63
Caplug, CD-6, Threated
1
39
B-492297-00
Battery, 9-volt
1
40
B-702127-00
O-Ring, Silicon
2
41
B-702128-00
Spacer, Compression
1
42
B-776175-00
Spring
1
43
B-701740-00
Filter Sintered
1
44
B-778157-00
Hose Fitting, Barbed, .10 I.D.
1
45
B-775063-00
Ferrule, 1/4 Tube, Brass
1
46
B-701694-00
Tube, Urethane, 1/16 I.D. X 15 Red
1
47
B-701695-00
Tube, Urethane, 1/16 I.D. X 12 Black
1
48
B-701583-00
Tube, Urethane, 1/16 I.D. X 3 inches
2
49
Reference
Wire Twist, .080 dia.
2
50
B-701640-00
Grommet, Pressure Gauge
1
51
B-701526-00
T Connector
1
52
B-702076-00
Gauge, 0-100 psi, 1 1/2-in dia.
1
53
B-701630-00
Tube, Economizer
1
54
Reference
Tube, Teflon Withdrawal
1
Item
70
Qty.
Illustrated Parts List
Figure 51: U-46EU Reservoir
Universal Reservoir Service Manual
71
Illustrated Parts List
Expanded View, U-36EU
72
Item
Part
Number
Description
1
Reference
Assembly, Bottle, Welded
1
2
10005529
Label, U-36EU
1
3
10005527
Label, Cleaning Instructions
1
4
10005523
Label, O2, Non-flammable
1
5
10005349
Label, Contents
1
6
10005525
Label, Flow Control
1
7
B-775322-00
Male Fill Connector
1
8
10003033
Shroud, Upper
1
9
10009690
Fitting, Demand Check Valve, Oxygen Outlet
1
10
B-701543-00
Shroud, Lower
1
11
B-701626-00
Seal, Umbrella
1
12
B-701622-00
Tee Fitting, LOX withdrawal
1
13
B-702105-00
R/E Valve
1
14
10002910
Warming Coil
1
15
B-701631-00
Inverted Tube Nut, 1/4-in. O.D. Tube
1
16
B-778167-00
Barbed Hose Fitting
1
17
B-775139-00
Relief Valve, 30 psi
1
18
B-775133-00
Assembly, Vent to Fill, w/Wrench Adapter
1
19
B-775479-00
Vent Valve Orifice, Black
1
20
10003034
Reservoir Bracket
1
21
B-701635-00
Socket HD Cap Screw, 10-24 X 3/8-inch
4
22
B-702106-00
Lever, Release
1
23
B-701545-00
Button, Release
1
24
B-701634-00
Shaft, Pivot
1
25
B-777505-00
E-Ring
2
26
B-701524-00
Screw, 8-16 X .75, Large Plastic
2
27
B-775794-00
Hose Clamp, Brass
2
28
B-701629-00
Connector, Male
1
Qty.
Illustrated Parts List
Part
Number
Description
29
B-702145-00
Pipe Nipple
2
30
B-702225-00
Adaptor, Vent Valve
1
31
B-702226-00
Screw, Set, Flat Point, 8-32
1
32
B-702207-00
Contents Indicator
1
33
B-701002-00
Screw, Pan Head, 1/4-28 X 1 1/4
2
34
B-701546-00
Collector, Condensation
1
35
B-702108-00
Oxygen Outlet Block
1
36
B-702109-00
Screw, SFHC, 1/4-20 X 1/2 long
1
38
B-730040-63
Caplug, CD-6, Threated
1
39
B-492297-00
Battery, 9-volt
1
40
B-702127-00
O-Ring, Silicon
2
41
B-702128-00
Spacer, Compression
1
42
B-776175-00
Spring
1
43
B-701740-00
Filter Sintered
1
44
B-778157-00
Hose Fitting, Barbed, .10 I.D.
1
45
B-775063-00
Ferrule, 1/4 Tube, Brass
1
46
B-701694-00
Tube, Urethane, 1/16 I.D. X 15 Red
1
47
B-701695-00
Tube, Urethane, 1/16 I.D. X 12 Black
1
48
B-701583-00
Tube, Urethane, 1/16 I.D. X 3 inches
2
49
Reference
Wire Twist, .080 dia.
2
50
B-701640-00
Grommet, Pressure Gauge
1
51
B-701526-00
T Connector
1
52
B-702076-00
Gauge, 0-100 psi, 1 1/2-in dia.
1
53
B-701630-00
Tube, Economizer
1
54
Reference
Tube, Teflon Withdrawal
1
Item
Universal Reservoir Service Manual
Qty.
73
Illustrated Parts List
Figure 52: U-36EU Reservoir
74
Illustrated Parts List
Expanded View, U-46SW
Item
Part
Number
Description
1
Reference
Assembly, Bottle, Welded
1
2
10006005
Label, U-46SW
1
3
10005527
Label, Cleaning Instructions
1
4
10005523
Label, O2, Non-flammable
1
5
10005349
Label, Contents
1
6
10005525
Label, Flow Control
1
7
B-775322-00
Male Fill Connector
1
8
10003033
Shroud, Upper
1
9
10009690
Fitting, Demand Check Valve, Oxygen Outlet
1
10
B-701543-00
Shroud, Lower
1
11
B-701626-00
Seal, Umbrella
1
12
B-701622-00
Tee Fitting, LOX withdrawal
1
13
B-702105-00
R/E Valve
1
14
10002910
Warming Coil
1
15
B-701631-00
Inverted Tube Nut, 1/4-in. O.D. Tube
1
16
B-778167-00
Barbed Hose Fitting
1
17
B-775139-00
Relief Valve, 30 psi
1
18
B-775479-00
Assembly, Vent to Fill, w/Wrench Adapter
1
19
B-701699-00
Vent Valve Orifice, Black
1
20
10003034
Reservoir Bracket
1
21
B-701635-00
Socket HD Cap Screw, 10-24 X 3/8-inch
4
22
B-702106-00
Lever, Release
1
23
B-701545-00
Button, Release
1
24
B-701634-00
Shaft, Pivot
1
25
B-777505-00
E-Ring
2
26
B-701524-00
Screw, 8-16 X .75, Large Plastic
2
27
B-775794-00
Hose Clamp, Brass
2
28
B-701629-00
Connector, Male
1
Universal Reservoir Service Manual
Qty.
75
Illustrated Parts List
Part
Number
Description
29
B-702145-00
Pipe Nipple
2
30
B-702225-00
Adaptor, Vent Valve
1
31
B-702226-00
Screw, Set, Flat Point, 8-32
1
32
B-702207-00
Contents Indicator
1
33
B-701002-00
Screw, Pan Head, 1/4-28 X 1 1/4
2
34
B-701546-00
Collector, Condensation
1
35
B-702108-00
Oxygen Outlet Block
1
36
B-702109-00
Screw, SFHC, 1/4-20 X 1/2 long
1
38
B-730040-63
Caplug, CD-6, Threated
1
39
B-492297-00
Battery, 9-volt
1
40
B-702127-00
O-Ring, Silicon
2
41
B-702128-00
Spacer, Compression
1
42
B-776175-00
Spring
1
43
B-701740-00
Filter Sintered
1
44
B-778157-00
Hose Fitting, Barbed, .10 I.D.
1
45
B-775063-00
Ferrule, 1/4 Tube, Brass
1
46
B-701694-00
Tube, Urethane, 1/16 I.D. X 15 Red
1
47
B-701695-00
Tube, Urethane, 1/16 I.D. X 12 Black
1
48
B-701583-00
Tube, Urethane, 1/16 I.D. X 3 inches
2
49
Reference
Wire Twist, .080 dia.
2
50
B-701640-00
Grommet, Pressure Gauge
1
51
B-701526-00
T Connector
1
52
B-702076-00
Gauge, 0-100 psi, 1 1/2-in dia.
1
53
B-701630-00
Tube, Economizer
1
54
Reference
Tube, Teflon Withdrawal
1
Item
76
Qty.
Illustrated Parts List
Figure 53: U-46SW Reservoir
Universal Reservoir Service Manual
77
Blank Page
Unpacking, Installation, and Repacking
Perform the following procedures when unpacking, installing or repacking a
HELiOS Reservoir unit.
Unpacking
1. Examine the shipping carton for damage. If the carton is damaged, or its
contents are suspected of being damaged, photograph the damaged carton
before the Reservoir is unpacked. Contact the carrier to request a damage
inspection. Contact the shipping point immediately.
2. Place the shipping carton on a flat surface with the shipping arrows pointing
upwards.
3. Open the top flaps of the shipping carton and remove accessory items.
4. Remove the plastic bag covering the Reservoir and any loose packing inserts.
5. With the assistance of a helper, grasp a handle on the side of the Reservoir.
Hold the carton down with one hand and carefully lift the Reservoir up and
out of the carton.
6. Compare the packing list attached to the carton’s exterior with the shipment
received. If any discrepancies exist, contact CAIRE Inc. immediately.
7. Thoroughly inspect the exterior of the Reservoir for damage (dents, cracks,
etc.).
8. Save all packing materials and the shipping carton for reuse.
Installation
Before installing the Reservoir in a patient’s home, read and understand Controls,
Indicators, and Connectors, Filling Instructions, and Operating Procedures, all
found in the section Reservoir General Information. Perform the following steps
upon receipt of shipment:
1. Record the Reservoir serial number, which is located on one of the handle
brackets.
2. Verify the fill connector release button and mechanism move freely.
3. Press the button on the contents indicator. Verify that the yellow low contents
LED lights.
4. Verify that a Reservoir vent wrench is available for filling the unit.
Universal Reservoir Service Manual
79
Unpacking, Installation, and Repacking
5. Verify receipt of the Universal Home Use Guide. Note that there are 4 multilanguage manuals containing 17 languages. Select the one appropriate for you
language.
6. Verify receipt of the Universal Reservoir Reference Guide (p/n 10005660).
7. Install the external flow control valve. To attach the external flow control
valve, screw the flow control valve hand tight nut onto the Reservoir oxygen
outlet connector (in the Home Use Guide, see External Flow Control Valve).
WARNING: Only use the manufacturer-specified external flow control valve
provided with your Universal Reservoir (p/n 10000554).
Repacking for Return
To return a product, contact your Puritan-Bennett Representative. A Return
Goods Authorization (RGA) number will be issued to track the product return.
Please have available your account number, the model and serial number of the
product, and the reason for returning the product when you call to request an
RGA. Return the unit in its original carton, if possible. If the original carton is not
available, you may purchase a new carton (see Accessories).
WARNING: Fire hazard and extreme cold hazard. Do not package or ship
units that contain liquid or gaseous oxygen. Liquid oxygen spillage and high
oxygen concentrations are possible. Empty oxygen contents completely
before packaging or shipping units. See Emptying a Reservoir in the Service
and Repair section.
1. Obtain the proper carton and inserts for the Reservoir you wish to package.
2. Remove the external flow control valve before packaging.
3. Make sure that the carton inserts are properly in place. The Reservoir handles
must engage the inserts.
4. With the assistance of a helper, grasp a handle on the side of the Reservoir and
carefully lift the Reservoir up and into the carton. Make sure the inserts
snugly support the Reservoir.
5. Fold down the set of carton top flaps that press against the top of the
Reservoir. Fold down the second set of flaps and insert the locking tabs into
the first set of flaps.
6. Secure the carton with packing tape. Double-tape the carton’s bottom seam.
80
Specifications
The Universal Reservoir performance specifications are listed below.
U-36EU
U-46EU
U-46SW
Volume of Liquid Oxygen
(typical)
36 liters/1.27 ft3
46 liters/1.62 ft3
46 liters/1.62 ft3
Weight of Liquid Oxygen at
24 psig (166 kPa) Saturation
(typical)
85 lbs/38.6 kg
110 lbs/49.9 kg
110 lbs/49.9 kg
Gaseous Oxygen Equivalent
at 1atm. and 70°F
29,069 liters/1027 ft3
37,619 liters/1328 ft3
37,619 liters/1328 ft3
Height
33.5 in./85.1 cm
37.5 in./95.3 cm
37.5 in./95.3 cm
Diameter
15.4 in./39.1 cm
15.4 in./39.1 cm
15.4 in./39.1 cm
Empty Weight
53 lbs/24.0 kg
60 lbs/27.2 kg
60 lbs/27.2 kg
Full Weight
138 lbs/62.6 kg
170 lbs/77.1 kg
170 lbs/77.1 kg
Outlet Pressure
(Economizer Pressure)
22 psig/152 kPa Nominal
(Acceptable Range 20.5-23.5
psig/141-162 kPa)
22 psig/152 kPa Nominal
(Acceptable Range 20.5-23.5
psig/141-162 kPa)
22 psig/152 kPa Nominal
(Acceptable Range 20.5-23.5
psig/141-162 kPa)
Primary Relief Valve
Pressure
26 psig/179 kPa Nominal
(Acceptable Range
24-28 psig/166-193 kPa)
26 psig/179 kPa Nominal
(Acceptable Range
24-28 psig/166-193 kPa)
26 psig/179 kPa Nominal
(Acceptable Range
24-28 psig/166-193 kPa)
Secondary Relief Valve
Pressure
30 psig/207 kPa Nominal
(Acceptable Range
27-37 psig/173-255 kPa)
30 psig/207 kPa Nominal
(Acceptable Range
27-37 psig/173-255 kPa)
30 psig/207 kPa Nominal
(Acceptable Range
27-37 psig/173-255 kPa)
1.2 lbs/0.54 kg per Day
1.5 lbs/0.68 kg per Day
1.2 lbs/0.54 kg per Day
1.5 lbs/0.68 kg per Day
1.2 lbs/0.54 kg per Day
1.5 lbs/0.68 kg per Day
(fast fill technique)
Warm < 7 min./Cold < 6
min.
Warm < 4 min./Cold < 3
min.
Warm < 8 min./Cold < 7
min.
Warm < 5 min./Cold < 4
min.
Warm < 8 min./Cold < 7
min.
Warm < 5 min./Cold < 4
min.
Maximum Outlet Flow
10 L/min
10 L/min
10 L/min
Contents Indicator
Electronic, Differential
Pressure Based
Electronic, Differential
Pressure Based
Electronic, Differential
Pressure Based
-20°C to 40°C
95% max. relative humidity
-40°C to 70°C
90% max. relative humidity
-20°C to 40°C
95% max. relative humidity
-40°C to 70°C
90% max. relative humidity
-20°C to 40°C
95% max. relative humidity
-40°C to 70°C
90% max. relative humidity
Normal Evaporation Rate
(NER)
(typical)
(maximum)
Fill Time
(standard technique)
Environmental
(Operating Temp.)
(Storage Temp.)
Universal Reservoir Service Manual
81
Blank Page
Theory Of Operation
This section describes the theory of operation for the HELiOS Universal
Reservoir liquid oxygen system. Three Universal Reservoir models are available:
U-46EU, U-36EU, and U-46SW. The U-36EU model holds 36 liters (85 lbs/38.6
kg) of liquid oxygen while the U-46EU and U-46SW models hold 46 liters (110
lbs/49.9 kg) of liquid oxygen. Information presented in this section will help you
understand how the Reservoir system works. Items covered include functional
descriptions of Reservoir components and complete Reservoir system operation.
Note: Numerical values used in this section are nominal values.
Reservoir Components
The following is a brief description of each of the major functional components of
the Universal Reservoir.
Cryogenic Container
Liquid oxygen stored in the HELiOS Reservoir is typically saturated and boiling
at a temperature somewhere between about -277°F (-186°C) and -268°F (-167°C).
The constant transfer of heat from the atmosphere into the system keeps the liquid
oxygen boiling and vaporizing into gas. If the heat flow into the liquid oxygen is
not controlled, vaporization occurs too rapidly, and excess oxygen is vented to the
atmosphere and wasted. The cryogenic container (Figure 54) is designed to
minimize the transfer of heat from the atmosphere to the liquid oxygen contents.
This is done by slowing the three methods of heat transfer: conduction,
convection, and radiation.
Liquid
Pressure
Sense
Tube
Inner
Container
Insullation
Neck Tube
Vacuum Plug
Outer
Container
Fill Tube
Molecular
Sieve
Figure 54: Cryogenic Container
Universal Reservoir Service Manual
83
Theory Of Operation
Conduction is the transfer of heat through a material, such as metal, by collisions
of molecules in the material. Molecules at the hotter end of the material are
moving faster than molecules at the cooler end. Heat is transferred from molecule
to molecule as fast moving molecules run into the slower moving ones.
Conductive heat transfer is kept to a minimum by placing the liquid oxygen in a
stainless steel inner container suspended within a stainless steel outer container.
This reduces the number of places where the warmer outer container comes into
physical contact with the colder inner container that holds the liquid oxygen.
Convection is the transfer of heat by motion of a heated fluid (gas or liquid) from
one place to another. When a layer of gas, for example, is heated, it tends to rise
above or move away from the surrounding gas. Cooler gas moves in to take its
place. This gas is heated, rises and moves away. Heat is transferred by circulation
of the heated gas. To minimize convective heat transfer between the warm outer
container and cold inner container, air is removed from the sealed space between
the outer and inner containers. A vacuum applied through the evacuation port
removes most of the gas molecules in this space. Since no vacuum created on
earth is perfect, a molecular sieve material is placed in the vacuum space against
the inner container. When liquid oxygen in the inner container cools the molecular
sieve to cryogenic temperatures, remaining gas molecules are removed from the
vacuum space by adsorption into the sieve. This substantially improves the
vacuum and reduces heat transfer by convection.
Radiation is the transfer of energy at the speed of light in the electromagnetic
spectrum. Warm bodies emit infrared radiation, a form of light. Like visible light,
mirrors and shiny surfaces reflect infrared. When infrared is absorbed, it creates a
rise in temperature of the absorbing material. To minimize energy transfer by
radiation, the inner container is orbital wrapped with multiple, alternating layers
of aluminum foil and fiberglass paper. This insulation wrap reflects back radiant
energy from the outer container and reduces radiant energy absorption by the
liquid oxygen.
Fill Connector/Quick Connect
The fill connector/quick connect (Figure 55) on the Reservoir is the male half of a
fluid coupling system. It mates with the female fill connector on HELiOS and
Companion portables. The Reservoir fill connector allows liquid oxygen to
transfer from the Reservoir unit into the Portable. It also allows transfer of liquid
oxygen from a fill source through a transfer line into the Reservoir. Within the
male fill connector is a cartridge assembly made up of a spring and a poppet.
When the fill connector is disengaged, the spring holds the poppet closed and
maintains a leak-tight seal. When the female fill connector engages the male fill
connector, both connector poppets move back off of their respective seats (Figure
56). This creates an open path for liquid oxygen to transfer through the
connection. A lip seal in the female fill connector assembly prevents leakage
between the female and male fill connectors during liquid oxygen transfer.
84
Theory Of Operation
Cartridge
Assembly
Figure 55: Fill Connector/Quick Connect
Figure 56: Male/Female Fill Connectors Fully Engaged
Vent Valve
The vent valve (Figure 57) is a quarter turn ball valve that vents the Reservoir
inner container to atmosphere. Venting of the inner container is required to fill the
Reservoir with liquid oxygen. A vent valve wrench engages the valve shaft to
activate the valve. When the valve is closed, the hole through the valve ball is at
90° to the inlet and outlet ports of the valve. Flow through the valve is stopped.
When the valve shaft is rotated 90° with the vent wrench, the hole in the valve ball
lines up with the inlet and outlet ports. Flow through the valve occurs. The fill
technician can partially close the vent valve to restrict maximum vent flow and
help maintain adequate pressure in the Reservoir during filling.
Figure 57: Vent Valve
Universal Reservoir Service Manual
85
Theory Of Operation
Relief/Economizer Valve
The relief/economizer valve is a pressure-regulating device that combines the
function of a primary relief valve and an economizer valve into one component
(Figure 58).
The primary relief valve establishes the system pressure of the Reservoir when
there is no oxygen flow through the oxygen outlet (“Standby” condition). It
contains a spring-loaded diaphragm that, in its normal state, seals a port that is
vented to atmosphere. System pressure acts on one side of the diaphragm. When
this pressure overcomes the force created by the spring and atmospheric pressure
acting on the opposite side, the diaphragm lifts off of the port. This allows gas in
the space above the liquid oxygen (headspace) to vent to atmosphere. The venting
gas lowers the system pressure until equilibrium is established between the
opening and closing forces on the diaphragm. The rate at which gas is vented out
the primary relief valve is determined by the normal evaporation rate (NER) of the
system. The Universal Reservoir maintains a primary relief valve nominal
pressure of 26 psig (179 kPa) when in the Standby condition.
The economizer valve establishes the system pressure of the Reservoir when there
is oxygen flow through the oxygen outlet (“Oxygen Flow” condition). It allows a
patient to first breathe gaseous oxygen from the headspace in the Reservoir. This
headspace gas accumulates and builds pressure due to the constant boiling of the
liquid oxygen at the normal evaporation rate (NER).
Oxygen is conserved by allowing the patient to withdraw and use this gas rather
than letting it build pressure and eventually vent away through the primary relief
valve. The economizer valve contains a spring-loaded diaphragm that, in its
normal state, seals a port that is connected to the Reservoir oxygen outlet circuit.
When system pressure exceeds 22 psig /152 kPa, the economizer diaphragm lifts
off of its port. This opens a flow path between the gaseous headspace and the
oxygen outlet. When flow through the oxygen outlet is established, gas moves
from the headspace through the open economizer valve. When this flow is greater
than the NER of the system (about 1/4 L/min.), headspace pressure begins to
decrease.
The pressure will eventually decrease to a point where the opening force on the
diaphragm created by the pressure and the closing force created by the spring
come to equilibrium. This equilibrium is maintained at 22 psig/152 kPa because
the economizer valve stays open just enough to allow the small NER flow to pass
through. If the outlet flow demand exceeds the NER flow (about 1/4 L/min.) when
at economizer pressure, liquid oxygen is withdrawn and vaporized in the warming
coil. This flow, together with the small NER flow through the economizer valve,
satisfies the flow demand on the system. When the flow demand at the oxygen
outlet stops, the NER causes pressure to build toward the primary relief valve set
point.
86
Theory Of Operation
Figure 58: Relief/Economizer Valve
Secondary Relief Valve
The secondary relief valve in the Reservoir is used as a safety backup in the event
that the primary relief valve fails to limit system pressure to an acceptable range.
It is mounted on the relief/economizer valve body. The secondary relief valve
consists of a poppet with an elastomer seal and a spring (Figure 59). In its normal
state, the poppet seals a port that vents to atmosphere. When system pressure
acting on one side of the poppet overcomes the force created by the spring and
atmospheric pressure, the poppet lifts off its seat and allows headspace gas to vent
to atmosphere. The venting gas lowers the system pressure until equilibrium is
established between the opening and closing forces on the poppet. If system
pressure increases further, the relief valve poppet opens a greater amount and
vents additional gas to maintain the force equilibrium on the poppet. The
secondary relief valve has a nominal pressure setting of 30 psig/207 kPa.
Figure 59: Secondary Relief Valve
Universal Reservoir Service Manual
87
Theory Of Operation
Warming Coil
The warming coil on the HELiOS Universal Reservoir is a loosely wound coil of
¼ in. aluminum tubing over 20 feet (6 meters) long that connects the liquid
withdrawal tube and the economizer valve outlet to the oxygen outlet (Figure 60).
The warming coil is a heat exchanger that transfers heat from the surrounding
atmosphere to the fluid contents inside the coil. Oxygen flows through the
warming coil only when there is a flow demand at the oxygen outlet. The
warming coil performs two functions on the Reservoir. First, it warms the cold
gaseous oxygen from the headspace that flows through the economizer valve. The
patient breathes this gas while the Reservoir pressure is greater than the
economizer setting. Second, it vaporizes liquid oxygen that is discharged from the
Reservoir liquid withdrawal tube. This occurs when there is ongoing patient flow
demand once system pressure stabilizes at the economizer setting.
Figure 60: Warming Coil
Oxygen Outlet with Poppet Valve
The HELiOS Reservoir oxygen outlet is a 9/16-18 threaded connector with an
integral poppet valve (Figure 61). When a mating nut and nipple or the
manufacturer-specified flow control valve is threaded onto the oxygen outlet, the
poppet valve lifts off its seat to, allowing flow through the connection. When the
nut and nipple are disconnected, the poppet valve spring reseats the poppet to stop
flow.
Closed
Open
Figure 61: Oxygen Outlet w/Poppet Valve
88
Theory Of Operation
Pressure Indicator
The pressure indicator (Figure 62) is a bourdon tube pressure gauge that indicates
the status of the system headspace pressure. The indicator dial is calibrated from 0
to 100 psig (0 to 7 bar). The pressure indicator is used to evaluate the Reservoir
system headspace pressure during a fill and during system operation.
60
40
3
4
20
80
5
2
6
1
7
bar
psi
10
0
Figure 62: Pressure Indicator
Contents Indicator
The contents indicator, visible through the upper shroud of the Reservoir,
measures and displays the amount of liquid oxygen remaining in the Reservoir
(Figure 63). It is powered by a 9-volt alkaline battery. The system is based on the
principle that the pressure created at the bottom of a tank of liquid is proportional
to the height of the liquid.
An electronic pressure transducer measures the pressure at the bottom of the inner
container created by the level of liquid oxygen. However, this pressure signal is
also a function of gaseous headspace pressure acting on top of the liquid. So the
transducer measures the gaseous headspace pressure and subtracts the value from
the total pressure at the bottom of the inner container. It sends the resulting
electronic signal that is proportional to the level of liquid oxygen to the circuit
board in the indicator.
Eight green LEDs on the indicator display panel represent the full to empty range
of the system. When the patient depresses a push button, a proportional number of
green LEDs light to represent the relative level of liquid oxygen remaining in the
Reservoir. In addition to the green LEDs, a yellow “low contents” LED on the
contents indicator lights when 8.5 pounds (3.9 kg) or less of liquid oxygen remain.
A yellow “low battery” LED lights when the battery voltage drops below a
predetermined value.
Universal Reservoir Service Manual
89
Theory Of Operation
Figure 63: Contents Indicator
Reservoir Operation
The Universal Reservoir provides a source of liquid oxygen to fill HELiOS and
Companion portable units. It also provides gaseous oxygen to the H300 and H850
Portables through the 22-psig, manufacturer-specified flow control valve. The
following information provides a brief description of Reservoir system operation
while filling the unit, at fill termination, during no use standby, during gaseous
oxygen withdrawal, and over a 24-hour period.
Filling the Reservoir
A technician typically fills the Reservoir from a liquid oxygen source saturated at
40 to 50 psig (276 to 345 kPa). The fill sequence begins by engaging the liquid
oxygen transfer line assembly to the Reservoir fill connector. The technician then
opens the Reservoir vent valve to permit gas within the Reservoir to escape to
atmosphere (Figure 64). This creates the pressure drop necessary for the liquid
oxygen to flow from the source vessel into the Reservoir.
At first, the liquid oxygen that leaves the source vessel vaporizes into gas in the
transfer line and vents to atmosphere through the Reservoir vent valve. This “flash
off” is due to the relatively warm temperature of the transfer line and Reservoir
container. Also the pressure drop created by the open vent valve lowers the
pressure on the saturated liquid oxygen in the source vessel. This creates a
supersaturated condition where the liquid oxygen boils and vaporizes rapidly to
reduce its saturation temperature to match the new lower pressure.
The vaporization process cools the transfer line and Reservoir inner container
within a short time to a temperature that enables liquid oxygen to remain in the
container. The technician can adjust the vent valve opening to control the rate of
vent gas flow and to maintain a desired liquid oxygen saturation pressure of 22-24
psig (152-165 kPa) in the Reservoir.
90
Theory Of Operation
Pressure Guage
Fill Connector
Contents Indicator
Oxygen Outlet
Gas Sense Tube
Liquid Sense Tube
Secondary
Relief Valve
Relief*/
Economizer**
Valve
Vent Valve
Warming Coil
Neck Tube
Vacuum Plug
Inner Container
Liquid Withdrawal
Tube
Insulation
Outer Container
Fill Tube
Molecular Sieve
Figure 64: Filling the Reservoir
Universal Reservoir Service Manual
91
Theory Of Operation
Fill Termination
When the liquid oxygen level in the Reservoir inner container reaches the end of
the neck tube, liquid oxygen travels up the neck tube and discharges through the
open vent valve (Figure 65). The venting sound changes and the liquid oxygen
creates a dense vapor cloud as it discharges from the vent valve. When this occurs,
the technician terminates the filling operation by closing the vent valve and
disengaging the transfer line from the Reservoir.
Figure 65: Fill Termination
92
Theory Of Operation
Standby
When the Reservoir contains liquid oxygen, and there is no oxygen flow demand
on the system, the pressure in the system increases and eventually stabilizes at the
primary relief valve set point, approximately 26 psig / 179 kPa (Figure 66). The
pressure increases due to the Normal Evaporation Rate (NER) of the system. The
NER is a function of the constant rate at which ambient heat “leaks” into the
liquid oxygen and causes it to boil when saturated. This constant boiling vaporizes
some of the liquid oxygen into gas. Pressure increases in the container over time
until it reaches the primary relief valve opening point. The primary relief valve
maintains pressure equilibrium in the system by allowing gas in the container
space above the liquid (headspace) to vent at the same rate that it is created by the
NER. The vented gas represents the system’s NER loss. Due to the efficient
design of the container, NER losses are kept to a minimum.
Figure 66: Standby
Universal Reservoir Service Manual
93
Theory Of Operation
Gaseous Oxygen Use
Oxygen that flows through the Reservoir oxygen outlet can come from two
locations within the Reservoir: the headspace above the liquid oxygen and the
liquid withdrawal tube. When the pressure inside the Reservoir unit is greater than
the economizer set point, the economizer valve opens. A flow demand at the
oxygen outlet moves gas out of the pressure regulator and warming coil and
creates a pressure drop at the outlets of the economizer valve and liquid
withdrawal tube. As a result, headspace pressure drives gaseous oxygen from the
headspace, through the open economizer valve, warming coil, and pressure
regulator to meet the demand at the oxygen outlet (Figure 67). Liquid oxygen
does not move up through the liquid withdrawal tube because the gas pressure
above the liquid in the tube remains the same as the headspace pressure above the
liquid in the container. When the oxygen outlet flow demand is greater than the
NER of the system, gas leaves the headspace faster than it is created by the NER.
The pressure in the headspace begins to decrease. If the flow demand continues,
the pressure in the headspace will eventually reach the set point of the economizer
valve, 22 psig / 152 kPa.
Figure 67: Oxygen Flow Through Economizer Circuit
94
Theory Of Operation
When headspace pressure reaches the economizer set point, the economizer valve
spring force overcomes the opposing force created by the pressure acting on the
valve diaphragm and closes down the valve. However, the economizer valve stays
open just enough to allow the small flow of headspace gas created by the NER to
pass through. Since this creates equilibrium, where there is no net increase or
decrease of gas in the headspace, system pressure remains constant. If the flow
demand at the oxygen outlet is greater than the NER flow passing through the
economizer valve, pressure at the outlet of the liquid withdrawal tube now drops
below the headspace pressure over the liquid oxygen in the container. The higher
headspace pressure moves liquid oxygen up the liquid withdrawal tube and into
the warming coil (Figure 68).
The liquid oxygen vaporizes in the warming coil and the resulting oxygen flow
combines with the small NER flow coming from the economizer valve. The
combined total flow passes through the warming coil to the oxygen outlet at the
desired rate. The Reservoir remains at economizer pressure until the flow demand
at the oxygen outlet stops. The economizer valve maintains a constant outlet
pressure of 22 psig (152 kPa) while gas flows to the patient.
Figure 68: Oxygen Flow Through Liquid Withdrawal Circuit
Universal Reservoir Service Manual
95
Theory Of Operation
Figure 69 shows the change in pressure in the Universal Reservoir as a patient
uses the system over a typical 24-hour period. The operation is similar to the
Standard Reservoir. However, when there is no gaseous oxygen flow from the
Reservoir to the H300 or H850, the time it takes for the headspace pressure to
build to the relief valve opening point is shorter. This is because the Universal
Reservoir primary relief valve is set to open at 26 psig/179 kPa. As a result, it
typically takes only 3-4 hours before the Universal Reservoir begins to vent gas
through the relief valve. Evaporative losses are greatly reduced but typically not
eliminated with this system.
Figure 69: Universal Reservoir Pressure Over 24 Hours
96
© 2009 CAIRE Inc. All rights reserved. 10005663C
">