Ultra Optics Rx User manual

www.ultraoptics.com

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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 Rx 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.
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.
©2016
Ultra Optics

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Safety SAFETY FIRST!
The Rx 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

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General Safety Notes:
Never change or deactivate safety switches or protection devices in any way!
Work on the Rx must only be performed with the working chamber door closed.
If a lens is lost from the suction cup, remove all remaining lenses from the remaining
spindles, turn off the power and retrieve the lens accordingly. Take proper caution as
various surfaces may be hot.
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 Rx 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 connections.............................................................................................................. 1
System Overview....................................................................................................................... 2
General Overview................................................................................................................... 2
Lens Load/Unload.................................................................................................................. 2
Wash process......................................................................................................................... 3
Dry process............................................................................................................................ 3
Coating application................................................................................................................. 3
Cure process.......................................................................................................................... 4
System Operation...................................................................................................................... 5
Start-up Procedure................................................................................................................. 5
HMI Screens........................................................................................................................... 5
Lamp Warm Up Screen....................................................................................................... 5
Main Screen........................................................................................................................ 6
Single Lens Cycle Screen................................................................................................... 7
Two Lens Cycle Screen...................................................................................................... 8
Machine Set-up Screen....................................................................................................... 9
System Detail Screen.........................................................................................................11
Lamp Removal Screen.......................................................................................................12
Diagnostics Screen............................................................................................................13
Vacuum Test Screen .........................................................................................................14
Position Test Page.............................................................................................................15
Lamp Cool Down Screen...................................................................................................15
Maintenance.............................................................................................................................16
Preventative Maintenance Schedule .....................................................................................16

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Maintenance Procedures.......................................................................................................17
Setting spindle speeds.......................................................................................................17
Adjusting the curing lamp time...........................................................................................18
Removing the curing lamp .................................................................................................18
Adjusting the coating height...............................................................................................19
Priming the wash pump......................................................................................................19
Ensuring the lens is dry before coating ..............................................................................19
Replacing the coating filter.................................................................................................20
Lens retrieval from UV light module ...................................................................................20
Flushing coating.................................................................................................................21
Changing Filters.................................................................................................................22
Replace Air Filter Packs.....................................................................................................22
Replacing Consumable Parts................................................................................................22
Light Module......................................................................................................................22
Spindle Suction Cups.........................................................................................................23
Replacing sensors.................................................................................................................23
Prox Sensors Index, and Lamp Home and Extend.............................................................23
Lift cylinder up and down sensor........................................................................................23
Vacuum Sensor .................................................................................................................23
Replacing the Spindle Motor Assembly .................................................................................24
Air Regulator Adjustment.......................................................................................................24
Electrical Panel Layout Information .......................................................................................25
Common Replacement Parts.................................................................................................29
Coating Troubleshooting Solutions............................................................................................30
Alarm Codes.............................................................................................................................32
Spare/Replacement Parts.........................................................................................................33
Warranty Statement..................................................................................................................34
Warranty................................................................................................................................34
Responsibility........................................................................................................................34
Product Liability.....................................................................................................................35

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Required Utilities
The following facility utilities are required to operate the Rx. 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.
Electrical Power
115 VAC, 15 amp circuit required. Machine is supplied with a
grounded three-prong receptacle. The machine requires earth
ground.
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 resistivity2. 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.
Machine connections
The Rx requires two cords to be plugged into the back of the machine. One cord is the power
cord that connects the 115 VAC power supply to the back of the machine. With reference to
Figure 1, the connector on the right is round and is used to connect the supplied foot switch.
Figure 1 - Electrical and foot switch connections
2
It is possible to install a sensor that will test the water quality for proper resistance levels.

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System Overview
General Overview
The Rx is a robust backside hard coating machine that performs all of the required operations
within a single machine. The core coating functions utilize the same technology as the highly-
touted MR3 coating system. These key processes are arranged and packaged in a way to
reduce cost for today’s small to medium sized labs.
The Rx is a completely self-contained system that is not required to be installed/operated in a
cleanroom environment. The system utilizes a pre-filter and HEPA filter to maintain a
continuous positive pressure of extremely clean air, which reduces the dependability on
operating in a clean environment. Further, the ultraviolet (UV) curing system is an integral part
of the Rx’s operation, eliminating the need to transport a freshly coated and wet lens manually
to an external curing system.
Lens Load/Unload
Before being loaded into the Rx, the lens should be
washed by hand with a small amount of isopropyl
alcohol (IPA), or Ultra Optics Lens Cleaner. When the
lens is clean, center the front side of the lens onto the
suction cup and remove your hand. The machine will
sense when your hand has been removed and will
automatically start the wash process. The PLC will
control the over-all process and all subsequent steps
required to coat and cure the lens. When the lens is
complete, reach in and hold onto the lens while
depressing the foot switch. This will release the vacuum
and allow you to place the next lens into the machine.
In Two Lens Mode, at cycle completion, depressing the
foot switch will release both lenses.
Figure 2 - Loading a lens

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Wash process
The lens is washed with high pressure,
deionized water. The clean deionized water is
stored in a reservoir in the bottom of the
machine. When a wash cycle starts, clean
water is drawn through a filter (located inside
the reservoir) and out of the reservoir, into the
pneumatically driven pump. The pump
increases the pressure of the water to 2000
psig. The high pressure water is then sprayed
through a nozzle onto the back-side of the lens.
The lens is spinning during the wash process to
help assure a complete surface cleaning. The
spent water is collected in the bottom of the wash
bowl and drained into a reservoir in the bottom of
the machine. At the end of the wash cycle, the water pump stops, and any residual water
downstream of the pump is emptied through the dump valve.
The system PLC monitors all system sequencing to control the water pump and solenoid valves.
Dry process
After the wash process is complete, the machine will initiate the drying process. The lens is
dried by use of compressed air. In the drying station the air nozzle is articulated in a manner
that ensures a complete drying of the entire lens surface. Similar to the wash process, the lens
is spun while in the drying station to help remove all of the water.
As shown in Figure 4, the air that is used for drying the lens passes through several filtration
and drying stages to obtain the clear and dry air that is used for the drying process. The timing
of the drying process is controlled by the system PLC.
Figure 4 - Drying system schematic
Coating application
With the lens down in the coating application station, the coating pump draws coating material
from the reservoir and pumps it through a filter, up to the surface of the lens. The lens is being
Figure 3 - Wash system schematic

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spun during the time of application to ensure a sufficient amount of coating is applied to the
entire surface. After the coating has been applied, the pump will stop and the spin speed of the
lens changes to a new value which will generate the proper film thickness of coating, based
upon the specific coating being used. The timing and spin speeds are controlled by the system
PLC. This process is shown schematically in the following diagram.
Figure 5 - Coating system schematic
Cure process
The Rx is designed to cure Ultra Optics’ line of UV-based coatings. After the lens has
completed the coating application cycle, the lift cylinder will raise the arm assembly, which will
then rotate and drop down into the curing station. An ultra-violet lamp resides in the curing
station. The radiation energy from this lamp is used to effectively cure the coating to the lens
with the proper characteristics of adhesion, hardness, etc.

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System Operation
Start-up Procedure
The following procedure should be followed upon machine start-up.
1. Inspect the machine to be sure nothing is in it that would impede the movement of the
spindle assembly
2. Turn air supply on
3. Fill clean/wash water reservoir with deionized water and empty the waste water reservoir
4. Turn machine power on
5. Check coating level and coating height, see procedure on page 18
6. Run test to be sure the lens is getting completely dry by following procedure on page 19
HMI Screens
Lamp Warm Up Screen
This is the first screen that will appear upon power-up of the machine. A five-minute UV lamp
warm up timer will start and its progress (in %) will be indicated by the progress bar. Once the
warm up is complete, the screen will advance to the Main Screen.
If needed, touching LAMP WARM UP will bypass the warm up mode and advance directly to the
Main Screen.
IMPORTANT NOTE: If the machine is not given adequate time to warm up, proper curing
of the coating on the lens will not occur!
LAMP WARM UP
%

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Main Screen
SINGLE LENS CYCLE –Selecting this button will bring up the SINGLE LENS screen. Only one
spindle will be utilized during this cycle.
TWO LENS CYCLE –Selecting this button will bring up the TWO LENS screen. Two spindles
will be utilized during this cycle.
MACHINE SET UP –Selecting this button will bring up the SET UP screen.
SYSTEM DETAILS –Selecting this button will bring up the SYSTEM DETAILS screen.
DIAGNOSTICS –Selecting this button will bring up the DIAGNOSTICS screen.
SINGLE LENS
CYCLE
TWO LENS
CYCLE
MACHINE SET UP
SYSTEM DETAILS
DIAGNOSTICS

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Single Lens Cycle Screen
Use the following procedure to begin the single lens cycle:
1. Select ON/OFF button to put it in the ON position
a. At this time, the vacuum will turn
on
2. After pre-cleaning, center the front side
of the lens on the suction cup that is
above the wash bowl
a. When facing the machine, this is
on the operator’s right side as
shown in Figure 6.
3. Remove hand from the lens and out of
the machine and the wash cycle will start
4. When wash cycle is complete, the
spindle arm assembly will lift up, index to
the next position, and the lens will go down into the coating station and the coating cycle
will start.
5. Once the coating is applied, the spindle arm assembly will lift up, index to the next
position, and the lens will go down into the curing station and the curing cycle will start.
6. When the curing is complete, the spindle arm assembly will lift up and index, bringing
the lens back to the position it was in when placing the lens into the machine in step #2.
7. Place hand on lens and depress the foot switch to release the vacuum and remove the
lens from the machine.
Important Note: If CYCLE STOP is utilized when the lens is not in the home index position, the
lens can still be returned to the home index position by touching the CYCLE
STOP button. At that time, the lens will be able to be removed from the suction
cup by depressing the foot switch.
CYCLE
STOP
MENU
SINGLE LENS
IN
CYCLE
ON
DIAGNOSTICS
VAC1
-18
325
ALARM
S
LENS
#
Figure 6 - Placement of lens in single lens
cycle

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Two Lens Cycle Screen
Use the following procedure to begin the two lens cycle:
1. Select ON/OFF button to put it in the ON position
a. At this time, the vacuum will turn on
2. After pre-cleaning, center the front side of the lens on the suction cup that is above the
wash bowl
a. When facing the machine, this is on the operator’s right side as shown in Figure
6 on previous page.
3. Remove hand from the lens and out of the machine and the wash cycle will start
4. When wash cycle is complete, the spindle arm assembly will lift up, index to the next
position
5. After pre-cleaning, center the front side of the second lens on the suction cup that is now
above the wash bowl (the first lens will now be on the left side of the machine)
6. Remove hand from the lens and out of the machine and the spindle arm assembly will
drop down
a. The coating cycle will start on the first lens and the wash cycle will start on the
second lens
7. When this cycle is complete, the spindle arm assembly will lift up, index to the next
position
a. The first lens will now be in the curing position
b. The second lens will now be in the coating positon
8. When this cycle is complete, the spindle arm assembly will lift up, index to the next
position
a. The first lens will now be cured and will index over to the wash station and will
remain on the suction cup (lens will not be re-washed)
b. The second lens will now be in the curing positon
9. When this cycle is complete, the spindle arm assembly will lift up and index to the next
position with both lenses cured. Place a hand on each lens and then depress the foot
switch to release the vacuum and remove the two completed lenses from the machine.
10. Select the ON/OFF button to reset the two lens program.
CYCLE
STOP
MENU
TWO LENS
IN
CYCLE
ON
DIAGNOSTICS
VAC1
-18
325
ALARM
S
LENS
#
VAC2
-18

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Important Notes: If CYCLE STOP is utilized when the machine is in operation, all lenses will
remain attached to the suction cups and must be removed.
To restart the production cycle, select CYCLE STOP and turn Two Lens
Screen to OFF, then back to ON, and start new production.
Machine Set-up Screen
This screen is used for individual activation of major functions of the Rx.
MENU –Selecting this button will return to the Main Screen.
COAT ON/OFF –Selecting this button will turn the coating pump on/off.
DUMP VALVE –Selecting this button will release pressure build up in high pressure lines
AIR JET –Selecting this button will activate high pressure airflow through the air jet nozzle
WASH PRIME –The following sequence must be followed to activate the wash prime:
1. Select VACUUM button –vacuum will turn on
2. Place lens on suction cup that is above the wash bowl (as shown in Figure 6 on page 7)
3. Select WASH PRIME button –spindle will lower and high pressure pump will start
4. Select DUMP VALVE button –this will release pressure and allow to prime wash
5. Select WASH PRIME button –high pressure pump will stop and spindle will rise
6. Select DUMP VALVE button to shut this valve off
7. Select VACUUM button –vacuum will turn off and lens will release
VACUUM –Selecting this button turns on the vacuum for testing
LAMP CYCLE –Selecting this button will activate the travel of the UV lamp
INDEX –Selecting this button will index spindles to the next position
HOME DONE –Indicates spindles are in the home position
MENU
COAT
ON/OFF
DUMP
VALVE
WASH
PRIME
LAMP
CYCLE
HOME
INDEX
INDEX
VACUU
M
AIR
JET
HOME DONE
REMOVE LAMP
90
COVER COATING CYCLE
TIMER IN SECONDS

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Important Note: If button reads “INDEX NOT HOME”, the spindles will rotate to the
home index position by selecting the HOME INDEX button.
HOME INDEX –Selecting this button will return the spindles to the home position
REMOVE LAMP –Selecting this button will bring up the Lamp Removal Screen
90 –Selecting this numeric button will allow changing the set amount of time (in seconds) when
the spindle will rotate and drop to cover the coating bowl.
COVER COATING CYCLE TIMER IN SECONDS –Selecting this button will activate after the
machine has finished the warm up cycle, or will activate once the machine has set idle for
the preset amount of time (in seconds) while in the Main Menu, or after all lenses have
been removed while in any production screen. To ensure proper operation, all doors must
be closed and all alarms must be cleared. In addition, you must be in the Main Menu
Screen or a Production Cycle screen to allow spindles to move for this function. Failure to
do so could result in the coating hardening within the bowl and reservoir. Selecting this
option will bring you to the cover coating cycle time adjustment screen.
COVER COATING CYCLE RESUME –Selecting the RESUME button will return the machine
and spindles to a running position after the cover timeout has been initiated.
COVER COATING CYCLE TIME ADJUSTMENT –This option allows you to set the cover cycle
time out in seconds. This time should be set between a minimum of 15 and a maximum of
300 seconds.
COVER COATING CYCLE
ACTIVE
RESUME
7
9
8
6
5
4
1
2
3
0
E
S
9
0

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System Detail Screen
This screen is used to measure individual spindle speeds. Each spindle is numbered. Locate
spindles #1 or #2 by selecting the INDEX button.
SPINDLE1 ON COAT –Selecting this button allows adjustment of the coat speeds for spindle
#1 using the COAT potentiometer as shown in Figure 8 on page 18.
COAT SPIN OFF –Selecting this button, with COAT SPEED button ON, allows adjustment of
coat spin-off speeds with the COAT SPIN OFF potentiometer as shown in Figure 8.
SPINDLE 1 WASH –Selecting this button, with COAT SPEED button ON, allows adjustment of
the wash speed with the WASH SPEED potentiometer as shown in Figure 8.
NOTE: The same procedures can be followed to set the speeds for spindle #2.
MENU
COAT
SPIN
OFF
SPINDL
E1
WASH
SPINDL
E2
WASH
HOME
INDEX
INDEX
SPINDL
E2 ON
COAT
SPINDL
E1 ON
COAT
HOME DONE
RESET
COUNTE
R
469
LENS
#

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Lamp Removal Screen
MENU –Selecting this button will return to the Main Screen.
LAMP REMOVE –Selecting this button will put the lamp in position for removal.
LAMP HOME –Selecting this button will put the lamp back in the home position.
LAMP HOMED –Must be selected to leave the Lamp Removal Screen.
UV Lamp
MENU
LAMP
HOMED
LAMP
REMOVE

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Diagnostics Screen
MENU –Selecting this button will return to the Main Screen.
VACUUM –Selecting this button will bring up the Vacuum Test Screen.
POSITION –Selecting this button will bring up the Position Test Screen.
ALARM HISTORY –Selecting this button will bring up the Alarm History screen.
VACUUM
MENU
POSITION
ALARM HISTORY
HMI Rev. X.XX
PLC Rev. X.XX