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SERVICE MANUAL
Pony
Pony
PonyPony
graphic
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
P/N. C01414-01-91 / Date of Issue: January 2002.
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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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.
This manual has been compiled by means of Adobe Page Maker 6.5 , Microsoft Word, Corel
Draw and CAD programs.
COSMED Software can be installed only in one device.
Word and Excel are registered trade marks of Microsoft Corporation.
DBIII is a registered trade mark of Bordland International Inc.
Lotus 123 is a registered trade mark of Lotus Development Corporation.
Page Maker is a registered trade mark of Adobe Corporation.
Corel Draw! is a registered trade mark of Corel Corporation
Pony graphic service Manual
October 2001 II Edition
Copyright © 1998 COSMED
COSMED Srl - Italy
Part No. C01414-01-91 Rev A.
Page 3
WARNING
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.
For using this equipment along with other medical ones, contact
COSMED.
The following symbols are used into the equipment, in accordance
of the actual standards:
Type B equipment (according to EN60601-1)
DANGER: high temperature
OFF
ON
Protective earth
AC
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WARNING
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.
Pay attention to the directions in this service manual, along with the
warning and cautions that appear throughout this manual.
Read through each step in every procedure before beginning the
repair. Always use the proper tools, test equipment and the most
recent revision of this service manual.
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. Familiarize yourself with it before operating and repairing
the device.
Page 5
Table Of Contents
1. Introduction..........................................................................................1.2
1.1. 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. Windows PC Software.............................................................................................1.3
1.4.6. PC configuration required........................................................................................1.3
1.4.7. Safety and conformity..............................................................................................1.3
2. 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
3. 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. Display Assembly (C01344-01-30)...............................................................................3.5
3.3.1. Function...................................................................................................................3.5
3.3.2. Description...............................................................................................................3.5
3.3.3. Adjustments & checks .............................................................................................3.5
3.3.4. Assembly Drawing...................................................................................................3.5
3.3.5. Warnings & Indications in Event of Failure..............................................................3.5
3.4. Keyboard Assembly (C01352-01-15)...........................................................................3.5
3.4.1. Function...................................................................................................................3.5
3.4.2. Description...............................................................................................................3.5
3.4.3. Adjustments & Checks ............................................................................................3.5
3.4.4. Assembly Drawing...................................................................................................3.6
3.4.5. Warnings & Indications in Event of Failure..............................................................3.6
3.5. Printer (C01386-01-08)..................................................................................................3.6
3.5.1. Function...................................................................................................................3.6
3.5.2. Description...............................................................................................................3.6
3.5.3. Adjustment & checks...............................................................................................3.6
3.5.4. Assembly Drawing...................................................................................................3.7
3.5.5. Warnings & Indications in Event of Failure..............................................................3.7
Service Manual Ponygraphic
Table of Contents
i
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3.6. Opto Electronic Assembly(C00095-01-05) .................................................................3.7
3.6.1. Function...................................................................................................................3.7
3.6.2. Description...............................................................................................................3.7
3.6.3. Adjustment & checks...............................................................................................3.8
3.6.4. Assembly Drawing (Refer to Section: Schematics & Layouts)................................3.8
3.6.5. Warnings & Indications in Event of Failure..............................................................3.8
3.7. Battery Charger (C00766-01-30) (C00767-01-30)........................................................3.8
3.7.1. Function...................................................................................................................3.8
3.7.2. Description...............................................................................................................3.8
3.7.3. Adjustments & checks .............................................................................................3.8
3.7.4. Assembly Drawing...................................................................................................3.8
3.7.5. Warnings & Indications in Event of Failure..............................................................3.9
4. UNIT MAINTENANCE AND CONSUMABLE REPLACEMENT ........... 4.2
4.1. Operator Maintenance Program..................................................................................4.2
4.2. 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
5. TROUBLESHOOTING .......................................................................... 5.2
5.1. Careless mistakes during the use of the system ......................................................5.3
5.1.1. Warning ...................................................................................................................5.3
5.1.2. Tools........................................................................................................................5.3
5.1.3. 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. Serial Communication error.....................................................................................5.5
5.1.9. The keyboard doesn't work .....................................................................................5.5
5.1.10. The LCD Display back-light doesn't work ............................................................5.5
6. Service Procedures............................................................................. 6.2
6.1. Consumable Replacement...........................................................................................6.2
6.1.1. Disassembling the Pony graphic .............................................................................6.2
6.1.2. Replacing the internal Rechargeable batteries .......................................................6.3
6.2. Electronics.....................................................................................................................6.3
6.2.1. Display contrast Adjustment....................................................................................6.3
6.2.2. Flow measurement Check and Calibration .............................................................6.4
6.3. Auto Test Mode.............................................................................................................6.4
6.3.1. Running the Auto-test program ...............................................................................6.4
6.3.2. 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
Service Manual Ponygraphic
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ii
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6.4.4. Configuration of the Pony Graphic ..........................................................................6.6
7. 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. Serial Cable (C00032-01-12)................................................................................7.2
8. Appendix A: Replaceable Part List....................................................8.2
Service Manual Ponygraphic
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Page 9
1. Introduction..........................................................................................1.2
1.1. 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. Windows PC Software.............................................................................................1.3
1.4.6. PC configuration required........................................................................................1.3
1.4.7. Safety and conformity..............................................................................................1.3
Service Manual Pony Graphic
Chapter 1 Introduction
1.1
Page 10
1. Introduction
This manual provides the basic procedures for the maintenance and the technical support of
the Pony Graphic. Perform the service procedures descr ibed in this m anual on l y if you are a
trained and authorized COSMED service person. You must have a through knowledge and
experience with medical electronic equipment.
Pay attention to the directions in this service manual, along with the warning and cautions that
appear throughout this manual.
Read through each step in every procedure before beginning the repair. Always use the proper
tools, test equipment and the most recent revision of this service manual.
The Pony Graphic User’s Manual is an integral companion to this manual. Familiarize yourself
with it before operating and repairing the equipment.
1.1. Organisation of the manual
This manual is organized as follows:
Functional Description
Provides a general description of the device, the theory of operation and the main usage
modes. This chapter is useful to use the device in the most complete and proper mode.
Part Description:
Provides a detailed description of the device and the theory of operation of the modules. This
chapter is useful to identify cause for problems and to operate properly.
Maintenance
Provides general specifications for maintenance and calibration.
Trouble-shooting
Trouble-shooting guidelines for detecting problems and their respective solutions
Service Procedures:
Description of the adjustments and checks to carry out for a problem
Schematics & Layouts
A collection for drawing for disassembling of the parts, electric and pneumatic schematics,
mounting planes and PCB Layouts
Appendix A
Technical information, replaceable part list, customer communication.
1.2. Reference Documents
The following document contains information that you may find useful for further reference as
you read this manual:
Pony Graphic: User’s Manual P/N: C00296-02-91.
1.3. Customer Communication
COSMED would like to receive your comments and suggestions on its products and manuals.
We are interested in your application with our products, and we would like to help you if you
have problems with them. To make it easier for you to contact us, this manual contains our
address and a Technical Support Form in the Appendix
Our contact Address
COSMED S.r.l,
Via Dei Piani di Monte Savello, 37, P.O Box 3, Pavona di Albano, ROMA
00040 ITALY.
Voice +39 (6) 931 5492
Fax +39 (6) 931 4580 Internet Web site: http://www.cosmed.it
Service Manual Pony Graphic
Chapter 1 Introduction
1.2
Page 11
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
1.4.2. Flow meter
Flow meter: Digital bi-directional turbine
Flow range 0.03 -20 l/s
Volume range 10 l
Accuracy F/V ± 3%%or ± 50 ml
Dynamic res at 12 l/s <0.7 cm H2O/l/s
Mouthpieces Ø 31 and 22 mm
1.4.3. Power supply:
Ni-Cd Batteries, 5V, 1.2 AH, Rechargeable.
Battery Autonomy 200 tests including prints out
1.4.4. Battery charger
Power supply 120V - 240 V
1.4.5. Windows PC Software
The PC software, running on Windows™, allows the user to manage data stored in the Pony
graphic Unit or transmitted to PC. Here following a list of the main features available:
• Test data management.
• Viewing data in table and graphic form
• Spirometry (FVC, VC, IVC, MVV).
• Adding parameters and predicted equations trough the "Formula Editor" tool-kit.
• DDE with Microsoft Excel.
• Customizing software environments (colours, printed parameters...).
• on line Help.
1.4.6. PC configuration required
• Pentium 133 MHz. Or higher
• Windows 95, 98, NT.
• 16 MB RAM .
• 3.5 drive.
• VGA, SVGA monitor.
• Serial Port RS 232 available ( two serial ports available in case of Ergometer control)
• Any Mouse and Printer compatible with the MS Windows™ operating system.
• PC confirm to European Directive 89/336 EMC
1.4.7. Safety and conformity
SAFETY
IEC 601-1 (1988)/EN 60 601-1 (1990)
Below is reported the complete classification of the device:
• Class B "internally powered equipment" device
• IP00, ordinary equipment unprot ec ted aga ins t water pene tr ati on;
• Non sterile device
• Device not suitable in the presence of flammable aesthetics;
• Continuous functioning equipment;
Service Manual Pony Graphic
Chapter 1 Introduction
1.3
Page 12
EMC
The system meets the EMC Directive 89/336
EN 60601-1-2,EN 55011 Class B (emission)
IEC 1000-4-2 (immunity ESD): 4KV CD, 8KV AD
IEC 1000-4-3 (immunity EM): 3 V/m
IEC 1000-4-4 (immunity Bursts): 1 KV
QUALITY AS S UR ANCE
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
1.4
Page 13
2. 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
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2. Functional description
2.1. General Overview
Pony graphic is a portable spirometer designed for carrying out the typical test of the screening
spirometry: Forced Vital Capacity (Pre and Post), Slow Vital Capacity (Inspiratory and
Expiratory) and Maximum Voluntary Ventilation.
The system is mainly composed of following parts
2.1.1. Pony graphic Unit
It is the core of the system; contains the microcontroller and the electronics necessary to
operate the peripherals and to manage the different measurements. It can be operated either in
stand alone mode using the internal rechargeable NiCd batteries or connected to the AC/DC
adapter. It is connected to the Turbine flowmeter during the measurement. It can be connected
to a PC compatible or an external printer by the RS232 interface for data management and
direct printing.
2.1.2. Flowmeter
It is composed by the turbine and the Optoelectronic transducer; the air passing through the
helical conveyors, makes a spiral motion which causes the rotation of the turbine rotor. The
rolling blade interrupts the infrared light sources beamed by the diodes of the optoelectronic
transducer. Every interruption represents half turn of the rotor, this allows to measure the
number of turn in the time. There is a constant ratio between air passing trough the turbine and
number of turns. This allows to calculate an accurate measurement of volume and flows.
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. It is also possible to use the charger in car using cigar light adapter
cable supplied with standard accessories.
The battery charge status is indicates by a flashing green Led and completely charged one with
Non Flashing one on the top cover pony unit.
2.1.4. RS232 cable
It allows to download the data of the test to a PC compatible or to print the result with an
external Printer (see the User's Manual for the printer specifications).
Service Manual Pony Graphic Chapter 2 Functional Description
2.2
Page 15
3. 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. Display Assembly (C01344-01-30)...............................................................................3.5
3.3.1. Function...................................................................................................................3.5
3.3.2. Description...............................................................................................................3.5
3.3.3. Adjustments & checks .............................................................................................3.5
3.3.4. Assembly Drawing...................................................................................................3.5
3.3.5. Warnings & Indications in Event of Failure..............................................................3.5
3.4. Keyboard Assembly (C01352-01-15)...........................................................................3.5
3.4.1. Function...................................................................................................................3.5
3.4.2. Description...............................................................................................................3.5
3.4.3. Adjustments & Checks ............................................................................................3.5
3.4.4. Assembly Drawing...................................................................................................3.6
3.4.5. Warnings & Indications in Event of Failure..............................................................3.6
3.5. Printer (C01386-01-08)..................................................................................................3.6
3.5.1. Function...................................................................................................................3.6
3.5.2. Description...............................................................................................................3.6
3.5.3. Adjustment & checks...............................................................................................3.6
3.5.4. Assembly Drawing...................................................................................................3.7
3.5.5. Warnings & Indications in Event of Failure..............................................................3.7
3.6. Opto Electronic Assembly(C00095-01-05) .................................................................3.7
3.6.1. Function...................................................................................................................3.7
3.6.2. Description...............................................................................................................3.7
3.6.3. Adjustment & checks...............................................................................................3.8
3.6.4. Assembly Drawing (Refer to Section: Schematics & Layouts)................................3.8
3.6.5. Warnings & Indications in Event of Failure..............................................................3.8
3.7. Battery Charger (C00766-01-30) (C00767-01-30)........................................................3.8
3.7.1. Function...................................................................................................................3.8
3.7.2. Description...............................................................................................................3.8
3.7.3. Adjustments & checks .............................................................................................3.8
3.7.4. Assembly Drawing...................................................................................................3.8
3.7.5. Warnings & Indications in Event of Failure..............................................................3.9
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3. Part Description
This section deals with the electronic circuits and their functions; it gives an overview regarding
the general aspect of the PCB assembly, its electronic description and the possible errors and
faults, which can occur due to malfunction in the component from that assembly. 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. Keyboard Assembly (C01352-01-15)
4. Printer unit Assembly (C01386-01-08)
Opto electronic Reader
5. Opto electronic Assembly (C00095-01-05)
Battery Charger Unit
6. Battery Charger Assembly(220V) (C00766-01-30)
7. Battery Charger Assembly(110V) (C00767-01-30)
The circuit diagrams and PCB Layouts are attached for ready reference
Service Manual Ponygraphic Chapter 3 Part Description 3.2
Page 17
3.1. Pony graphic Unit
The Pony graphic Unit '96 version (P/N: C00307-0X-04), distributed since May 1996, is made
of 4 different PCBs:
Mother Board P/N: C01350-01-15
Display: P/N: C01344-01-30
Keyboard: P/N: C01352-01-15
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.
3.2. Mother Board (C01350-01-15)
3.2.1. Function
The Mother Board carries the components shown in the above diagram, all the connection
between them perform the following functions:
• Control of the all peripherals (display, internal printer, keyboard...) through the micro
controller U1 (CDP6805);
• Data Acquisition and amplification of the pulses coming from the opto electronic reader.
• Serial communication management (RS232 unidirectional) and interface level regulation
through U11 (MAX233);
• Battery voltage le vel detec ti on;
• Battery charging management through U10 (TEA1100) of Power Supply Board PCB.
The mother Board layout is enclosed in the Appendix.
3.2.2. Description
(1) Micro controller (CPU) (U1)
The micro controller U1 (CDP6805E3) used in the Pony graphic is responsible for
Data management through its address bus for control data transfer function in accordance with
the firmware: stored in EPROM U4 (27C512 ,64KB)
(2) Clock
The frequency of the clock signal is controlled by the crystal X1 (4.194.304MHz) ,
Connected between pin 2 and pin 3 of the Real Timer Clock U2 (146818A).
The RTC (146818A) send the squared clock pulses to pin 39 of U1 (CPU) and generates the
interrupt signal necessary to measure the turbine pulses width (pin 19 of 146818A).
(3) I/O control(U9)
The I/O control is carried out within the component FPGA (Field Programmable Gate Array) U9
(Actel A1010B). This IC compensates the Latches, Buffers, Logic Gates for control logic.
(4) Reset
The task of the Reset circuit is to boot the CPU program; when the reset signal (pin 1 of U1)
toggles from Low to High, the CPU executes the bootstrap program.
(5) Power down (U13)
The Power Down circuit protects data stored in RAM in event of power failure. It disable the
RAM access by toggling pin 20 and 22 of the RAM U3 (62256). To logic level High
(6) RAM (U3)
The IC (U3) 62256 is a 32KByte Random Access Memory used for saving the tests data and
for temporary memory during calculations. A dedicated circuit supplies power to the IC even if
the Pony graphic is switched off.
Service Manual Ponygraphic Chapter 3 Part Description 3.3
Page 18
(7) RS232
The serial communication is completely managed by the CPU; the only external component is
U11 (MAX233) which does the voltage level conversion from TTL (0-5V) to RS232 (-12+12V).
The protocol used is the following:
Data bit: 8 Parity: none
Baud rate: 4800 Handshake: DTR Hardware
(8) 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.
The IC U12 (MAX635) generates a negative voltage of -18 Volts (pin 11) in order to power the
LCD Display contrast.
The LCD back-light power supply is controlled by software (battery saving mode) and
generated by an switching circuit composed by T1, C32, C33, R33, R34 and Q10; the supply
voltage is about 90 VAC RMS.
The battery voltage directly powers the Optoelectronic Transducer and the Printer.
The IC U10 (TEA1100) performs the battery charging management. The NiCD batteries are
charged with two different levels:
Fast charging: 800mA (front panel green led fix)
Slow charging: 15mA (green led blinking)
The circuit Switches from fast to slow charging when one of the following conditions is verified:
• Battery fully recharged (Voltage Decrement CutOff System; the battery voltage is
continuously monitored by pin 7, when a decrement is detected TEA1100 switch to
slow mode).
• Battery temperature higher than 45°C (the temperature is monitored by thermistor RV2)
• Battery voltage lo wer tha n pr ef ix ed thresh old
• Battery Voltage higher than prefixed threshold
• Charging time higher than 2 hours.
3.2.3. Adjustments & checks
There are no adjustments to be performed on the motherboard.
3.2.4. Assembly Drawing
RAM EPROM
U1 micro controller
RTC
U12 Display control
RS 232
I/O
FPGA
3.2.5. Warnings & Indications in Event of Failure.
• The system does not operate when switched on (refer to Troubleshooting section)
• Printer / serial communication does not work
Service Manual Ponygraphic Chapter 3 Part Description 3.4
Page 19
3.3. 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.
3.3.2. Description
The LCD display is CPU controlled by means of the Data Bus (B0-B7) and powered with the
following voltages (see the Display layout in Schematics and Layouts section):
3.3.3. Adjustments & checks
(1) Display contrast adjustment
Adjustment VR Test Point Adjustment Item
VR54 Display Display contrast
It is automatically compensated for temperature variations.
(2) Test Points
Pin 3 of P1 Digital Logic supply (VCC 5V)
Pin 5 of P1 LCD supply (VEE-18V)
Pin 4 of P1 Contrast level VDAJ(-15V)
Pin 1,2 of P1 back-light supply (VEL*90VAC)
3.3.4. Assembly Drawing
3.3.5. Warnings & Indications in Event of Failure.
• Display failure
• Backlight failure
3.4. Keyboard Assembly (C01352-01-15)
3.4.1. Function
The keyboard is the primary input device for the patient data and for executing the test it is
passive device hardwired to the CPU.
3.4.2. Description
The keyboard is directly interfaced with the I/O ports of the CPU by the connector JP7.
Pins 12-13-14 of U1 are outputs while pins 33-34-35-36 Inputs.
3.4.3. Adjustments & Checks
There are no adjustments to be performed on this assembly.
Service Manual Ponygraphic Chapter 3 Part Description 3.5
Page 20
3.4.4. Assembly Drawing
3.4.5. Warnings & Indications in Event of Failure.
• Key failure
3.5. 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.
3.5.2. Description
The following schematic shows the control circuitry for the printer.
The Printer motor is activated and stopped by the two signals M_ON (Motor On) and M_OFF
(Motor Off).The signal Fast Line Feed controls the paper feed and it is directly operated by the
CPU (pin 30).The feedback signals coming from the Printer are monitored in order to detect the
exact position of the solenoids.
The supply voltage comes directly from the Batteries and the peaks of the current can reach
10A.
3.5.3. Adjustment & checks
There is no adjustment on this assembly.
Service Manual Ponygraphic Chapter 3 Part Description 3.6
Page 21
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).
Expired Flow
Conveyor
Rotor
(blade)
3.6.2. Description
The Optoelectronic transducer contains 2 couples of Infrared Emitter/Receiver diodes to detect
the position of the rotor. The air passing through the helical conveyors, takes a spiral motion
which causes the rotation of the turbine rotor. The rolling blade interrupts the infrared light
beamed by the diodes of the optoelectronic reader, each interruption represents half turn of the
rotor, this is used to measure the number of turn in the time. There is a constant ratio due to
software linearization between air passing through the turbine and number of turns. This allows
for an accurate measurement of volume and flows. Refeto the electrical diagram and layout of
the output signals from the infrared receivers D4 (Rx1) and D3 (Rx2) as shown following figure.
Conveyor
Service Manual Ponygraphic Chapter 3 Part Description 3.7
Page 22
The flow and volume measurement is carried out as follows:
Volume It is proportional to the number of pulses detected by the receiver diode during
expiration (expired volume) or inspiration (inspiratory volume);
Flow the absolute value of the flow (positive for both expiration and inspiration) is
proportional to the inverse of the pulse width detected by the receiver diode;
IN/EX The flow direction is detected by verifying which pulse (rx1, rx2) is received first. The
turbine doesn't need to be calibrated daily as it is not affected by pressure, humidity and
temperature.The turbine should be maintained with regular ordinary sterilization to move freely
without friction, free of dust.
3.6.3. Adjustment & checks
There are no adjustments to be performed on this assembly.
3.6.4. Assembly Drawing (Refer to Section: Schematics & Layouts)
3.6.5. Warnings & Indications in Event of Failure.
• Flow and Volume errors
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 P/N: C00766-01-30
Pony graphic AC/DC adapter 110V 12V 1A P/N: C00767-01-30
3.7.2. Description
The battery charger is a classified Class II equipment according to "IEC 601-1: 1990: Safety of
medical electrical equipment “General requirements"
The diagram in assembly drawing shows the polarity of the connections between the Pony
graphic Unit and the AC/DC adapter.
3.7.3. Adjustments & checks
There is no adjustment to be performed on this assembly
3.7.4. Assembly Drawing
Service Manual Ponygraphic Chapter 3 Part Description 3.8
Page 23
3.7.5. Warnings & Indications in Event of Failure.
• Power failure
• Battery charging failure.
Service Manual Ponygraphic Chapter 3 Part Description 3.9
Page 24
Page 25
4. UNIT MAINTENANCE AND CONSUMABLE REPLACEMENT ........... 4.2
4.1. Operator Maintenance Program..................................................................................4.2
4.2. 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
4. UNIT MAINTENANCE AND CONSUMABLE
REPLACEMENT
4.1. Operator Maintenance Program
The following log is recommended to be maintained by the user or by operator on daily /Weekly
basis
General Precautions
• DO NOT autoclave, gas sterilize or immerse the electrical parts of the in liquid.
• The person operating the Pony graphic should not perform any servicing except as
specifically stated in the 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.
• Always turn the PONY graphic off before cleaning or servicing.
• DO NOT immerse any electrical part (i.e. Optoelectronic transducer) in water or any
liquid.
• DO NOT touch any exposed wiring or conductive surface while the cover is off and the
system is running if using a grounding wrist strap.
• Use insulated tools when touching the components of the PCBs.
• Electrostatic Dis char ge thr o ugh the PC Bs will damage the components of the system.
Handle all circuit boards (replacements and defectives) by their non conductive edges
and use anti-static containers when transporting them. Before servicing the equipment,
ground yourself and the tool to discharge any accumulated static charge by wearing a
static control wrist strap.
• Check Power Supply Adapter voltage before connecting the AC main power.
• Replace fuses ONLY with the same type and rating ones.
THINGS TO DO DAILY WEEKLY MONTHLY
General
Clean & disinfect Turbine √√√√
Charge batteries √√√√
Clean the Unit √√√√
(Follow Instructions in Users Manual for cleaning of the unit &Turbine.
Refer the Pony graphic User's Manual for cleaning instructions
Checks
Check display √√√√
Check Display backlight √√√√
Check Cables (power, flow meter) √√√√
Check battery status using the charger √√√√
Calibration
Carry out Turbine calibration √√√√
4.2. Replacement Schedule
The replacement of parts should be followed for smooth functioning of the system.
THINGS TO DO DAILY MONTHLY HALF YEAR YEARLY
Replace Internal Rechargeable batteries (Every 2 years)
(For replacement of the batteries follow the service procedure section of this manual)
Refer Users manual for details on maintenance.
For any replacement of accessories please refer operators manual.
For any procedure for replacement of consumables refer section on Service procedures
Service Manual Ponygraphic Chapter 4 Maintenance
4.2
Page 27
The part numbers are as given in the parts list section (Appendix A) of this manual.
Service Manual Ponygraphic Chapter 4 Maintenance
4.3
Page 28
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
Besides tools normally used by a technician, it is necessary to have:
Calibration syringe 3 L (C00243-01-06)
Voltmeter
Oscilloscope (20MHz Bandwidth)
The Engineer attending the preventive maintenance schedule must follow the guidelines given
below
General checks.
4.3.2. Charger cable A381-003-202:
Check the integrity of the cable especially on the plugs at the ends and verify with a voltmeter
the absence of electrical short circuit on it.
4.3.3. RS232 serial cable C00032-01-12:
Check the integrity of the cable especially on the plugs at the ends. Check electrically the cable
by using a ohm meter for continuity check.
4.3.4. Turbine C00292-01-05:
Check the integrity of the external transparent tube of the turbine. Verify that the rotor moves
freely without friction and that the turbine is clean.
4.3.5. Optoelectronic reader C00095-01-05:
Check for any physical damage to the turbine or surface. Check the integrity of the cable
especially on the plug at the end.
4.3.6. Pony graphic unit
Check the batteries using voltmeter, for replacement follow service procedure section of this
manual. Check the Display for proper brightness and contrast, if found faulty follow the service
procedure section for replacement of the display. Check the printer for by carrying a test and
then printing the data on the printer with flow and volume curves.
The above ensure the complete check of the unit
Service Manual Ponygraphic Chapter 4 Maintenance
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5. TROUBLESHOOTING .......................................................................... 5.2
5.1. Careless mistakes during the use of the system ......................................................5.3
5.1.1. Warning ...................................................................................................................5.3
5.1.2. Tools........................................................................................................................5.3
5.1.3. 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. Serial Communication error.....................................................................................5.5
5.1.9. The keyboard doesn't work .....................................................................................5.5
5.1.10. The LCD Display back-light doesn't work ............................................................5.5
Page 30
5. TROUBLESHOOTING
The following list is an extension of the troubleshooting section outlined in the operator's
manual. The reader shou ld f am iliarize with the s etup, operat io n and troub lesho oting sec tions of
the operators manual before attempting to service the unit.
This section deals with the following problems and their recommended solutions
o The system does not operate when switched ON.
o The Printer does not wor k properl y.
o The Pony graphic is unable to measure properly flow and volume.
o The optoelectronic transducer does not work.
o The batteries cannot be recharged or green LED remains OFF.
o Serial Communication Error.
o The Keyboard does not work
o The LCD Display backlight does not work.
Note:
It is very important while diagnosing problem to look at the non-instrumental aspects of
troubleshooting. This will save time and efforts for reaching to the correct solution
Please ensure the following before opening the instrument.
• There are no operator level problems.
• There are no environmental problems.
Service Manual Ponygraphic Chapter 5 Troubleshooting
5.2
Page 31
GENERAL
5.1. Careless mistakes during the use of the system
Effects: malfunction of the equipment or unreliable measurements.
While doing a test, ensure that the right height and weight are entered for the subject and
desired predicted values are selected. Ensure proper procedure for doing the test as instructed
in the User manual.
5.1.1. Warning
This chapter contains the indications useful to find out and repair most of the possible troubles
of the Pony graphic. Pay attention to the version of the Pony graphic Unit you are repairing
before following the Trouble-shooting indications (see next paragraph).
Before implementing this chapter it is strongly recommended to read the "Functional
Description" chapter of this manual.
Before trying to solve the trouble, be sure that the battery is charged and the system is in a
steady condition. If the system indicates any malfunction or precautionary messages on the
Display find out the source of error, rectify it and then only proceed with the test.
5.1.2. Tools
Besides the tools normally used by a technician, it is necessary to hav e:
A Voltmeter to measure voltage.
A screwdriver with a thin point, to adjust the trimmer
5.1.3. The system doesn't operate when switched on;
Reference Layouts: mother board P/N: C01350-01-15
1. Turn-off the instrument, connect the AC/DC adapter to the Pony graphic Unit and verify
if the green led is on otherwise proceed from to "The batteries cannot be recharged or
the green led is off" item.
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"
item.
4. Turn off the instrument and verify if voltage on pin 6 of U13 is about 5 Volt (RAM
disabled) otherwise replace U13.5.
5. Verify if the signal on pin 3 of U2 is the same as the following figure
6. otherwise replace X1 (crystal 4.194.304 MHz).
7. Verify if the signal on pin 39 of U1 is the same as the following figure otherwise replace
the RTC U2.
8. Verify if the frequency of the squared waveform on pin 3 of U1 is about 839 KHz
otherwise replace U1.
9. Verify if after the replacement of the EPROM U4, the RAM U3 and the FPGA U9 the
unit works otherwise contact COSMED.
Service Manual Ponygraphic Chapter 5 Troubleshooting
5.3
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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.
3. Verify transistors Q1, Q2, Q3 and Q6 and eventually replace the broken ones.
4. Verify if after the replacement of the components U5, U6, U7 and U9 the unit works
otherwise replace the printer.
5.1.5. The Pony graphic is unable to measure properly flow and volume;
Reference Layouts: mother board
P/N: C01350-01-15
1. Take off the turbine from the Optoelectronic Transducer and verify that the rolling blade
is clean from dust, hairs or any external agent, otherwise refer to the "Pony graphic
User's Manual" for cleaning procedures.
2. Blow gently into the turbine and verify if the rolling blade moves freely otherwise
replace the turbine itself .
3. Verify that the turbine is inserted completely into the Optoelectronic transducer (an
incomplete insertion doesn't allow the photo diodes to work properly).
4. Verify that the connector of the Optoelectronic Transducer is properly inserted in its
plug.
5. Open the above-mentioned connector and verify the integrity of the contacts (See
Appendix/Optoelectronic Transducer).
6. Perform any test (FVC, VC or MVV) and verify if the pin 10 of U1 is high (NOTE the
enable signal remains high for only 5 seconds if no flow is detected), otherwise replace
U1.
7. Perform any test and verify if pin 1 of the Optoelectronic Transducer connector J5 is
about 5 Volts otherwise control L6, L7, L8 and Q4 (photo diodes power supply)
8. Perform any test and, blowing into the turbine flowmeter, verify if both signals on pin 2
and pin 3 of J5 are similar to the following figure: otherwise refer to the "The
Optoelectronic transducer doesn't work" section below;
5.1.6. The Optoelectronic transducer doesn't work;
Reference Layouts: Optoelectronic Transducer Board
P/N: C00609-01-15;
1. Disassemble the Optoelectronic Transducer in order to access the internal PCB. Run
the flow acquisition by pressing FVC, VC or MVV (NOTE the circuitry is powered for
only 5 seconds if no flow is detected).
2. Verify if the voltage of pin E1 is about 5 Volt otherwise check the cable connections.
3. Verify if the voltage of the infrared emitters D1 and D2 is about 1.3 Volt and eventually
replace the PCB.
4. Verify if voltage of the infrared emitter E2 and E3 (without turbine) is about 5 Volt or
eventually replace optoelectronic reader (only PCB is not sold due to alignment problems)
5.1.7. The batteries cannot be recharged or the green led remains off;
Reference Layouts: mother board
P/N: C01350-01-15
1. Connect the AC/DC adapter to the main supply and verify if the output voltage is about
20 Volt DC otherwise verify the wire connection inside the adapter or replace it.
2. Connect the AC/DC adapter to the Pony graphic and verify if the green led is on
3. Open J8 on the mother board and connect (series) to its pins a multimeter in order to
check the charging current (about 800 mA) (if the charging current is correct and the
voltage of the batteries remains lower than 5 Volt, the batteries must be replaced).
4. Verify and eventually replace F1 (1.5 A).
5. Verify the contacts of the connections between the mother board and the power supply
board.
6. Verify if the thermistor RV1 s properly soldered to the mother board;. Even if this is not
visible, the impurities may reduce capacity of the sampling line to de-humid saturate
the humidity elimination capacity.
Service Manual Ponygraphic Chapter 5 Troubleshooting
5.4
Page 33
5.1.8. Serial Communication error
Reference Layouts: mother board P/N: C01350-01-15.
1. Verify if the serial cable is connected to the port configured on the PC software.
2. Open the 2 connectors of the serial cable and verify if the wires are properly connected
to the relative pins.
3. Replace iteratively the following components: U11, U1, U9
5.1.9. The keyboard doesn't work
1. Disassemble the Pony graphic Unit and verify if the keyboard PCB is properly
connected to the mother board.
2. Replace U1.
5.1.10. The LCD Display back-light doesn't work
Reference Layouts: mother board
P/N: C01350-01-15
1. Note: the LCD back- light is autom atic all y switche d of f during prin tin g and one m inu te
later last key is pressed.
2. Turn on the Pony graphic and verify if pin 11 of U1 is about 5 Volt otherwise replace
U1.
3. Verify if the voltage between pin 2 and 3 of J3 is 90 VAC otherwise replace T1.
Service Manual Ponygraphic Chapter 5 Troubleshooting
5.5
Page 34
Page 35
6. Service Procedures............................................................................. 6.2
6.1. Consumable Replacement...........................................................................................6.2
6.1.1. Disassembling the Pony graphic .............................................................................6.2
6.1.2. Replacing the internal Rechargeable batteries .......................................................6.3
6.2. Electronics.....................................................................................................................6.3
6.2.1. Display contrast Adjustment....................................................................................6.3
6.2.2. Flow measurement Check and Calibration .............................................................6.4
6.3. Auto Test Mode.............................................................................................................6.4
6.3.1. Running the Auto-test program ...............................................................................6.4
6.3.2. 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
6. Service Procedures.
6.1. Consumable Replacement
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.
(1) Flow meter
1. Remove the Turbine from the Optoelectronic Transducer as described in the Pony
graphic User's Manual.
2. Remove the 2 screws and open the cases to access the internal parts as shown in the
following figure.
Optoelectronic Transducer
Board
Screw
(2) Pony graphic unit
Remove the 4 rubber pins from the bottom of the Unit, take off the 4 screws and open the
cover;
Mother Board
fixing screws
Rubber pin
Top Cover
Rear Cover
fixing screw
After removing the Rear cover you may remove the following sub-assemblies:
• Mother Board fixed with 4 screws to the top cover;
• Keyboard fixed with 2 screws to the top cover;
• [Power Supply Board fixed to the Mother Board];
• Printer fixed to the Mother Board;
• LCD Display fixed to the Mother Board
Service Manual Ponygraphic Chapter 6 Service Procedures
6.2
Page 37
6.1.2. Replacing the internal Rechargeable batteries
The Pony graphic Unit is supplied by 2 rechargeable Nickel Cadmium Batteries (2.4 Volt, 1200
mAh), soldered to the mother board.
The life duration of the batteries depends strongly from how they are used (frequent charges
and discharges stress the elements). When you verify that the autonomy of the system is
unacceptably reduced (this can occur normally in 2 years), it is time to replace the batteries.
Procedure
1. Be sure that the Pony graphic is off.
2. Open the rear panel of the Pony graphic as the described in the chapter
"Disassembling the Pony graphic - Pony graphic Unit".
3. Disassemble the Mother board from the front case (4 screws fixes the PCB to the
plastic case).
4. Unsolder the terminals of the batteries from the PCB and pull them out gently.
5. Place the new batteries paying attention to fix the thermistor on the older battery as
found before the replacement.
6. Solder the connections of the batteries on the PCB.
7. Reassemble the Pony graphic unit.
Parts required
For the mentioned procedure you need the following items:
P/N Description
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. Wait until the green led is blinking.
3. Wait for 20-30 minutes with the system off in order to bring the LCD display to the
ambient temperature (the LCD contrast is compensated for the ambient temperature
but, during recharging the sensor is affected by the heating of the batteries).
4. Open the rear panel of the Pony graphic as the described in the section
"Disassembling the Pony graphic - Pony graphic Unit".
Display Adjustment R54
1. Turn on the Pony graphic and adjust the Contrast R54 trimmer until the contrast meets
the requirement.
2. Reassemble the Pony graphic unit.
Service Manual Ponygraphic Chapter 6 Service Procedures
6.3
Page 38
6.2.2. Flow measurement Check and Calibration
Carrying out a VC test and verifying the real-time curve displayed on the LCD screen can easily
check the flow measurement. The flowmeter is working substantially properly if:
1. The volume/time curve follows the ventilatory pattern both during expiration (pixels
drawn from up to down) and inspiration (pixels drawn from down to up).
2. The Volume/time curve is regular and doesn't present peaks or clipped edges (see
figure below)
Slow Vital Capacity
Volume (l)
4
3
2
1
0
-1
-2
-3
-4
Peak INSPIRATION
Clipped Edge
EXPIRATION
Time (sec)
For further information Refer to the Pony graphic User's Manual on “turbine calibration.”.
6.3. 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.
The electrical diagram of the Auto-test-adapter is shown in the following figure.
P1
1
6
Dtr
2
Tx
7
3
Rx
8
4
Dsr
9
5
Gnd
CONNECTOR DB9M
D1
LED
R1
10K
Check Clock
The adapter can be easily constructed or contact COSMED directly to procure it.
6.3.1. Running the Auto-test program
1. Switch off the Pony graphic Unit
2. Insert the Auto-test Adapter in the serial port of the instrument
3. Switch on the Pony graphic and verify the LEDs on the Auto-test adapter
The Pony graphic Unit runs a self-test routine in order to verify the integrity of the
• Serial Communication,
• RAM access and
• The clock function
The results of these tests are prompted with glowing of the 2 LEDs of the Auto-test Adapter
(refer to the electrical diagram above reported):
D2 switched on Serial Communication OK
D2 is switched OFF RAM Access OK
Test menu is prompted on the display CLOCK Functions OK.
D2
LED
R2
10K
Check RAM
Service Manual Ponygraphic Chapter 6 Service Procedures
6.4
Page 39
6.3.2. Operating the interactive Diagnosis Program
Once the automatic Self-test has been completed, the interactive diagnosis program is run. The
display of the Pony graphic prompts the following items:
1. Keyboard
2. Printer
3. Display
4. Low-Battery
5. Turbine
(1) Keyboard Check
• From the Program menu select item 1 to run the Keyboard control
• Press all the keyboard buttons in the following order.
• 1, 2, 3, 4, 5, 6, 7, 8, 9, 0, Enter, Cancel.
Whenever a malfunction of the keyboard is detected, an error message will be prompted.
(2) Printer check
• From the Program menu select item 2 to run the Printer control
• Verify if the printout report is comparable with the following figure:
(3) Display Check
• From the Program menu select item 3 to run the Display control
• Verify if the image shown on the Display is comparable with the following figure with
the back-light off:
Press any key and verify if the image shown on the Display is comparable with the above
reported figure with the backlight on.
6.4. 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.
The data transmission passes through the serial port of the Pony Graphic using the same
communication cable DB9M-DB9F supplied with the standard equipment (transmission data to
PC) with the addition of an adapter (9M-25M non inverter).
If the printer does not have the serial interface, it is possible to use a common converter serial
to-parallel or the Kit Serial to parallel converter for external printers P/N: C01391-01-11.
6.4.2. Main features of the test report
The test report shows the data (Forced Vital Capac ity, Slow Expiratory Vital Capacity, Slow
Inspiratory Vital Capacity , Maximum Voluntary Ventilation ), curves Flow/volume and
Volume/time relative to the Forced Vital Capacity.
All the information is printed on one sheet; the scales and the resolution of the graphs (F/V and
V/t) are in compliance with the ATS 1987/1994 standards for the use "Validation & Hand
Measurement".
Service Manual Ponygraphic Chapter 6 Service Procedures
6.5
Page 40
Graphic F/V
Flow (L/s) Volume (L)
Range -12*-12 0*8
Resolution 5 mm/L/s 10 mm/L
Scale 2:1 1:2
Disposition Upwards Right
Graphic V/t
Time (s) Volume (L)
Range 0*8 0*8
Resolution 20 mm/s 10 mm/L
Disposition Right Upwards
6.4.3. Configuration of the printer
Attention: The Pony Graphic has to be configured correctly before connecting to the printer.
1. Check whether the printer supports the HP PCL3 (or Higher) language or following.
2. Use the user's manual of the printer in order to configure the following communication
protocol:
Number of bit 8
Parity no
Rate (BAUD) 9600
Stop Bit 2
Handshake DTR Hardware
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.
Pony Graphic (DB9F)
shield
Printer/Serial to parallel
shield
1
Tx
Tx
2
Rx
Rx
3
DSR
DTR
4
5
GND
6.4.4. Configuration of the Pony Graphic
1. Switch on the Pony Graphic and insert date
2. Choos e "ut i lity" (key 4)
3. Select "Configure" (key 6)
4. Select "PRINTER" (key 5) "PRINTER"
5. Make choice: 1 EXTERNAL, 2 INTERNAL
Note: the choice made remains memorized, also after the equipment has been switched off.
Printing procedure
The printing procedure is the same if one uses the internal conventional printer or the external
printer; a detailed description of the print possibilities can be found in the user's manual
Before starting to print with the external printer it is necessary to check the following:
1. The communication cable and the adapter must both be connected correctly
2. The printer must be switched on
Before and during the process of data transmission, the Pony Graphic checks the correct
connection with the printer, if the connection is not correct an error message will be prompted.
Service Manual Ponygraphic Chapter 6 Service Procedures
6.6
Page 41
If you wish to interrupt the printing process press CANC EL.
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.
Service Manual Ponygraphic Chapter 6 Service Procedures
6.7
Page 42
Page 43
7. 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. Serial Cable (C00032-01-12)................................................................................7.2
Page 44
7. 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.
Remove the base cover by unscrewing the four screws at the base.
Schematic & Layouts
7.1.1. Motherboard (C01350-01-15)
7.1.2. Display (C01344-01-30)
7.1.3. Key board PCB (C01352-01-15)
7.1.4. Printer (C00551-01-08)
7.1.5. Optoelectronic Reader (C00095-01-05)
7.1.6. Optoelectronic PCB (C00609-01-15)
7.1.7. Adapter Plug for Car charging (C00297-01-12)
7.1.8. Serial Cable (C00032-01-12)
Service Manual Ponygraphic Chapter 7 Schematics & Layouts
7.2
Page 45
Page 46
GND
Tav.3 - Mother board: schematic
4.194304
MHz
GND
5 6
9 8
11 10
13 12
GND
VBB
5X100K
R30
VCC
121K
1N4148
VCC
100NF
VCC
C2
47PF
X1
R1
10M
C1
22PF
U8C
74HC14
U8D
74HC14
U8E
74HC14
U8F
74HC14
D13
BAT85
D1 SF
D1 SF
R44
2.15K
D14
4.3V
5
2
+
C40
100uF
VCC
U13
CE
VBAT1
U2
1
MOT
2
OSC1
3
OSC2
4
B0 VADJ
B0 VADJ
AD0
5
B1 VADJ
B1 VADJ
AD1
6
B2 -Y0 AS R/W
B2 -Y0 AS R/W
AD2
7
B3 DS BLOW2 RD Y5
B3 DS BLOW2 RD Y5
AD3
8
B4 RS-TX A0
B4 RS-TX A0
AD4
9
B5 R/W BEEP R/W RESET B0
B5 R/W BEEP R/W RESET B0
AD5
10
B6 AS FAS-LF B1 B2
B6 AS FAS-LF B1 B2
AD6
11
B7 PB7 B3 B4
B7 PB7 B3 B4
AD7
146818A
100NF
C3
GND
11
B0 A0 SA
B0 A0 SA
O0
12
B1 A1 F-1B F-G
B1 A1 F-1B F-G
O1
13
B2 A2
B2 A2
O2
15
B3 A3 A14 CS-R
B3 A3 A14 CS-R
O3
16
B4 A4 A13 F-2B F-3B
B4 A4 A13 F-2B F-3B
O4
17
B5 A5 A12 R/W SB
B5 A5 A12 R/W SB
O5
18
B6 A6 A11 SC
B6 A6 A11 SC
O6
19
B7 A7 A10 CS-R
B7 A7 A10 CS-R
O7
27C512
100NF
8
VCC1
GND
4
MXD1210
GNDGNDGND GND GND
VCC
GND
C41
VCC
TOL
CEO
VBAT2
28
VCC
GND
14
GND
GND
24
VDD
GND
12
U4
A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
CE
OE
1
3
6
7
CKOUT
CS-R
CS-R
D11
C30
GND
18
RESET
23
SQW
22
PS
21
20
CKFS
19
IRQ
17
DS
16
STBY
15
R/W
14
AS
13
CS
10
9
8
7
6
5
4
3
25
24
21
23
2
26
27
1
20
CEEPR B0 F-2BX A0 B0 F-2BX F-3BX FT2
CEEPR B0 F-2BX A0 B0 F-2BX F-3BX FT2
22
GND
GND
A8 A9 FT1
A8 A9 FT1
A9 A8
A9 A8
A10 A7 B7
A10 A7 B7
A11 A6 B6
A11 A6 B6
A12 A5 B5 SH
A12 A5 B5 SH
A13 A4 B4 SD
A13 A4 B4 SD
A14 A3 B3 F-1BX F-H
A14 A3 B3 F-1BX F-H
PB7 A2 B2
PB7 A2 B2
-DS B1 D1 SE
-DS B1 D1 SE
VCC-RAM
+
C42
10uF
VCC VCC VCC VCC VCC
R31
4.64K
C31
100NF
GND
R9
100K
47PF
GND
GND
RS-RX DS PR-REE
RS-RX DS PR-REE
BLOW VOLUME M-STOP
BLOW VOLUME M-STOP
-Y1 FT1
-Y1 FT1
RS-DSR RNA14 SB
RS-DSR RNA14 SB
AS A15 SD
AS A15 SD
C43
100NF
J7
1
2
3
4
5
6
7
TASTIERA
C16
BZ1
BC212
3
GND
S1
VCC
2
U9
10
B0
11
B1
12
B2 M-STOP SF
B2 M-STOP SF
B3 A13
B3 A13
GND
B4
B4
B5 CEEPR
B5 CEEPR
B6 FT2
B6 FT2
B7 FF
B7 FF
VCC
VCC
VCC
100NF
C15
13
14
15
16
17
18
19
20
21
22
23
24
25
26
B2
B3
GND
GND
B4
B5
B6
B7
RS-RX
VCC
BLOW
-Y1
RS-DSR
VCC
AS
GND
GND
R35 R36 R37R38
VCC
R32
Q9
2.15K
1
VCC GND
F-H A0
F-3BX A1
F-1BX A2
PR-TIM A3A4PR-REE A5
F-H A0
F-3BX A1
F-1BX A2
PR-TIM A3A4PR-REE A5
F-H9F-3BX8F-1BX7PR-TIM6BLOW25VCC4PR-REE3F-3B2F-G1F-2B68R/W67GND66F-1B65Y764Y563M-ON62-Y0
A027A128A229A330A4
31
F-3B A6
F-G A7
F-3B A6
F-G A7
GND
32A533A634A735A836A937
F-2B A8
F-2B A8
VCC
R10
VOLUME B3
VOLUME B3
RESET B4
RESET B4
PA3
PA3
ON-T A10
ON-T A10
A13 A11
A13 A11
A14 A12
A14 A12
A15
A15
R/W A9
F-1B A10
Y7 A11
Y5 A12
M-ON RD
F-1B A10
VCC
A1039A1140A12
38
Y7 A11
Y5 A12
41RD42
-Y0 -DS
M-ON RD
-Y0 -DS
61
F-2B
M-STOP
A13
A14
VCC
GND
CEEPR
FT2
POR
GND
VOLUME
FT1
RNA14
CEEXP
A15
-DS
43
ACTEL101
D1
DS
VCC
VCC
R/W A9
VCC
U1
39
OSC1
2
IRQ
37
TIMER
1
RESET
14
PA0
13
PA1
12
PA2
11
PA3
10
PA4
9
A13
8
A14
7
A15
36
PB0
35
PB1
34
PB2
33
PB3
32
PB4
31
PB5
30
PB6
29
PB7
146805E3
R12
1K
60
59
58
57
56
A14
A14
55
54
53
52
51
50
49
48
47
46
45
44
100NF
VCC
GND
GND
GND
CEEXP M-ON SC
CEEXP M-ON SC
R15
100K
GND
C8
GND
100NF
C5
GND
GND
A10
A11
A12
OSC2
R/W
FF
FF
Q6
BC337
R13
2.15K
28
B0
B0
27
B1
B1
26
B2 RF-GND
B2 RF-GND
25
24
23
B5
B5
22
B6
B6
21
B7
B7
19
A8
A8
18
A9
A9
17
16
15
38
3
6
4
5
100NF
C39
GND
U3
1
26
2
23
21
24
25
3
4
5
6
7
8
9
A1 B1
A1 B1
10
84256A
AS
DS
B0
B1
B2
B3
B4
B5
B6
B7
A8
A9
L1
A14
A13
A12
A11
A10
A9
A8
A7
A6
A5
A4
A3
A2
A1
A0
+VB
GND
GND
GND
28
14
Q5
BC337
VCC-RAM
20
CE
27
WE
22
OE
19
D7
18
D6
17
D5
16
D4
15
D3
13
D2
12
D1
11
D0
T1
VEL
VEL
VBATVCC
R43
10K
R41
15K
VBAT
R14
100K
PR-REE SH
PR-REE SH
Q10
BC547
R33
6.8uF
R39
46.4K
C26
68pF
33
C33
+
1
R40
261K
2
3
4
GNDGND
1uF
C35
1uF
C36
GND
1uF
C37
1uF
C38
C4
100NF
GND GND GND GND
47NF
C32
100V
U12
LBR
LBD
CX
GND
MAX634
+
+
Short
+
+
Q1
BC237B
R3
221
GND
D5
GND
VBAT
VBAT
VFB
VREF
+VS
LX
R34
6.81K
8
7
6
5
1N4148
D1
1N4148
RS-DSR
RS-DSR
VBAT
U5
1
CLA
2
1C
3
1B
4
GND
5
GND
6
2B
7
2C
8
CLAMP
ULN2064B
U6
1
CLA
2
1C
3
1B
4
GND
5
GND
6
2B
7
2C
8
CLAMP
ULN2064B
D2
R29
68.1K
R4
R5
562
+
322
100NF
C27
10uF
C28
20
19
18
17
16
15
14
13
12
11
4C
NC
4B
GND
GND
3B
NC
3C
4C
NC
4B
GND
GND
3B
NC
3C
U11
R2OUT
R2IN
T2OUT
VC2C2+
V+
C1VC2+
MAX233
R42909K
16
15
14
13
12
11
10
9
16
15
14
13
12
11
10
9
D4
1N4148
+
GND
GND
1
T2IN
2
RS-TX
C1+
C2-
1N4148
+
+
+
+
3
4
5
6
7
8
9
10
D10
L15
680uH
RS-TX
RS-RX
RS-RX
GND
GND
VEE
Q3
2N2907
TLC271
1
8
6
5
R54
5KMVH
RV2
K164
15K
GND
GND
74HC14
74HC14
7 4
+
U7
-
ON-T
ON-T
100NF
C9
D3
1N4148
3
2
T1IN
R1OUT
R1IN
T1OUT
GND
VCC
GND
C29
100uF
GND GND
SG
SG
C12 1uF
GND
GND
C11 1uF
C10 1uF
GND
GND
C34 1uF
R6
1
Q2
ZTX689B
PR-TIM SA
PR-TIM SA
L1
GND
L2
L3
L4
L5
10uF
C6
+
VCC
VCC
VEE
B5 B6
B5 B6
B7
B7
VEL
VEL
GND
GND
R11
4.64K
14 7
VCC
12
U8A
GND
34
U8B
C7
100NF
C13
100NF
GND
R7
100K
R8
2.15K
33uH
33uH
33uH
33uH
33uH
VCC
GND
R24.64
BAT85
J2
1 2
3 4
5 6
7 8
9 10
11 12
13 14
15 16
17 18
19 20
J3
1
2
3
4
Q4
BC212
D12
GND
DSR
RX
TX
DTR
VCC
DISPLAY
L633uH
L733uH
L833uH
L9SHORT
GND
SE
SE
SG
SG
GND
RF-GND
10uF
+
C14
RF-GND
J1
5
9
4
8
3
7
2
6
1
GND
TURBINA
J5
1
2
3
4
GND
PRINTER
J6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
GND
VCC
J4
2
1
RF-GND
RF-GND
F1
F2A
BNP002
L10
1N5820
+
C44
100uF
25V
D8
681 ½Watt
R16
C17
47NF
BC548B
BD227
Q11
Q7
R17
147
R21
464
L11
400uH
D9
1N5820
BAV20
C23
10uF
VBB VBAT
Q8
R18
BC548B
22
LED
+
C20
22uF
R22
681
R46
6.19K
R47
46.4K
R19
619
D15
680pF
C18
C25
1NF
C19
82pF
15
A
5
B
4
C
R45
+
5.11K
D7
D6
BZX79
R25
1W.33
R48
7.87K
GND
91286786145
U10
TEA1100
D
1E9F2H16113
3
4
3
2
RV1
4K7NTC
7
10
11
C21
1NF
GND
R20
27K
R23
147K
R24
147K
10uF
+
C24
680pF
BC237
Q12
C22
VBAT
R49
4.99K
BLOW2
BLOW2
R50
100K
+
C45
47uF
SW1
GND
GND
100NF
+
C46
150uF
1
6
2
MAX761
C53
L1222uH
U14
LB0
GND
LB1
V+
GND
GND
1N4148
D16
8
4
LX
FB
B
10uF
C47
+
5
100NF
GND
7
3
C52
F2
T3A
R26
46.4K
P1
J8
12
BT1
1.2X2
BT2
1.2X2
R27
100K
BLOW
BLOW
R28
1M
R51
21.5K
VCC
GND
47uF
+
C48
C54
220pF
1N5819
D17
L13
22uH
GND GND GND
+
150uF
C49
C50
47pF
R52
147K
L14680uH
R53
60.4K
VCC
+
C51
100uF
E1
1
GND
1
Page 47
Page 48
Page 49
Page 50
Page 51
Page 52
Page 53
Page 54
8. Appendix A: Replaceable Part List....................................................8.2
Page 55
8. Appendix A: Replaceable Part List
P/N Description
C01805-01-98 Adult Mouthpieces * 30 mm (500 pieces)
C01814-01-98 Pediatric mouthpieces * 22 mm (500 pieces)
C00214-01-20 Adapter for pediatric mouthpieces ID 22mm
C00063-01-20 Conic plastic mouthpiece
C00441-01-98 Nose clips (5 pieces)
A 666 905 001 Printer ribbon (5 pieces)
C00643-01-98 Printer paper (10 pieces)
C00600-01-11 Calibration syringe 3 liters
C00296-XX-91 Pony graphic User manual (XX:01=IT/02=EN/03=FR/ 04=ES/ 05=DE)
C00109-01-30 Carrying case Pony graphic
C00766-01-30 AC/DC adapter Pony graphic 220V
C00767-01-30 AC/DC adapter Pony graphic 110V
A 362 110 001 Plug + cable x AC/DC adapter Pony graphic
C00297-01-12 Adapter plug for car charging Pony graphic
A 388 010 002 RS232 adapter for external printer (serial interface available)
C00032-01-12 Serial cable (D9M-D9F)
C01391-01-11 Kit Serial to parallel converter for external printers
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 Turbine Pony graphic
C00086-01-30 Display Pony graphic (before may 1996 models)
C01344-01-30 Display Pony graphic (after may 1996 models)
C00096-01-20 Film safe x Pony graphic display
C00551-01-08 Printer Pony graphic (after may 1996 models)
C01350-01-15 Mother Board Pony graphic (after ma y 1996 models)
C00087-01-15 Keyboard Pony graphic (Till may 1996 models)
C01352-01-15 Keyboard Pony graphic (after may 1996 models)
C00609-01-15 Optoelectronic transducer (Pony graphic) board
C00126-01-20 Top cover Pony graphic
C00089-01-92 Keyboard panel Pony graphic
C01338-01-92 Keyboard panel Spirotur 610
C01572-01-92 Keyboard panel Discovery graphic
C00126-01-08 Bottom cover Pony graphic
A 256 210 001 Rubber feet x bottom cover Pony graphic
A 410 700 004 Pony graphic Ni Cd batteries (1 of 2)
Service Manual Ponygraphic Appendix A 8.2
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