Cosmed Pony graphic User manual

SERVICE MANUAL
Pony
PonyPony
Pony graphic
Corporate Office:
COSMED Srl
PO Box n °3, Pavona di Albano RM,
00040 -Italy
Tel:[phone]
Fax:[phone]
email:[e-mail]
North American Office:
COSMED USA,Inc.
2758 North Paulina Street,
Chicago,IL 60614 USA
Phone:[phone]
Fax:[phone]
email:[e-mail]
P/N. C01414-01-91 / Date of Issue: January 2002.

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.

Service Manual Ponygraphic Table of Contents
i
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
ii
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 Table of Contents
iii
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 Pony Graphic Chapter 1 Introduction
1.1
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
1.2
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.
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 [phone]
Fax [phone] Internet Web site: http://www.cosmed.it