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Intellipuff Service Manual

Page 10 of 51

Issue D 27/02/2014

EP59-12317

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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Summary of Contents for IntelliPuff

Page 1: ...iPuff 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 44 0 1 753 857177Fax No 44 0 1 753 830247 ...

Page 2: ...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 ...

Page 3: ... 2014 EP59 12317 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 ...

Page 4: ...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 ...

Page 5: ...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 ...

Page 6: ...Intellipuff Service Manual Page 6 of 51 Issue D 27 02 2014 EP59 12317 Software Installation Guide Load the CD provided into the PC and follow the instructions ...

Page 7: ...ensors 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 trans...

Page 8: ...ounting 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 ve...

Page 9: ...h 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 ...

Page 10: ...ils 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 ...

Page 11: ...ssfully 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 ...

Page 12: ...Intellipuff Service Manual Page 12 of 51 Issue D 27 02 2014 EP59 12317 Pressing NO button on the above form displays the form below after which programming is complete ...

Page 13: ...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 extern...

Page 14: ...e 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 h...

Page 15: ... 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 prev...

Page 16: ...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 ...

Page 17: ...f 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 ...

Page 18: ... 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 blo...

Page 19: ...ument 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 proc...

Page 20: ...ff_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 ...

Page 21: ...l and external pressure readings versus time as well as a table of values as shown in the form above On completion of the calibration table a checksum will be calculated and stored in the entry FCS The user then presses the Next button to progress to the Program request form Program Request Form The calculated look up table ADC and corresponding pressure values along with various parameters calcul...

Page 22: ...will be prompted to confirm that the calibration run is not required After completion of this form the user can press the Cancel button and the Mode selection form is loaded from which the Exit button is pressed to return the unit under test to local mode At this point the unit will switch itself off to reset the system Reading the EEPROM Data The Mode selection form also provides a button for rea...

Page 23: ... calibration data including last calibration date which can be printed by pressing the print button Pressing the OK button takes the user to Mode selection form from which the program can be exited It will also inform the user if the data was read correctly If the read fails the user will be alerted appropriately for instance if the checksum read disagrees with the expected value the following wil...

Page 24: ...rm from which the EXIT button can be pressed to abandon calibration Exiting the calibration process in this way allows the host PC to release the occupied RS232 port resources properly so that they are available for the next time the calibration process or any other program that needs access to these resources is run In this case the form below is displayed and EXIT button can be pressed to end th...

Page 25: ...available as spare parts which will reduce the amount of work involved as well as eliminating some difficult setup procedures The unit comprises the following main assemblies Handset complete with Umbilical Pump Assembly Printer Assembly Power PCB Main PCB Main unit housing Access to the components inside the main unit is by removing 6 off 4 x 10 Pozi head screws from the rear cover of the unit DI...

Page 26: ...the mainframe and PCB is a factory supplied unit it should only be necessary to clean the outside of the eyepiece and puff tube lenses Remove the eyepiece and puff tube lens shrouds Carefully clean the lenses using lens wipes Do Not Use Solvents Refit the 2 shrouds Eyepiece Shroud Puff tube Shroud ...

Page 27: ...t of the retaining bracket Release the tube from each connector by pushing the ring on the connector towards the connector and pulling the tube gently Fit a new filter by replacing the tubes into the connectors Resistance will be felt after which the tube should be pushed in approx 1 cm Replace the filter in the bracket by carefully aligning the grommets and pushing towards the base of the unit Ai...

Page 28: ...ector as possible so that the old unit can be returned for rework Remove the ferrite filter and save it for reassembly Remove the cable clamp nut and save it for reassembly Remove the old umbilical completely through the cable clamp To replace the new unit Carefully thread the end of the umbilical through the cable clamp on the front of the main unit taking special care not to damage the connector...

Page 29: ... Fit new cable ties to retain the cableform as originally fitted Refit the air tube to the air filter see changing air filter Whilst the handset assembly has been calibrated as part of the test procedure it is recommended that the calibration is checked in accordance with the instructions under Calibration including checking the air pressure relief valve setting ...

Page 30: ...ng the tube out Disconnect the 6 mm air tube form the pressure relief valve as described above Unscrew the cable clamp on top of the pump housing to allow the 6 mm air tube to move down through it Remove 4 off M3 x 16 Pozi screws holding the pump housing to the base unit Lift the pump housing off of the pump by easing the 6 mm tube through the cable clamp It should now be possible to unstick 2 lay...

Page 31: ...valve Reconnect the 4 mm tube to the pressure relief valve Reconnect the 4 mm tube from the umbilical to the air filter assembly Make sure that all tools etc have been removed from the front and rear parts of the unit Connect the 12 volt PSU to the socket on the rear unit Switch the power on by pressing the on off button on the front panel Briefly press the button at the bottom of the handset crad...

Page 32: ...5018 if replacing the PCB Disconnect 2 off 2 way connectors on the underside of the PCB To replace the PCB Offer PCB to the main unit and fit 2 off 2 way connectors LED 09 is the printer LED and LED 10 is the on off button LED Push EP39 55305 Pulsair Button Adaptor into back of on off switch prior to pushing the PCB into position Make sure the blue locking section of the printer ribbon cable conne...

Page 33: ...bon cable connector Gently withdraw the ribbon cable from the connector Remove 2 off M3 x 10 Pozi screws Remove the printer assy Replacing the Printer Offer the printer into the main unit Replace 2 off M3 x 10 Pozi screws Carefully put the ribbon cable into the connector on the main PCB When the ribbon cable is fully inserted push the blue section home Carefully refit the printer door by offering ...

Page 34: ... bring the retainer lugs outside the handset and then pull it right off Take care not to damage the 2 target LEDs on their PCB Undo the cable clamp on the umbilical Carefully lift the 2 wings of the large white shroud they are retained by double sided adhesive tape Remove the shroud from the handset Pierce 3 off plastic plugs concealing screws joining the 2 case halves together The remnants of the...

Page 35: ...he ring where the 4 mm air tube goes into the connector on each of the air tubes at the umbilical end of the reservoir and remove the tubes Replace the Valve and Reservoir Assembly Carefully reconnect the 2 off 4 mm air tubes to the connector on the umbilical end of the reservoir Refit the coil to the valve and replace the spring clip Carefully refit the 4 mm air tube from the mainframe to the val...

Page 36: ...nit Adjustment of the unit is also discouraged as it has been set up to a strict test procedure using jigs only available in our production department Replace Mainframe and PCB Assembly Lay the case half with the browrest fitted down Refit the umbilical cable with the 12 way connector onto the PCB Lay the mainframe and PCB assembly onto the case half carefully following the routing of the cables a...

Page 37: ...assembly valve and reservoir assembly browrest assembly and front panel assembly are all correctly fitted The cables connecting the coil to the PCB and the front panel to the PCB should now be laid flat so that they do not cross each other retain them in place with a piece of insulating tape Refit the 2 rubber sections in the top and bottom of the case half Ensure that no cables or tubes would pre...

Page 38: ...8 of 51 Issue D 27 02 2014 EP59 12317 Figure 1 PRE 21 11 2012 UNIT Figure 2 POST 21 11 2012 UNIT Ensure that a M3 nut is fitted as shown to receive the screw retaining the target LED cover It is fitted from the outside of the case half ...

Page 39: ...e halves Apply fresh double sided adhesive tape as shown Refit the white shroud ensuring that it fits within the boundaries of the case half Ensure that the browrest is open Refit the target LED cover ensuring that is under the browrest and that the target LEDs are not damaged The lugs on the cover will drop into the slots on the white shroud and it can then be slid home ensuring that the ears are...

Page 40: ...14 EP59 12317 Refit the white cable clamp nut to retain the umbilical Fit 3 new plugs to hide the exposed cap head screws joining the case halves Refit the target LED mask and the Puff Tube Shroud which retains it Refit the Eyepiece Shroud on the front panel ...

Page 41: ...changed 3 Clean front end optics Instrument is too easy to fire and the readings are widely spread Suggested Solution 1 Check the insulation tape around the photosensors and 45º mirror which masks ambient light is in place and recalibrate Can Not Get K Value Into The Green Zone This happens either due to 45º mirror misalignment relative to the photo sensors or there is a large background light fal...

Page 42: ...Reservoir assembly Keypad and Display PL1 Keypad Switch Connector 6 way Molex Connector Pin Number Wire Colour Code Assignment Signal to Measure 1 Black Vcc 5V 2 White PBS1 3 Green PBS2 4 Brown PBS3 5 Yellow PBS4 6 Orange GND 0V Pressing the keypad buttons shown in Figure 1 above should result in OD OS Button should toggle the unit to Left Right eye as signified by the two green LED s which come o...

Page 43: ... pressing Demo button after a valid reading As explained above the printer does not have to be switched on in this way to be able to print a valid reading by pressing the PRINT button Pressing the print button will print a valid reading regardless of this setting i ON ii OFF Default setting this is set during calibration b BUZZ Switched the Buzzer to ON OFF i ON Default setting this is set during ...

Page 44: ...ion between the base unit PCB and the Hand Piece PCB and subsequently to the host PC The PIN colour codes as well as the PIN assignments are shown below Communication ERROR This is usually flagged during calibration or Boot Mode programming While in most cases such failure would not allow and communication to the PC and thus the calibration software would flag it in some cases limited communicatio...

Page 45: ...e above problem also Suggested Solution 1 Check the wiring is as per assembly instructions 2 Check crimp terminals are not lose 3 Check for any wire cuts in particular GREEN and BROWN wires used for data communication between the Hand Piece and the host PC It has been observed that as shown in the picture below when the unit is cased up during assembly the wires get caught in the screw holes as sh...

Page 46: ...CB This plug connects Target LEDs LED Block Main light source and Solenoid to the Hand Piece PCB Pin Number Wire Colour Code Assignment Signal to Measure 1 Grey Solenoid Return 0V 2 Blue Solenoid 12v 12V 3 RED LED1 5V 4 RED LED2 5V 5 BLACK GND 6 YELLOW LED Light source 4 6V 7 BLACK GND2 0v Figure 4 PL4 Connector ...

Page 47: ...ain LED Target LEDs Do Not Light and Solenoid Does not Fire Suggested Solution 1 Check for wire cuts and that the crimp terminals are not lose 2 Measure Voltage levels between the various PINS as shown in the above PIN assignment table above Figure 5 PL1 PL2 PL4 Connectors ...

Page 48: ...lace the Mainframe and PCB assembly Erratic reading indicate that the operation of the valve in the handset is suspect and it may be necessary to change it If a leak occurs in the pressure system the intelliPuff will indicate this with a message on the handset display The pressure is verified after every puff If the pump seems excessively noisy try adjusting the 6 mm tube in the pump housing befor...

Page 49: ... only applicable when the faulty unit has been received by our Technical Service Department prior to shipping a replacement Service Exchange units may be purchased at the full price with no exchange unit being sent in Service Exchange units have the same part number as the original assembly with SX added to the end The service exchange handset is especially useful as this is pre calibrated and can...

Page 50: ...e and PCB Assembly Yes 2414 P 7025 Handset Assembly Yes 2414 P 7026 Case Half Right with Pinion Gear 2414 P 7027 Printer Assembly 2414 P 7028 Printer Door 2414 p 7029 Target LED PCB Complete 2414 P 7030 Pressure Relief Dump Valve EP19 70007 Case Half Left EP29 32777 Power Supply 12 Volt EP29 70022 Target LED Cover EP29 70023 Rear Cover Assembly EP39 05332 Microswitch Plunger EP39 19822 Microswitch...

Page 51: ... 27 02 2014 EP59 12317 Part No Description Serv Exch EP39 70274 Browrest Pad EP39 70278 Pinion Rack EP39 70290 Handset Screw Plugs EP39 70309 DIL Switch Cover EP79 70031 Browrest Latch EP79 70282 Browrest Spring RP99 99704 Double Sided Adhesive Tape ...

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