Nidek Medical Le 1000 User manual

PATTERNLESS EDGER
Model
SERVICE MANUAL
June 2008
Pages in total: 152
LLE14BRDA001A/E

NIDEK CO., LTD. : 34-14, Maehama, Hiroishi-cho, Gamagori, Aichi 443-0038, Japan
(Manufacturer) Telephone: [phone]
Facsimile: 81-533-67-6610
NIDEK CO., LTD : 3F Sumitomo Fudosan Hongo Bldg., 3-22-5, Hongo,
(Tokyo Office) Bunkyo-Ku, Tokyo 113-0033, Japan
Telephone: [phone]
Facsimile: 81-3-5844-2642
NIDEK INCORPORATED : 47651 Westinghouse Drive, Fremont, California 94539, U. S. A.
(United States Agent) Telephone: [phone]
Facsimile: 1-510-226-5750
NIDEK SOCIETE ANONYME : Europarc 13, rue Auguste Perret, 94042 CRETEIL, France
(EU Authorized Representative) Telephone: [phone]
Facsimile: 33-1-49 80 32 08

I
Table of Contents
§ 1 INTRODUCTION ..............................................................................1-1
§ 2 SAFETY PRECAUTIONS.................................................................2-1
§ 3 PRODUCT OUTLINE .......................................................................3-1
3.1 Quality Standard .................................................................................................... 3-1
3.2 Configuration .......................................................................................................... 3-3
3.3 Model Configuration ............................................................................................... 3-9
3.4 Wheel Configuration ............................................................................................ 3-10
3.5 Labels ....................................................................................................................3-11
3.6 ASSY. Layout ....................................................................................................... 3-13
3.7 Electrical Component Layout ............................................................................... 3-14
3.8 Replacement Part List.......................................................................................... 3-17
§ 4 TROUBLESHOOTING ....................................................................4-1
§ 5 REMOVING PROCEDURES ............................................................5-1
5.1 Prior to Removal Work ........................................................................................... 5-1
5.2 Abbreviations for Screws ....................................................................................... 5-1
5.3 Opening Top Cover ASSY. ..................................................................................... 5-2
5.4 Removing Covers ................................................................................................... 5-2
§ 6 REPLACEMENT PROCEDURES ....................................................6-1
6.1 Rocker Switch (80460-00123) ............................................................................... 6-1
6.2 Main Board (44401-BA01) ..................................................................................... 6-1
6.3 Inverter (80607-00027) .......................................................................................... 6-2
6.4 Monochrome LCD (80607-00025) ......................................................................... 6-2
6.5 Trace SW Board (44001-BA02) ............................................................................. 6-3
6.6 Setting SW Board (44401-BA03) .......................................................................... 6-3
6.7 Main SW Board (44401-BA04) .............................................................................. 6-4
6.8 Cover Relay Board (44401-BA07) ......................................................................... 6-5
6.9 Sensor Cable (44401-CA37) ................................................................................. 6-5
6.10 Wheels ................................................................................................................. 6-6
6.11 Grooving Wheel and Safety Bevel Finishing Wheel ........................................... 6-8
6.12 Stylus (40340-M474) ............................................................................................ 6-8
6.13 Tracing unit ASSY. (43401-4000) ........................................................................ 6-9
6.14 Feelers ............................................................................................................... 6-10
6.15 Feeler ASSY. (40340-4100) ................................................................................6-11
6.16 Lens Measurement Unit ASSY. (44401-4000) .................................................. 6-12
6.17 Lens Measurement Board (40340-BA06) ......................................................... 6-12

II
6.18 Pulse Motor (40340-E033) ................................................................................. 6-13
6.19 Encoder (40340-E043) ...................................................................................... 6-13
6.20 Cables (40340-CA31, CA32, CA33) .................................................................. 6-13
6.21 Safety Beveling/Grooving ASSY. (44001-6000) ................................................ 6-14
6.22 Spindle ASSY. (44001-6600) ............................................................................. 6-15
6.23 Pulse Motor (40340-E035) ................................................................................. 6-15
6.24 Sensor Cable (44001-CA42) ............................................................................. 6-15
6.25 Brushless Motor (40347-E054) .......................................................................... 6-16
6.26 Guide (44401-M931) .......................................................................................... 6-17
6.27 Processing Chamber ASSY. (44401-9300) ....................................................... 6-17
6.28 Lower Processing Chamber ASSY. (44001-9100) ............................................ 6-18
6.29 Carriage ASSY. (44401-5000) ........................................................................... 6-19
6.30 Chuck Axis Motor ASSY. (44001-5300) ............................................................. 6-19
6.30.1 Y axis motor ASSY. (44001-5400) ............................................................ 6-20
6.30.2 Y axis stepping motor (44001-E035) ....................................................... 6-20
6.31 DC Motor (44001-E042)..................................................................................... 6-21
6.32 θAxis Stepping Motor (44401-E022) ................................................................. 6-21
6.33 Carriage Relay Board (44401-BA05) ................................................................ 6-22
6.34 Sensor Cables (44001-CA27, CA29) ................................................................ 6-22
6.35 Sensor Cables (44001-CA26, CA28) ................................................................ 6-22
6.35.1 X axis motor ASSY. (44001-1100) ............................................................ 6-23
6.35.2 Pulse motor (44001-E037), Sensor cable (44001-CA17) ....................... 6-23
6.36 Feedwater ASSY. (44001-1600) ........................................................................ 6-24
6.37 Lid ASSY. (44401-2200) .................................................................................... 6-24
6.38 DC Fan (40350-E016)........................................................................................ 6-25
6.39 Communication Connector Board (44401-BA08) ............................................. 6-25
6.40 Cables CA07 (44001-CA07) .............................................................................. 6-25
6.41 Fuse Holder (80401-00038) .............................................................................. 6-26
6.42 Inlet (80457-00085) ........................................................................................... 6-26
6.43 Reactor (40350-E043) ....................................................................................... 6-27
6.44 Regenerative Resistor for BL Motor (40340-E069) ........................................... 6-27
6.45 Mains Part ASSY. (44401-1200, 12A0) ............................................................. 6-28
6.46 Inverter for BL Motor (40340-E066, E067) ........................................................ 6-28
6.47 Switching Regulator (80602-00107) .................................................................. 6-29
6.48 Motor Driver (44001-E036) ................................................................................ 6-29
6.49 SSR Board (44001-BA09) ................................................................................. 6-29
6.50 Line Noise Filter (80404-00043) ........................................................................ 6-30
§ 7 SETTING/ADJUSTMENT .................................................................7-1
7.1 Notes for Proper Settings and Adjustments .......................................................... 7-1
7.2 Utility Program ........................................................................................................ 7-2
7.2.1 Writing program to Master CPU ................................................................... 7-2
7.2.2 EEPROM initialization .................................................................................. 7-3
7.2.3 Writing program to tracing unit CPU ............................................................ 7-4
7.2.4 Parameter settings ....................................................................................... 7-5
7.2.4.1 Displaying PARAMETER SETTING screen ........................................ 7-5
7.2.4.2 Displaying WHEEL PARAMETER screen .......................................... 7-6
7.2.4.3 Parameter list ...................................................................................... 7-7
7.2.5 HARDWARE TEST program ...................................................................... 7-10

III
7.3 Mechanical Components ..................................................................................... 7-13
7.3.1 Carriage ASSY. (44401-5000) .................................................................... 7-13
7.3.1.1 Rattle removal of carriage ASSY. bearing ........................................ 7-13
7.3.1.2 Engagement of X axis motor ASSY. motor gear .............................. 7-14
7.3.1.3 Height of carriage ASSY. Y axis ........................................................ 7-15
7.3.1.4 θaxis of carriage ASSY. Y axis ......................................................... 7-16
7.3.1.5 Position of carriage ASSY. left/right shaft ......................................... 7-17
7.3.2 Lens measurement unit ASSY.................................................................... 7-18
7.3.2.1 Feeler ASSY. height .......................................................................... 7-18
7.3.2.2 Initial position of feeler ASSY. ........................................................... 7-19
7.3.2.3 Voltage of lens measurement unit ASSY. ......................................... 7-19
7.3.3 Safety beveling/grooving ASSY. (44001-6000) ......................................... 7-21
7.3.3.1 Position of safety beveling/grooving ASSY. arm .............................. 7-21
7.3.4 Chuck pressure .......................................................................................... 7-22
7.3.4.1 Tentative chuck pressure .................................................................. 7-22
7.3.4.2 Chuck pressure ................................................................................. 7-23
7.3.5 Tracing unit (43401-4000) .......................................................................... 7-24
7.3.5.1 Tilt of tracing unit stylus ..................................................................... 7-24
7.3.5.2 Position of cable CA63...................................................................... 7-24
7.3.5.3 Cleaning of pattern tracing pin .......................................................... 7-25
7.4 Electrical Components ......................................................................................... 7-26
7.4.1 Parameters BL motor inverter .................................................................... 7-26
7.4.2 Parameter list of BL motor (40340-E066, E067) inverter .......................... 7-27
7.4.3 Trip table of BL motor inverter .................................................................... 7-30
7.5 Calibration ............................................................................................................ 7-31
7.5.1 Displaying calibration screen ..................................................................... 7-31
7.5.2 Attaching calibration jig............................................................................... 7-31
7.5.3 Calibration of safety beveling/grooving ASSY. .......................................... 7-32
7.5.4 Wheel calibration ........................................................................................ 7-33
7.5.5 Calibration of lens measurement unit ASSY. ............................................. 7-34
7.5.6 Torque calibration of tracing unit ................................................................ 7-35
7.5.7 Frame auto calibration of tracing unit ........................................................ 7-35
7.5.8 Pattern auto calibration of tracing unit ....................................................... 7-35
7.5.9 Full calibration of tracing unit ..................................................................... 7-36
7.6 Processing Adjustment ........................................................................................ 7-38
7.6.1 Feeler axis .................................................................................................. 7-38
7.6.2 Finish size ................................................................................................... 7-41
7.6.3 Bevel position ............................................................................................. 7-41
7.6.4 Lens axis..................................................................................................... 7-42
7.6.5 Polish (differential, polishing wheel height, bevel, axis) ............................ 7-44
7.6.5.1 Polish (differential, polishing wheel height) ...................................... 7-44
7.6.5.2 Bevel position to be polished ............................................................ 7-45
7.6.5.3 Flat polish axis................................................................................... 7-47
7.6.5.4 Bevel polish axis ............................................................................... 7-48
7.6.5.5 Polycarbonate polish differential....................................................... 7-49
7.6.5.6 Polish size ......................................................................................... 7-49
7.6.6 Groove ........................................................................................................ 7-50
7.6.6.1 Groove depth .................................................................................... 7-50
7.6.6.2 Groove position ................................................................................. 7-51

IV
7.6.6.3 Groove axis ....................................................................................... 7-52
7.6.7 Safety bevel ................................................................................................ 7-53
7.6.8 Bevel/safety bevel axis ............................................................................... 7-54
7.6.9 Flat edge/safety bevel axis ........................................................................ 7-55
7.7 Other Settings and Adjustments .......................................................................... 7-57
7.7.1 Dressing wheels ......................................................................................... 7-57
§ 8 SUPPLEMENT .................................................................................8-1
8.1 Wiring Diagram ...................................................................................................... 8-1
8.2 Connector Cable .................................................................................................... 8-2
8.3 Main Board (44401-BA01) ..................................................................................... 8-7
8.4 Grease .................................................................................................................... 8-8
8.5 Grease MSDS ...................................................................................................... 8-10
8.5.1 NIPPECO LLP ............................................................................................ 8-10
8.5.2 BE-4 ............................................................................................................ 8-12
8.5.3 SHV-2.......................................................................................................... 8-14
8.5.4 NBU15 ........................................................................................................ 8-16
8.6 Troubles and Measures ....................................................................................... 8-21
8.7 Jigs ....................................................................................................................... 8-26
8.8 Tools ..................................................................................................................... 8-27
8.9 Consumables ....................................................................................................... 8-27

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• This Service Manual is for the NIDEK PATTERNLESS EDGER, Le 1000.
• For correct service, thorough understanding of the contents of this manual is required
prior to the service.
• This manual mainly describes simple remedies such as part replacement.
• Disassembly or repair must be performed by NIDEK service persons or other qualified
personnel.
• Refer to the Operator’s Manual, Parts List, and Installation Manual for the Le 1000.
• Refer to the Service Manual Annex for important changes.
• In case the system cannot be repaired according to the procedures described in this
service manual, please report the serial number of the system, version of the software,
and details of the symptom or symptoms.
§
1 INTRODUCTION

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§
2 SAFETY PRECAUTIONS
<General precautions>
• Maintenace must be performed by NIDEK service persons or other qualified personnel.
• Perform all maintenance according to the procedures described in this manual.
Failure to do so may cause unexpected accident or malfunction.
• When moving the system, use two or more persons. You may hurt your back or may fall
down if you carry it alone.
• When performing maintenance, turn off the power switch and disconnect the power cord
from the wall outlet unless the power needs to be on.
• Never wipe the covers using an organic solvent such as a paint thinner. Doing so may ruin
the surface and damage the appearance of the system.
<Maintenance precautions>
• In case of system malfunction, check the symptom and turn off the power .
• Do not drop parts or screws inside the system, nor bump it against surrounding objects.
• Prepare storage cases so as not to lose the removed parts or screws.
• Tighten or loosen screws with proper tools.
• After loosening the screws fixed by a threadlocking adhesive, be sure to reapply the
threadlocking adhesive to the screws when retightening them.
• After replacing parts, confirm that they are fixed in their original positions securely before
turning on the power.
• Should you observe smoke or strange odors being issued from the system, immediately turn
off the power switch, disconnect the power cord from the outlet, and investigate the cause.
If the system is powered in abnormal conditions, fire, electric shock, or total loss of the
system may result.
• See Wiring Diagram and Connecting Cable to check cable breaks as described in
“TROUBLESHOOTING”. In addition, check cables for the following:
1. Connectors are connected and crimped securely.
2. No contact failure occurs after re-connection of connectors.
3. Cables are soldered properly.
Do not yank the cables with excessive force. Doing so could cause cable breakage.
• Do not perform servicing with wet hands. Doing so could cause electric shock or malfunction.
• Prevent water seepage into the system.
• Do not apply excessive force to the stylus of the tracing unit. Doing so could cause deformation
or malfunction of the stylus.
• Make a lens material selection correctly according to the lens to be processed. If an improper
material is selected, the lens may break or the lifetime of processing wheels may be shortened
substantially.
• Never open the processing chamber door while the wheel is rotating. Spray containing
processing waste may come into your eyes.
• Keep hands and face away from the rotating wheel.
• Replace the wheel with gloves on after cleaning the wheel and inside of the processing
chamber. Bare hands can be hurt by glass-processing waste.
• Safety bevel the front and rear surfaces of glass lenses after processing. Subtle burrs may
damage your skin.
• Never use the adjustment jigs for purposes other than those intended.

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