Ultra Optics Training and Maintenance Instruction booklet

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Ultra Optics
Training and Maintenance
Instruction booklet
Ultra RX Coating Procedures
ULTRA RX COATING SYSTEM
SYSTEM INSTALLATION
Physical Location
Choose a physical location with good ventilation and an air exchange
rate of 4-5 time per hour. A normal Heating/Cooling A/C system will
provide 3-6 air exchange per hour. The Ultra RX has it’s own positive
air clean room environment.
Space Required
The Stand Alone Unit needs only 80” height and has a
25”x30” footprint.
Hook-Ups
Electrical
One 115VAC/15 AMP with grounded three-prong receptacle.
Water
Deionized or Distilled water of 1 mega ohm or better is
adequate for the cleaning system
Compressed Air
80psi (9-10 CFM) minimum of air at constant source. An air
regulator is supplied on the system.
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WARNING! NEVER CHANGE OR
DEACTIVATE SAFETY SWITCHES OR
PROTECTIVE DEVICES IN ANY WAY
INTENDED USE OF MACHINE
The Ultra RX is a backside scratch resistant coating system used for
coating optical lenses.
RISK-REDUCTION PROCEDURES
The Ultra RX should not be used for any other purpose other than the
process of coating optical lenses. Any other use may result in injury or
machine damage.
PROTECTIVE EARTHING
The Ultra RX machine requires Protective Earth grounding.
ADDITIONAL ACCESSORIES
The Ultra RX is equipped with 2 outlets on the back of the system. One
for main power and One for Foot Pedal.
GENERAL SAFETY
•
•
•
The Ultra RX has been designed and built in accordance with
European and International safety standards. The Ultra RX design is
such that it can be used safety.
The Ultra RX should be checked for any visible damage during each
shift. Any changes including changes in operation behavior must be
reported to supervisors in charge.
The Ultra RX Coating System is intended to have an operator
present at all times during operation of the equipment.
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SUMMARY
Safety Requirements:

Protective Gloves

Protective Eye Wear
Equipment
Requirements:

90% or greater IPA
and Acetone

Coating Solution


Deionized or Distilled
water, 1 mega ohm
or better
3/8” x 25’ Air Line
with a ¼” Female
Quip Coupler “Quick
Disconnect”
Set-up & Start up
procedures:

Slowly turn air
pressure on.

Turn power on

Verify there are no
coating bubbles in
coating filter and
correct coating height
is achieved.

Prime coating for 5
minutes

Add coating fluid if
needed.

Check level of
deionized water.


Make sure lens is dry
after wash and dry
cycle.
Verify positive air
flow.
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PROCEDURE SUMMARY

Start Single or Two
lens cycle.

Prioritize trays.

Turn vacuum on.






Clean lens with 90%
or greater IPA.
Chuck lens on spindle
over wash bowl.
Chuck next lens on
suction cup over the
wash bowl.

When the completed
lenses comes around,
un-chuck by pressing
foot pedal to release
both lenses.
Continue this process
until all trays are
complete.
Press ON/OFF button
on the Touch Screen
to turn vacuum off
when last lens is
removed.
Repeat process for
next lens.
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SET-UP & START UP PROCEDURES
Powering up Ultra RX coating machine


Slowly press the air
valve down to raise
spindles. This valve is
located on the right
side of the Ultra RX.
Press the Red Power
Button on the front of
the machine to the
ON position.
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SET-UP & START UP PROCEDURES
Bleeding Coating filter


Open the front door
of the Ultra RX. Look
at the coating filter to
ensure there are no
air bubbles. If so,
refer to the
“Operation Tips”
page.
Check the level of the
clean deionized water
bucket and fill if
needed. (Remember
to clean out the
buckets if algae
and/or debris are
visible.) Check to
make sure your
waste bucket is
empty.
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SET UP & START UP PROCEDURE
Checking the Coating Fountain height
To adjust coating
height:
Press MACHINE SET-UP.
Press COATING
ON/OFF. Adjust flow
height to top of coating
bowl using “Coating
Pump” pot.
~Clockwise to
increase.
~Counter Clockwise to
decrease.
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SET-UP & START UP PROCEDURES
How to check if a lens is dry before production.




Chuck up a lens on the
suction cup located over the
wash bowl in the Single Lens
or Two Lens Cycle.
Allow the lens to wash and
dry.
As soon as the spindles start
to come up, press CYCLE
STOP.
Un-chuck the lens using the
Foot Pedal and ensure the
back side of the lens is dry.
*If there is moisture on the
backside of the lens, refer to
“Priming Your High Pressure
Wash” page and ensure your
Wash Tip and Screen are free
from debris and that the Air Jet
Nozzle is correctly aligned.
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SET-UP & START UP PROCEDURES
Adding coating fluid to reservoir

When coating needs to
be added, pour the
coating directly into the
coating bowl. There is
no need to wait for the
coating to mix. Ensure
there are no air bubbles
in the coating filter
before starting
production.
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SET-UP & START UP PROCEDURES
Verifying positive air flow


Using a tissue, hold it
above the window
opening. If the tissue
flows outward at a 45
degree angle or more,
the flow is good. If
the tissue flows
inward, the Hepa
Filter needs to be
adjusted higher.
To adjust the Hepa
Filter, turn the knob
located on the upper
right side of the Hepa
Filter unit.
~ Counter Clockwise
to increase
~Clockwise to
decrease
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PROCEDURES FOR COATING A LENS
Cleaning your lens before placing it in the
Ultra RX

Holding the lens
concave side up,
trying to keep your
fingers only on the
edges, squirt a dime
size amount of IPA
on the backside.
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PROCEDURES FOR COATING A LENS
Cleaning your lens before placing it in the
Ultra RX


Swirl the IPA around
the lens starting in
the center and
moving to the outside
edge.
Holding the lens in a
vertical position,
rinse the lens off into
a waste container.
This will ensure the
lens is as clean as
possible.
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PROCEDURES FOR COATING A
SINGLE LENS
Single Lens Cycle



Press SINGLE. Press
ON/OFF button on
Touch Pad. Chuck the
lens on the suction cup
located above the wash
bowl.
The machine will run
the lens through the
entire cycle. When the
lens comes back over
the wash station, the
lens will be completed.
Press the foot pedal,
this will release the
lens.
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PROCEDURES FOR COATING
TWO LENSES
Two Lens Cycle


Press TWO LENS. Press
ON/OFF button on the
Touch Pad. Chuck the
first lens on the suction
cup above the wash
bowl. When the second
spindle is over the wash
station, chuck the next
lens on the suction cup
over the wash bowl.
Reach into the machine
and hold onto both
lenses (One above the
wash bowl, and one
located above the
Coating bowl) Press the
foot pedal, this will
release BOTH lenses at
the same time.
.
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Coating Cover Cycle




When the machine is
not being used for 90
seconds or more, the
coating cover cycle
activates and covers
the coating and wash
bowls.
Coating cover cycle
will not activate in
the machine set-up
screen.
This is done to
prevent coating from
curing and prevent
contaminants from
entering the coating
bowl.
Press Resume to
continue production.
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PREVENTATIVE MAINTENANCE
Daily
Daily Duties Include








Wipe wash bowl and deck area with IPA and a clean
damp cloth.
Wipe out inside of Coating Bowl with a lint free rag
slightly dampened with Acetone or IPA.
Clean Coating Bowl screen.
Check the level of deionized or Distilled water, refill as
needed. Empty waste water pail.
Check coating level in reservoir, refill as needed.
Check coating fountain height, level should be even
with top edge of coating bowl.
Check lamp hours (Replace at 1,000 hours).
Check that the lens is dry after wash and air-dry cycle
(Check by pushing CYCLE STOP after air jet turns off).
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PREVENTATIVE MAINTENANCE
Weekly & Monthly
Weekly Duties Include


Visual check suction cups for deterioration replace
as necessary.
Check spindle speeds:
Coating speed
Coat spin off speed
Wash speed
400 RPM
2000 RPM
1800 RPM

Check that the lamp cycle time is at 16 seconds.

Check regulator PSI @ 80

Wipe clean water bucket with IPA




Clean out top Hepa unit and replace top Pre-Filter
as needed using a 10x10x2 furnace filter.
Check vacuum pressure using the digital Convum
gauge located on the right side door.
Inspect complete vacuum chuck assembly for any
dried coating and/or debris. Clean as needed.
Check Air Drier Filter gauge and filters. Replace all
three if needle points to “Change” or if filters are
moist/dirty, or every 6 months.
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PREVENTATIVE MAINTENANCE
WEEKLY & MONTHLY
CONT.
Monthly Duties Include



Every 6-8 weeks replace Meissner filters in both
coating system and clean water bucket.
Check Capacitor to make sure it is reading 20uf or
higher.
Check positive air flow. Using a kimwipe or similar,
hold it up to Ultra Optics logo to see the positive air
flow. Adjust if needed.
Semi -Annual Duties Include

Replace all 3 air drier filter packs (P/N 1428).

Replace Air jet filter cartridge (if applicable).

Yearly check or replace Hepa filter (P/N 1469).
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TROUBLE SHOOTING



Figure 1: Wagon wheel
effect may be caused from
the coating fountain height.
The coating fountain should
be even with the top edge of
the top of the bowl.
Figure 2: One or two streaks
across the lens may be
caused from air in the
coating filter. While pump is
running, crack the bleed
valve on the Meissner Filter
¼ turn. This will allow the air
to escape.
Figure 3: Tiny pits that
appear to have indented the
lens. If these pits are always
in the same position check to
ensure spindle is spinning at
the correct speeds and or
even spinning at all. The
indentations may be caused
from the wash tip always
returning to the same
position on the lens while
spindle is not spinning.
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TROUBLE SHOOTING



Figure 4: Pits on the outer
edge of the lens and or in
clumps may be caused by either
the Air jet pressure, dirty wash
tip or poor prime on the wash
pump. Clean tip, run wash
pump prime for 30 seconds to
purge out air bubbles. If
problems still exists adjust the
air flow from air jet nozzle.
Make sure lens is dry after wash
and dry cycle are completed.
Figure 5: Large pits with runs
behind streak: if you can feel
the pit with your finger it is most
likely debris on the lens. Check
your cleaning procedures,
ensure wash tip is free and clear
of debris.
Figure 6: Glob of coating left
on the center of the lens; maybe
caused from spindle not
spinning. Check for loose wires
on spindle motor. Check and or
replace bearings in vacuum
chuck assembly.
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ULTRA RX LENS RETRIEVAL FROM
UV LIGHT MODULE
1)
Detach remaining lenses off the suction cups.
2)
Turn off the power to the machine and disconnect power
cord from electrical outlet.
3)
With the power off and disconnected from the outlet,
open the lamp doors of the Ultra RX.
4)
Remove the two pan head screws that hold the UV Light
in the carriage.
5)
After screws are removed, pull the UV Light Module out of
the carriage.
6)
Allow UV Light to cool for 15 minutes or until it reaches
room temperature.
7)
Remove the lens from the lamp area.
8)
Check for lens debris on lamp module and if clear then
return UV Light to carriage and return to machine
operations. If lens debris or burning is present and
cannot be removed, replace UV Light Module with a new
one and return to machine operations.
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DEFLECTOR CUP ASSEMBLY
1
2
3
4
1. Chuck Assembly
2. Deflector Cup
3. Retaining Ring
4. Clear Cleated Suction Cup
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ULTRA RX POCKET-TACH
INSTRUCTIONS
Preparation
To prepare the rubber chuck for non-contact
measurement of speed, carefully clean an area on the
deflector cup of all grease and dirt. Apply approximately a 1/8
inch piece of reflective tape to the deflector cup. Always use
the T-5 reflective tape supplies
Aiming
The ergonomic design of the Pocket-Tach makes the
non-contact measurement of speed extremely simple. Aim
Pocket-Tach at the reflective target using the sight bars on
the top surface on the instrument as an aid in locating the
target. A visible light projects from the underside of the
Pocket-Tach parallel to the top surface and in line with the
sight bars. This design allows you to view the target on the
rotating shaft and the display on the instrument
simultaneously.
Measuring
To measure, press and hold the power button on the
front panel and aim the instrument at the reflective tape on
the deflector cup until a steady illumination of the “bulls eye”
symbol in the instruments display indicates you are on target.
Once a measurement is completed, released the power button
while still viewing the target. Pocket-Tach will continue to
display the last reading for approximately 90 seconds and
then automatically shut off.
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FLUSHING COATING SYSTEM
INSTRUCTIONS
Go into Machine Set-up screen.
Disconnect the nut on the nylon straight fitting
attached to the stainless elbow at the bottom of your
reservoir. Point nut and tubing from the filter into a
clean container. Press coating ON/OFF button and the
coating will pump out of the tubing into the clean
container. When the reservoir is empty, press Coating
ON/OFF button to turn off coating pump.
If the coating is contaminated, it may be necessary to
flush system with Acetone. With the tubing
disconnected from the bottom of the reservoir, pour
Acetone into the Coating Bowl as you would with
coating.
**DO NOT RUN ACETONE THROUGH NEW
COATING FILTER. SIMPLY FLUSH INTO
WASTE CONTAINER.**
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COATING FLUSHING
INSTRUCTIONS
continued
Follow the other black tube from the pump up to
the coating reservoir and disconnect. Both coating
tubes should now be free.
The coating reservoir can now be unscrewed and
removed from the coating bowl for easy cleaning.
Once the coating reservoir is out of the machine
flush it out using Acetone and allow to dry. Ensure
any debris in the coating reservoir has been
removed. Flush again if not. Unscrew elbow from
coating filter and save. Unscrew and discard
coating filter. Wipe out coating bowl using a clean
lint free towel. A coating bowl screen sits on the
bottom on the bowl make sure it has been cleaned
before reassembling.
Reassemble and either put new coating in or reuse
your old coating if it has not been contaminated.
Re-prime the system and release any air in the
coating filter using the “bleeder” cap. Make sure
to use Teflon tape on the new coating filter before
reattaching the fittings.
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OPERTION TIPS
Priming the High pressure pump
To prime high pressure pump:
Press MACHINE SET-UP.
Press VACUUM.
Chuck lens on spindle over wash bowl.
Press WASH PRIME then DUMP VALVE allow to
prime for 45 seconds.
Press DUMP VALVE again to close to ensure
constant beat (like a heartbeat).
If wash prime has not been achieved, allow to run
with Dump Valve open for another 45 seconds.
After your wash is primed, press DUMP VALVE
again and allow to run for 20 seconds. It is
important to press WASH PRIME FIRST and then
DUMP VALVE LAST when you are finished priming.
Following these steps will help keep air out of the
system.
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OPERATION TIPS
To ensure lens is dry before it is coated:
Press PRODUCTION CYCLE
Press OFF/ON
Prepare lens and chuck on spindle over wash bowl. Allow
to wash and dry. When spindles start to come up press
CYCLE STOP. Release lens and ensure backside is dry. If
not dry, ensure wash tip and screen is clean and free of
debris and that Air Jet is correctly aligned and is set to
correct pressure. Then repeat priming high pressure wash.
To replace Coating Filter:
Disconnect the nut on the elbow at the bottom of your
reservoir. Point nut and tubing from the filter into a clean
container. Press coating ON/OFF button and the coating
will flow out of the tubing into the clean container. When
the reservoir is empty, press coating ON/OFF button to
turn off coating pump. Disconnect the nut on the elbow at
the bottom of your coating filter. Remove both elbows
from the old coating filter and save. Discard old filter.
Place Teflon tape on the new coating filter before
reassembling. Pour coating back into coating bowl
chamber and re-prime system.
To release trapped air during priming, turn “bleeder” cap
¼ of a turn, this will allow air to escape. Always keep
ahold of cap to ensure that pressure from priming does
not blow cap off.
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