Ultra Optics Mini2 User manual

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Introduction
This manual is intended for use by Ultra Optics customers. It is important to read and
understand the information in this manual before installing or operating the system. This
manual is provided by Ultra Optics to its customers as a courtesy and, except as expressly
provided in this manual, ULTRA OPTICS MAKES NO WARRANTIES, EXPRESS OR
IMPLIED, REGARDING THE CONTENTS IN THIS MANUAL. ULTRA OPTICS ASSUMES NO
RESPONSIBILITY FOR ANY OUTCOMES AS A RESULT OF USING THIS MANUAL.
Any information contained in other manuals for equipment supplied by third party manufacturers
(including, but not limited to the PLC, motors, etc.) shall take precedence over information
contained within this manual with respect to that third party equipment.
Thank You
The employee-owners of Ultra Optics wish to thank you for your business. If, after reading this
manual, you are not confident in carrying out any task, please call Ultra Optics’ technical service
team at 763.488.6030 between the hours of 7:00 am –7:00 pm cst, Monday - Friday.
Symbols
Symbols and statements used throughout this manual include:
Text following this symbol needs extra attention.
NOTE: Text like this is extra information that may be helpful to the situation.
CAUTION: Text like this is information to help avoid personal injury and/or property damage.
WARNING!: Text like this is information to help avoid serious personal injury or
death and/or property damage.
Service
The Mini2 back-side coating unit was designed and manufactured for many years of safe and
dependable operation. In the event service is required, please contact Ultra Optics at:
Ultra Optics
9200 Wyoming Avenue North, Suite 360
Brooklyn Park, MN 55445
www.ultraoptics.com
763.488.6030

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Design Modification
DO NOT use this product in any manner not consistent with the instructions outlined in this
manual!
NEVER alter the design, or perform service that is not consistent with the instructions outlined in
this manual, without the prior written approval of Ultra Optics.
ALWAYS refer to the manual supplied by the component manufacturer for the most accurate
and current information regarding that item and its particular use. Any information in the
component manufacturer’s manual shall take precedence over information contained in this
manual.
WARNING!: Do not turn on or operate this machine until this manual has been
read and understood. If anything is unclear, please call our technical support team
immediately for help at 763.488.6030 or [e-mail].
Additional Copies
Additional copies of this manual are available by contacting Ultra Optics by phone at
763.488.6030, or by visiting our website at www.ultraoptics.com. No part of this document may
be reproduced or copied in any form, or by any means, without the prior written permission of
Ultra Optics.
©2018
Ultra Optics

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Safety SAFETY FIRST!
The Mini2 is a complex piece of equipment that contains various safety hazards. Some of these
hazards include, but are not limited to:
Do not service machine while it is plugged in.
Service work should only be conducted by
properly trained technicians.
UV-light is used to cure the coating on the
lens. Exposure to this light can damage the
eyes.
Rear panels and top deck may be hot due to
UV light source.
Personal protection equipment should be worn
at all times when operating or maintaining this
equipment. Several chemicals may be used
that should not come in contact with skin,
eyes, etc. Refer to all SDS sheets for clear
instructions.
WARNING! High pressure water wash
Water is sprayed at high pressure to provide a
thorough cleaning of the lens. This water jet
could cause injury if directed on skin.
WARNING! Air jet drying
Compressed air is blown at the lens surface to
dry it after being washed. This compressed air
could entrain particles and cause damage to
the eyes.
WARNING! Moving components
The machine contains several moving
components that could cause pinch points.
WARNING! Chemicals1
The chemicals used can cause skin and eye
irritation and damage clothing. Protective
gloves and safety glasses should be worn
when operating this equipment.
Because of these issues, it is important that only trained and qualified technicians operate and
work on these machines. When doing so, in addition to following the guidelines in this manual,
appropriate personal protective equipment (PPE) should be worn. The PPE may include, but is
not limited to gloves, safety glasses, protective gown/coat.
1
All Safety Data Sheets (SDS) for Ultra Optics coatings are available by visiting our website at
www.ultraoptics.com/technical-support

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General Safety Notes:
Never change or deactivate safety switches or protection devices in any way!
Work on the Mini2 must only be performed with the power disconnected.
The machine should be checked for any visible damage during each shift. Any changes,
including changes in operation behavior, must be reported to the supervisor.
The Mini2 is intended to run with an operator present at all times. It is not intended to be
operated unattended.

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Table of Contents
Introduction..................................................................................................................................i
Thank You................................................................................................................................i
Symbols ...................................................................................................................................i
Service.....................................................................................................................................i
Design Modification.................................................................................................................ii
Additional Copies ....................................................................................................................ii
Safety ........................................................................................................................................iii
Required Utilities........................................................................................................................ 1
Machine Setup........................................................................................................................... 2
Unpack and Inspect................................................................................................................ 2
Electrical connections............................................................................................................. 2
HEPA Filter System................................................................................................................ 2
Spindle Arm............................................................................................................................ 2
Air and Water Tubing Setup ................................................................................................... 3
System Overview....................................................................................................................... 4
General Overview................................................................................................................... 4
Wash process......................................................................................................................... 4
Dry process............................................................................................................................ 4
Coating application................................................................................................................. 5
Cure process.......................................................................................................................... 6
System Operation...................................................................................................................... 6
Start-up Procedure................................................................................................................. 6
Coating Machine Operation Procedure................................................................................... 6
Cure Unit.................................................................................................................................... 8
Set-Up.................................................................................................................................... 8
Operation ............................................................................................................................... 8
UV Lamp Replacement .......................................................................................................... 9
Maintenance.............................................................................................................................10
Preventative Maintenance Schedule .....................................................................................10
Maintenance Procedures.......................................................................................................11
Setting spindle speeds.......................................................................................................11
Adjusting the coating height...............................................................................................12

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Priming the wash system...................................................................................................13
Priming the coating system................................................................................................13
Flushing the coating system...............................................................................................13
Air Regulator Adjustment...................................................................................................14
Coating Troubleshooting Solutions............................................................................................15
Spare/Replacement Parts.........................................................................................................17
Warranty Statement..................................................................................................................18
Warranty................................................................................................................................18
Responsibility........................................................................................................................18
Product Liability.....................................................................................................................19

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Required Utilities
The following facility utilities are required to operate the Mini2. The provisions for these facilities
are the responsibility of the customer and are not included in the scope of supply for this
machine.
Physical Location
The machine should be installed in a location that is accessible
for easy disconnect of power and has good ventilation with an
air exchange of 4-5 times per hour. It should be located in a low
traffic area to minimize possible dust contamination. While it is
not necessary to install the Mini2 in a clean room, it is not a
good idea to place it near a lens edger either.
Dimensions
Coating Unit
21” D x 25” W x 36” H
Cure Unit
25” D x 16” W x 13” H
Electrical Power
Coating Unit
115 VAC, 5 amp circuit required. Machine is supplied
with a grounded three-prong receptacle, OR
One single phase 220 VAC/5A circuit.
Cure Unit
115 VAC, 15 amp circuit required. Machine is supplied
with a grounded three-prong receptacle, OR
One single phase 220 VAC/12A circuit.
Compressed Air
80 psig, 10 cfm. The connection on the machine is a 1/4” quick
connect
Deionized Water
Consumption of 7.6 L/hr at periodic rates of 0.3 L/min of
deionized water flow rate with ≥ 1 megaohm resistivity. The
machine is supplied with a reservoir that needs to be
periodically filled by the user. The pH value should be greater
than 4.9 and less than 9.1.
Water Drain
The machine is supplied with a drain reservoir that needs to be
periodically dumped by the user.

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Machine Setup
Unpack and Inspect
Begin by inspecting all components that shipped with the coating and curing unit. These may
include HEPA filter and blower assembly, tubing, a squirt dispensing bottle, gloves, adapter
suction cup, 5-gallon reservoirs, etc. If any parts or the machines are damaged in any way,
contact Ultra Optics immediately. Place the coating and UV cure units on a level table/bench
with the two 5-gallon reservoirs below the table/bench. It can be very helpful to install an
inspection light on the bench near the coating unit as well.
Electrical connections
Plug the Mini2 coating unit into a 110V, 5A circuit. Plug the Mini2 cure unit into a 110V, 15A
circuit. Each device is supplied with its own power cord.
HEPA Filter System
Place the HEPA filter system on top of the coating machine and secure it with screws. Plug the
HEPA system power cord into one of the provided outlets on the back of the coating unit.
Spindle Arm
Before connecting the air source to the coating unit, remove the bolt (see “A” in Figure 1). This
bolt is only used to secure the spindle arm during transportation. After the bolt is removed,
replace it with the guide pin (see “B” in Figure 1). The pin can be found in a plastic bag inside
the wash bowl.
Figure 1 - Spindle arm guide pin installation

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Air and Water Tubing Setup
The following diagram should be used to route the tubing between the Mini2 coating unit and
the UV Cure unit, as well as the tubes that need to be run to the two water reservoirs.
Figure 2 - Tubing setup diagram
Connect one end of the ½” tubing to the wash (Clean DI Water) connector on the lower right
side (viewed from the back) of the Mini2 coating unit. Pass the other end of the ½” tubing
through the hole in the lid of the reservoir and attach filter connector and filter inside of the
reservoir.
Connect the small ¼” diameter clear tubing to the smaller fitting in the reservoir cover and the
other end to the by-pass fitting located on the upper right side (viewed from the back) of the
Mini2 coating unit. Fill the reservoir with clean deionized water and secure the cover.
Connect the other piece of ½” tubing to the water drain fitting on the rear of the Mini2 coating
unit. Connect the other end of this ½” tube to the ½” fitting on the cover of the Waste Water
reservoir.
Adjust the air pressure regulators as follows:
Mini2 coating unit = 80 psi
Mini2 UV cure unit = 10-15 psi
Be sure to prime the coating and the wash systems prior to operating. These procedures
can be found in the Maintenance section of this manual.