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Cosmed Pony graphic Service Manual

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Corporate Office:
COSMED Srl
PO Box n °3, Pavona di Albano RM,
00040 -Italy
Tel:+39 (06)931.5492
Fax:+39 (06)931.4580
email:info@cosmed.it
Pony
Pony
Pony
Pony
P/N. C01414-01-91 / Date of Issue: January 2002.
SERVICE MANUAL
graphic
North American Office:
COSMED USA,Inc.
2758 North Paulina Street,
Chicago,IL 60614 USA
Phone:+1 (773)528-8113
Fax:+1 (773)528-8116
email:usa.sales@cosmed.it

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  • Page 1 SERVICE MANUAL Pony Pony Pony Pony graphic Corporate Office: North American Office: COSMED Srl COSMED USA,Inc. PO Box n °3, Pavona di Albano RM, 2758 North Paulina Street, 00040 -Italy Chicago,IL 60614 USA Tel:+39 (06)931.5492 Phone:+1 (773)528-8113 Fax:+39 (06)931.4580 Fax:+1 (773)528-8116 email:info@cosmed.it...
  • Page 2 No part of this manual may be reproduced or transmitted in any form without the express permission of COSMED srl. COSMED does not assume the liability for mistakes in this documentation or for casual or consequential damages in connection with the provision, representation or use of this documentation.
  • Page 3 Do not use the equipment in presence of flammable gases or anesthetic mixtures. Perform the service procedures described in this manual only if you are a trained and authorized COSMED service person. Keep the equipment away from heat, flames, sparks, flammable liquid mixtures and explosive gases.
  • Page 4 Warning If you deviate from the instructions and/or recommendations in this manual, you may cause the Pony Graphic to operate improperly or unsafely, and you may damage the Pony Graphic itself. The Pony Graphic User's Manual is an integral companion to this manual.

  • Page 5: Table Of Contents

    Organisation of the manual ..................1.2 1.2. Reference Documents ....................1.2 1.3. Customer Communication................... 1.2 1.4. Technical Specifications....................1.3 1.4.1. Pony graphic Unit ....................1.3 1.4.2. Flow meter ....................... 1.3 1.4.3. Power supply: ......................1.3 1.4.4. Battery charger ......................1.3 1.4.5.
  • Page 6 The system doesn't operate when switched on; ............. 5.3 5.1.4. The printer doesn't work properly; ................5.4 5.1.5. The Pony graphic is unable to measure properly flow and volume;......5.4 5.1.6. The Optoelectronic transducer doesn't work; ............5.4 5.1.7. The batteries cannot be recharged or the green led remains off; ......5.4 5.1.8.
  • Page 7 6.4.4. Configuration of the Pony Graphic ................6.6 SCHEMATICS AND LAYOUTS ............7.2 7.1.1. Motherboard (C01350-01-15)................7.2 7.1.2. Display (C01344-01-30) ..................7.2 7.1.3. Key board PCB (C01352-01-15) ................7.2 7.1.4. Printer (C00551-01-08)..................7.2 7.1.5. Optoelectronic Reader (C00095-01-05) ..............7.2 7.1.6.
  • Page 9 Organisation of the manual ..................1.2 1.2. Reference Documents ....................1.2 1.3. Customer Communication................... 1.2 1.4. Technical Specifications....................1.3 1.4.1. Pony graphic Unit ....................1.3 1.4.2. Flow meter ....................... 1.3 1.4.3. Power supply: ......................1.3 1.4.4. Battery charger ......................1.3 1.4.5.

  • Page 10: Introduction

    This manual provides the basic procedures for the maintenance and the technical support of the Pony Graphic. Perform the service procedures described in this manual only if you are a trained and authorized COSMED service person. You must have a through knowledge and experience with medical electronic equipment.

  • Page 11: Technical Specifications

    1.4. Technical Specifications 1.4.1. Pony graphic Unit Graphic display Backlight LCD 70x80 mm Display LCD 2 lines x 16 characters Printer Graphic,24 char/lin,2,5 lines/s Keyboard 12 multifunction keys Serial cable RS 232, bi-directional, 4800 baud Dimensions Dimensions 237x127x46 mm Weight 1.2 kg...
  • Page 12 IEC 1000-4-3 (immunity EM): 3 V/m IEC 1000-4-4 (immunity Bursts): 1 KV QUALITY ASSURANCE UNI ISO EN 9001 (Reg 387 Cermet) MEDICAL DEVICE DIRECTIVE (CE MARK) MDD 93/42CEE (Notified Body 0476) Class IIa. Service Manual Pony Graphic Chapter 1 Introduction...
  • Page 13 Functional description ................ 2.2 2.1. General Overview......................2.2 2.1.1. Pony graphic Unit ....................2.2 2.1.2. Flowmeter ........................ 2.2 2.1.3. Battery Charger (AC /DC Adapter) ................2.2 2.1.4. RS232 cable ......................2.2...

  • Page 14: Functional Description

    2.1.3. Battery Charger (AC /DC Adapter) The battery charger (AC /Dc Adapter) can charge NiCd batteries of the Pony graphic unit at the same time battery pack inside the unit and also supply power to the unit. It can operate at both, 110 or 220V AC inputs.
  • Page 15 Part Description ................... 3.2 3.1. Pony graphic Unit ......................3.3 3.2. Mother Board (C01350-01-15) ..................3.3 3.2.1. Function ........................3.3 3.2.2. Description....................... 3.3 3.2.3. Adjustments & checks ..................... 3.4 3.2.4. Assembly Drawing ....................3.4 3.2.5. Warnings & Indications in Event of Failure.............. 3.4 3.3.

  • Page 16: Part Description

    It provides the complete reference for the service personnel for diagnosis. The section consists of the following. Pony graphic Unit 1. Mother board Assembly (C01350-01-15) 2. Display Assembly (C01344-01-30) 3.

  • Page 17: Pony Graphic Unit

    Printer: P/N: C01386-01-08 The physical structure of the Pony graphic Unit is described in the following block diagram: The Unit contains most of the parts constituting the spirometer and can be interfaced to the, the turbine flow meter and with the User's PC or external printer via the serial cable. AC/DC adapter powers the unit.

  • Page 18: Adjustments & Checks

    Handshake: DTR Hardware Power Supply The power supply to the Pony graphic Unit and the Optoelectronic transducer is done by 4 rechargeable NiCD batteries (1.2V, 1.2Ah).( they are packed in set of 2 ,each set containing two batteries) The IC U14 (MAX761) regulates the supply Voltage of the digital components. It also detects the Low battery status when the battery voltage goes lower than 4.7 Volts.

  • Page 19: Display Assembly (C01344-01-30)

    Display Assembly (C01344-01-30) 3.3.1. Function The display of pony graphic is the main interface for user to enter the patient details , to view the results and to print a particular test performed by the patient and for all the control functions to be performed.

  • Page 20: Assembly Drawing

    Printer (C01386-01-08) 3.5.1. Function The printer used in the Pony graphic is the EPSON M190; it has 8 print solenoids horizontally placed. Each solenoid moves from left to right in order to print 18 dots so the total number of dots/line is 144.

  • Page 21: Assembly Drawing

    3.5.4. Assembly Drawing 3.5.5. Warnings & Indications in Event of Failure. • Printing Failure • Paper jam during Printing • No Printout 3.6. Opto Electronic Assembly(C00095-01-05) 3.6.1. Function The flow meter is composed by a Bi-directional turbine and an Optoelectronic transducer. The Turbine is made of (see figure) a transparent tube with two helical conveyors to which is fixed (rotating free) a very lightweight rotor (blade).

  • Page 22: Adjustment & Checks

    3.7. Battery Charger (C00766-01-30) (C00767-01-30) 3.7.1. Function The Battery charger of the Pony graphic supplies power to the Battery charging circuit (see Mother Board). Two models are available depending of the country where you purchased the system: Pony graphic AC/DC adapter 220V 12V 1A...

  • Page 23: Warnings & Indications In Event Of Failure

    3.7.5. Warnings & Indications in Event of Failure. • Power failure • Battery charging failure. Service Manual Ponygraphic Chapter 3 Part Description...
  • Page 25 Replacement Schedule ....................4.2 4.3. Preventive Maintenance....................4.4 4.3.1. Necessary tools ....................... 4.4 4.3.2. Charger cable A381-003-202: ................4.4 4.3.3. RS232 serial cable C00032-01-12: ..............4.4 4.3.4. Turbine C00292-01-05: ..................4.4 4.3.5. Optoelectronic reader C00095-01-05:............... 4.4 4.3.6. Pony graphic unit ..................... 4.4...

  • Page 26: Unit Maintenance And Consumable Replacement

    Pony graphic User's Manual. • If the Pony graphic fails to respond as described, DO NOT use it until you have corrected the situation. Refer to the trouble-shooting section of this manual for more detailed discussion.
  • Page 27 The part numbers are as given in the parts list section (Appendix A) of this manual. Service Manual Ponygraphic Chapter 4 Maintenance...

  • Page 28: Preventive Maintenance

    4.3. Preventive Maintenance. (Preventive maintenance is to be carried out by the COSMED authorized personnel only.) Important note : the preventive maintenance procedure must be performed only using original parts of the standard packaging of each equipment 4.3.1. Necessary tools...
  • Page 29 The system doesn't operate when switched on; ............. 5.3 5.1.4. The printer doesn't work properly; ................5.4 5.1.5. The Pony graphic is unable to measure properly flow and volume;......5.4 5.1.6. The Optoelectronic transducer doesn't work; ............5.4 5.1.7. The batteries cannot be recharged or the green led remains off; ......5.4 5.1.8.

  • Page 30: Troubleshooting

    The system does not operate when switched ON. The Printer does not work properly. The Pony graphic is unable to measure properly flow and volume. The optoelectronic transducer does not work. The batteries cannot be recharged or green LED remains OFF.

  • Page 31: Careless Mistakes During The Use Of The System

    2. Recharge completely the batteries and remove the rear panel. 3. Turn on the Pony graphic Unit and verify if the voltage of pin 1 of U1 is about 5 Volts, otherwise proceed from to "The batteries cannot be recharged or the green led is off"...

  • Page 32: The Printer Doesn't Work Properly

    5.1.4. The printer doesn't work properly; Reference Layouts: mother board P/N: C01350-01-15 1. Turn off the Pony graphic, remove the printer cover and verify that the paper is jam; 2. Verify if the batteries voltage is between 5.0 and 6.2 volt otherwise recharge the instrument.

  • Page 33: Serial Communication Error

    2. Turn on the Pony graphic and verify if pin 11 of U1 is about 5 Volt otherwise replace 3. Verify if the voltage between pin 2 and 3 of J3 is 90 VAC otherwise replace T1.
  • Page 35 Operating the interactive Diagnosis Program............6.5 6.4. Connecting to External Printer..................6.5 6.4.1. External printer: features and connections.............. 6.5 6.4.2. Main features of the test report................6.5 6.4.3. Configuration of the printer ..................6.6 6.4.4. Configuration of the Pony Graphic ................6.6...

  • Page 36: Service Procedures

    6.1.1. Disassembling the Pony graphic It is necessary to open the unit for repair and adjustment , the procedure described bleow deals with the disassembling of the pony graphic unit. Flow meter 1. Remove the Turbine from the Optoelectronic Transducer as described in the Pony graphic User's Manual.

  • Page 37: Replacing The Internal Rechargeable Batteries

    6.2. Electronics 6.2.1. Display contrast Adjustment This is necessary when the it is not possible to se any data on the display of pony graphic, one has to adjust the LCD contrast electronically. Procedure 1. Switch off the Pony graphic and completely charge the batteries 2.

  • Page 38: Flow Measurement Check And Calibration

    Auto Test Mode Auto Test Mode In the EPROM of the Pony graphic is stored an Auto-test program that is particularly useful to check eventual malfunctions of the main components. The program can be activated by switching-on the Pony graphic Unit while a special adapter is connected to the RS232 port.

  • Page 39: Operating The Interactive Diagnosis Program

    Connecting to External Printer 6.4.1. External printer: features and connections The Pony Graphic version 3.0 (and higher) allows you to print the test report through the small dot matrix printer of the spirometer as well as through any printer (Laser or inkjet) which supports the HP PCL3 (or higher) language.

  • Page 40: Configuration Of The Printer

    Note : The paper size used should be European A4 (210 x 297 mm). Pony-Printer connection The electric diagram of the connection between the Pony Graphic and the printer is useful in case the printer has a serial connector which is not compatible with the adapter which is supplied with the equipment.
  • Page 41 If you wish to interrupt the printing process press CANCEL. Note: the external printer can only be used to print the test report; the other print-out (list test...) and possible messages (delete archive, calibration turbine...) can be printed only through the internal printer even if the external printer has been selected.
  • Page 43 SCHEMATICS AND LAYOUTS ............7.2 7.1.1. Motherboard (C01350-01-15)................7.2 7.1.2. Display (C01344-01-30) ..................7.2 7.1.3. Key board PCB (C01352-01-15) ................7.2 7.1.4. Printer (C00551-01-08)..................7.2 7.1.5. Optoelectronic Reader (C00095-01-05) ..............7.2 7.1.6. Optoelectronic PCB (C00609-01-15) ..............7.2 7.1.7. Adapter Plug for Car charging (C00297-01-12) ............7.2 7.1.8.

  • Page 44: Schematics And Layouts

    General This Chapter provides the service personnel with information about the different Layouts, disassembling schematics and circuit diagrams of the Pony graphic. Before disassembling the unit please take care that all the transducers and cables are disconnected from the unit.
  • Page 46 Tav.3 - Mother board: schematic 5X100K VBAT VCC VCC VCC VCC BC337 33uH 2.15K RS-DSR RS-DSR 100NF BC547 R2OUT T2IN 121K RS-TX RS-TX R2IN T1IN 47NF 33uH RS-RX RS-RX 4.64K T2OUT R1OUT 1N4148 R1IN 33uH R35 R36 R37 T1OUT 100V 100NF 33uH 6.81K...
  • Page 54 Appendix A: Replaceable Part List ............ 8.2...

  • Page 55: Appendix A: Replaceable Part List

    C00095-01-05 Optoelectronic transducer Pony graphic C00213-01-12 Cable+plug x Optoelectronic transducer Pony graphic C00121-XX-31 Eprom Pony graphic (XX: 01=IT, 02=EN, 03=FR, 04=ES, 05=DE) C01339-XX-31 Eprom Spirotur 610 (XX: 02=EN, 03=FR, 04=ES, 05=DE) C00187-XX-31 Eprom Discovery graphic (XX: 02=EN, 03=FR, 04=ES) C00292-01-05...

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