Keeler IntelliPuff User manual

IntelliPuff
Non-contact Tonometer
Service Manual
ISSUE D
27/02/2014
ALWAYS READ THE INSTRUCTIONS
Keeler Limited, Clewer Hill Road, Windsor, Berks, United Kingdom. SL4 4AA.
Tel No. [phone]Fax No. [phone]

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CONTENTS
CONTENTS 2
Tools Required 3
Precautions 4
System Requirements 5
Software Installation Guide 6
intelliPuff - Principles of Operation 7
Calibration Principles 8
Boot Mode Programming 9
Calibration 13
Disassembly and Reassembly 25
Cleaning the Optics 26
Replacing the Air Filter 27
Replacing the Handset Assembly 28
Replacing the Pump Assembly 30
Replacing the Main PCB 32
Replacing the Printer Assembly 33
Handset 34
Trouble Shooting 41
Spare Parts List 50

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Tools Required
Most of the tools required will be in standard electro-mechanical toolkit.
In addition the following are required.
Pozi No 2 Screwdriver with a blade at least 200mm long
Torque Spanner – Tool No TD699 – available from Keeler Ltd

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Precautions
Adjustment or replacement of any of the active elements of the system will
result in the need to check the calibration and probably re-calibrate the unit.
This includes any of the optical or pneumatic active components with the
exception of the air filter.
Care should be taken when checking calibration not to drop the handset.
Normal antistatic precautions should be taken when handling any of the
electronic components including PCBs.

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System Requirements
Use of the Pulsair Calibration Jig requires the use of a PC. This PC has the
following minimum requirements:-
Desk top, Tower, or Laptop loaded with Windows XP (earlier versions of
Windows and Vista will not work reliably)
CD ROM drive to load software.
One free USB port
Printer if a hard copy of the results of calibration are required.

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Software Installation Guide
Load the CD provided into the PC and follow the instructions.

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intelliPuff - Principles of Operation
The intelliPuff handset is positioned in front of the eye being tested until it fires
the solenoid valve releasing a pulse of air which rises in pressure with time
and causes the surface of the eye being examined to deflect.
This deflection is monitored by the optical sensors within the handset and the
pressure noted for a given deflection. This is then translated from the internal
pressure curve to an inter-ocular pressure measured in millimetres of
mercury.
During calibration the unit’s internal curve is standardised by storing a number
of parameters determined during the calibration process by firing the handset
automatically against a calibrated pressure transducer. The values of these
parameters compensate for variations in the speed of operation of the
solenoid valve and the variations in the pneumatic path from one unit to
another.

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Calibration Principles
The calibration jig is set up against a standard unit and a number of
parameters are stored within the jig software. This ensures that the results
obtained from each calibration jig are the same.
The handset is located accurately on the calibration jig and the position of a
test eye is adjusted to the optimum position using the x, y, z adjustments on
the mounting platform of the test eye.
The eye is then replaced with the matched pressure transducer and several
sets of pressure readings are taken with varying drive pulse widths to the
solenoid valve.
The required parameters are then calculated and written to the internal
memory of the handset.
This ensures that the readings from the intelliPuff will be correct against the
standard.
It is possible to verify the calibration without resetting it.
The calibration jig can only be re-calibrated by Keeler Ltd and we recommend
that this is carried out annually by returning it to
Technical Service
Keeler Ltd
Clewer Hill Road
Windsor
SL4 4AA
United Kingdom

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Boot Mode Programming
From time to time the software in the intelliPuff may be updated to incorporate
the latest version based on Keeler’s continued research and development.
This process should not be undertaken unless instructed by Keeler. New
software will be issued and instructions on loading it to the main PC will be
given at that time.
The Pulsair 5000 intelliPuff can be programmed through its RS232 port. Both
the Hand unit and the base unit PCB (in this order) can be programmed this
way. Although the PCB’s come programmed from the manufacturer at the
testing stage, the boards are also programmed after calibration in order that
the latest code (current modification state) is applied.
The procedure to conduct boot mode programming follows a similar pattern to
the calibration in that the user is always prompted to do certain tasks to
facilitate this. The following series of forms guide the user in this task.
Initially when the bootmode program is fired, the form below is displayed with
the available serial port for programming.
The user then presses Program button to start programming the hand unit
PCB. The program instructs the user to set the dip switches on the back of the
tonometer to ON position prior to proceeding to the next stage as shown in the
form below.

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Following that, the program looks for the connected Pulsair to establish
communication, if this fails because of unit being switched off or cable not
connected, the form below is displayed advising the user to switch off unit
and try again providing the cable connection are made.
If however connection is established successfully, the form below is loaded
which looks for the instrument and then initiates bootmode controller loading
to prepare for programming the unit.

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Once the controller is loaded successfully, programming the hand unit
resumes progress of which is shown in the form below.
When programming the hand unit is complete, the user is prompted if
programming the base unit is necessary. Usually the base unit is programmed
prior to calibration of the unit, so at this stage it is not normally necessary.

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Pressing NO button on the above form displays the form below after which
programming is complete.

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Calibration
This section details the calibration software for running on a PC connected to
the calibration system via a serial link (RS232 port or USB to RS232 hub) and
the operations that will be carried out by a user in the calibration process in
the order that the software is run.
Equipment Used:
Pulsair 5000
Calibrated Pulsair 5000 calibration unit
12V Keeler power supply (x2)
PC with 2 RS232 ports (or 2 port USB to RS232 hub) running the calibration
software
The handset needs to be prepared for mounting on the calibration jig by
removing the Puff Tube Shroud on the patient end of the handset and the
Eyepiece Shroud on the rear panel of the handset. The handset can then be
laid in the calibration jig and the clamps closed.
The main unit should also be opened by removing 6 off M3 x 10 Pozi screws
from the back of the unit to allow the pump pressure to be measured.
Disconnect the long 4 mm air tube from the air filter and connect the test
gauge to both the filter and the tube just disconnected. Check that the air
pressure reads 21 psi. If not go the section on replacing the pump assembly
to set the pressure relief valve.
The Pulsair is connected to the PC via a calibration unit. The calibration unit
has 3 serial ports, a 9 pin port connected to an external pressure transducer,
a second 9 pin port connected to the Pulsair and also a 15 pin serial port
connector which splits in to two 9-pin serial ports connecting to the host PC.
Connect external pressure transducer to port labelled as Pressure Transducer
port on the calibration unit.
Connect Pulsair to the port labelled as Tonometer Port on the calibration unit.
Connect the calibration box through the15 pin serial port connector to the host
PC via the two 9 pin serial port connectors.
Switch on the Tonometer with the pump switched off and Run the Tonometer
calibration software, which prompts the operator to follow the instructions
throughout the process and each stage during the calibration is discussed in
the following sections.

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The Introduction Form
On starting the calibration software, an introduction is provided via a splash
screen shown below. During the loading of the Splash screen, the system
checks to see if there are available ports to connect to the Pulsair and the
calibration unit before setting-up the communication ports to make remote
connection to the instrument under test and loading the Mode Selection form.
If connection is established successfully, the mode selection form is loaded
automatically. At this stage, if the Handset has not been calibrated previously,
or if it is a brand new Handset, the following dialog box will appear to indicate
uncalibrated system, pressing OK dismisses the message and the mode
selection form is loaded.
If however connection is not established with the host PC or calibration unit,
the dialog shown below is displayed, in which case press OK to dismiss the
dialogue and switch OFF the Pulsair and Switch it back ON and try again,
assuming all the necessary communication leads are connected. If this fails,

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reset the PC, switch OFF the Pulsair and the calibration box and then switch
them back ON and try again until uninterrupted communication is established.
Mode Selection Form
The first form that the user interacts with is the mode select form. This will
provide the user with several options.
An option to read the current contents of a Pulsair EEPROM and check its
validity via a checksum, it also allows the user to print current calibration data.
An option to automatically read the EEPROM data and carry out a full
calibration.
An option to enter a setup form to setup serial ports if necessary and also
calibrate the calibration system if not previously calibrated.
An Option to completely Exit the calibration process.
Each of the options is further described below.

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Run Calibration
This mode selection consists of a sequence of forms to prompt the user to set
up the instrument under test correctly before calibration measurements are
taken. If cancelled at any stage the software returns to the mode selection
form.
Data entry form
Selecting the Run Calibration button triggers the data entry form shown below
in which the user and instrument details pertinent to calibration can be
entered. When the minimum required details are entered the user is allowed
to continue. The date is set automatically to the current date. All these data
are retained in the EEPROM of the unit under calibration until it is changed on
another calibration.
The data entry form has two buttons, Restart and Next allowing the user to
either progress to the next stage of calibration or go back to the previous. On
selection of on the Next button, the calibration program prompts the user to

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switch the pump off if it was ON at that stage so that ambient pressure can be
recorded.
On pressing Next, the ambient pressure is recorded, the user is prompted to
switch the pump on as shown in the form below.
The next form prompts the user to enter measured pump pressure (21psi) in
the text input field provided.

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At this stage the reservoir pressure is checked before progressing to the next
step of the calibration process, the result of this check is communicated to the
user via the form below to indicate a PASS or FAIL, in the case of FAIL,
calibration is terminated and the program advises the user to take corrective
action. If this test passes the reservoir pressure check, the value is recorded
in the hand piece EEPROM and will be used as a system reservoir pressure
check after every puff during the life of the instrument. If the pressure drops
due to air leaks or any other reason, while using the instrument (i.e. after a
puff) the user will be alerted with a rolling message on the instrument’s 4
character display to run the self test program.
Having checked the reservoir pressure, pressing the next button displays the
alignment form shown below.
Alignment Form
The test eye should be fitted in front of the handset on the calibration jig.
In this form the ADC values of the detected light at the three photo detectors
A, B and C as well as the K value is displayed. This form allows light level
adjustment in order to set the light intensity to meet a predefined firing
condition. The form displays photosensor readings in ADC units, i.e. in the
range 0 to 4095 for all three diodes and a calculated K factor from those
diodes. The photosensor values will be presented block averaged at an
update rate of approximately 5 per second for viewing purposes.
During this stage, the test eye is aligned using the x, y, z table on the
calibration jig to give ADC values on photosensors A and C balanced to within
100 ADC units and the smallest K value.
Whilst the - in focus - condition is met the K factor display will be lime green
and the Next button enabled otherwise the display will be red and the
continue button disabled to force the user to align the system against the test
eye for best K position before progressing with the remaining calibration
process.
The Restart button is available to send the program to its previous stage. The
LED brightness can also be adjusted if necessary in achieving the best K with
selection of the Adjust LED option. The new LED brightness settings are
retained as EEPROM values.

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If the - in focus - condition is met and the continue button is selected, the
currently measured k value and the values of the three photosensors A, B and
C at calibration will be recorded to the EEPROM for use during the operation
of the instrument as part of firing condition parameters.
Having achieved an alignment that satisfies the firing condition, pressing the
next button, displays another form, as shown below, which displays the
photosensor levels A, B, & C as well as K-value achieved at best K. This is
preceded by a routine that does a sanity check on the photosensor signal
levels that will be subsequently saved to the EEPROM during the
programming stage of the instrument.
If this test is passed, the program prompts the user with the form below
instructing the user to replace the test eye with the external pressure
transducer. In the event that the above sanity check fails, the calibration
process will take the user few steps back in the process to the alignment
procedure.
Solenoid Valve Opening Time (Puff Time) Calibration
At this stage, the Pulsair calibration process works out the solenoid valve
opening times iteratively. The form sends a command to fire the solenoid
valve for a preset opening time as a starting point to the iteration. At each puff
time, 8 pulses will be measured for maximum and minimum generated
external pressure in mmHg. The opening time is then decremented or
incremented accordingly to achieve the shortest opening time to produce the
smallest pressure value that is greater or equal to the maximum pressure
required for Soft puff pressure (30mmHg). When this criterion is reached, the

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previous time in the data set is then defined as being the soft puff time and is
recorded.
The form will present a graph of the data set being currently collected of up to
8 puffs per timing. It will also present a table of the puff times used with the
minimum, maximum and average external puff pressures. The table will allow
the user to select a puff time for display on the graph. It will also indicate the
determined soft and hard puff times.
Once this process is successfully completed, the soft puff and hard puff times
are recorded for later loading into the EEPROM as entries S_Puff_Time and
H_Puff_Time in 38us units. On selection of the continue button the skew
timing and regression stage will be entered.
Pressure Calibration - Skew Timing and Regression
For the calculation of measured pressure from internal pressure readings, two
calibration stages are required; firstly external pressure reading is related to
mmHg units through calibrating the calibration ADC voltage against a known
pressure source and secondly relating internal pressure readings to external
pressure readings. The constants derived from the first calibration stage (ADC
to mmHg conversion) are stored in the hand piece EEPROM in both the unit
under test and the calibration unit in parallel. They will not however be used
by the hand piece software.
The skew and timing regression form relates the internal to external pressure
readings. At this stage both internal and external pressure are measured