Ultra Optics Rx User manual

www.ultraoptics.com

www.ultraoptics.com page i
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

www.ultraoptics.com page ii
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

www.ultraoptics.com page iii
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

www.ultraoptics.com page iv
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.

www.ultraoptics.com page v
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

www.ultraoptics.com page vi
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

www.ultraoptics.com page 1
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.

www.ultraoptics.com page 2
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

www.ultraoptics.com page 3
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