Ultra Optics Rx - User Manual

www.ultraoptics.com

Summary

Introduction to the Rx Operation Manual

Thank You and Technical Support

Expresses gratitude for business and provides contact information for technical assistance.

Symbols and Warning Explanations

Explains the meaning of various symbols and cautionary statements used throughout the manual.

Service and Contact Information

Provides contact details for Ultra Optics technical service and support.

Manual Usage and Modification Guidelines

Design Modification Policy

States that the product should not be modified and to refer to component manuals.

Manual Availability and Copies

Information on how to obtain additional copies of the operation manual.

Safety Precautions and Hazards

Hazard Identification and Warnings

Details specific hazards like high voltage, UV light, hot surfaces, and chemicals.

Personal Protective Equipment (PPE)

Emphasizes the mandatory use of PPE, including gloves and safety glasses, when handling chemicals.

General Safety Guidelines

Required Utilities and Machine Connections

Physical Location and Ventilation

Specifies the need for accessible location and good ventilation for the machine.

Electrical, Air, and Water Specifications

Details required electrical power, compressed air, and deionized water for operation.

Machine Power and Foot Switch Interface

Describes the connection of power cord and foot switch to the machine.

System Overview and Lens Handling

General Machine Description

Provides a summary of the Rx's design and capabilities as a coating machine.

Lens Loading and Unloading Procedure

Step-by-step instructions for loading and unloading lenses into the machine.

Core Process Descriptions

Wash Process Details

Details the lens washing procedure using high-pressure deionized water.

Dry Process Explanation

Explains the lens drying method utilizing compressed air and filtration.

Coating Application Method

Describes the process of applying coating material to the lens surface.

UV Coating Cure Process

System Operation and Start-up

Machine Start-up Procedure

Lists the sequence of steps to properly start the machine.

HMI Lamp Warm-up Screen

Describes the initial Human-Machine Interface screen for UV lamp warm-up.

Main Screen Navigation and Functions

Single Lens Cycle Selection

Explains how to initiate a single lens processing cycle.

Two Lens Cycle Selection

Explains how to initiate a two-lens processing cycle.

Accessing Machine Setup

Describes accessing the machine setup configuration screen.

Accessing System Details

Describes accessing the detailed system information screen.

Accessing Diagnostics Screen

Describes accessing the diagnostic functions of the machine.

Single Lens Cycle Operation Steps

Initiating a Single Lens Cycle

Step-by-step guide to perform a single lens processing cycle.

Important Note on Cycle Stop

Important note regarding the use of the CYCLE STOP function for lens retrieval.

Two Lens Cycle Operation Steps

Initiating a Two Lens Cycle

Step-by-step guide to perform a two-lens processing cycle.

Machine Set-up Screen Functions

Main Menu and Core System Controls

Accessing the main menu and controlling core functions like coating and vacuum.

Wash Pump Prime Procedure

Detailed sequence to prime the wash pump for optimal operation.

UV Lamp and Spindle Indexing Controls

Operating the UV lamp cycle and indexing the spindles.

Advanced Machine Set-up Options

Home Index Functionality

Returns spindles to their home position.

Lamp Removal Screen Access

Accesses the screen for UV lamp removal.

Cover Coating Cycle Timer Settings

Setting and adjusting the time-out for the cover coating cycle.

System Detail Screen for Spindle Speeds

Spindle Speed Adjustment Procedures

Procedures for adjusting spindle speeds for coating and washing.

UV Lamp Removal Screen Operations

Lamp Positioning and Home Controls

Buttons to position the UV lamp for removal or return to home.

Diagnostics Screen Options

Accessing Diagnostic Sub-menus

Accessing vacuum tests, position checks, and alarm history.

Vacuum Test Screen Procedures

Vacuum Activation and Testing

Procedures to test vacuum on individual spindles.

Spindle Indexing for Access

Using INDEX and HOME INDEX for spindle positioning.

Position Test and Lamp Cool Down Screens

Machine Position Monitoring Screen

Visual screen to monitor machine positions and PLC inputs.

Lamp Cool Down Screen Function

Screen displayed during lamp module cool down after power interruption.

Maintenance Overview and Schedule

Importance of Regular Maintenance

Highlights the need for regular maintenance by trained technicians to ensure performance.

Preventative Maintenance Daily and Weekly

Provides a schedule for daily and weekly preventative maintenance tasks.

Preventative Maintenance and Procedures

Preventative Maintenance Schedule: Quarterly

Lists quarterly maintenance tasks and their descriptions.

Setting Spindle Speeds Procedure

Detailed procedure for checking and adjusting spindle speeds.

Spindle Speed and Lamp Time Adjustments

Setting Wash Spindle Speed

Steps to set the wash speed for the spindle.

Curing Lamp Time Adjustment

Procedure for adjusting the duration of the UV lamp cycle.

Curing Lamp Removal Procedure

Steps for safely removing the UV curing lamp module.

Coating System Adjustments and Verification

Adjusting Coating Discharge Height

Procedure to set the correct coating discharge height.

Priming the Wash Pump

Steps to prime the wash pump for optimal operation.

Ensuring Lens Dryness Before Coating

Procedure to ensure the lens is completely dry before coating application.

Coating Filter and UV Module Maintenance

Coating Filter Replacement Procedure

Detailed instructions for replacing the coating filter, including priming.

UV Light Module Lens Retrieval

Safe procedure for retrieving lenses from the UV light module.

UV Light Module Removal and Coating Flush

UV Light Module Removal Steps

Comprehensive steps for removing and reinstalling the UV light module.

Flushing the Coating System

Procedure for flushing the coating system, including cleaning and re-priming.

Filter and Consumable Replacements

HEPA Filter and Air Filter Pack Replacement

Instructions for replacing HEPA pre-filters, main HEPA filter, and air filter packs.

Light Module Consumable Replacement

Procedure for replacing the UV light module.

Component Replacement Procedures

Spindle Suction Cup Replacement

Instructions for replacing suction cups on the spindles.

Sensor Replacement Procedures

Steps for replacing proximity, lift cylinder, and vacuum sensors.

Spindle Motor and Air Regulator Maintenance

Spindle Motor Assembly Replacement

Detailed procedure for replacing the entire spindle motor assembly.

Air Regulator Adjustment Procedure

Steps to adjust the air regulator to the specified pressure.

Electrical Panel Layout Information

PLC Interface Signal Mapping

PLC Output Signal Descriptions

Lists and describes the PLC output signals and their functions.

PLC Input Signal Descriptions

Lists and describes the PLC input signals and their functions.

Circuit Breaker Configuration Details

Replacement Parts and Consumables

Commonly Replaced Parts List

Lists commonly replaced parts with part numbers.

Consumables and Supplies List

Lists consumables like gloves, wipes, and cleaning agents.

Coating Troubleshooting Guide

Wagon Wheel Effect Troubleshooting

Addresses the wagon wheel effect and suggests adjusting coating height.

Streaks and Tiny Pits Troubleshooting

Guides on resolving streaks from filter air and tiny pits from wash tips.

Edge Pits and Clumps Troubleshooting

Explains causes for pits on lens edges and suggests adjustments for air jet and pump prime.

Advanced Coating Defect Troubleshooting

Large Pits with Runs Troubleshooting

Discusses troubleshooting large pits and runs, often due to debris.

Glob of Coating on Lens Troubleshooting

Addresses issues with glob of coating on the lens, checking spindle and bearings.

Alarm Code Reference

Abort Cycle Alarms and Causes

Lists critical alarms that stop the lens cycle and their causes.

Warning Alarms and Descriptions

Lists non-interrupting alarms displayed on the operator's screen.

Spare and Replacement Parts Ordering Information

Warranty and Liability Statements

Equipment Warranty Terms and Conditions

Outlines the warranty period and conditions for new equipment.

Corporation Responsibility Limitations

Defines limitations on the corporation's liability for delays or unforeseen events.

Product Liability and Safety Compliance

Ultra Optics Rx Specifications