HELiOS® Portables

Technical Service ManualI Preface
HELiOS Portables

SERVICE MANUALHELiOS Portables
CAIRE, Inc.
2200 Airport Industrial Dr., Ste. 500
Ball Ground, GA 30107
www.caireinc.com
Customer/Technical Service:North and South America
Phone (US Only):
800-482-2473
US:
770-721-7759
Asia, Australia, Pacific Rim
Phone:
770-721-7759
EuropePhone:+44 (0) 1189 367080

Fax: 888-932-2473
Fax: 770-721-7758
Fax: 770-721-7758
Fax: +44 118 9799245

For Customer or Technical Service needs (product assistance, ordering, part numbers, specifications, unexpected events, etc.) contact:
CAIRE Inc.
2200 Airport Industrial Dr., Ste. 500
1-800-482-2473
www.caireinc.com

NOTE: CAIRE Reservoir and Portable units are intended only for the delivery of medical grade oxygen as prescribed by aphysician.
NOTE: SI pressure values expressed in manual are referenced to atmosphere.
HELiOS™and Companion® are trademarks of CAIRE INC.
SNOOP® is a trademark of the SWAGELOK Co.
Teflon® and Krytox® are trademarks of E. I. DUPONT DE NEMOURS & Co.
Kel-F® and Scotch-Brite™ are trademarks of the 3M Co.
Magnehelic® is a trademark of the DWYER INSTRUMENT Co.
QUICK-GRIP® is a trademark of the AMERICAN TOOL Co.
Sporicidin® is a trademark of SPORICIDIN INTERNATIONAL.

Disclaimer

This manual is intended for use by experienced personnel only. No attempt should be made to fill or maintain this equipment until both thismanual and the Patient Operating Instruction booklet have been read and fully understood.

HELiOS Portables Technical Service Manual • PN 20562190 Rev F

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I Preface
FCV
LED
LOX
LPM
NER
POI
N2
TF
DF
DISS

Flow Control Valve
Light Emitting Diode
Liquid Oxygen
Liters Per Minute
Normal Evaporation Rate
Patient Operating Instructions
Nitrogen Gas
Top Fill
Dual Fill
Diameter Index Safety System

PRV
QDV
RMA
RP
RR
SRV
O2
SF
PTFE

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

HELiOS Portables

Abbreviations

Definition of Terms

WARNING Description of a condition that can result in personal injury or death.
CAUTION Description of a condition that can result in equipment or component damage.
NOTE
A statement containing information important enough to emphasize or repeat.
(ITEM)
Item numbers used throughout this manual are shown on the illustrations beginning in the Troubleshooting
section.

HELiOS Portables Technical Service Manual • PN 20562190 Rev F

2

1
ISO 7000; Graphical symbols for use on equipment—Index andsynopsis

Read user’s manual before operation. Reg.
1641#

Operating temperature limitation of these units
is -10°C to 40°C. Storage temperature limitation range is -40°C to 70°C. Reg. # 0632

ADR: European Agreement concerning the International
Carriage of Dangerous Goods by Road

Non-toxic gas.
Hazard Oxidizing substances: fire intensifying
risk.

Keep away from rain, keep dry. Reg. # 0626
Name and address of manufacturer. Reg.
3082

This device complies with the requirements of
Directive 2010/35/EU concerning medical devices. It bears the pi marking as shown.

#

Caution, consult accompanying documents.
Reg. # 0434A
Catalog Number. Reg. # 2493

Refrigerated Liquid, USP; Produced by Air
Liquefaction

Internal Symbols

Keep unit well ventilated at all times

Serial Number. Reg. # 2498

Keep away from flammable materials, oil andgrease.

This way up. Reg. # 0623

Portable Empty

Fragile, handle with care. Reg. # 0621

Portable Full

ISO 7010: Graphical symbols—Safety colors and safety signs—
Registered safety signs

Frostbite may occur on contact with cold liquid
or gaseous oxygen, or frosted parts. Warning
low temperature. To warn of low temperatureor freezing conditions. Reg.
# W010Keep away from open flame, fire, sparks. Open
ignition source and smoking prohibited. Reg. #P003
Do not smoke near unit or while operating unit.
Reg. # P002
Type BF applied part (degree of protection
against electric shock). Reg. # 5333
Warning. Reg. # W001

Council Directive 93/42/EEC; concerning medical devices

Authorized representative in the European
Community
This device complies with the requirements of
Directive 93/42/EEC concerning medical devices. It bears the CE marking as shown.

HELiOS Portables

Symbols Glossary

Always keep Portable in one of the following
positions: upright, flat on its back, or any position in between.
Wipe connector with clean dry cloth before
filling.
IEC 60417: Graphical Symbols for use on equipment

Do not cover unit or carry portable unit under
your clothing. These units normally vent oxygen. No. 5641
21 CFR 801.15: Code of Federal Regulations Title 21

Federal law restricts this device to sale by or on
the order of a physician.

Council Directive 2012/19/EU: waste electrical and electronicequipment (WEEE)

WEEE
IEC 60601-1: Medical electrical equipment Part 1 General requirements for basic safety and essential performance
Drip ProofHELiOS Portables Technical Service Manual • PN 20562190 Rev F

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II Table of Contents
II. Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . .  3
III. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3–5IV. Equipment Description . . . . . . . . . . . . . . . . . . . . . .  6

HELiOS Portables

I. Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2

V. Theory of Operation . . . . . . . . . . . . . . . . . . . . .  7–10
VI. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .  11
VII. Saturation Principles. . . . . . . . . . . . . . . . . . . .  12–14
VIII. Unpacking and Setup . . . . . . . . . . . . . . . . . . . . . .  15
IX. Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .  16–18
X. Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . .  19–22
XI. Troubleshooting & Repair Procedures . . . . . .  23–50
XII. Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  51
XIII. Ordering Information. . . . . . . . . . . . . . . . . . . . . . .  52
XIV. Return & Restocking Policy. . . . . . . . . . . . . . . . . .  53
XV. Service Tools/Equipment/Supplies. . . . . . . . .  54–55

HELiOS
Portables Technical Service Manual • PN 20562190 Rev F
4

4

III Safety
Oxygen, as it exists at standard atmospheric pressure and temperature, is a colorless, odorless, and tasteless gas. Oxygen constitutes 21% of the atmosphere, by volume. Aside from its welldocumented ability to sustain life, oxygen also supports combustion, even though it is nonflammable. Many substances which
will burn in air, burn at a faster rate and at a higher temperature inan oxygen enriched atmosphere. Other materials that do not burnin air will burn as oxygen concentration increases. Additionally,
many greases and liquid solvents become extremely hazardous
materials when placed in an oxygen-enriched environment. In its
liquid form, oxygen is still odorless and tasteless, but is pale bluein color. At an operating pressure of 1,4 bar /20 psig, the temperature of liquid oxygen is about -173°C/-280° F. Skin exposed
to such a low temperature can become severely frostbitten.
Contraindications

While CAIRE, Inc. equipment is designed and built to the mostrigid standards, no piece of mechanical equipment can ever bemade 100% foolproof. Strict compliance with proper safety
practices is necessary when using any CAIRE unit. We
recommend that our distributors emphasize safety and safe
handling practicesto their employees and customers. While safety
features have been designed into the unit and safe operations
are anticipated, it is necessary that all distributor personnel
carefully read and fully understand WARNINGS, CAUTIONS,
and NOTES throughout the manual. Periodic review of thisinformation is recommended.
These hazards require certain safety precautions to be taken
when working with or around gaseous and/or liquid oxygen.
WARNING: Never permit combustible substances suchas greases, oils, solvents, or other compounds not oxygencompatible to contact any component of the unit exposed tohigher-than atmospheric concentrations of gaseous or liquid
oxygen. This especially applies to tubing, fittings, and valves.
WARNING: Keep oxygen equipment away from open
flames or electrical appliances such as heaters, stoves,toasters, and other devices with heating elements.
WARNING: Never permit smoking in an area where oxygen
equipment is repaired, filled, or used.
WARNING: Always wear goggles, a face shield, andinsulated gloves when working with or around liquid oxygen.
WARNING: These devices are not intended for life
supporting applications nor do they provide patientmonitoring capabilities.

WARNING: Excess accumulation of oxygen creates anoxygen-enriched atmosphere (defined by the Compressed
Gas Association as an oxygen concentration above 23%).
In an oxygen-enriched atmosphere, flammable items may
burn vigorously and may explode. Certain items considered
noncombustible in air may burn rapidly in such anenvironment. Keep all organic materials and other flammable
substances away from possible contact with oxygen;particularly oil, grease, kerosene, cloth, wood, paint, tar, coaldust, and dirt which may contain oil or grease. DO NOT
permit smoking or open flame in any area where oxygen isstored, handled, or used. Failure to comply with this warning
may result in serious personal injury.

HELiOS Portables­­­Safety Guidelines and Operational Safety

WARNING: In the event a unit is dropped, tipped over, or
unreasonably abused, immediately, but cautiously, raise thecontainer to its normal operating position. If substantial
container damage has occurred, remove the liquid oxygenfrom the vessel in a safe manner (RP3). Purge the unit withan inert gas (nitrogen) and promptly return it to CAIRE forinspection. The container should be prominently marked“CONTAINER DROPPED, INSPECT FOR DAMAGE.”
Failure to comply with these procedures may result inpersonal injury and can seriously damage the container.
WARNING: Personnel must remove liquid oxygen anddepressurize the unit before removing parts or loosening
fittings from a unit. Failure to do so may result in personal
injury from the extreme cold of liquid oxygen and/or thepressure in the vessel.
WARNING: During transfer of liquid oxygen, components
will become extremely cold. Care should be used to avoid
any contact with these components, as serious frostbite may
result.
WARNING: Extreme high pressure can rupture containeror plumbing components. Be sure specified pressure relief
devices are present, in the proper location, and functioning
properly.
WARNING: The possibility of fire exists when the
combination of a fuel, source of ignition, and oxygen ispresent. High concentrations of oxygen (air is approximately
21% oxygen) greatly enhance the possibility of combustion.
WARNING: Liquid oxygen vessels periodically releasesmall amounts of oxygen gas that must be ventilated toprevent pressure buildup. Do not store liquid oxygen
equipment in a car trunk, closet, or other confined area. Do
not place bags, blankets, draperies, or other fabrics over theequipment when it contains liquid oxygen.

WARNING: In certain circumstances, the use of nonprescribed oxygen can be hazardous. These devices should
only be used when prescribed by a physician.
HELiOS Portables Technical Service Manual • PN 20562190 Rev F

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III Safety
WARNING: Always keep oxygen tubing or cannulas awayfrom the path of walking to avoid potential injury.
CAUTION: Consistent with the recommendations of the
medical community on the use of conserving devices (which
includes the nasal cannula), it is recommended that the H300
& H850 be qualified on patients in the situations it will be
used (rest, exercise, sleep). Differences in nasal cannuladesign may vary the ability to trigger a conserving device.

HELiOS Portables

NOTE: Liquid oxygen at atmospheric pressure expands
at a ratio of approximately 860:1 (at 0 bar/ 0psig) whenvaporizing into a gas. This can occur very rapidly when
exposed to the heat in the atmosphere. See Figure 1 forcomparison.

NOTE: Figure 2 below is referred to as the fire/combustion
triangle. This triangle describes the three factors required for
fire/combustion to occur.

Figure 1: LOX to Gas ratio
WARNING: When using concentrated oxygen, the risk offire is increased.
WARNING: When transporting the H300 or H850, position
it horizontally, flat side down, to ensure that it does not tip
over. Tipping over and falling off a transport surface could
damage the portable or cause personal injury.
WARNING: Do not carry the H300 or H850 under clothing.
These units normally vent oxygen. Placing a portable unit
under clothing may saturate fabrics with oxygen and cause
them to burn rapidly if exposed to sparks or flame. It may
take several hours for oxygen levels in the fabric to return tonormal.
WARNING: Do not open the vent valve during non-fill use.
Do not put it in any position other than closed, upright, andvertical.

Figure 2: Fire/Combustion Triangle
NOTE: To reduce the risk of combustion/fire when dealing
with LOX, please refer to the following suggestions•

Obtain all replacement parts for medical oxygen
equipment from the manufacturer.

•

Use only recommended oxygen compatible cleaning andleak 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 andwindows to ventilate the area. Avoid sources of ignitionand do not walk on or roll equipment over the affected
area.

•

Any clothing or porous material that is splashed withliquid oxygen or otherwise absorbs high concentrations ofoxygen should be removed and aired for at least one houraway from any source of ignition.

HELiOS Portables Technical Service Manual • PN 20562190 Rev F

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IV Equipment Description
HELiOS Portables

Figure 3: HELiOS portables components

The HELiOS 300 and HELiOS 850 are lightweight portableliquid oxygen units designed to deliver supplementary oxygentherapy to patients as prescribed by a physician. The units arefilled from a liquid reservoir for ambulatory use, or used as astationary conserving device when attached to a HELiOS reservoir using a flexible oxygen supply line. Enclosed in a durable
plastic case, HELiOS portable units incorporate a stainless steel
cryogenic container with the valves, plumbing, and associatedhardware necessary to convert liquid oxygen to gaseous oxygenand deliver it to the patient at or near room temperature.
1. Cryogenic Container This assembly is a double walledvacuum insulated Dewar for storing liquid oxygen (LOX) atapproximately -173°C/-280°F. The inner vessel is designed
to safely hold liquid oxygen and is protected from over pressurization by the primary relief valve. Vacuum insulation
between the inner and outer vessel keeps outside heat from
causing the cold liquid inside to evaporate.
2. Plumbing System The plumbing system consists of thebreathing (warming) and vaporizing coils, vent valve, R/E
valve, SRV, and QDV. The plumbing is responsible forboth filling the portable and drawing the liquid oxygen outof the cryogenic container so that it can be delivered to thepatient.
3. Case The durable plastic case protects and encloses the cryogenic container, plumbing system, and flow control valve.
The plastic case also contains vents to improve circulation of
air and minimize icing.
4. Liquid Content/Level Indicator A mechanical spring-balanced indicator used to display the liquid oxygen contentsof the HELiOS portable. It is built into the rear cover of theunit, and contains a viewing window. When the patient lifts
the unit by its strap, the window displays a green bar whose
height is proportional to the amount of liquid in the unit.
5. Demand Flow Control Valve (FCV) The flow control valve
allows the patient to select either demand or continuous oxygen flow. It is a pneumatic demand valve that utilizes a dual
lumen cannula to detect the negative pressure produced by apatient’s inhalation and initiate flow.

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V Theory of Operation
The H300 & H850 cryogenic container is designed to slow thetransfer of heat from the atmosphere to the liquid oxygen contents.
The contents of H300 & H850 portables are contained within adouble-walled, vacuum-insulated cryogenic container. The liquid
oxygen is stored in an inner container that is suspended within anouter container. Air is removed from the space between the twocontainers to minimize heat transfer between the warm outer tankand the cold inner tank. This is achieved by applying a vacuum
though the outer container’s vacuum port.
In addition to the vacuum insulation, a molecular sieve is placed
within the vacuum space against the inner container to absorb
any moisture or gas molecules that remain in the vacuum space.
Also, the inner containers of the H300 & H850 are wrapped in
multiple layers of an aluminum foil and fiberglass paper insulation to reflect radiant energy and minimize heat transfer.
The unique design of cryogenic container and the location of the

The H300 & H850 is filled by coupling its female quick disconnect valve (QDV) with the male QDV on the reservoir and opening the vent valve.
Once the QDV’s have been connected, the vent valve on the portable unit must be opened to initiate flow of liquid into the unit.
When the vent valve is opened, it vents the contents of the innercontainer to the atmosphere.
Venting the gas inside of the container creates a pressure drop
inside of the H300 or H850. This pressure differential causes liquid oxygen to flow up the reservoir fill tube, through the coupled
QDV’s, and into the inner container of the H300 or H850.

HELiOS Portables­­­Cryogenic Container

At the beginning of a fill, the liquid oxygen that leaves the reservoir will vaporize into a gas because the inside of the H300
or H850 container is relatively warm. This gas is discharged
through the vent valve. After a short time, the container cools
and liquid oxygen is contained.
When the unit is full, liquid oxygen is expelled through the ventvalve. The venting sound also changes and the liquid oxygen
creates a dense vapor cloud coming from under the reservoir’s
shroud. Closing the vent valve and separating the H300 or H850
from the reservoir terminates the fill process.
Figure 5 is a diagram showing the filling process of a portable
unit.
The saturation pressure (explained in Section VII of this manual)of the liquid oxygen can seriously affect the overall efficiency
and operation of the H300 & H850.

Figure 4: Cryogenic Container Design
gas withdrawal tube allow the unit to be operated safely on its
back. If the H300 or H850 is laid flat on its back, liquid oxygen
will not escape and be discharged. The unit can be operated upright, flat on its back, or any position in between.
Filling
The H300 & H850 potable units are designed to be filled fromany top-fill (TF) reservoir with a standard Puritan Bennett malefill connector (QDV). Below is a list of CAIRE reservoirs thatwill fill the H300 & H850.
Companion C21, C31, C41••
Liberator (TF/DF) 10, 20, 30, 37, 45, 60•
Low Loss (TF/DF) 31, 42•
HELiOS Universal U36, U46•
HELiOS Standard H36, H46

Figure 5: Filling Process
Please note that the section outlined in the above filling process shows aconfiguration of a unit equipped with an optional CPC Connector Kit.

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V Theory of Operation
When the H300 or H850 contains liquid oxygen, the vent valve
is closed, and there is no flow demand, the pressure in the system
will remain at or near its primary relief valve (PRV) pressure.
As with all vacuum-insulated cryogenic containers, the liquid
oxygen in the H300 & H850 is always evaporating into a gas.
The rate of generation of this gas (called head gas) is called thenormal evaporation rate (NER). When the flow control knob
is in the off position, this gas will build up pressure. When thepressure reaches the PRV setting, this gas is released through theprimary relief valve into the atmosphere. Figure 6 gives and internal view of PRV when there is no oxygen flow demand.

If the pressure in the container increases over the economizer
valve setting, the economizer valve opens again and the cycle
repeats. This maintains the correct gaseous oxygen flow to thepatient at all times.

HELiOS Portables

StandbyTo Flow Control
Valve (Total Flow From
Headspace Gas)

Oxygen Withdrawal

To Flow Control Valve(No Flow)

Figure 7: R/E Valve Head Gas Flow (Approaching
Economizer Pressure)

Figure 6: Standby (At Relief Valve Pressure)
When the flow selection knob is at any setting other than off andthe pressure in the inner vessel is between the economizer valvepressure and the PRV pressure, the economizer valve is open.
When the economizer valve is open, gaseous oxygen is forced
from the head space in the inner vessel, through the economizer
valve, and to the conserver. This process “economizes” andconserves liquid oxygen by withdrawing the head gas first, rather
than allowing it to escape through the relief valve. Figure 7 is adiagram of the economizer valve when it is open and head gas is
being delivered to the patient.

Figure 8: R/E Valve Liquid Withdrawl (At Economizer
Pressure)

Whenever head gas is removed from the space above the liquid
oxygen, the inner vessel internal pressure begins to slightly decrease. When the pressure drops to the economizer valve setting,the economizer valve closes. This causes liquid oxygen to flow
up the withdrawal tube and through the warming coils, where
it expands and warms into a gas. Figure 8 is a diagram of theeconomizer valve when it is closed and liquid withdrawal is thesource of oxygen to the patient.

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V Theory of Operation
The H300 & H850 are equipped with a pneumatic demand flow
control valve. Both have 12-position flow control knobs thatallow the user to select their prescribed flow rate for delivery.
The H300 has demand flow at a setting of 1.0 and above, andcontinuous flow at all settings below 1.0 LPM. The H850 has
continuous flow (C) from 1-6LPM and demand (D) flow settingsfrom 1-4.
The pneumatic demand valve contains a series of chambers,
valves, and diaphragms that are shown below in Figure 9.

An initial volume of oxygen (called a bolus) is delivered immediately when a patient breathes in. The amount of oxygen that isdelivered in this bolus is determined by the setting selected on
the FCV. After the initial bolus, a smaller volume of oxygen,called a tail flow, is delivered continuously until the patient’s
inhalation stops. Figure 10 below is a graph showing the bolusdelivery of oxygen when the H300 or H850 is in demand (D)mode.
When a patient stops inhaling, the sensor diaphragm raises upward and blocks the bleed flow from under the slave diaphragm.
In turn, the slave diaphragm pushes upward and stops the tailflow to the patient.

HELiOS Portables

Oxygen Delivery

Table 2: H300 Demand Flow Delivery

Figure 9: Demand FCV Internal Diagram
A dual lumen cannula provides the patient interface to the demand valve. The lower cannula port on the H300 or H850 is responsible for detecting an inhalation, and the upper cannula port
is responsible for delivering the dose of oxygen.

Demand Setting

Bolus Size (mL)

Tail Flow (LPM)

1

9.0

0.50

1.5

9.0

0.65

2

12.0

0.75

2.5

12.0

1.00

3

15.0

1.50

3.5

15.0

1.75

4

15.0

2.00

Table 3: H850 Demand Flow Delivery
Demand Setting

Bolus Size (mL)

Tail Flow (LPM)

D1.5

9.0

0.65

CAUTION: A dual lumen cannula MUST be used on both
continuous and demand flow settings.

D2

12.0

0.75

D2.5

12.0

1.00

NOTE: Oxygen will only flow from the top cannula port. This
is normal behavior.

D3

15.0

1.50

D4

15.0

2.00

Demand Flow
When a patient inhales on a demand (D) flow setting, a negative
pressure travels through the dual lumen cannula and the bottom
cannula barb on the H300 or H850. This pressure acts on thebottom of the sensor diaphragm and combines with atmosphericpressure acting on the top of the diaphragm to push it downward.
The lowering of the sensor diaphragm allows the pressure to
bleed from under the slave diaphragm out of the vent, causing
the slave diaphragm to push downward. This releases a stored
volume of oxygen in the precharge chambers and delivers it to
the patient through the upper cannula barb.
Figure 10: H300 & H850 Demand Delivery CurveHELiOS Portables Technical Service Manual • PN 20562190 Rev F

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V Theory of Operation
Serial Number Identification

When the FCV is on continuous (C) mode, the oxygen flow
is delivered in a continuous stream rather than a bolus and tailflow deivery. In these settings, the flow orifice plate blocks thegas supply to the area under the slave diaphragm. The negative
pressure from the patient’s first breath vents any residual pressure that may be present under the slave diaphragm and pushes
it off of the demand flow port. This causes a continuous flow ofoxygen.

1 Units manufactured prior to October 2010 are identified byunique 8-digit serial numbers shown in Figure 12. The serial
number contains the year and calendar day of manufacture,
as well as the unit’s production number that day. The H300
& H850 serial number is etched on the cryogenic container
and is visible through the contents indicator window on theback of the unit.

HELiOS Portables

Continuous Flow

It is important that the FCV still sense a breath periodically incontinuous flow to keep the slave diaphragm pushed down. If alength of time passes without any negative pressure applied by apatient’s breath, the diaphragm may close and continuous flow
may stop.
Liquid Level Measurement
H300 & H850 units are equipped with mechanical spring scales
for liquid measurement. The spring indicator is built into therear cover. When the unit is suspended by its contents indicator strap and held perpendicular to the ground, a green bar isdisplayed in a window on the back of the unit. The height of thegreen bar is proportional to the weight of liquid oxygen inside
the H300 or H850.
Indicator

Figure 12: Serial Number Structure (Before 2010)
2 As of October 2010, H300 & H850 units are identified bydifferently structured serial numbers as shown in Figure
13. The number begins with the letters CB signifying the
manufacturing location, followed by the reservoir productcode B30, followed by digits signifying the year of manufacture, followed by a two digit number to signify the weekof the year that the unit was manufactured and ends withdigits signifying the unit’s production number for that week.
This serial number is found on a white, rectangular sticker
placed on the outside of the cryogenic container. It can beseen thorough the vents on the side of the outer case. Units
manufactured after August 2016 will have the UDI label.
The serial number structure remains the same.

Figure 13: Current Serial Number Structure
Springs

Figure 11: Contents Indicator

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VI
1 Specifications
HELiOS Plus (H300)

HELiOS Marathon (H850)

Volume of LOX (typical)

0.38 L

0.84 L

Weight of LOX at 24 psig (166 kPa)
Saturation (typical)

0.9 lb (0.41 kg)

2.0 lb (0.90 kg)

Gaseous Oxygen Equivalent @ 1atm.
and 70°F

308 L

685 L

Height10.5 in (26.67 cm)

15.2 in (38.61 cm)

Dimensions (Footprint)

5.78 x 3.68 in (14.68 x 9.34 cm)

5.78 x 3.68 in (14.68 x 9.34 cm)

Empty Weight

2.7 lb (1.22 kg)

3.6 lb (1.63 kg)

Full Weight

3.6 lb (1.63 kg)

5.6 lb (2.54 kg)

Economizer Pressure

1.41-1.59 bar (20.5-23 psi)

1.53-1.71 bar (22.25 - 24.75 psi)

Primary Relief Valve Opening Pressure≤1.90 bar (≤27.5 psi)

1.79-2.07 bar (26-30 psi)

Primary Relief Valve Reseat Pressure>1.59 bar (>23 psi)

>1.72 bar (>25psi)

Secondary Relief Valve Opening
Pressure

5.24-5.79 bar (76-84 psi)

5.24-5.79 bar (76-84 psi)

Secondary Relief Valve Reseat Pressure>4.41 bar (>64 psi)

>4.41 bar (>64 psi)

Normal Evaporation Rate (NER)(typical)

0.85 lb/day (0.39 kg/day)

1.0 lb/day (0.45 kg/day)Continuous (LPM): .12, .25, .5, .75

Continuous (LPM): 1, 2, 3, 4, 5, 6

Demand: 1, 1.5, 2.0, 2.5, 3, 3.5, 4Demand: 1.5, 2, 2.5, 3, 4Contents Indicator

Spring Scale

Spring Scale

Operating Temperature-10°C to 40°C (14°F to 104°F)
95% max. relative humidity-10°C to 40°C (14°F to 104°F)
95% max. relative humidity

Storage Temperature-40°C to 70°C (-40°F to 158°F)
95% max. relative humidity-40°C to 70°C (-40°F to 158°F)
95% max. relative humidity

Selectable Flow Rates

HELiOS Portables Technical Service Manual • PN 20562190 Rev F

HELiOS Portables

Table 4: Equipment Specifications

5 12

VII
1 Saturation Principles
Oxygen, like most gases, will condense into a liquid with an increase in pressure or decrease in temperature. As a liquid, oxygen ispale blue in color and is about 860 times as dense as its gaseous form. At atmospheric pressure (14.7 psia), oxygen condenses into its
liquid form at a temperature of about -297°F (-184°C). Liquid oxygen (LOX) is an efficient form of oxygen to meet a patient’s portable, ambulatory oxygen needs. A volume of liquid oxygen, when vaporized, yields about 860 volumes of gaseous oxygen (Figure 1).
As you can see, a relatively small volume of liquid oxygen provides a much larger volume of gaseous oxygen for a patient to use.

HELiOS Portables

Oxygen, in its normal state, is a colorless, tasteless, and odorless gas that is non-flammable, although it greatly accelerates combustionin high concentrations. It constitutes about 21% of the Earth’s atmosphere by volume. Oxygen in higher concentrations is medicallybeneficial to patients suffering from certain respiratory diseases.

In medical liquid oxygen systems, liquid oxygen, and the gaseous oxygen resulting from its vaporization or boiling, is stored underpressure. The elevated pressure, typically 1.52 bar (22 psig), 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. 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 14).

Figure 14: 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 15).

Figure 15: Saturated (Boiling) Water at Higher Pressure
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VII
1 Saturation Principles
HELiOS Portables

If the pressure in a container of saturated liquid decreases, the temperature required for saturation to occur will decrease. This leaves
the liquid “super saturated” or too warm. When this occurs, rapid boiling and vaporizing of some of the liquid occurs. The rapid boiling and evaporation of the liquid dissipates the excessive heat until the remaining liquid cools down to the new saturation temperatureassociated with the decreased pressure (Figure 16).

Figure 16: 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 nd 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 17).

Figure 17: Liquid Oxygen Saturation Curve
It is important to maintain liquid oxygen saturation (boiling) at the specified operating pressure of the HELiOS portable. As an oxygen flow demand is put on the system, a slight decrease in pressure occurs due to oxygen withdrawal. The saturated liquid oxygen in
the system vaporizes enough gaseous oxygen to maintain system operating pressure. This ensures proper oxygen flow to the patient.
If the liquid oxygen saturation temperature is too low, the corresponding lower saturation pressure causes low oxygen flows to thepatient.

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VII
1 Saturation Principles
HELiOS Portables

If the saturation pressure of the liquid in the portable is greater than 1.93 bar (28 psi) the following symptoms may occur:• Increased product loss and evaporation rate
• Decreased durations• High flow rates• Continuous flow on demand settings• Venting from relief valves• Relief valves frozen open
If the saturation pressure of the liquid in the portable is lower than 1.2 bar (18 psi) the following symptoms may occur:• Decreased evaporation rates• Low flow rates• No oxygen flow
• Portable will not fill
The saturation pressure of the HELiOS portable will be equal to the saturation pressure of the reservoir it was filled from. These problems can be prevented by always ensuring that the reservoir is filled according to its respective service manual.

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VIII Unpacking and Setup
HELiOS Portables

Unpacking
1. Inspect carton for shipping damage. Report any damage
to freight company before signing bill of lading.
2. Check description on carton against your order.
3. Unpack unit, including all accessories and documentation.
4. Set aside packing materials in case unit must be returnedto the factory.
Setup
1. Record the serial number of the unit.
2. Visually inspect the unit for damage from improper handling. Note any dents, cracks, or missing parts.
3. Ensure the vent valve is in the closed position. Be sure
its lever opens and closes smoothly.
4. If possible, connect the H300 or H850 to a reservoir tocheck for smooth coupling.
5. Hold the unit on a table and carefully pull up on the contents indicator strap. Verify that the mechanism moves
smoothly.
6. Verify that the unit has all its warning/caution labels.
Check labels for damage.
7. Wipe away any dust on the unit with a clean, dry, lintfree cloth.
8. Verify that a standard dual lumen cannula will attach tothe unit. It should be rated at least 6 LPM in flow andshould be a maximum of 7 ft (213.4 mm) in length.

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IX Operation
1. Dry the male QDV on the reservoir using a clean, dry, lintfree cloth.
2. Dry the female QDV on the H300 or H850 using a clean, dry,lint-free cloth.
WARNING: The fill connectors must be clean and dry before
filling the H300/H850. Moisture on the fill connectors canlead to leakage of liquid oxygen. Moisture can also cause theunits to freeze together, and can lead to malfunctions of theportable and reservoir.
WARNING: Keep the H300 or H850 upright while drying its
fill connector. Do not turn upside-down.

11. Hold the handle on the H300 or H850 and push the releasebutton on the reservoir down until the fill connectors separate.
NOTE: If the H300 or H850 does not separate easily, do not use
force. The units may be frozen together. Allow the units a few
minutes to warm up and they should separate easily.
WARNING: Should there be any leakage from either the
reservoir or the portable after separation, engage the fillconnectors again immediately. Engaging and disengaging
the connectors will help to dislodge any ice crystals that arepresent. If major leaking and discharge continues, open thevent valve of the reservoir to stop the release of liquid oxygen.
WARNING: Do not touch frosted parts.

3. Check the reservoir contents indicator to make sure there isenough liquid oxygen for the filling process.

12. Check the contents indicator scale to make sure that the unit isfilled to the desired level.

4. Make sure the H300 or H850 FCV is in the off (0) position.

Liquid Level Measurement

5. Hold the H300 or H850 upright with one hand and position its
female QDV over the male QDV on the reservoir.

1. Lift the H300 or H850 by the contents indicator strap.

WARNING: Do not depress or disturb the plastic poppet in
the center of the reservoir’s fill connector. This will cause an
uncontrolled release of liquid oxygen from the reservoir.
6. Place one or both hands on top of the H300 or H850 and press
straight downward. This will lower the unit and properly engage the QDV’s.
NOTE: Do not depress the release button on the reservoir whenengaging the portable unit.
7. While holding the unit firmly in this position, pull the ventvalve lever downward into its open position. A hissing soundwill be heard.

2. Push the bottom backside of the unit forward to that it isstraight up and down.
3. Observe the green indicator bar that displays the liquid oxygen contents level inside the clear window on the back of
the unit. The window is completely filled with the green bar
when the unit is full.
Operation (Filled with Liquid Oxygen)
1. Push one of the tubes from the dual lumen cannula onto the
top cannula barb on the H300 or H850. Place the other tube
onto the lower cannula barb.
2. Properly position the nasal cannula on the patient.

8. Maintain a downward pressure on the H300 or H850 with one
hand during the entire filling process.

WARNING: Do not use a single lumen cannula or a cannula
longer than 7 ft (213.4 cm).

9. Approximately 20-30 seconds into a fill, close and reopen thevent valve one or more times to prevent the vent valve fromfreezing open.

3. Turn the flow control knob on the top of the unit to the prescribed flow setting. Oxygen flow will begin when a breath isdetected.

WARNING: Do not leave the HELiOS portable unattended
during the filling operation. Excessive liquid oxygen
discharge can occur.

NOTE: On the H850, Continuous flow settings are designatedby the letter “C,” and demand flow settings are designated by
the letter “D.” On the H300, all settings of 1.0 and above aredemand flow only.

10. The unit is full when the hissing sound changes in tone and adense white vapor is seen coming from the under the shroudof the reservoir. When this is observed, close the vent valve
by releasing and raising its lever.

HELiOS Portables

Filling

4. To stop oxygen flow, turn the flow control knob to a setting of“0.”

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IX Operation
1. Verify that there is adequate liquid oxygen in the reservoir.
2. Insert the flexible oxygen supply tube connector (P/N
B-701656-SV) into the quick connect on the front of the
H300 or H850 and snap it into place.
3. Locate the DISS nut and tailpiece assembly attached to the
opposite end of the flexible oxygen supply tube.
4. Thread the nut and tailpiece assembly onto the HELiOS reservoir oxygen outlet connector until secure.

WARNING: Use only the recommended flexible oxygen
supply tube and oxygen gas source. Connecting the unit to
an incorrect gas source can cause inhalation of hazardous
substances.
CAUTION: Connect the portable only to a reservoir or othergaseous oxygen source that operates at pressures between
1.41 to 1.62 bar (20.5 and 23.5 psi). Oxygen sources outsideof this range can cause the unit to operate improperly or
damage the unit.

HELiOS Portables

Operation (Using the Oxygen Supply Line)NOTE: The H850 must be used in demand (D) flow settings
when operating from the oxygen supply line.

Figure 18: HELiOS Supply Line Connection
NOTE: If a hissing sound is heard, tighten the connection until
the hissing stops.
5. Push one of the tubes from the dual lumen cannula onto the
top cannula barb on the H300 or H850. Place the other tube
onto the lower cannula barb.
6. Properly position the nasal cannula on the patient.
7. Turn the flow control knob on the top of the unit to the prescribed demand flow setting.

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IX Operation
Product Disposal

The H300 or H850 external case should be cleaned wheneverdirt or grime is visibly evident. It can also be disinfected inaccordance to local regulations and/or the schedule of theindividual DME provider. The below procedure should be
followed for both cleaning and disinfecting the outer case of the
H300 or H850.

At the end of the unit’s life, all reservoir units must be returned toa recycling facility in compliance with applicable codes andregulations. Alternatively, CAIRE may be contacted for disposal
information.

1. Verify that the unit is empty and contains no liquid oxygen.

HELiOS Portables

Exterior Cleaning & Disinfecting

2. Apply a mild cleaning solution and/or disinfectant to a clean
cloth. Wipe the exterior case using this cloth. Table 5 below
is a list of recommended cleaners and disinfectants.
Table 5: Recommended Cleaning & Disinfecting Agents
Cleaning

Disinfecting

Household Glass Cleaner

Sporicidin Disinfectant
Solution

Mild Solution of Dish Washing
Detergent & Warm Water

Household Bleach (1:10
Dilution With Water)

3. Buff out any scuff marks using a Scotch-Brite adhesive padwith detergent.
4. Wipe the case completely dry with a towel.
Interior Cleaning
The H300 and H850 plumbing can be cleaned lightly if necessary.
Follow the below procedure for cleaning the internal componentsof the unit.
1. Remove the cover (RP4).
2. Apply a mild solution of detergent and water to a clean cloth.
Wipe the interior case and plumbing with this cloth.
3. Use a cotton swab to dust and clean in tight places.
4. Dry all components thoroughly with a dry towel and oil-freecompressed gas.
NOTE: Only use disinfectants or cleaning agents approved
for use with this equipment by CAIRE such as Sporicidin,
Hydroklean, or others as specified by CAIRE.

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X Maintenance

CAIRE, Inc. recommends returning the unit to a CAIRE service
facility every 10 years for vacuum check and re-evacuation
if necessary.

a.

Verify that the spring scale reads full.

c.

NER Test (RP22)e.

Demand Flow Control Valve Test (RP19)a.

Empty the liquid oxygen from the unit.

b. Inspect the outer container for cold sweaty conditions
and excessive venting from the relief valve.
d. Economizer Test (RP9)6.

Prepare For Use

HELiOS Portables

There are two schedules for routine maintenance which the homehealth care distributor may follow. These schedules allow the
distributor maximum flexibility while assuring that the equipment is operating properly. CAIRE suggests a continuous (asneeded) and 30 Months schedule for routine maintenanceof the H300 and H850. The distributor may follow eitherschedule, or a combination of the two schedules. Maintenancechecklists are provided for each schedule. See Below.

b. Verify that the contents indicator scale reads empty.

Schedule A – 30 Months Schedule
A. Introduction

The 30-month schedule is a series of tests that should be performed at a minimum of once every 30 months to ensure thatthe equipment is functioning properly.

1. If the unit fails a given test, one of two things may be done:
Refer to the Troubleshooting section of this manual-or-Return the unit to CAIRE, Inc. for repair

2. Schedule – Maximum of 30 months between routine
main-tenance testing.
The unit should be tested
whenever a problem is suspected.

A. Procedure

Follow the steps in order listed. If the unit fails any step, refer toTroubleshooting section of this manual.
1. Visual Inspection:a.

Remove any LOX prior to maintenance (RP3).

b. Inspect the case, flow knob, and vent lever for cracks,
warping, or discoloration.
c.

Verify that the label on the rear cover is present andlegible.

d. Verify that the fill connector poppet is not worn or broken.

e.
f.
3.
4.

Verify that the lip seal in the fill connector is notcracked.
Move the vent lever down to the open position. Verify
that it moves smoothly when opening and closing thevent valve.

Clean and Disinfect the Exterior Case
Gaseous Oxygen Functional Testsa.

Primary Relief Valve Test (RP7)c.

Liquid Leak Detector Test (RP2)

b. Secondary Relief Valve Test (RP8)5.

Fill the unit full of liquid oxygen.

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X MaintenanceStep 10 Year Service Life
1

LOX Purged From Reservoir (Repair Procedure RP3)

Performed or Verified By/Date2

Inpection for Damaged/Missing Parts

Performed or Verified By/Date

3

Contents Indicator Reads Empty and Spring Scale Moves Performed or Verified By/Date
Freely4Remove Cover (Repair Procedure RP4)

Performed or Verified By/Date5

Perform Liquid Leak Detector Test (Repair Procedure
RP2)

Performed or Verified By/Date6

Perform PRV Test (Repair Procedure RP7)

Performed or Verified By/Date

Year 2

Year 4

Year 6

Year 8

NA

NA

NA

NA

Year 10HELiOS Portables

Schedule A (30-Month) Maintenance Checklist
Unit Serial Number:

PRV Crack Pressure
PRV Reseat Pressure
7

Perform SRV Test (Repair Procedure RP8)

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

8

Liquid Contents/Level Indicator Test (Repair Procedure
RP6)

Performed or Verified By/Date

Contents Indicator Window Shows No Green When
Empty And Completely Green When Full
9

Pressure Retention Test (Repair Procedure RP12)

Performed or Verified By/Date
Internal Pressure after 10 Minutes
Internal Pressure after 60 Minutes

10

Replace Case (Repair Procedure RP5)

Performed or Verified By/Date

11

Flow Rate Test (Repair Procedure RP19)(C=continuous; D=demand)

Performed or Verified By/Date
H300

H850

Flow Rate at:

OFF

Off

Flow Rate at:

0.12 (C)

1.0 (C)

Flow Rate at:

0.25 (C)

2.0 (C)

Flow Rate at:

0.5 (C)

3.0 (C)

Flow Rate at:

0.75 (C)

4.0 (C)

Flow Rate at:

1.0 (D)

5.0 (C)

Flow Rate at:

1.5 (D)

6.0 (C)

Flow Rate at:

2.0 (D)

1.5 (D)

Flow Rate at:

2.5 (D)

2.0 (D)

Flow Rate at:

3.0 (D)

2.5 (D)

Flow Rate at:

3.5 (D)

3.0 (D)

Flow Rate at:

4.0 (D)

4.0 (D)

12

Inspect for Cold or Sweaty condition/ Excessive Venting
from RV

Performed or Verified By/Date

13

Perform NER Test (Repair Procedure RP22)

Performed or Verified By/Date
NER Results

14

Empty Contents from Portable (Repair Procedure RP3)

Performed or Verified By/Date

15

Clean and/or Disenfect Outside of Unit

Performed or Verified By/Date16

10 Year vacuum check

Performed or Verified By/Date

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X Maintenance
HELiOS Portables

Schedule B – Continuous (As Needed) Schedule
A. Introduction

Continuous maintenance is a set of tests and inspections to bedone periodically to ensure that the equipment is functioning
properly. It can be done while the equipment is in service bydrivers or other personnel.

1. If a unit fails a given test, it should be taken out of service
and sent to the repair center/department for further inspection.

2. Schedule – The continuous schedule should be performed
every time the driver visits a patient or when their reservoir is filled or replaced. It should also be performed whenequipment is transferred between patients.

B. Procedure
1.
2.

Ensure the unit is empty of liquid oxygen contents.
Visual Inspection

a. Inspect the case, flow knob, and vent valve lever forcracks, warping, or discoloration.

b. Verify that the label on the rear cover is present and legible.

c. Verify that the fill connector poppet is not worn or broken.
d. Verify that the lip seal in the fill connector is not cracked
or showing signs of wear.

e. Move the vent valve lever down to the open position.
Verify that it moves smoothly when opening and closing the vent valve.

3. Clean and disinfect the unit if necessary using the procedures
described in the Operations section of this manual.
4.

5.

Fill the H300 or H850 with LOX.
Post-Fill Inspection

a. Verify that the QDV poppet is closed and not leaking.
b. Verify that the Vent Valve is closed and not leaking.
c. Carefully pull up on the contents indicator strap.

Verify that it moves smoothly and reads accurately.

d. Flow Control Valve Test (RP19)

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X Maintenance
Unit Serial Number:
Pre Fill Visual Inspection
1

Cracking, Discoloration or Warping

Verified By/Date2

QDV Deformation

Verified By/Date3

Liquid Contents/Level Indicator Functionality

Verified By/Date

4

Cryogenic Reservoir Damage (Dents,Dings)

Verified By/Date

5

Visible Dirt or Contamination

Verified By/Date

6

Presence of All Required Labels

Verified By/Date7

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

Verified By/Date

8

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

Verified By/Date9

FCV knob moves smoothly and encounters a detent at each setting.

Verified By/Date

HELiOS Portables

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

Post Fill Visual Inspection
1

QDV Poppet is Closed and Not Leaking

Verified By/Date

2

Vent Valve is Not Leaking

Verified By/Date

3

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

Verified By/Date

4

Liquid Level Contents/Indicator Reads the Accurate Amount

Verified By/Date

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

Introduction------------------------------------------------------------------------------------------ 20
Troubleshooting Charts-------------------------------------------------------------------------21–27
Repair Procedures
RP1
General---------------------------------------------------------------------------------- 31
RP2
Liquid Leak Detector Test------------------------------------------------------------ 31
RP3A
Emptying the Unit (H300)------------------------------------------------------------ 33
RP3B
Emptying the Unit (H850)------------------------------------------------------------ 33
RP4
Cover Removal------------------------------------------------------------------------- 34
RP5A
Front Cover R/R----------------------------------------------------------------------- 34
RP5B
Rear Cover R/R------------------------------------------------------------------------ 35
RP6
Contents Indicator Test--------------------------------------------------------------- 35
RP7
Primary Relief Valve Test------------------------------------------------------------ 36
RP8
Secondary Relief Valve Test--------------------------------------------------------- 37
RP9A
Economizer Test (H300)-------------------------------------------------------------- 38
RP9B
Economizer Test (H850)-------------------------------------------------------------- 38
RP10
R/E Valve R/R------------------------------------------------------------------------- 39
RP11
SRV R/R-------------------------------------------------------------------------------- 39
RP12
Pressure Hold Test--------------------------------------------------------------------- 40
RP13A
Liquid Withdrawl Warming Coil R/R (H300)------------------------------------- 40
RP13B
Liquid Withdrawl Warming Coil R/R (H850)------------------------------------- 41
RP14A
Gas Withdrawl Warming Coil R/R (H300)---------------------------------------- 42
RP14B
Gas Withdrawl Warming Coil R/R (H850)---------------------------------------- 42
RP15A
Vent Valve Assembly R/R (H300)-------------------------------------------------- 42
RP15B
Vent Valve Assembly R/R (H850)-------------------------------------------------- 43
RP16
Vent Valve Disassembly & Repair-------------------------------------------------- 43
RP17A
QDV Assembly R/R (H300)--------------------------------------------------------- 44
RP17B
QDV Assembly R/R (H850)--------------------------------------------------------- 45
RP18
QDV Lip Seal R/R--------------------------------------------------------------------- 45
RP19
Demand Flow Control Valve Test--------------------------------------------------- 46
RP20
Demand FCV R/R--------------------------------------------------------------------- 48
RP21
Demand FCV Filter Screen Replacement------------------------------------------ 48
RP22
Normal Evaporation Rate (NER) Test---------------------------------------------- 49
RP23
Oxygen Supply Line Quick Connect R/R------------------------------------------ 49
RP24
Inline Check Valve R/R--------------------------------------------------------------- 49
RP25
Compression Fitting (Nut & Ferrule) Replacement------------------------------- 50
RP26
Flexible Tubing Replacement-------------------------------------------------------- 50
RP27
CPC Connector Kit Installation------------------------------------------------------ 50HELiOS Portables

Table of Contents

Introduction
1. These procedures are designed to be performed only by qualified personnel with proper equipment.
2. Any failure during routine maintenance checks will refer you to this section. See troubleshooting chart for appropriate
procedure.
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XI
1 Troubleshooting & Repair Procedures
When more than one probable cause is identified, the causes are listed in order of most likely to least likely reasons for the problem.
Table 6: Troubleshooting
Symptom
1) Unable to start fill orexcessively long filltimes2) Liquid leaks from thecoupled QDVs during
the fill3) Unable to disconnect
the portable from thereservoira)Probable Cause

Corrective Action

QDV not properly engaged on the reservoir

Make sure the QDV on the portable and reservoir areproperly aligned and ensure that a downward force isbeing applied to the portable.

b) Reservoir is empty

Swap or re-fill the reservoirc)Ensure that the vent valve lever is fully in the open
position. The lever must be open to begin a fill.

Vent valve not opend) FCV is open

Be sure that the FCV knob is in the off (“0”) position. If the valve is open, fill times can increase.

e)Reservoir saturation pressure is too low

Swap reservoirs or allow the reservoir time to stabilize and build pressuref)Vent valve is obstructed

Inspect the vent tubes for blockages. Clean by blowing out with compressed gas or replace parts if necessary.

g) Leak in the system

Check the portable for leaks (RP2) and repair ifneeded.

h) QDV damaged or faulty

Inspect the QDV and be sure the poppet opens properly and smoothly. If necessary, replace the QDVassembly (RP17)i)

Faulty vent valve

Replace the vent valve (RP15)a)Worn or damaged lip seal

Replace the QDV lip seal (RP18)a)Pop-off assembly not being utilized

Ensure that the pop-off assembly on the reservoir isbeing used. Do not use force to separate the QDVs.

b) QDVs are frozen together

HELiOS Portables

Table 6 below provides troubleshooting procedures for the HELiOS portables. 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.

Leave the units coupled with the vent valve closed
and let them sit until they warm up enough to disconnect. Always ensure that male and female QDV’s
are cleaned and dried prior to each fill.

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XI
1 Troubleshooting & Repair Procedures
Symptom
4)5)6)Liquid leaks from the
QDV poppet after filling

Liquid leaks from thevent valve tube/outlet

Excessive venting fromrelief valves (hissing
sound)a)

No Flow

Corrective Action

Ice crystal preventing the QDVfrom closing properly.

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

b) Dirty or damaged QDV poppet

Replace the QDV assembly (RP17)a) Vent valve is not fully closed

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

The portable has been transb) ported or laid in an improper
operating position

Return the portable to an upright or acceptable operating position and allow several minutes for stabilization.

c) Vent valve is frozen open

Allow the portable to warm until the vent valve can close.
After the warm up, allow up to 60 minutes for the portable tostabilize and build pressure before operating.

d) Faulty vent valve

Replace the vent valve (RP15)

The portable has been transa) ported or laid in an improper
operating position

Return the portable to an upright or acceptable operating position and allow several minutes for stabilization.

b) Saturation pressure too high.

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

c) Relief valve frozen open

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

d) Faulty relief valve

Test the relief valve (RP7 & RP8) and replace if necessary(RP10 & RP11)e)7)

Probable Cause

Partial or complete loss of
vacuumConduct the NER test (RP22) and return the unit to CAIRE,
inc. if necessary.

a) Portable is empty

Check the contents indicator/level gauge and fill the portable
if needed.

b) Flow control valve turned off

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

c)

HELiOS Portables

Table 6 (cont.)

Nasal cannula kinked or disconEnsure proper nasal cannula functionality and positioning
nectedd) Saturation pressure is too low

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

e) Leak in the system

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

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XI
1 Troubleshooting & Repair Procedures
Symptom

Probable Causef)Vent valve is openg) FCV inlet filter is obstructed

8)

Low flow at all
LPM settings

Ensure that there is no venting from the vent valve outlet/tube. If
there is refer to the corrective actions for “Liquid leaks from thevent valve tube/outlet”
Clean or replace (RP21) the filter screen.

h)­­­­­Blockage in the liquid withdrawal Check the warming coils and withdrawal tubes for blockages.
circuitReplace if necessary.

i­­­)

FCV Faulty

Replace the FCV (RP20)a)

Nasal cannula kinked or leaking

Inspect the functionality of the nasal cannula.

b) Saturation pressure is too low

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

c)Leak in the system

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

d)Flow control valve inlet filter
screen dirty

Clean or replace (RP21) the filter screen.

e)Economizer valve faulty

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

f)Blockage in the liquid withdrawal Check the warming coils and withdrawal tubes for blockages.
circuitReplace if necessary.

g) FCV faulty
9)

Corrective Action

Unit stops pulsing ina)demand mode

Cannula is disconnectedb) Cannula is blocked or kinked

Replace the FCV (RP20)
Ensure the nasal cannula is firmly attached to the barb(s).
Inspect the cannula for kinks, bends, or water droplets. Replace
the cannula if necessary.

c)Cannula tips not positioned prop- Ensure the cannula remains in the nostrils and do not slide to one
erly in the nose
side.

d)

Patient is breathing with theirmouth open.

Patient must inhale through their nose to initiate pulse/demand
flow.

e)

Saturation pressure is out ofspecification

Reference symptom 14). Inspect the saturation pressure of the reservoir used for filling. Allow at least 30 minutes at no flow for the
portable to saturate properly.

f)Leak in the system

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

g) Faulty FCVHELiOS Portables

Table 6 (cont.)

Test the FCV (RP19) and replace if necessary.

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XI
1 Troubleshooting & Repair Procedures
HELiOS Portables

Table 6 (cont.)
Symptom

Probable Cause

10) Flow stops suda)
denly on continuous setting
NOTE: For continuous flow to continue b)
a inhalation must
be detected periodi- c)cally. Refer to the
Theory of Operationd)
section of thismanual for more information.
e)f)11) Unit flows continuously on demanda)settings12) Increased NER

Corrective Action

Cannula is disconnected

Ensure the nasal cannula is firmly attached to the barb(s). Must be
using a dual lumen cannula connected to both ports.

Cannula is blocked or kinked

Inspect the cannula for kinks, bends, or water droplets. Replace
the cannula if necessary.

Cannula tips not positioned prop- Ensure the cannula remains in the nostrils and do not slide to one
erly in the nose
side.
Patient is breathing with theirmouth open.

Patient must inhale through their nose to initiate continuous flow.

Saturation pressure is out ofspecification

Reference symptom 14. Inspect the saturation pressure of the reservoir used for filling. Allow at least 30 minutes at no flow for the
portable to saturate properly.

Faulty FCV

Test the FCV (RP19) and replace (RP20) if necessary.

Saturation Pressure is too highInspect the saturation pressure of the reservoir used for filling.
Allow at least 30 minutes at no flow for the portable to saturate
properly.

b) Faulty FCV

Test the FCV (RP19) and replace (RP20) if necessary.

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

Saturation Pressure is too highb) Leak in the system

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

c)Relief valve open

Ensure that there is no venting from the relief valves. If there isrefer to the corrective actions for “Excessive venting from relief
valves (hissing sound)”d)Partial or complete loss of vacuum

Conduct the NER test (RP22) and return the unit to CAIRE, Inc. ifnecessary.

13) Excessive Frost
NOTE: Minimal
frost on the case and a) Frost is acceptableon the plumbing isnormal. This symptom applies to frostthat is much greater b) High humidity level
than what is normally observed.
c) Saturation pressure is too highSome frost on the outer case and on the plumbing is acceptable,
especially at high flow rates during continuous use. This is due tothe evaporation of LOX to gas and the temperature difference between the LOX and room temperature.
High humidity levels can increase frost accumulation.
Inspect the saturation pressure of the reservoir used for filling.
Allow at least 30 minutes at no flow for the portable to saturate
properly.

d) Leak in the system

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

e)Relief valve open

Ensure that there is no venting from the relief valves. If there isrefer to the corrective actions for “Excessive venting from relief
valves (hissing sound)”f)Partial or complete loss of vacuum

Conduct the NER test (RP22) and return the unit to CAIRE, Inc. ifnecessary.
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XI
1 Troubleshooting & Repair Procedures
Symptom

Probable Cause

14) Unit will not maintain acceptable pres- a)sure when in use

15) Unit will not maintain acceptablepressure in standby
mode

Saturation pressure is out ofspecification

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

b) Leak in the system

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

c)

Economizer valve faulty

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

a)Saturation pressure is out ofspecification

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

b) Leak in the system

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

c)Test the PRV (RP7) and replace (RP10) if necessary.

PRV faulty

HELiOS Portables Technical Service Manual • PN 20562190 Rev F

HELiOS Portables

Table 6 (cont.)

5 29

XI
1 Troubleshooting & Repair Procedures
HELiOS Portables
HELiOS Portables Technical Service Manual • PN 20562190 Rev F

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XI Troubleshooting & Repair Procedures
HELiOS Portables
HELiOS Portables Technical Service Manual • PN 20562190 Rev F

5 31

XI Troubleshooting & Repair Procedures
RP2 – Liquid Leak Detector Test

The following procedures have been carefully prepared to allow
proper removal and replacement of defective components andshould be used in conjunction with the Troubleshooting Chart andthe tests in this section.

1. Remove the covers (RP4).

WARNING: Parts that are welded in place must not be
replaced in the field. Should these parts fail, return complete
assembly or sub-assembly to factory for repair. DO NOT use
solder or silver solder to repair broken welds.

2. Place the cryogenic container assembly on a portable test
fixture (B-778202-00). Stand the front cover, with the tubing still connected, next to the bottle assembly as shown in
Figure 19.
NOTE: For newer units manufactured without the CPC
Connector, the CPC Connector Kit will need to be installed,please refer to RP27.

HELiOS Portables

RP1 – General

WARNING: The manufacturer of Fluorolubricant warns users
not to allow Fluorolubricant to contaminate tobacco products.
Wash Fluorolubricant from hands before smoking.
WARNING: Do not use glue type thread locking compounds
or unapproved sealants on any repairs.
CAUTION: When replacing components, make sure the newpart is oriented exactly the same as the original part prior to
installation.
CAUTION: Some components require a specific amount of
torque when assembling. Follow torque requirements where
specified.
NOTE: All replacement parts must be factory approved,
cleaned for oxygen service, and stored in sealed plastic bags.
The repair area must be clean and separate from other areas.
Room air should be filtered, and free from dust, soot, and othercontaminants.
NOTE: When replacing components with pipe threads, use
PTFE tape thread sealant. Apply two rounds of PTFE tape tothreads near end of component, avoiding first thread.
NOTE: When assembling new compression fittings, tighten
1/8”, 1/4” and 1/2” nuts eight flats past finger tight and 3/16”
nuts five flats past finger tight. When reassembling previously
used compression fittings, tighten nuts one to two flats past
finger tight.

Figure 19: Portable Test Fixture
3. Attach a test pressure gauge (B-701732-00) to the top (delivery) cannula barb of the unit.
4. Turn the flow control knob to a continuous flow setting(0.75 on the H300, C6 on the H850)
5. Attach the DISS nut and tailpiece of a HELiOS oxygen supply line (B-701656-SV) to a 0-6.89 bar (0-100psi) gaseous
oxygen source as shown in Figure 20.
NOTE: If an adjustable 0-6.89 bar (0-100 psi) gaseous
oxygen source is not available, the H300 or H850 may bepressurized from a HELiOS reservoir that is at operatingpressure.
6. Insert the opposite end of the HELiOS oxygen supply line
into the quick connect on the front cover of the H300 or
H850 as shown in Figure 20.
7. Increase the gaseous oxygen source pressure until the test
pressure gauge reads 1.52 to 1.59 bar (22-23 psi).
8. Use a liquid leak detector to test all fittings, connections,and joints.
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XI Troubleshooting & Repair Procedures
14. Disconnect the test pressure gauge and the HELiOS oxygen
supply line.
15. Reinstall the case (RP4).
NOTE: This is not required for newer units manufactured
without the CPC Fitting.

HELiOS Portables

bling occurs, replace the inline check valve (RP24).

Figure 20: Pressurizing the HELiOS Portable
9. Repair or replace any fittings, connections, or components
found to be leaky.
CAUTION: Do not apply leak detector to the vent port near thebottom of the demand flow control valve. Valve malfunction
will occur.
10. Wet a finger with leak detector and lightly place it against
the open end of the vent tube near the bottom of the unit asshown in Figure 21. If bubbling occurs, verify that the ventvalve closes completely. If bubbling continues, replace thevent valve (RP15).
NOTE: Continually monitor the test pressure gauge while
leak checking the unit to verify that the pressure in the systemremains above 1.52 bar (22 psi).
11. Disconnect the HELiOS oxygen supply line from the quickconnect on the front cover.
12. Insert an open-ended HELiOS oxygen supply line coupling(B-701686-00) into the quick connect on the front cover.

Figure 22: Inline Check Valve Leak Test
NOTE: A large leak in the check valve may bleed down thepressure before you can insert the coupling for the bubble test.
You will typically hear gas escape from the quick connect
when there is a large check valve leak. Verify that 22psi stillreads on the pressure gauge.

NOTE: If unit was equipped without CPC fittung, remove kit
and install tube in reverse order of RP27.

Figure 21: Vent Outlet Leak Testing
13. Wet a finger with leak detector and lightly place it against
the open end of the coupling as shown in Figure 22. If bubNOTE: Steps 11-13 are not required for newer units
manufactured without the CPC Fitting.

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XI Troubleshooting & Repair Procedures
2. Remove the DISS barb adaptor from the Jet Venturi
Assembly (B-778210-00).

7. Allow the H300 to deliver continuous flow until the unit isempty.

3. Attach that end of the Jet Venturi to the top cannula barb of
the H300.

8. Set the flow control to 0 and disconnect the tubing and Jet
Venturi.

4. Attach the opposite end of the Jet Venturi to the bottom
cannula barb of the H300.

9. Verify that the unit is empty using the contents indicatorscale.

5. Open the Jet Venturi needle valve. Ensure that the Jet
Venturi outlet and the bleed port remain open.

10. Open the vent valve to vent any residual pressure.

CAUTION: Damage to the demand flow control valve ispossible. Make sure you hook up the tube exactly as shown in
Figure 19 and do not block the Jet Venturi outlet or the bleed
port.

HELiOS Portables

1. Set the flow control valve to a setting of 4.

6. Squeeze the tube connected to the bottom cannula barb.
You should hear and/or feel a continuous flow of oxygen
coming from the open connection of the Jet Venturi.

RP3A – Emptying the Unit (H300)

RP3B – Emptying the Unit (H850)
1. Set the flow control valve to a setting of 6.0 LPM
Continuous (C6).
NOTE: The procedure for the H300 can be duplicated on the
H850 if continuous flow is not achieved by blowing into thecannula.
2. Blow into the bottom cannula barb to initiate oxygen flow.
3. Allow the H850 to deliver continuous flow until the unit isempty.
4. Turn the FCV knob to 0 and verify that the H850 is empty
by picking up the contents indicator strap.

Figure 23: Jet Venturi installation

5. Open the vent valve to vent any residual pressure.

Figure 24: Jet Venturi assembly
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XI Troubleshooting & Repair Procedures
HELiOS Portables

RP4 – Cover Removal
1. Empty the unit (RP3).
2. Place the unit on its side with the rear cover facing you.
3. Use a T10 Torx driver to remove the Torx screws (7 in the
H300, 10 in the H850) from the rear cover.
4. Pull both legs of the carrying handle away from the covers
simultaneously.
5. Separate the rear cover about 3/4 in (2 cm) from the front
cover, and then slide it down about 3/4 in (2cm).
6. Rotate the cover counterclockwise until the vent valve lever can be pulled thought the clearance opening in the rearcover.
7. H850 Only: Remove the screw holding the vent valve to thefront cover and unsnap the QDV from the front cover.
8. Carefully lift the container assembly up and away from thefront cover and place it on the table next to the cover.
9. Re-install the case by reversing steps 1-8.

Figure 26: H850 Container Removal
NOTE: Use the two longer cover screws in the top two screw
holes. Do not over tighten the screws.
NOTE: Make sure that the two indexing pins on the front of
the demand flow control valve engage the corresponding index
holes in the front cover. Center the container assembly in thefront cover mounting bosses. Ensure that the container liquid
withdrawal tube is not pinched between the front cover and thefill connector.
NOTE: Fully seat the carrying handle in the cover handle
bosses. The handle should angle toward the front of the unit.
RP5A – Front Cover R/R
1. Remove the cover (RP4)
2. Pull straight back on the flow control knob from the outsideof the front cover to remove it.
3. Pull the demand flow control valve back out of its seat inside the front cover.
4. Disconnect the two flexible silicone tubes from the back of
the cannula barbs.

Figure 25: H300 Container Removal

5. Disconnect the black urethane tube from the inlet barb of theinline check valve.
NOTE: This is not required for newer units manufactured
without the CPC Fitting.
6. Remove the C-Clips that secure the cannula barbs to thefront cover using a flat head screwdriver.
7. Remove the cannula barbs from the outside of the front
cover.

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XI Troubleshooting & Repair Procedures
NOTE: This is not required for units manufactured without
the CPC Fitting.
9. Remove the quick connect from the outside of the cover.
NOTE: This is not required for units manufactured without
the CPC Fitting.
10. To replace the front cover, reverse steps 1-9.

HELiOS Portables

8. Remove the nut that secures the oxygen supply line quickconnect to the front cover using a 5/8 inch open-end wrench.

NOTE: Install the steel pull handle so that the arm with twoholes is the farthest from the vent lever opening. Insert thestraight leg of the hitch pin through the upper hole in the pullhandle until the pin snaps into place. The open end of thehitch pin should face the center of the rear cover.
NOTE: When installing the contents indicator springs, makesure that the open ends of the spring hooks face the centerof the rear cover. The top spring hooks must fit through theholes in the indicator plate arms and the steel pull handle.
The non-stick pad must be in position behind the steel pullhandle.
NOTE: When replacing the rear cover, be sure to install a
new warning label.

RP5B – Rear Cover R/R
1. Remove the case (RP4)
2. Disconnect the two contents indicator assembly springs
from the spring hooks (shown in Figure 23) molded into thebottom of the rear cover by grasping the hooked ends withneedle-nose pliers.
3. Disconnect the two springs from the contents indicator assembly steel pull handle and indicator plate by grasping thehooked ends with needle-nose pliers.
CAUTION: Do not over-stretch the contents indicator spring.
This can cause inaccurate readings.
Non-stick Pad
Indicator
Plate
Hitch Pin

SpringHooks

RP6 – Contents Indicator Test
1. Verify that the unit is empty and nothing is attached to it.
2. Place the H300 or H850 on a table and hold it down whilegently pulling up on the contents indicator strap. Verify thatthe indicator operates smoothly and without binding.
3. Suspend the unit in the air by its contents indicator strap
only. Verify that the green bar does not appear in the window on the rear case.
4. Completely fill the unit with liquid oxygen.
5. Lift the unit in the air by its contents indicator strap.
6. Push the bottom backside of the unit gently forward so thatit stands straight vertically. Verify that the green bar fills thewindow on the rear case.
7. If the contents indicator reads inaccurately, replace the contents indicator (RP5B).

Figure 27: Contents Indicator Spring
4. Slide the indicator plate off the end of the steel pull handle.
5. Remove the hitch pin (if present) from the steel pull handle.
6. Slide the steel pull handle out the top of the rear cover.
7. Remove the non-stick pad located above the two pull handle
guides.
8. Remove the carrying strap from the steel pull handle.
9. To replace the rear cover, reverse steps 1-8.
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XI Troubleshooting & Repair Procedures
HELiOS Portables

RP7 – Primary Relief Valve Test
1. Remove the covers (RP4).
2. Set the container assembly on the portable test fixture (B778202-00).
NOTE: For newer units manufactured without the CPC
Connector, the CPC Connector Kit will need to be installed,please refer to RP27.
3. Stand the front cover, with tubing still connected, next to thecontainer assembly as shown in Figure 19.
4. Set the flow control knob in the off position (0).
5. Attach the DISS nut end of a HELiOS oxygen supply line
(B-701656-SV) to an 0-6.90 bar (0-100 psi) source of gaseous oxygen.
6. Insert the opposite end of the HELiOS oxygen supply line
into the quick connect.
7. Disconnect the flexible vent tube from the barbed fitting at
the vent valve outlet.
8. Connect the test pressure gauge tube to the vent valve
barbed fitting and secure it with a tie wrap as shown in figure 28.

Figure 29: PRV Liquid Leak Testing
11. Slowly increase the gaseous oxygen source pressure until
tiny, foam-like bubbles just begin to form on the surface ofthe silencer disk to indicate that the PRV has opened. You
can also listen for an audible hissing sound.
12. Verify that the PRV opens at ≤1.90 bar (≤27.5 psi) on the
H300, or 1.79-2.07 bar (26-30 psi) on the H850.
13. If the opening pressure is not within the acceptable range,
repeat the PRV test. If the PRV fails to open in the acceptable range a second time, replace the R/E valve (RP10).
14. Slowly reduce the gaseous oxygen source pressure until thestream of bubbles begins to diminish.
15. Verify that the PRV closes (bubble begin to diminish) at apressure greater than 1.59 bar (23psi) for the H300, or 1.72
bar (25 psi) for the H850.
16. If the closing pressure does not meet the acceptable range,
repeat the test. If the PRV fails to re-seat in the acceptable
range a second time, replace the R/E valve (RP10).
17. Remove the test pressure gauge and nut/spacer from the ventvalve.
18. Reconnect the flexible vent tube to the vent valve barbed fitting.
NOTE: If unit was equipped without CPC fitting, remove kit
and reinstall tube in reverse order of RP27.
19. Re-install the case (RP4).

Figure 28: Test Pressure Gauge Set-Up
9. Use a 3/16 inch tubing nut (B-775067-00) or 2 inch (5.08cm) spacer to prop the vent valve lever in the open position.
10. Place one drop of leak detector on the R/E valve bronze ventport silencer disk shown in Figure 29.
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XI Troubleshooting & Repair Procedures
1. Remove the covers (RP4).
2. Set the container assembly on the portable test fixture.

(1.27 cm) long. Place the smaller end of the rubber stopper
over the R/E valve vent port. Position the bar clamp stationary arm on the larger end of the stopper and the moveable
arm on the R/E valve body. Tighten the clamp to seal thevent port.

3. Place the front cover, with tubing still connected, next to thecontainer assembly as shown in Figure 19.
NOTE: Note: For newer units manufactured without the CPC
Connector, the CPC Connector Kit will need to be installed,please refer to RP27.
CAUTION: Disconnect and clamp off the demand flow
control valve oxygen inlet tube before performing thesecondary relief valve test. High test pressure can damage
the FCV.

4. Disconnect the 1/16 in (0.15 cm) diameter urethane tube
from the demand flow control valve inlet barbed fitting(toward the front of the valve). Clamp the inlet tube with atubing clamp or hemostat.

HELiOS Portables

RP8 – Secondary Relief Valve Test

Figure 31: Bar Clamp Sealing the R/E Port
12. Slowly pressurize the H300 or H850 by adjusting the gaseous oxygen source regulator.
13. Verify that the secondary relief valve opens (audible hiss) at
5.24-5.79 bar (76-84 psi).
NOTE: If the SRV opens at a pressure slightly higher than the
SRV setting, reduce the oxygen source pressure to 3.45 bar (50psi). Release the tubing clamp or hemostat until the pressurein the H300 or H850 drops to 3.45 bar (50 psi). Re-clamp theinlet tube and repeat the test a second time. If the SRV fails thetest again, replace the SRV (RP11).

inlet
fitting
hemostatclamp

Figure 30: Disconnecting the FCV Inlet Tube
5. Set the flow control knob in the off position (0).
6. Attach the DISS end of a HELiOS oxygen supply line
(B-701656-SV) to a 0-6.90 bar (0-100 psi) source of gaseous
oxygen.
7. Insert the opposite end of the HELiOS oxygen supply line
into the quick connect on the front cover.
8. Disconnect the flexible vent tube from the barbed fitting at
the vent valve outlet.
9. Connect the test pressure gauge tube to the vent valve
barbed fitting as shown in Figure 28 and secure it with a tie
wrap.
10. Use a 3/16 in (0.48 cm) tubing nut (B-775067-00) or 2 in
(5.08 cm) spacer to prop the vent valve lever in the open position.
11. Obtain a 6 in (15.24 cm) micro clamp bar and size 00 rubber
stopper. Trim the rubber stopper so that it is about 0.5 in

14. Slowly reduce the pressure of the gaseous oxygen source
until the audible hissing noise is no longer heard.
15. Verify that the SRV closes (audible hiss no longer heard) at
a pressure greater than 4.41 bar (64 psi).
NOTE: If the SRV does not close within this range the firsttime, repeat the SRV test. If it fails to close within an acceptable
range the second time, replace the SRV (RP11).
16. Reduce the oxygen source pressure to 0 bar/psi and disconnect the HELiOS oxygen supply line from the quick connect
on the front cover.
17. Disconnect the test pressure gauge from the vent valve andvent the pressure in the unit through the open vent valve.
18. Connect the flexible vent tube to the vent valve barbed fitting and remove the nut or spacer propping the vent lever
open.
19. Remove the bar clamp and the tubing clamp/hemostat.
20. Connect the urethane tube to the FCV.
NOTE: If unit was equipped without CPC fitting, remove kit
and reinstall tube in reverse order of RP27.
21. Re-Install the covers (RP4).
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XI Troubleshooting & Repair Procedures
1. Make sure the unit has been leak tested (RP2).
2. Fill the H300 from a properly saturated source of liquid oxygen.

15. If the economizer pressure is not within 1.41-1.59 bar (20.523.0 psi), replace the R/E valve (RP10).
16. Reassemble the unit by reversing steps 1-12.

3. Remove the case (RP4).

RP9B – Economizer Test (H850)

4. Set the unit on the portable test fixture.

1. Make sure the unit has been leak tested (RP2).

5. Stand the front cover, with tubing connected, next to the bottle assembly as shown in Figure 19.

2. Fill the H850 from a properly saturated source of liquid oxygen.

6. Allow the unit to sit undisturbed for 30 minutes to stabilize
at its primary relief valve setting.

3. Remove the case (RP4).

7. Disconnect the flexible vent tube from the barbed fitting on
the vent valve.
8. Connect a test pressure gauge to the vent valve barbed fitting and secure it with a tie wrap.
9. Prop the vent valve lever in the open position using a 3/16
in (0.48 cm) tubing spacer nut. Verify that the test pressuregauge reads 1.65-2.07 bar (24-30 psi) and that the primary
relief valve is venting.

HELiOS Portables

RP9A – Economizer Test (H300)

4. Set the unit on the portable test fixture.
5. Stand the front cover, with tubing connected, next to the bottle assembly as shown in Figure 19.
6. Allow the unit to sit undisturbed for 30 minutes to stabilize
at its primary relief valve setting.
7. Disconnect the flexible vent tube from the barbed fitting on
the vent valve.

10. Set the flow control knob to a setting of 2.

8. Connect a test pressure gauge to the vent valve barbed fitting
and secure it with a tie wrap.

NOTE: The H300 must deliver continuous flow to performthe Economizer Test. The following steps use the Jet Venturi
assembly to ensure that the H-300 provides continuous flow for
the economizer test.

9. Prop the vent valve lever in the open position using a 3/16
in (0.48 cm) tubing spacer nut. Verify that the test pressuregauge reads 1.79-2.07 bar (26-30 psi) and that the primary
relief valve is venting.

11. Connect the jet/venturi assembly to the sense cannula barbon the H300 front cover.

10. Set the flow control knob to a setting of C6.

12. Connect the DISS tubing adapter on the long tube of the jet/venturi assembly to an adjustable 0-6.90 bar (0–100 psi)
source of gaseous oxygen.
CAUTION: Damage to the demand FCV is possible. Make sure
you hook up the Jet Venturi exactly as described. Do not block
the outlet port on the Jet Venturi assembly.
13. Increase the adjustable gaseous oxygen source pressure until you feel a continuous oxygen flow from the top cannulabarb of the H300.

NOTE: The H850 must deliver continuous flow to test theeconomizer valve.
11. Check the reading on the test pressure gauge every 5 minutes
until the pressure stabilizes. Stabilization occurs when two
consecutive pressure readings are within 0.069 bar (1 psi) of
each other.
12. If the economizer pressure is not within 1.53-1.71 bar(22.25-24.75 psi), replace the R/E valve (RP10).
13. Reassemble the unit by reversing steps 1-9.

14. Check the reading on the test pressure gauge every 5 minutes until the pressure stabilizes. Stabilization occurs when
2 consecutive pressure readings are within 0.069 bar (1 psi)of each other.

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XI Troubleshooting & Repair Procedures
13. Install the barbed fitting in the R/E valve outlet arm.

1. Remove the covers (RP4).

14. Install the flexible urethane tube on the barbed fitting.

2. Remove the flexible urethane tube from the barbed fitting on
the R/E valve outlet arm. Use a 1/4 inch open-end wrench
to remove the barbed fitting.

NOTE: The R/E valve arms should face the container.

3. Use an adjustable wrench to hold the R/E valve inlet arm
stationary. Use a 7/16 inch open-end wrench to remove thegas withdrawal warming coil compression nut from the inlet
arm fitting.
4. Pull the gas withdrawal warming coil tube out of the fitting.
RE Valve

15. Replace the case (RP4).

HELiOS Portables

RP10 – R/E Valve R/R

RP11 – SRV R/R
1. Remove the covers (RP4).
2. Use an adjustable wrench to hold the R/E valve inlet arm
stationary.
3. Use a 1/2 inch open-end wrench to remove the SRV.
4. Apply Teflon tape to the threads of the new SRV.

Secondary Relief
Valve

Figure 32: Gas Withdrawal Coil Removal
5. Use an adjustable wrench to hold the R/E valve outlet arm
stationary. Use a 1/2 inch open-end wrench to remove theliquid withdrawal warming coil compression nut from theoutlet arm fitting.
6. Pull the liquid withdrawal warming coil tube out of the fitting.
7. Use an adjustable wrench to hold the R/E valve inlet arm
stationary. Use a 1/2 inch open-end wrench to remove thesecondary relief valve.

5. Install the new SRV in the R/E valve inlet arm port.
6. Use an adjustable wrench to hold the R/E valve stationary.
7. Use a 1/2 inch open-end wrench to tighten the SRV until
snug.
CAUTION: High pressure hazard. Over tightening the SRV
can cause it to operate improperly. Do not over tighten thevalve. Always perform the SRV test (RP8) after installation.
8. Replace the outer case (RP4).

8. Apply Teflon tape sealant to the threads of the SRV if
needed.
9. Install the SRV in the inlet arm port of the new R/E valve
and tighten it until snug.
10. Insert the gas withdrawal warming coil (smaller diametercoil) tube in the R/E valve inlet arm fitting and finger tighten
the compression nut.
11. Insert the liquid withdrawal warming coil (larger diametercoil) in the R/E valve outlet arm port and finger tighten thecompression nut.
12. Tighten both compression nuts using a 7/16 inch open-end
wrench on the nuts and an adjustable wrench on the R/Evalve arms.

HELiOS Portables Technical Service Manual • PN 20562190 Rev F

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XI Troubleshooting & Repair Procedures
RP13A – Liquid Withdrawal Warming Coil R/R (H300)

1. Attach a test pressure gauge (B-701732-00) to the top cannula barb on the front cover of the H300 or H850.

1. Remove the covers (RP4).

NOTE: For newer units manufactured without the CPC
Connector, the CPC Connector Kit will need to be installedfirst, refer to RP27, then reinstall the front case.
2. Set the flow control knob to a continuous flow setting (0.75
on the H300, C6 on the H850).
3. Attach the DISS nut and tailpiece of a HELiOS oxygen supply line (B-701656-SV) to a 0-6.90 bar (0-100 psi) source ofgaseous oxygen.

2. Use an adjustable wrench to hold the R/E valve outlet arm(with barbed fitting) stationary. Use a 7/16 inch open-end
wrench to remove the liquid withdrawal warming coil compression nut from the R/E valve fitting.
3. Use a 5/16 inch open-end wrench to hold the fitting on thestainless steel container tube stationary. Use a 7/16 inch
open-end wrench to remove the remaining liquid withdrawal
coil compression nut from the fitting.

HELiOS Portables

RP12 – Pressure Hold Test

4. Insert the opposite end of the HELiOS oxygen supply line in
the quick connect.
5. Increase the gaseous oxygen source pressure until the test
pressure gauge reads 1.52 bar (22 psi) for the H300, or 1.65
bar (24 psi) for the H850.
NOTE: If you do not get a reading on the pressure gauge, reset
the demand valve as follows. Connect one tube of a dual-lumen
cannula to the bottom cannula barb and breathe in once or
twice.
6. Disconnect the HELiOS oxygen supply line from the quickconnect.
7. Allow the unit to sit undisturbed for 10 minutes.

Figure 33: Compression Nut Removal
4. Pull the ends of the warming coil from their fittings and remove the coil.

8. Verify that the portable maintains a minimum pressure of
1.03 bar (15 psi) for the H300, or 1.24 bar (18 psi) for the
H850 at the end of the evaluation period.

NOTE: Make sure to route the flexible urethane vent tube
through the inside of the warming coil positioned directly
below the vent valve.

9. If the pressure drops below this level, locate the leak by performing the liquid leak detector test (RP2).

5. To reinstall the warming coil, reverse steps 1-4.

10. Disconnect the test pressure gauge.
NOTE: If unit was equipped without CPC fitting, remove kit
and reinstall tube in reverse order of RP27, then reinstall front
case.

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XI Troubleshooting & Repair Procedures
HELiOS Portables

RP13B – Liquid Withdrawal Warming Coil R/R (H850)
1. Remove the covers (RP4).
2. Remove the flexible urethane tube from the barbed fitting on
the R/E outlet arm.
3. Remove the flexible urethane tube from the barbed fitting on
the side of the vent valve.
4. Cut and remove the two zip ties (if present) that secure theliquid withdrawal coil to the gas withdrawal coil at the topof the cryogenic container.
5. Use a 3/8 inch open-end wrench to hold the R/E valve outletarm (with barbed fitting) stationary. Use a 1/2 inch open-end
wrench to remove the liquid withdrawal coil compression
nut from the R/E valve fitting.
6. Use a 3/8 inch open-end wrench to hold the fitting on thestainless steel container tube stationary. Use a 1/2 inch openend wrench to remove the liquid withdrawal compression
nut from the fitting.
7. Pull the ends of the warming coil from their fittings.
8. Remove the warming coil.
9. Remove the two plastic insulator wraps from the warming
coil (if present) and save them for use on the replacement
coil.

Insulator
Wraps

Figure 34: Insulator Wrap Locations
10. Replace the liquid withdrawal coil by reversing steps 1-9.
NOTE: Make sure to route the 1/8 in flexible urethane venttube through the inside of the warming coil positioned directly
below the vent valve.
NOTE: Install the two plastic insulator wraps on the new
warming coil at the locations shown in Figure 46.
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XI Troubleshooting & Repair Procedures
1. Remove the covers (RP4).
2. Use an adjustable wrench to hold the R/E valve inlet arm(with the SRV) stationary. Use a 7/16 inch open-end
wrench to remove the gas withdrawal warming coil compression nut from the R/E valve fitting.
CAUTION: Be careful not to dent the top of the container when
performing the following step.
3. Use an adjustable wrench to hold the vent valve mounting
block on the top of the container stationary. Use a 7/16 inch
open-end wrench to remove the remaining gas withdrawal
coil compression nut from the mounting block fitting.
4. Pull the ends of the gas withdrawal coil from their fittings
and remove the coil.
5. Replace the gas withdrawal coil by reversing steps 1-4.

RP14B – Gas Withdrawal Warming Coil R/R (H850)

5. Use a 7/16 inch open-end wrench to hold the manifold blockon the top of the container stationary. Use a 7/16 inch openend wrench to remove the remaining gas withdrawal coilcompression nut from the manifold block.
6. Remove the ends of the warming coil from their fittings.
7. Remove the gas withdrawal coil by pulling it up and out of
the liquid withdrawal warming coil.

HELiOS Portables

RP14A – Gas Withdrawal Warming Coil R/R (H300)

8. Replace the gas withdrawal coil by reversing steps 1-7.

RP15A – Vent Valve Assembly R/R (H300)
1. Remove the covers (RP4).
2. Disconnect the flexible vent tube from the barbed fitting at
the vent valve outlet.
3. Hold the vent valve large hex nut stationary using a 5/8 inch
open-end wrench and loosen the jam nut that holds the ventvalve to the mounting bracket using a 11/16 inch open-end
wrench.

1. Remove the covers (RP4).
2. Remove the flexible urethane tube from the barbed fitting on
the R/E valve outlet arm.
3. Cut and remove the two zip ties that secure the liquid withdrawal coil to the gas withdrawal coil at the top of the cryogenic container.
4. Use an adjustable wrench to hold the R/E valve inlet arm(with the SRV) stationary. Use a 7/16 inch open-end wrench
to remove the gas withdrawal warming coil compression nut
from the R/E valve fitting.

jam
nut

Figure 36: H300 Vent Valve Removal
4. Remove the two vent valve screws and lock washers using a
7/64 in hex wrench.
5. Slide the vent valve out of its mounting bracket.
6. Replace the vent valve assembly by reversing steps 1-5.

Figure 35: Removing the Compression Nut

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XI
1 Troubleshooting & Repair Procedures
4. Remove the torsion spring.

1. Remove the covers (RP4).

5. Remove the vent tube barbed fitting using a 1/4 inch openend wrench.

2. Disconnect the flexible vent tube from the barbed fitting on
the side of the vent valve.
3. Pull the vent lever down and place a 1/2 inch open-end
wrench on the vent valve body just above the hex nut.

6. Push out the lever pin using a 1/16 inch hex key, pin punch,or ball driver.

HELiOS Portables

RP15B – Vent Valve Assembly R/R (H850)

4. Loosen the tubing compression nut at the top of the valve
using a 1/2 inch open-end wrench.
5. Remove the vent valve mounting screw using a T10 torx
driver.
6. Lift the container assembly and the vent valve from the front
cover.
7. Continue to loosen and then remove the tubing compression
nut from the vent valve completely.

Figure 38: Pin Removal

8. Remove the valve from the tube.

7. Remove the lever and the Teflon washer.

9. Replace the vent valve assembly by reversing step 1-8.
Make sure that the valve is aligned properly in the back caseas shown below.

TorsionSpringPin

TeflonWasherValve

BarbedFitting

Lever

Figure 39: Vent Valve Disassembly

Figure 37: H850 Vent Valve Installation

8. Replace vent valve parts and re-assemble it by reversing
steps 1-7.

RP16– Vent Valve Disassembly & Repair
1. Remove the vent valve assembly (RP15)
2. Pry the short, straight end of the torsion spring off of its
anchor point on the vent valve lever using a small flat-blade
screwdriver.
3. Push the long, hooked end of the torsion spring off of thevalve body using a small flat-blade screwdriver.

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XI Troubleshooting & Repair Procedures
HELiOS Portables

RP17A – QDV Assembly R/R (H300)
1. Remove the case (RP4).
2. Use an adjustable wrench to hold the fill connector mounting bracket stationary. Use a second 9/16 inch open-end
wrench to remove the fill on the machined flats of the fillconnector body to loosen and remove the compression nutof the fill tube from the top of the fill connector.

Figure 42: H300 QDV Assembly Removal
7. To replace, reverse steps 1-6.

Figure 40: H300 QDV Removal
3. Use a 7/16 inch open-end wrench to hold the fill tube container fitting stationary. Use a 9/16 inch open-end wrench
to remove the fill tube lower compression nut from the cryogenic container.

NOTE: Use a torque wrench to tighten the fill connector to a
torque of 35 lb/ft (511 n/m) and the jam nut to a torque of 20
lb/ft (292N-m).
NOTE: The internal threads in the fill connector jam nut do not
run completely through the nut. Install the fill connector jam
nut with the unthreaded end toward the mounting bracket.
NOTE: Position the fill tube so that the ferrules on each end areseated in their fittings on the fill connector and the container.
Alternately hand tighten the fill tube nuts to seat the ferrules
evenly. Use two wrenches to tighten the nuts securely.

Figure 41: H300 Fill Tube Removal
4. Remove the fill tube.
5. Use an adjustable wrench to hold the fill connector mounting bracket stationary. Use a 7/8 inch open-end wrench to
remove the jam nut from the fill connector assembly.
6. Remove the QDV from the mounting bracket.

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XI Troubleshooting & Repair Procedures
RP18 – QDV Lip Seal R/R

1. Remove the covers (RP4).

1. Remove the QDV (RP17).

2. Use an adjustable wrench to hold the fill connector adaptor
stationary. Use a second adjustable wrench on the machined flats of the fill connector body to loosen and remove
the fill connector.

2. Hold the QDV body with an adjustable wrench placed on
the machined flats. Use a second adjustable wrench to remove the lip seal retainer sleeve.

HELiOS Portables

RP17B – QDV Assembly R/R (H850)

3. Pull the lip seal out of the fill connector body.

Figure 44: Lip Seal Removal
4. Insert the stepped (spring) end of the new lip seal into thecorresponding recess in the large end of the QDV body.
Make sure that it is squarely seated.

Figure 43: H850 QDV Removal
3. To replace the QDV assembly, reverse steps 1-2.

Figure 45: Lip Seal Replacement
5. Thread the lip seal retainer onto the large end of the fill connector body and tighten to a torque of 35 lb/ft (511 n/m).
6.

Replace the QDV assembly (RP17).

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XI Troubleshooting & Repair Procedures
1. Make sure the unit has been leak tested (RP2).
2. Fill the H300 or H850 from a properly saturated source ofliquid oxygen.

14. Set the flow control knob to the lowest continuous flow setting (0.12 for the H300, C1 for the H850)
15. Check the continuous flow at each flow setting. Verify thatthey are within the ranges listed in Table 6 (H300) or Table
7 (H850).

3. Allow the unit to sit undisturbed for approximately 30 minutes to allow it to stabilize at its primary relief valve pressure.

16. Disconnect the test flow meter.

4. Attach a calibrated flow meter to the top cannula barb on the
H300 or H850 using a length of 3/16 in (0.48 cm) diametertubing (B-778214-00) if necessary.

18. Adjust the cannula to your face and breathe normally.

5. Set the flow control valve to its lowest demand setting (1 on
the H300, D1.5 on the H850).

17. Attached a dual lumen cannula to the H300 or H850.

19. At all demand flow settings, verify that oxygen flow cycles
on and off in response to your inhalation and exhalation.
Verify that you sense a brief “puff” of oxygen at the beginning of each inhalation.

6. Verify that there is no oxygen flow from the unit and theflow meter reads “0”.

20. Disconnect the cannula.

7. Disconnect the calibrated flow meter.

NOTE: If continuous flow does not occur at these flow settings,
reset the demand valve by blowing across (not into) the bottom
cannula barb or by attaching a dual lumen cannula to the bottom
cannula barb and breathing in once or twice.

8. Connect the Jet Venturi assembly (B-778210-00) to the bottom cannula barb on the front of the H300 or H850.
9. Connect the DISS nut and tailpiece of the Jet Venturi assembly to a 0-6.90 bar (0-100 psi) source of gaseous oxygen.

Table 7: H300 Flow Tolerance
Flow
Setting

Measured Flow

Specification(LPM)

Acceptable
Range (LPM)

0

None

0.00

0.00

0.12

Continuous

0.12

0.02 - 0.22

0.25

Continuous

0.25

0.10 - 0.40

0.5Continuous

0.50

0.35 - 0.65

0.75

Continuous

0.75

0.60 - 0.90

1Tail Flow

0.50

0.35 - 0.65

1.5

Tail Flow

0.65

0.50 - 0.80

Figure 46: Jet Venturi Assembly Attachment

2

Tail Flow

0.75

0.60 - 0.90

NOTE: Do not block the open “bleeds” on the Jet Venturi
assembly. This can cause damage to the flow control valve.

2.5

Tail Flow

1.00

0.85 - 1.15

10. Slowly increase the pressure of the gaseous oxygen source
until a continuous flow comes from the top cannula barb.

3

Tail Flow

1.50

1.30 - 1.70

3.5

Tail Flow

1.75

1.40 - 1.90

4

Tail Flow

2.00

1.70 - 2.30

11. Reconnect a calibrated flow meter as described in step 4.

HELiOS Portables

RP19 – Demand Flow Control Valve Test

12. Check the demand inspiration tailflow at each demand flow
setting. Verify that they are within the ranges listed in Table
7 (H300) or Table 8 (H850).
13. Disconnect the Jet Venturi assembly from the unit.
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XI Troubleshooting & Repair Procedures
HELiOS Portables

Table 8: H850 Flow Tolerance
Flow
Setting

Measured Flow

Specification(LPM)

Acceptable
Range (LPM)

D1.5

Tail Flow

0.65

0.5 - 0.8

D2.5

Tail Flow

1.00

0.85 - 1.15

2.00

1.7 - 2.3

D2
D3
D4
0

Tail Flow
Tail Flow
Tail Flow
None

C1Continuous

C3

Continuous

C2
C4
C5
C6

Continuous
Continuous
Continuous
Continuous

0.75
1.50
0.00

0.6 - 0.9
1.3 - 1.7
0.00

1.00

0.85 - 1.15

3.00

2.6 - 3.4

2.00
4.00
5.00
6.00

1.7 - 2.3
3.5 - 4.5
4.4 - 5.7
5.3 - 6.8

NOTE: The values in Tables 7 & 8 are based on ambientconditions of 70oF (21oC) and 29.4 in Hg (74 mm Hg) and an
operating pressure range of 1.54 to 1.71 bar (22.3 psi to 24.8
psi). Any deviations from these conditions can affect flow
results.
NOTE: If the flow measurements are out of specification,
check the pressure in the unit. A combination of high or low
pressure and the tolerance of the particular flow meter can
result in inaccurate readings.

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XI Troubleshooting & Repair Procedures
1. Remove the covers (RP4).
2. Remove the flow control knob by pulling it straight backfrom the front cover.
3. Pull the demand flow control valve backwards out of its seat
inside the front cover.
4. Use a small flat head screwdriver to carefully pry the polyurethane tube off of the demand flow control valve inlet
barbed fitting.
5. Use a small flat head screwdriver to carefully pry the silicone tubes off of the cannula barb fittings.
6. Install the new flow control valve by reversing steps 1-5.
NOTE: The demand flow control valve is not field serviceable.
Only the barbs and inlet filter screen may be replaces as needed.
CAUTION: The demand flow control valve is manufactured toexacting tolerances and uses a number of small orifices. Ensurethat hands, tools, and work table are clean when working withthe valve. Do not allow liquids to enter the vent port locateddirectly across from the vent valve inlet fitting.

RP21 – Demand FCV Filter Screen Replacement
1. Remove the demand FCV (RP20).
2. Remove the inlet barbed fitting by unscrewing it from theFCV.
3. Hold the valve so that the inlet port faces downward.
4. Use a dental pick or other similar tool to carefully remove
the inlet filter screen.

5. Push the replacement filter screen into the inlet port until it
is seated on the internal support ledge.
NOTE: Do not install two filter screens. This may cause a flow
restriction.
6. Re-install the inlet barbed fitting.
NOTE: When installing the brass barbed fitting, verify thepresence and condition of the seal gasket on the threaded endof the fitting.

HELiOS Portables

RP20 – Demand FCV R/R

7. Replace the FCV (RP20).
RP21A- Sensitivity Adjustment
CAUTION: Damage to demand flow control valve possible.
One port of the jet/venturi assembly tee connector and the lon
port of the jet/venturi act as bleeds and must remain open.
NOTE: The Magnehelic gauge must be leveled and zeroedin the vertical position before making any adjustments tothe demand flow control valve. Check the gauge calibration
periodically according to the manufacturer’s specifications or
if it has been dropped or mishandled.
1. Make sure that the H300 or H850 has been tested for leaks
before continuing.
2. Set the demand flow control valve knob to 0 and fill the unit
with liquid oxygen saturated at 22-30 psig (152-207 kPa).
Let the system pressure for 10 minutes.
3. Connect the jet/venturi test setup to the H300 or H850 sense(bottom) connector. Connect the test flowmeter to theoxygen outlet (top) connector
4. Set the demand flow control valve to D4 on H850 or H300
set the demand flow control valve to 4 and lay the unit on its
back. Increase the oxygen source pressure to the jet/venturi
assembly until approximately 2L/min of flow registers
on the test flowmeter. Let the unit run at this flow for ten
minutes. This will bring the system pressure down to theeconomizer setting (H850 22.3-24.8psig/154-171 kPa) and(H300 20.5-23psig/154-171 kPa).
5. Decrease the oxygen source pressure to the jet/venturi
assembly to 0 psig. The test flowmeter should read 0 L/min
and the Magnehelic gauge should read 0-in. H2O.

Figure 47: Inlet Filter Screen Removal

6. With the Magnehelic gauge reading 0-in. H2O, slowly
increase the oxygen source pressure to the jet/venturi
assembly until oxygen flow (at least .25 L/min) first
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1
HELiOS Portables

registers on the test flowmeter. Verify a pressure readingof .038-.043-in. (.097-.109-cm) H2O vacuum on the
Magnehelic gauge.
7. If the Magnehelic gauge reads less than .038-in. (.097-cm)
H2O when oxygen flow first registers in step 6, adjust thedemand flow control valve as follows. With the H300 or
H850 laying flat on the work table, position the top one
third of the unit over the edge of the table. Insert a T10 Torx
driver through the small hole in the rear side cover above
the contents indicator window. Slowly turn the demand flow
control valve set screw about 1/16 turn clockwise. Repeat
steps 6 and 7 until you achieve the desired results in step 6.
8. If the Magnehelic gauge reads more than .043-in (.109-cm).
H2O when oxygen flow first registers in step 6, adjust thedemand flow control valve asfollows. With the H300 or
H850 laying flat on the work table, position the top one
third of the unit over the edge of the table. Insert a T10 Torx
driver through the small hole in the rear side cover above
the contents indicator window. Slowly turn the demand flow
control valve set screw about 1/16 turn counter clockwise.
Repeat steps 6 and 8 until you achieve the desired results instep 6.
9. Reorient the Helios Portable to the vertical position and increase the adjustable oxygen pressure regulator until the
Magnehelic gauge reads .080-in. H2O. Verify that the test
flowmeter reads about 2 L/min with the flow control set atthe D4 or 4 demand position. Decrease the regulator pressure
until the Magnehelic gauge reads 0-in. H2O. Verify that thetest flowmeter reads 0 L/min.
10. Disconnect the test setup from the H300 or H850 and connect a new dual-lumen cannula to the Helios Portable oxygen
outlet and sense connectors. Adjust the cannula to your faceand breathe normally. Verify that oxygen flow distinctly cycles on during inspiration and off during exhalation.
11. Cycle the demand flow control valve 25 times with the duallumen cannula connected. Disconnect the cannula and verify
that there is no flow through the oxygen outlet connector.
12. Connect the test setup. Repeat step 6 and verify that thedemand flow control valve sensitivity is in the acceptable
range.

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XI Troubleshooting & Repair Procedures
RP23 – Oxygen Supply Line Quick Connect R/R

1) Ensure the unit has been leak tested (RP2).

1. Remove the case (RP4).

2) Fill the H300 or H850 from a properly saturated source ofliquid oxygen.

2. Use a small flat head screwdriver to carefully pry theurethane tube from the inlet barbed fitting of the inline
check valve.

3) Allow the unit to sit undisturbed for 1-2 hours to allow it tostabilize at its PRV pressure.
4) Record the initial weight (w1) of the unit and the time thisweight was measured.
5) Allow the unit to sit undisturbed for 5-6 hours.
6) Record the final weight (w2) of the unit and the time thisweight was measured.
7) Calculate the NER (the weight of contents that evaporates
per day) using the formula below:

(

w2-w1

# hours
24

)

= NER

8) Verify that the NER is within the specifications listed inTable 4.

3. Use a 5/8 inch open end wrench to remove the nut that
secures the quick connect to the front cover.

HELiOS Portables

RP22 – Normal Evaporation Rate (NER) Test

4. Pull the quick connect down and out of its mounting hole.
5. Remove the urethane tube from the barb on the quickconnect.
6. Install the new quick connect by reversing steps 1-5.

RP24 – Inline Check Valve R/R
1. Remove the case (RP4).
2. Use a small flat head screwdriver to carefully pry theurethane tube from the inlet barbed fitting of the inline
check valve.
3. Use a small flat head screwdriver to carefully pry theurethane tube from the outlet barbed fitting on the inline
check valve.
4. Install the new inline check valve by reversing steps 1-3.

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XI Troubleshooting & Repair Procedures
1. Inspect the tube end. Make sure that it is cut square and thatthe outside surface is free of scratches or other marks at least
1 in (25 mm) back from the tube end.
2. Lightly buff the tube end with a Scotch-Brite pad or fineemery paper to remove any surface marks.
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 andcreate a seal.
4. Hold the fitting body stationary with an open-end wrench
while tightening the tube nut with a second wrench.
NOTE: Never permit the fitting body to rotate during thisprocedure. Always use two wrenches.
5. Tighten the tube finger-tight.
6. Using an open-end wrench, tighten the nut beyond fingertight.
a. For 1/4 in (0.64 cm) diameter tubing, tighten the nut andadditional 1 & ¼ turns.
b. For 1/8 in (0.32 cm) or 3/16 in (0.48 cm) diametertubing, tighten the nut an additional ¾ turn.

RP26 – Flexible Tubing Replacement
1. Use a small flat-blade screwdriver to carefully back thebrass collar (when used) off of the barbed fitting.
2. Work the screwdriver between the end of the tube and thefitting body.
3. Simultaneously pull on the tube and pry the end of the tube
back from the barb.

HELiOS Portables

RP25 – Compression Fitting (Nut & Ferrule)
Replacement

4. Inspect the end of the new tube. Be sure that the end is cut
square and that it is free of cuts and tears.
5. Install a brass collar on the tube (if used) so that the large
end of the collar is toward the barbed fitting.
6. Push the tube squarely onto the barb as far as possible.
7. Push the brass collar (if used) onto the tube end connected tothe barbed fitting.
RP27 - CPC Connector Kit Installation (For Testing
units without CPC Connector Installed)
1. Remove tubing from barbed fittings of Conserver and R/E
Valve.
2. Connect CPC Connector Kit’s (PN: 20748595) 7.5” tubing end to inlet barb of Conserver and 3” tubing end to R/E
Valve barbed fitting. Refer to Figure 49 for unit without
CPC Connector Kit converted to unit with CPC Connector
Kit

Figure 48: Compression Fitting

Figure 49: Newer Unit Manufactured without CPC Connector
and Fittings (Left). CPC Connector Kit Installed for Testing
Purposes (Right).

HELiOS Portables Technical Service Manual • PN 20562190 Rev F

49 52

XII
1 Parts Price List

HELiOS Portables Technical Service Manual • PN 20562190 Rev F

HELiOS Portables

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

49 53

XIII Ordering Information
The following steps should be used when ordering a new HELiOSor replacement parts for an existing unit:
1. Compile a list of all equipment and replacement parts to beordered.
Use the following part numbers to order a complete genericunit:
HELiOS Plus H300

#B-700848-00

HELiOS Marathon H850

#H850EU

2. Fill out a purchase order containing the following information:a. Purchase order number.
b. Name and address of billing location.
c. Name and address of shipping location.
d. Quantity, part number, description, and unit costfor each item ordered.

4. E-Mail or fax the completed purchase order for
confirmation to:
North and South America/Asia/Pac Rim email to:customerservice.usa@caireinc.com

Africa/Europe/Middle East email to:customerservice.europe@caireinc..com

HELiOS Portables

Ordering Information

North and South America fax to: 888-932-2473
Asia/Pac Rim fax to: 770-721-7758

Africa/Europe/Middle East fax to: +44 118 9799245
All new equipment will be shipped either “prepaid”, F.O.B. fromthe factory, or collect via your specified carrier. All replacement
parts will be sent by UPS “prepaid”, and the shipping charges forequipment and parts will be added to the final invoice. Payment
for replacement parts are located on CAIRE, Inc.’s, invoice withpayment date indicated. All shipments will originate from thefactory. If a particular carrier or method of shipment is desired,specify when placing order.

3. Telephone or fax CAIRE Inc. at one of the numbers listed
below to begin immediate processing of the order:
USA
Toll Free Phone:

800 48 CAIRE
			(800 482 2473)
Toll Free Fax:
888 WE CAIRE(To place an order):		(888 932 2473)
Phone:		770 257 1299
Fax:
		770 257 1300

For additional ordering and contact

information, visit www.caireinc.com.

Asia, Australia, Pacific Rim
Phone:+61 297 494333
Fax:
888 932 2473
EuropePhone:
Fax:+44 (0) 1189 367060+44 118 9799245

HELiOS Portables Technical Service Manual • PN 20562190 Rev F

49 54

XIV Return & Restocking Policy
If a problem with the unit should be encountered, reference
should be made to the Troubleshooting Chart in Section XI. If
these procedures do not provide a solution for the problem, thefollowing steps should be taken:
1. Call CAIRE, Inc. Customer Service.
North and South America/Asia/Pac Rim:
Phone (US Only)

800-482-2473

Phone

770-721-7759

If it becomes necessary to cancel an order with CAIRE Inc. after
the shipment has been received, use the following “Restock
Policy” procedure:
1. Call CAIRE, Inc. Customer Service.
2. When contacting Customer Service personnel, it will benecessary to relay the following information:a. State the quantity and description of equipment to be
returned.
b. Give the Serial Number of each unit to be returned.
c. State the equipment purchase date.

Africa/Europe/Middle East:
Phone

Restocking Policy

HELiOS Portables

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

+44 (0) 1189 367060

2. State the problem with the unit.
3. If it is determined that the problem cannot be solved by the
distributor, a Return Material Authorization (RMA) number
will be assigned to the unit or part(s).
4. If a Purchase Order Number is to be referenced, please givethis number to the Customer Service Representative at thattime.
5. Carefully package the parts, or repack the unit in its original
shipping container, precisely as shipped.
6. Write the Return Authorization Number on the top of theshipping container.
7. Customer Service will provide the correct shipping location
once the RMA is provided.

3. An RMA number will be issued in the name of the
distributor by CAIRE, Inc. for the equipment to be returned.
4. When the equipment is shipped to the factory, the RMA
number must appear on the packing slip and shipping boxes.
5. Customer Service will provide the correct shipping location
once the RMA is provided
6. Finally, a “Credit Memo”, minus a 15% restocking fee, will
be issued to the distributor when all equipment has been
received, inspected, and restocked by CAIRE, Inc
Return of Unused Non-Defective Merchandise
CAIRE Inc., at its discretion, charges a 15% restocking fee forunused non-defective merchandise that is returned. An RMA
number must be obtained from CAIRE Inc. Customer Service
prior to return of any goods. Merchandise cannot be returnedfor credit after sixty (60) days. Customer to pay all freightcharges. Tracking capability and insurance on all returned goods
is advised. CAIRE Inc. will not be responsible for misdirected
shipments.

HELiOS Portables Technical Service Manual • PN 20562190 Rev F

49 55

XV Service Tools/Equipment/Supplies
Required Tools
Adjustable Wrench – 10 inch
Adjustable Wrench – 8 inch
Clamp or Hemostat
Dental Pick
Flat Head ScrewdriverHex (Allen) Wrenches - Various Sizes
Jewler’s Screwdriver
Micro Bar Clamp
Needle Nose Pliers
Open Ended Wrench – 1/2 inch
Open Ended Wrench – 1/4 inch
Open Ended Wrench – 5/8 inch
Open Ended Wrench – 7/16 inch
Open Ended Wrench – 9/16 inch
Phillips Head ScrewdriverSide Cutters
T10 Torx Driver
Tie Wraps

Table #11­­­Required Supplies
Household Glass Cleaner
Krytox Lubricant
Lint-Free Cloth
Snoop Liquid Leak Detector
TEFLON TapeHELiOS Portables

Table #9

Scotch Brite Adhesive Pad

Table #10
Required Fixtures/Equipment
Calibrated Flow Meter
Calibrated Weight Scale
Jet Venturi Assembly
Liquid Oxygen Source
Portable Test Fixture
Test Pressure Gauge w/ Tubing
Gaseous Oxygen Source 0-6.89 bar (0-100 psi)
Oxygen Compatible Tubing – 3/16 inch (0.48 cm) diameter
Tee Connector – 3/16 inch (0.48 cm)

For a complete list of accessories, see the accessories catalog on www.caireinc.com.
HELiOS Portables Technical Service Manual • PN 20562190 Rev F

49 56

XV
1 Service Tools/Equipment/Supplies
Description­

Item Number

Backpack H850

069209Belt Pack H300

B-701654-00

Belt Pack H300 Large Waist Extension

14951835

CPC Quick Connect Kit

20748595

DISS Adaptor

B-776945-00

Dual Lumen Cannula – 5 ft (1.5 m) Delivery Both Nostrils (Concentric)

10035468

Dual Lumen Cannula – 7 ft (2.1 m) Delivery Both Nostrils (Concentric)

10035467

Dual Lumen Cannula – 5 ft (1.5 m) Delivery Both Nostrils (Split)

6-778058-00

Dual Lumen Cannula – 7 ft (2.1 m) Delivery Both Nostrils (Split)

6-778057-00

Dual Lumen Cannula – 4 ft (0.9 m) Delivery One Nostril

B-701931-00

Dual Lumen Cannula – 7 ft (2.1 m) Delivery One Nostril

B-701930-00

Erie Liter Meter (0-8 LPM)

B-775311-00

Erie Liter Meter (6-15 LPM)

10995620

Fluoro-Lubricant (2 oz tube)

CA200071

HELiOS Oxygen Supply Line – 50 ft (15.24 m)

B-701656-SV

HELiOS Oxygen Supply Line Coupler

B-701686-00

Jet Venturi Assembly

B-778210-00

Jewler’s Screw Driver

97403016

Krytox Lubricant (2oz Tube)

20605136

Oxygen Compatible Tubing – 3/16 inch (0.48 cm)

B-778214-SV

Portable Test Fixture

B-778202-00

Pressure Gauge (0-100 PSI)

B-776004-00

Pressure Gauge (0-60 PSI)

97403577

Shipping Carton H300

B-701688-00

Shipping Carton H850

10002939

Shipping Insert H300

B-701688-00

Shipping Insert H850

10000172

Snoop Liquid Leak Detector (8 oz bottle)

B-775272-00

Tee Connector 3/16 in (0.48 cm)

B-778211-CKTEFLON Tape

B-775036-00

Test Pressure Gauge w/ Tubing

B-701732-00

Zip Ties­B-775091-00

HELiOS Portables Technical Service Manual • PN 20562190 Rev F

HELiOS Portables

Tools and Accessories available from CAIRE

49 57

w w w . c a i r e i n c . c o m

CAIRE Inc.
2200 Airport Industrial Dr., Ste. 500
Ball Ground, GA 30107
Ph 770-721-7700 • Toll Free 1-800-482-2473
Fax 770-721-7701

CAIRE Medical, Ltd.
Unit 6, Ashville Way
Wokingham
Berks RG41 2PL, United Kingdom
Ph +44(0) 1189 367080 • Fax +44(0) 1189 799245

Copyright © 2021 CAIRE Inc. reserves the right to discontinue its products, orchange the prices, materials, equipment, quality, descriptions, specifications and/or
processes to its products at any time without prior notice and with no further
obligation or consequence. All rights not expressly stated herein are reserved by us,
as applicable.

18 March 2021 HELiOS Portables Technical Service Manual • PN 20562190 Rev F

49