h/p/cosmos 150/50 Service manual

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operating and service manual
h/p/cosmos®running machines
N150/50 (mercury®)
N170-190/65 (quasar®/ pulsar®)
N190/65 3p (pulsar®3p)
N200-450/75-300 (venus®/ saturn®)
h/p/cosmos®model names
h/p/cosmos mercury®/ mercury®med
h/p/cosmos stratos® / stratos®med
h/p/cosmos locomotion®150/50 E / DE med
h/p/cosmos gaitway®II F / S
incl. lt-models
h/p/cosmos quasar®/ quasar®med
h/p/cosmos stellar®/ stellar®med
h/p/cosmos pulsar®
h/p/cosmos locomotion®190/65 E / DE med
incl. lt-models
h/p/cosmos pulsar®3p
h/p/cosmos locomotion®190/65 3p E / DE med
incl. lt-models
h/p/cosmos venus®- all sizes
h/p/cosmos saturn®- all sizes
development, production, sales &service
h/p/cosmos®sports &medical gmbh
Am Sportplatz 8
DE 83365 Nussdorf-Traunstein
Germany
phone [phone]
fax [phone]
[email protected]
www.h-p-cosmos.com
manual-version
firmware MCU5-v1.07, revision 07.02.2013
manual order-no.: [cos14310m5-v1.07hpc-en]

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This user manual / operating instructions / service guide is only valid for the firmware-/software version noted on the first
page of this manual and only for the original configuration of the first delivery of the machine. Firmware updates, software
updates, changes of the system configuration or retrofittings of additional equipment or accessories can result in invalidity of
this manual. In case of alterations of the device or the additional equipment; the latest version of the manual or the
corresponding additional information always should be considered.
The latest manual version is always available in PDF version on the h/p/cosmos website:
http://www.h-p-cosmos.com/en/company/downloads.htm
NIt is strictly forbidden to perform any amendments of the technical design, technical
specifications, labelling and configurations (except allowed programming as described in this
manual) of this machine and the software and accessories connected to this machine.
NAny amendments, unauthorized, poor or lack of service / maintenance will result in loss of
manufacturer’s liability and warranty.

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Dear customer,
We would like to express our gratitude for putting your trust in us, in deciding for this top of the range running machine.
Since 1988 h/p/cosmos®has been developing and manufacturing running machines, systems and accessories for
applications in sports, rehabilitation, medicine, diagnostics and science. When it comes to technology, ergonomy, design and
safety, we have set extremely high standards for ourselves.
Because the running machine is a motor-driven device, you must pay special attention to the mentioned safety regulations.
If proper notice is taken of the safety regulations, the operation of our running machines is nearly without risk.
Neglect of the safety regulations could result in dangerous situations and accidents with serious injury or death. Therefore
please read this operating and service manual and the danger precautions in full before taking the device into operation.
Some simple maintenance and monitoring (no repair work!), as described, can easily be done or even have to be done by
yourself. All kinds of installation and repair work and most maintenance work are to be performed only by trained and
authorized technicians who have been certified by h/p/cosmos. The following symbols will indicate which work can be done
by the customer and which work has to be done only by authorized technicians:
The customer/user should perform this maintenance and monitoring work. Some safety checks or monitoring
(for examples harnesses and ropes, running belt condition and position, etc.) have to be performed on daily
basis. It is not expedient to contract certified technicians for such maintenance work. However, where it is
practical, all maintenance and monitoring work marked with this symbol can also be performed by certified
technicians.
All installation, maintenance, repair and monitoring work marked with this symbol must only be performed by
trained and authorized technicians who have been certified by h/p/cosmos. Customers/users must not
perform these kinds of tasks and work.
We recommend calling our competent service team or entering into a maintenance contract for a routine service at an
interval of 6 or 12 months for standard machines and standard applications. A form for registration of your institution and
device is included in the delivery. In order to be able to supply you with the latest technical information and service, it is
important for you to fill out the form. Therefore please fill out the form for registration immediately and send it back via fax,
email or mail.
This operating and service manual as a firm part of the delivery has to be accessible to the user at any time. It has been
written with great care. Should you, however, still find any details which do not correspond with your device, please notify us
so that we can correct any mistakes as soon as possible. Subject to alterations without prior notice.
Errors and omissions excepted. E & OE.
We wish you a lot of fun and success while exercising and working with your h/p/cosmos running machine.
h
Franz Harrer
President & CEO
h/p/cosmos sports & medical gmbh

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1Model overview...............................................................................................................................................................9
2Introduction ..................................................................................................................................................................11
2.1 Description .....................................................................................................................................................................11
2.2 Device components, including software and accessories..............................................................................................11
2.3 Safety equipment ...........................................................................................................................................................12
3Intended use / indications, contraindications, risks & forbidden use.....................................................................14
3.1 Intended use / indications...............................................................................................................................................14
3.2 Contraindications............................................................................................................................................................15
3.3 Risks...............................................................................................................................................................................16
3.4 Forbidden use ................................................................................................................................................................18
4Safety notes, warnings, precautions..........................................................................................................................19
4.1 General...........................................................................................................................................................................19
4.2 Preparation of the patient / user.....................................................................................................................................20
4.3 Preparation of the running machine...............................................................................................................................20
4.4 During treadmill exercise................................................................................................................................................21
4.5 Machine care..................................................................................................................................................................23
5Operation ......................................................................................................................................................................24
5.1 General...........................................................................................................................................................................24
5.2 Switch on procedure.......................................................................................................................................................26
5.2.1 Switch on procedure model range 150/50 up to 190/65....................................................................................26
5.2.2 Switch on procedure model range 200/75 up to 450/300 (venus/saturn).......................................................... 27
5.3 Switch off procedure.......................................................................................................................................................28
5.3.1 Switch off procedure model range 150/50 up to 190/65....................................................................................28
5.3.2 Switch off procedure model range 200/75 up to 450/300..................................................................................29
5.4 Emergency Stop, stop buttons, stop functions and safety features ...............................................................................30
5.5 UserTerminal / Control Terminal....................................................................................................................................32
5.5.1 The keyboard.....................................................................................................................................................33
5.5.2 The display.........................................................................................................................................................33
5.5.3 External UserTerminal control unit.....................................................................................................................35
5.5.4 TouchPanel........................................................................................................................................................36
5.6 Application: Ergometry / Cardiology ECG treadmill stress test......................................................................................38
5.7 Application: Gait analysis and rehabilitation with neurologic patients ............................................................................38
5.8 Application: Gait analysis and rehabilitation with force measurement plates.................................................................38
5.9 Modes of operation.........................................................................................................................................................40
5.9.1 Acceleration levels.............................................................................................................................................41
5.9.2 Manual mode.....................................................................................................................................................43
5.9.3 Profile mode.......................................................................................................................................................44
5.9.4 Cardio mode ......................................................................................................................................................49
5.9.5 Test mode..........................................................................................................................................................53
5.9.5.1 Standard ergometric tests........................................................................................................................54
5.9.5.2 Additional profiles.....................................................................................................................................59

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5.9.5.3 Programming example: user-defined profile ............................................................................................67
5.10 Optional settings: User Options......................................................................................................................................71
5.10.1 Standard settings for the user options...............................................................................................................77
6Operating manual: running machines for sports andfitness c...........................................................................78
7Service manual.............................................................................................................................................................79
7.1 Safety notes, warnings, precautions ..............................................................................................................................79
7.1.1 Room conditions................................................................................................................................................79
7.1.2 Transport and Installation .......................................................................................................................80
7.1.3 Maintenance and safety inspections ......................................................................................................81
7.2 Electrical safety features................................................................................................................................................82
7.3 Medical device software classification............................................................................................................................83
7.4 Installation & commissioning ..............................................................................................................................84
7.4.1 Unpacking and packaging ......................................................................................................................84
7.4.2 Transport ................................................................................................................................................85
7.4.3 Storage..............................................................................................................................................................87
7.4.4 Environmental requirements / room configuration ..................................................................................87
7.4.5 Mechanical installation ...........................................................................................................................89
7.4.6 Electrical installation ...............................................................................................................................90
7.4.6.1 Electric safety measurements and “First Measured Values“....................................................................92
7.4.6.2 Potential equalization (only for medical treadmills)..................................................................................92
7.4.6.3 General notes and benefits of potential equalization ...............................................................................92
7.4.6.4 Plug assignment at the UserTerminal......................................................................................................93
7.4.7 Cable connections models 200-300/75-125 (venus / saturn) ............................................................................98
7.4.8 Connection of external host and / or auxiliary devices via interface .....................................................100
7.4.9 Programmable, electrical medical systems (PEMS) / In-house production ..........................................101
7.4.10 Installation checklist and instruction of the user ...................................................................................106
8Maintenance and safety inspections........................................................................................................................108
8.1 Preventive maintenance ......................................................................................................................................108

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8.2 Immediate maintenance ...................................................................................................................................108
8.3 Regular inspections / examinations..............................................................................................................................109
8.3.1 Visual inspections .................................................................................................................................109
8.3.2 Protective earth resistance (RPE) measurement ...................................................................................110
8.3.3 Isolation resistance (RISO) measurement .............................................................................................110
8.3.4 Equivalent (alternative) leakage current (IEDL) measurement ...............................................................110
8.3.5 Leakage current measurement ............................................................................................................111
8.3.6 Electric safety tester and measurements .............................................................................................111
8.3.7 Building installation: Electric checks, protective earth function, RCD, leakage current ........................112
8.4 Lubrication of the running belt / running surface .................................................................................................112
8.4.1 Devices with UserTerminal and without automatic oil-pump ...........................................................................113
8.4.2 Lubrication film test .................................................................................................................................114
8.4.3 Devices without UserTerminal and without automatic oil pump .............................................................115
8.4.4 Devices with UserTerminal & automatic oil pump (models "r" for cycle & wheelchair) ...........................116
8.4.5 Refilling oil tank ......................................................................................................................................117
8.4.6 Resetting of oil message ........................................................................................................................118
8.5 Control and tightening of the running belt .........................................................................................................118
8.6 Adjustment (centring) of the running belt ............................................................................................................119
8.7 Control and tightening of the driving belt (poly-V belt system) .........................................................................120
8.7.1 Checking the tension of the driving belt with the “slipping-test“.......................................................................120
8.7.2 Checking the tension of the driving belt with the frequency test......................................................................121
8.8 Driving belt with timing belt system (from running deck size 200/75 upwards) ................................................122
8.9 Side step platforms: check for non-slipping ......................................................................................................122
8.10 Hygiene and cleansing.................................................................................................................................................122

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8.10.1 Cleansing of outside and applied parts ..................................................................................................122
8.10.2 Cleaning of the interior .........................................................................................................................123
8.11 Cleansing and adjustment of the speed sensor / light barrier ...........................................................................123
8.12 Light barrier at belt re-entry zones ...............................................................................................................................124
8.12.1.1 Cleaning of light barriers .............................................................................................................124
8.12.2 Adjustment of light barriers ...................................................................................................................124
8.13 Spare parts & consumables.........................................................................................................................................124
9Trouble shooting ............................................................................................................................................ 125
9.1 Mechanical noise problems..........................................................................................................................................125
9.2 Running belt adjustment problems...............................................................................................................................125
9.3 Fuses............................................................................................................................................................................125
9.4 Electrostatic discharge.................................................................................................................................................126
9.5 Sources of interference................................................................................................................................................126
9.6 Voltage on the device housing / electric shock ............................................................................................................127
9.7 POLAR heart rate measurement system .....................................................................................................................127
9.8 RS232 interface............................................................................................................................................................128
9.8.1 Troubleshooting and testing of the RS232 interface........................................................................................128
9.9 MCU control unit / circuit board, battery.......................................................................................................................128
9.10 Error messages............................................................................................................................................................129
10 Optional settings: administrator options .....................................................................................................135
10.1 List of running machines types.....................................................................................................................................145
11 Technical data ............................................................................................................................................................146
11.1 Running machines, 150/50 (mercury)..........................................................................................................................146
11.2 Running machines, 170-190/65 (quasar / pulsar)........................................................................................................148
11.3 Running machines, 190/65 (pulsar 3p) ........................................................................................................................150
11.4 Running machines, oversize 200-450/75-300 (venus / saturn)....................................................................................152
11.5 Electromagnetic compatibility (EMC) and immunity: Guidance and manufacturer's declaration .................................154
11.6 Compatible devices......................................................................................................................................................156
11.7 Interface protocols........................................................................................................................................................157
11.8 Economic life time........................................................................................................................................................157
12 Accessories and options...........................................................................................................................................158
12.1 Arm support..................................................................................................................................................................158
12.2 Additional keyboard and additional stop button for arm support and remote control...................................................159

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12.3 Special handrails..........................................................................................................................................................160
12.4 Handrails, adjustable with gear tooth locking elements ...............................................................................................161
12.5 Handrails, adjustable: Parallel bars with gas struts and locking lever..........................................................................162
12.6 Therapist’s seat and foot support, adjustable...............................................................................................................164
12.7 Unweighting system h/p/cosmos airwalk se 135..........................................................................................................165
12.8 Unweighting systems airwalk 70/160...........................................................................................................................166
12.9 Vests for subjects for airwalk systems..........................................................................................................................166
12.10 h/p/cosmos robowalk®expander..................................................................................................................................166
12.11 Wheelchair ramp..........................................................................................................................................................167
12.12 Wheelchair stabilizer for oversize running machines...................................................................................................167
12.13 Safety arch with chest belt system...............................................................................................................................167
12.14 Reversible running belt rotation for downhill walk........................................................................................................169
12.15 Pull cord safety stop actuator.......................................................................................................................................170
12.16 Bottle holder, drinking bottle.........................................................................................................................................170
12.17 Retrofitting UserTerminals / laptop for external control unit.........................................................................................171
12.18 Retrofitting emergency stop buttons.............................................................................................................................172
12.19 Safety multiple socket ..................................................................................................................................................172
12.20 RS232 interface / USB converter.................................................................................................................................173
12.21 POLAR heart rate measurement system .....................................................................................................................174
12.22 „Science port“ / raw data of speed sensor....................................................................................................................175
12.23 PC software h/p/cosmos para control®4.1...................................................................................................................176
12.24 PC Software h/p/cosmos para graphics®.....................................................................................................................177
12.25 PC Software h/p/cosmos para analysis®......................................................................................................................178
12.26 PC Software h/p/cosmos para motion®........................................................................................................................179
13 Disposal ......................................................................................................................................................................180
14 Appendix 1: Certificates............................................................................................................................................181
14.1 Certificate of the TSA (TÜV) according to ISO 9001....................................................................................................181
14.2 Certificate of the TSA (TÜV) according to EN ISO 13485............................................................................................182
14.3 EC Certificate of the TSA (TÜV)...................................................................................................................................183
15 Appendix 2..................................................................................................................................................................184
15.1 Calculation of the UKK Fitness Index...........................................................................................................................184
15.2 Instruction protocol, checklist.......................................................................................................................................185
15.3 Instruction protocol, signatures ....................................................................................................................................190
15.4 Service report – [cos15531] .........................................................................................................................................191
15.5 Control protocol – [cos11690en-02].............................................................................................................................192
15.6 Wiring diagram load circuit quasar®med / pulsar®.......................................................................................................193
15.7 Wiring diagram control circuit quasar®med / pulsar®– page 1....................................................................................194
15.8 Wiring diagram control circuit quasar®med / pulsar®– page 2....................................................................................195
16 Appendix 3: Symbols.................................................................................................................................................196
17 Contact........................................................................................................................................................................197

model overview
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1Model overview
n
medical
running machines
c
sports & fitness
running machines
h/p/cosmos locomotion®150/50 E med
h/p/cosmos locomotion®150/50 DE med
h/p/cosmos locomotion®190/65 E med
h/p/cosmos locomotion®190/65 DE med
h/p/cosmos locomotion®190/65-3p E med
h/p/cosmos locomotion®190/65-3p DE med
h/p/cosmos stratos®lt med
h/p/cosmos stratos®med
h/p/cosmos mercury®lt med
h/p/cosmos mercury®med
h/p/cosmos Kistler Gaitway®II F
h/p/cosmos Kistler Gaitway®II S
h/p/cosmos stratos®lt
h/p/cosmos stratos®
h/p/cosmos mercury®lt
h/p/cosmos mercury®
h/p/cosmos stellar®lt med
h/p/cosmos stellar®med
h/p/cosmos quasar®lt med
h/p/cosmos quasar®med
h/p/cosmos pulsar®lt
h/p/cosmos pulsar®
h/p/cosmos pulsar®lt 3p
h/p/cosmos pulsar®3p
h/p/cosmos stellar®lt
h/p/cosmos stellar®
h/p/cosmos quasar®lt
h/p/cosmos quasar®
h/p/cosmos venus®200/75
h/p/cosmos venus®200/75r
h/p/cosmos venus®200/100
h/p/cosmos venus®200/100r
h/p/cosmos saturn®250/75
h/p/cosmos saturn®250/75r
h/p/cosmos saturn®250/100
h/p/cosmos saturn®250/100r
h/p/cosmos saturn®250/125r
h/p/cosmos saturn®300/75
h/p/cosmos saturn®300/75r
h/p/cosmos saturn®300/100
h/p/cosmos saturn®300/100r
h/p/cosmos saturn®300/125r
h/p/cosmos saturn®450/300rs

model overview
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h/p/cosmos saturn®300/125r
h/p/cosmos saturn®450/300rs