COSMED Pony graphic spirometer Service manual

COSMED Pony graphic spirometer Service manual

Below you will find brief information for spirometer Pony graphic. The 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.

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COSMED Pony graphic Service Manual | Manualzz

SERVICE MANUAL

Pony

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:[email protected]

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:[email protected]

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.

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

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.

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 i

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 ii

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 iii

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

1. 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.

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.

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.

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

1.4.1. Pony graphic Unit

Graphic display

Display

Printer

Keyboard

Serial cable

Backlight LCD 70x80 mm

LCD 2 lines x 16 characters

Graphic,24 char/lin,2,5 lines/s

12 multifunction keys

RS 232, bi-directional, 4800 baud

Dimensions

Dimensions

Weight

237x127x46 mm

1.2 kg

Flow meter: Digital bi-directional turbine

Flow range

Volume range

0.03 -20 l/s

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

Ni-Cd Batteries, 5V, 1.2 AH, Rechargeable.

Battery Autonomy 200 tests including prints out

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

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 unprotected against water penetration;

• Non sterile device

• Device not suitable in the presence of flammable aesthetics;

• Continuous functioning equipment;

Service Manual Pony Graphic Chapter 1 Introduction

1.3

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 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

1.4

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

2. Functional description

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.

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

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

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)

(C01344-01-30)

(C01352-01-15)

(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

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

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 level detection;

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).

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

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

(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:

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:

Slow charging:

800mA (front panel green led fix)

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 lower than prefixed threshold

Battery Voltage higher than prefixed threshold

Charging time higher than 2 hours.

There are no adjustments to be performed on the motherboard.

RS 232

I/O

FPGA

U1 micro controller

RTC

BATTERY

U12 Display control

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

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):

(1) Display contrast adjustment

Adjustment VR Test Point Adjustment Item

It is automatically compensated for temperature variations.

(2) Test Points

Pin 3 of P1 Digital Logic supply (VCC 5V)

Pin 5 of P1

Pin 4 of P1

Pin 1,2 of P1

LCD supply (VEE-18V)

Contrast level VDAJ(-15V) back-light supply (VEL*90VAC)

3.3.5. Warnings & Indications in Event of Failure.

Display failure

Backlight failure

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

3.4.5. Warnings & Indications in Event of Failure.

Key failure

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

3.5.5. Warnings & Indications in Event of Failure.

Printing Failure

Paper jam during Printing

No Printout

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

Rotor

(blade)

Conveyor

Conveyor

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.

Service Manual Ponygraphic Chapter 3 Part Description 3.7

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.

There is no adjustment to be performed on this assembly

Service Manual Ponygraphic Chapter 3 Part Description 3.8

3.7.5. Warnings & Indications in Event of Failure.

Power failure

Battery charging failure.

Service Manual Ponygraphic Chapter 3 Part Description 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

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 Discharge through the PCBs 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 display

√√√√

Check Display backlight

√√√√

Check Cables (power, flow meter)

Check battery status using the charger

Calibration

Carry out Turbine calibration

√√√√

√√√√

√√√√

√√√√

√√√√

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

The part numbers are as given in the parts list section (Appendix A) of this manual.

Service Manual Ponygraphic Chapter 4 Maintenance

4.3

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

Besides tools normally used by a technician, it is necessary to have:

Voltmeter

Oscilloscope (20MHz Bandwidth)

The Engineer attending the preventive maintenance schedule must follow the guidelines given below

General checks.

Charger 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.

RS232 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.

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.

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

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

5. TROUBLESHOOTING

The following list is an extension of the troubleshooting section outlined in the operator's manual. The reader should familiarize with the setup, operation and troubleshooting sections 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 work properly. 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

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 have:

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

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

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.

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 automatically switched off during printing and one minute 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

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

6. 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.

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.

Screw

Optoelectronic Transducer

Board

(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

Top Cover

Rubber pin

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

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

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

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

Peak INSPIRATION

3

Clipped Edge

2

1

0

-1

-2

-3

EXPIRATION

-4

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

2

7

3

8

1

6

4

9

5

Dtr

Tx

Rx

Dsr

Gnd

D1

LED

Check Clock

D2

LED

Check RAM

CONNECTOR DB9M

R1

10K

R2

10K

The adapter can be easily constructed or contact COSMED directly to procure it.

6.3.1. Running the Auto-test program

1.

2.

Switch off the Pony graphic Unit

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.

Service Manual Ponygraphic Chapter 6 Service Procedures

6.4

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

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.

From the Program menu select item 2 to run the Printer control

Verify if the printout report is comparable with the following figure:

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 Capacity, 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

1

2

3

4

5

Graphic F/V

Range

Resolution

Flow (L/s)

-12*-12 0*8

5 mm/L/s

Volume (L)

10 mm/L

Scale 2:1 1:2

Disposition Upwards Right

Graphic V/t

Range

Resolution

Time (s)

0*8

20 mm/s

Volume (L)

0*8

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

Rate (BAUD)

Stop Bit

Handshake

no

9600

2

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) Printer/Serial to parallel shield

Tx

Rx

DSR

GND shield

Tx

Rx

DTR

6.4.4. Configuration of the Pony Graphic

1.

2.

Switch on the Pony Graphic and insert date

Choose "utility" (key 4)

3.

4.

Select "Configure" (key 6)

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.

2.

The communication cable and the adapter must both be connected correctly

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

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.

Service Manual Ponygraphic Chapter 6 Service Procedures

6.7

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

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

7.1.3. Key board PCB (C01352-01-15)

7.1.7. Adapter Plug for Car charging

(C00095-01-05)

(C00609-01-15)

(C00297-01-12)

Service Manual Ponygraphic Chapter 7 Schematics & Layouts

7.2

Tav.3 - Mother board: schematic

C2

47PF

GND

4.194304

MHz

GND

X1

C1

22PF

5 6

U8C

74HC14

R1

10M

B0

B1

B2

B3

B4

B5

B6

B2

B3

B4

B5

B6

R30

VCC

5X100K

VCC VCC VCC VCC VCC

VCC

VCC

VCC

100NF

C30

121K

1N4148

D11

GND

GND

C31

100NF

R31

4.64K

1

2

3

U2

MOT

OSC1

OSC2

9

10

11

4

5

6

7

8

AD0

AD1

AD2

AD3

AD4

AD5

AD6

AD7

146818A

GND

RESET

SQW

PS

CKOUT

CKFS

IRQ

DS

STBY

18

23

22

21

20

19

17

16

R/W

AS

CS

15

14

13

R/W

AS

GND

R9

100K

C16

47PF

GND

J7

1

2

3

4

5

6

7

TASTIERA

BZ1

GND

VCC

BC212

Q9

R38 R35 R36 R37 R10

VOLUME

RESET

PA3

ON-T

A13

A14

A15

RS-TX

BEEP

FAS-LF

VCC

36

35

34

33

32

31

30

29

39

2

U1

OSC1

IRQ

37

1

TIMER

RESET

14

13

12

11

10

9

8

7

PA0

PA1

PA2

PA3

PA4

A13

A14

A15

PB0

PB1

PB2

PB3

PB4

PB5

PB6

PB7

146805E3

R32

2.15K

R12

1K

100NF

C5

GND

Q6

BC337

A8

A9

A10

A11

A12

B0

B1

B2

B3

B4

B5

B6

B7

OSC2

L1

AS

DS

6

4

R/W

5

38

3

22

21

19

18

17

16

15

28

27

26

25

24

23

GND

9 8

U8D

74HC14

11 10

U8E

74HC14

GND

13 12

U8F

74HC14

B1

B2

B3

B4

B5

B1

B2

B3

B4

B5

B6

B7

GND

100NF

C3

VCC

11

12

13

15

16

17

18

19

O0

O1

O2

O3

O4

O5

O6

O7

27C512

GND

U4

A6

A7

A8

A9

A10

A11

A12

A13

A14

A15

A0

A1

A2

A3

A4

A5

CE

OE

20

22

24

21

23

2

26

27

1

10

9

8

7

6

5

4

3

25

CEEPR

-DS

A1

A2

A3

A4

A5

A1

A2

A3

A4

A5

A6

A7

A8

A9

A10

A11

A12

A13

A14

VBB

D13

BAT85

R44

2.15K

GND

D14

4.3V

GND

VCC

U13

5

CE

2

VBAT1

+

C40

100uF

GND

100NF

C41

GND

VCC

1

3

TOL

CEO

6

7

VBAT2

MXD1210

VCC-RAM

B0

B1

B2

GND

B4

B5

B6

B7

VCC

-Y1

RS-DSR

VCC

GND

VCC

3

S1

2

U9

17

18

19

20

21

22

23

24

25

26

10

11

12

13

14

15

16

B0

B1

B2

B3

GND

GND

B4

B5

B6

B7

RS-RX

VCC

BLOW

-Y1

RS-DSR

VCC

AS

GND

+

C42

10uF

GND

C43

100NF

GND

VCC

GND

100NF

C15

GND

1

VCC GND

F-2B

D1

M-STOP

A13

A14

VCC

GND

CEEPR

FT2

POR

DS

GND

VOLUME

FT1

RNA14

CEEXP

A15

53

52

51

50

49

48

47

46

45

44

60

59

58

57

56

55

54

F-2BX

D1

M-STOP

A13

A14

FT1

RNA14

CEEXP

A15

VCC

GND

GND

GND

ACTEL101

R15

100K

VCC

VCC

GND

100NF

C8

GND

R13

2.15K

B0

B1

B2

B3

B4

B5

B6

B7

B3

B4

B5

B6

B7

A8

A9

A10

A11

AS

DS

Q5

BC337

GND

VBAT

T1

VCC

R41

15K

VBAT

R43

10K

GND

BC547

6.8uF

R39

46.4K

C33

R40

261K

C26

68pF

Q10

GND

R33

33

1

2

3

4

47NF

C32

100V

CX

U12

LBR

LBD

GND

MAX634

R34

6.81K

VFB

VREF

+VS

LX

8

7

6

5

R29

68.1K

VBAT

909K

20

19

18

17

16

15

14

13

12

11

U11

R2OUT

R2IN

T2OUT

V-

C2-

C2+

V+

C1-

V-

C2+

MAX233

R42

100NF

C27

10uF

C28

+

C29

100uF

GND

T2IN

T1IN

R1OUT

R1IN

T1OUT

GND

VCC

C1+

GND

C2-

4

5

6

7

1

2

3

8

9

10

GND

RS-TX

RS-RX

GND

GND

D10

1N4148

GND

L15

680uH

GND

L1

L2

L3

L4

L5

33uH

33uH

33uH

33uH

33uH

GND

DSR

RX

TX

DTR

VEE

GND

R54

RV2

K164

15K

GND

5KMVH

10uF

C6

VCC

VEE

RD

A0

RESET

B1

B3

B5

B7

4.64

VCC

R2

VCC

RF-GND

BAT85

D12

J2

1

3

5

7

9

8

10

11 12

13 14

15 16

2

4

6

17 18

19 20

R/W

Y5

B0

B2

B4

B6

GND

GND

J3

1

2

3

4

DISPLAY

8

3

7

2

5

9

4

6

1

J1

GND

VCC

A6

A5

A4

A3

A2

A1

A0

A14

A13

A12

A11

A10

A9

A8

A7

100NF

GND

C39

U3

A6

A5

A4

A3

A2

A1

A0

A14

A13

A12

A11

A10

A9

A8

A7

25

3

4

5

6

7

8

9

10

1

26

2

23

21

24

84256A

GND

CE

20

27

WE

22

OE

D7

D6

D5

D4

D3

D2

D1

D0

19

18

17

16

15

13

12

11

VCC-RAM

B6

B5

B4

B3

B2

B1

B0

VBAT

R14

100K

GND

1uF

C35

1uF

C36

GND

C4

1uF

C37

1uF

C38

100NF

Q1

Short

R3

221

D5

BC237B

GND

GND

VBAT

VCC

1N4148

D1

6

7

8

1

2

3

4

5

1

2

3

4

5

6

7

8

1N4148

U5

CLA

1C

1B

GND

GND

2B

2C

CLAMP

ULN2064B

4C

NC

4B

GND

GND

3B

NC

3C

U6

CLA

1C

1B

GND

GND

2B

2C

CLAMP

ULN2064B

D2

GND

R4

322

R5

562

4C

NC

4B

GND

GND

3B

NC

3C

16

15

14

13

12

11

10

9

16

15

14

13

12

11

10

9

D4

1N4148

GND

R11

GND

GND

C12 1uF

F-G

GND

GND

C11 1uF

C10 1uF

C34 1uF

R6

1

Q2

ZTX689B

GND

4.64K

Q4

BC212

10uF

C14

GND

GND

100NF

C9

VCC

2

74HC14

U8A

1

GND

33uH

33uH

33uH

L6

L7

L8

TURBINA

J5

1

2

3

4

GND

4

74HC14

U8B

3

GND

Q3

2N2907

1

8

6

5

TLC271

+

U7

-

3

2

D3

1N4148

C7

100NF

C13

100NF

R7

100K

R8

2.15K

GND

FF

PR-REE

GND

SB

SC

SD

SE

SF

SG

SH

GND

PRINTER

J6

11

12

13

14

15

6

7

8

9

10

1

2

3

4

5

16

17

18

RF-GND

F1

F2A

J4

2

1

BNP002

L10

1N5820

D8

Q7

BD227

+

C44

100uF

25V

R16

681 ½Watt

R17

147

C17

47NF

BC548B

Q11

R21

464

L11

400uH

R18

Q8

BC548B

22

C23

10uF

+

D9

1N5820

R45

5.11K

BAV20

D6

D7

BZX79

R25

1W.33

R22

681

R46

6.19K

R47

46.4K

+

C20

22uF

LED

D15

680pF

R19

619

C18

C25

1NF

15

A

5

B

4

C

C19

82pF

R48

7.87K

GND

U10

TEA1100

RV1

4K7NTC

GND

4

7

10

3

2

11

C21

1NF

R20

27K

VBB

R23

147K

R24

147K

10uF

C24

C22

680pF

VBAT

BC237

Q12

R49

4.99K

+

SW1

R50

100K

C45

47uF

J8

F2

T3A

R26

46.4K

P1

VBAT

22uH L12

R27

100K

R28

1M

VCC

+

C46

150uF

GND

U14

1

LB0

GND

6

GND

2

LB1

1N4148

D16

10uF

C47

GND

LX

FB

7

3

BT1

1.2X2

MAX761

R51

21.5K

BT2

1.2X2

C53

100NF

C52

100NF

47uF

C48

1N5819

GND

C54

220pF

GND

L13

22uH

D17

+

C49

150uF

GND

C50

47pF

680uH L14

R52

147K

R53

60.4K

+

VCC

C51

100uF

GND

E1

GND

GND

8. Appendix A: Replaceable Part List .................................................... 8.2

8. Appendix A: Replaceable Part List

P/N Description

C01805-01-98

C01814-01-98

C00214-01-20

Adult Mouthpieces * 30 mm (500 pieces)

Pediatric mouthpieces * 22 mm (500 pieces)

Adapter for pediatric mouthpieces ID 22mm

C00441-01-98

A 666 905 001

C00643-01-98

C00600-01-11

C00296-XX-91

C00109-01-30

C00766-01-30

C00767-01-30

A 362 110 001

C00297-01-12

A 388 010 002

C00032-01-12

C01391-01-11

C00095-01-05

C00213-01-12

C00121-XX-31

C01339-XX-31

C00187-XX-31

C00292-01-05

C00086-01-30

C01344-01-30

C00096-01-20

C00551-01-08

C01350-01-15

C00087-01-15

C01352-01-15

C00609-01-15

C00126-01-20

C00089-01-92

C01338-01-92

C01572-01-92

C00126-01-08

A 256 210 001

A 410 700 004

Service Manual Ponygraphic

Nose clips (5 pieces)

Printer ribbon (5 pieces)

Printer paper (10 pieces)

Calibration syringe 3 liters

Pony graphic User manual (XX:01=IT/02=EN/03=FR/ 04=ES/ 05=DE)

Carrying case Pony graphic

AC/DC adapter Pony graphic 220V

AC/DC adapter Pony graphic 110V

Plug + cable x AC/DC adapter Pony graphic

Adapter plug for car charging Pony graphic

RS232 adapter for external printer (serial interface available)

Serial cable (D9M-D9F)

Kit Serial to parallel converter for external printers

Optoelectronic transducer Pony graphic

Cable+plug x Optoelectronic transducer Pony graphic

Eprom Pony graphic (XX: 01=IT, 02=EN, 03=FR, 04=ES, 05=DE)

Eprom Spirotur 610 (XX: 02=EN, 03=FR, 04=ES, 05=DE)

Eprom Discovery graphic (XX: 02=EN, 03=FR, 04=ES)

Turbine Pony graphic

Display Pony graphic (before may 1996 models)

Display Pony graphic (after may 1996 models)

Film safe x Pony graphic display

Printer Pony graphic (after may 1996 models)

Mother Board Pony graphic (after may 1996 models)

Keyboard Pony graphic (Till may 1996 models)

Keyboard Pony graphic (after may 1996 models)

Optoelectronic transducer (Pony graphic) board

Top cover Pony graphic

Keyboard panel Pony graphic

Keyboard panel Spirotur 610

Keyboard panel Discovery graphic

Bottom cover Pony graphic

Rubber feet x bottom cover Pony graphic

Pony graphic Ni Cd batteries (1 of 2)

Appendix A 8.2

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Key Features

  • Portable spirometer
  • Forced Vital Capacity (Pre and Post)
  • Slow Vital Capacity (Inspiratory and Expiratory)
  • Maximum Voluntary Ventilation
  • Graphic printer
  • RS232 interface
  • Ni-Cd Rechargeable Batteries
  • PC software
  • External printer

Frequently Answers and Questions

What is the function of the Pony Graphic unit?
The Pony graphic unit is the core of the system and controls all peripherals such as the display, printer, and keyboard. It also handles data acquisition, amplification of pulses from the optoelectronic reader, serial communication, battery management, and charging.
What is the purpose of the flow meter?
The flow meter, composed of a turbine and an optoelectronic transducer, measures the air flow passing through it. It uses infrared light to detect the rotation of the turbine rotor, which is proportional to the air flow. This allows for accurate measurement of volume and flow.
How can I connect the Pony graphic unit to a PC?
The Pony graphic unit has a RS232 interface that allows you to download test data to a PC compatible computer.
What is the battery autonomy of the Pony graphic unit?
The Pony graphic unit has a battery autonomy of about 200 tests, including printouts.
What is the power supply for the Pony graphic unit?
The Pony graphic unit can be powered by either a 120V-240V AC adapter or by its internal rechargeable NiCd batteries.

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