Manual CHC60-4 Rev1 ING - Tool-Shop-Optic CHC60-4 Rev1_ING.pdfOperator’s Manual CHC60-4 For RXP Oftalmica ... The design is innovative and the process it delivers ... the external

Operator’s Manual

CHC60-4 For RXP Oftalmica S.r.l.

Cleaning & Hard Coating System Serial No: 02-206

Optimal Technologies Ltd The Marquis Business Centre Royston Road, Baldock Hertfordshire, SG7 6XL. UK Tel: +44 (0)1462 491616 Fax: +44 (0)1462 491600 E-mail: [email protected] Web: www.optimaltechnologies.co.uk

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Operator’s Manual for the CHC60-4 Mk1 Revision 1 2

Contents

PART

CONTENTS

1.1 1.2 2.1 3 4 5 6 7 8 9 10 11 12 13 14

Cleaning Introduction Coating Introduction Cleaning Machine Installation & Start-Up Safety Precautions About Ultra-Sonics Operating Instructions Lens Preparation Process and Configuration Menu’s Cleaning Machine Maintenance Hard Coat Material Technical Specification Electrical Schematics Plumbing Schematics Pneumatic Schematics Appendix Appendix 1……….Temperature Controller Appendix 1……….Conductivity Meter Appendix 2……….System Status Message Display (Trouble Shooting)

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Part Part Part Part

1.11.11.11.1 Cleaning

Introduction

1.11 Overview The Optimal CHC 60 has been designed to prepare ophthalmic lenses for hard coating and thin film vacuum deposition. The process guarantees a high degree of cleaning and can be used on other inter-stage cleaning operations. The system stands on castors. It is easy to move and is as easy to install as a domestic washing machine. The design is innovative and the process it delivers is comprehensive. The compact construction of the machine means that it can be positioned in small production areas, enabling it to be installed in manufacturing cells where previously a centralised cleaning facility would have been used. This can improve quality and efficiency. In designing the Optimal CHC 60 fully automated system, we have brought together all of the features required to produce an exceptionally clean surface, but at a price which opens up new opportunities for decentralised cleaning and all of the benefits this brings.

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1.12 Cleaning Process Overview

Process Stage

1 Clean (Etch)

2 Rinse

3 Clean

4 Rinse

5 DI

Rinse

6 DI Rinse

7 Dry IR

Ultra-Sonics

40kHz 40kHz 40kHz

Heating

0-55°C 0-55°C 0-55°C 0-55°C 0-55°C 0-55°C 0-65°C

Filtration

1µm 1µm 1µm 1µm 1µm 1µm

Oscillation

Yes Yes Yes Yes Yes

Capillary Dry

Yes

Flow Control

Yes Yes Yes Yes

Weir Overflow

Yes Yes Yes Yes Yes Yes

Time Minutes

5 2 3 2 4

5 5

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1.13 Cleaning Description

The system comprises seven process stages mounted in a box section steel framework. The cleaning tanks and the top surround are manufactured in stainless steel. The framework is clad in steel panels and doors which are finished in semi-gloss pale grey paint. The Optimal CHC 60 is automated by means of a unique transfer mechanism (Patent pending) mounted to the rear of the system. This indexes the carriers along, one tank at a time, at the end of the chosen cycle time. During cleaning and rinsing, the carriers are oscillated vertically through 30mm, to enhance the process. Lens cleaning takes place in stages 1 and 3. Stage 1 contains a cleaning fluid that removes most of the contamination and etches the lens surface. The lenses are then manually transferred to stage 2 which is the load station and first rinse tank, the lenses are then automatically transferred to stage 3 to be ultrasonically cleaned for a second time. The clean lenses are hen transferred to stage 4 for a final city water rinse before being transferred to the pure water rinse stages that follow. Rinsing in pure water is required to ensure a contamination-free surface after drying. Stages 5 and 6 contain de-ionised water, which is constantly polished by means of a closed-loop water purification system. This includes activated carbon to scavenge organic contamination and a mixed-bed resin, which removes ionic contamination. The de-ionised water is heated to improve its rinsing properties and to aid drying. Stage 6 is fitted with a slow drain facility. This slowly removes the water from the final rinse stage. The capillary action as the water drains from the surface of the lenses leaves them dry with only residual water on the carrier. The final stage is an infrared dryer. This removes the remaining water from the tooling. The temperature of the IR dryer can be adjusted to suit the process. After drying the lenses are transferred to the coating stages

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1.21.21.21.2 Coating

Introduction

1.21 Overview The hard coat lacquer will have a manufacturer’s ‘coating’ temperature and ‘stand-by’ temperature. Basically the coating temperature is the optimum temperature to achieve a good quality coating and the stand-by temperature is that at which the solvent can be stored with minimal solvent evaporation. For this reason the coating tanks are fitted with externally mounted cooling coils. Each coil is controlled by an independent refrigeration system fitted on the lower shelf within the machine.

Application of the coating is by dipping and the coating thickness is controlled by the speed at which the lenses are removed from the lacquer. The manufacturer of the lacquer will recommend the coating thickness and the speed at which to remove the lenses. This is covered in more detail later. In order to achieve the maximum stability when the lenses are being withdrawn from the lacquer, the coating tank moves with respect to the lenses. The tank is powered up and down using an oil dampened pneumatic system. Adjusting the speed at which the oil is bled through one of three speed control valves can vary the withdrawal rate very precisely. The system also provides the facility for three different speeds to be pre-set, with automatic speed selection according to the lens carrier being used. Coated lenses entering an uncontrolled environment would be susceptible to particulate contamination sticking to their wet surface. In order to minimise this risk we have included a pre-cure zone within the machine’s class 100 HEPA filtered environment. This will evaporate solvents from the lacquer leaving the lenses ‘touch dry’ and ready for final curing in a standard laboratory oven. Final curing should be in accordance with the instructions provided by the lacquer manufacturer. We recommend that the lenses are inspected before they a given the final cure. Should a lens be found to have a defect in the coating it can be stripped and re-coated after the pre-cure stage.

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1.22 Coating Process Overview

Process Stage

8 Cool

9 Primer Coat 1

10 Primer IR Dry

11 Hard

Coat 1

12 Hard Coat 2

13 Hard

Coat 3

14 Pre- Cure

15 Unload

Heating

20°C 18°C 0-55°C 18°C 18°C 18°C 0-65°C 20°C

Filtration

1µm 1µm 1µm 1µm

Weir Overflow

Yes Yes Yes Yes

Time Minutes

5 1 5 15 Sec

15 Sec 15 Sec 5 5

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PartPartPartPart

2 2 2 2 Machine

Installation & Start-up

2.1 Siting the Machine The machine should be sited on a flat surface to enable the weir overflows on the rinse tanks and the four-sided weir overflows on the coating tank are level to ensure an efficient operation. Try to choose a location that already has a water supply and a low level drain connection nearby. The machine is fitted with levelling feet so some compensation for an uneven floor can be made. The levelling feet are combined with the castors. These can be adjusted by rotating the red plastic wheel below the mounting point. It is best to lever the machine up, then adjust the height of the feet, one by one, then lower the machine to rest at the new height.

2.2 Connecting the Services

• Check pipe-work integrity following transport and installation – make sure all connections and fittings appear to be sound.

• Connect town-mains supply to 15mm pipe at the back of the machine. Do not turn on the water supply at this stage.

• Connect drain to the two 22mm pipes on rear of machine. These are a gravity drain and should fall from this position. If there is not a suitable drain on site, this should be connected to a collector tank fitted with a sump pump. We recommend a polypropylene header tank (domestic type) and a sump pump with automatic level control. Please contact us if you are unsure of what to do.

• Connect a 415V 20 Amp Three phase & neutral supply to the machine.

• Connect a compressed air supply to the connection on the rear of the machine and check that the pressure is set to 4 bar.

• The air conditioning unit will also have to be connected to the machine in accordance with the enclosed installation instructions. This involves the siting of the external heat exchanger to the cooler in the roof of the machine. There are two pipes and two electrical cables. There is also a water drain connection for condensate.

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2.3 Preparing the Machine

• Remove the black lid from the reservoir tank inside the machine. Check the drain valve from the reservoir tank is closed – this is the plastic valve accessible from the right hand side panel. The valve is positioned just above the drip tray

at the rear right hand side of the machine. Closed is with the blue line at 90° to the pipe.

• Open the mains water supply to the system and check that water flows into the reservoir tank. Whilst the tank is filling check for leaks. Watch the water level and make sure that it automatically turns off at about 35mm (1inch) above the heating element.

• Place the water purifying cylinders inside the machine. They stand in the drip try behind the front access door. The carbon cylinder should be placed to the left and the de-ionising cylinder to the right. Water flows in from the left so make sure that the inlet (marked on the connector) is on the left-hand side of the cylinder.

• Connect the two cylinders together using the small connector provided.

• Connect the flexible pipes inside the machine to the cylinders. The flexible pipes are connected together for transport. Simply unscrew the connectors and reconnect them to the cylinders. Make sure that the pipes are free, not twisted and not putting a strain on the rigid pipe-work.

• Check that the drain valves on tanks 1 to 6 are closed (located under tanks). These Tanks will Fill automatically until the correct water level is reached.

• Add the cleaning fluids. Refer to the separate chemical data sheet for concentration levels. If you are unsure, please contact Optimal Technologies for advice.

• The heater thermostats fitted to the CHC 60 are all factory set to provide the

correct fluid temperatures: stages 1,2,3 and 4 are between 40 and 50°C; stages

5 and 6 are between 53 and 55°C. The temperatures are measured by a thermometer reading taken at the stage identified and should not be adjusted.

2.4 Powering up the Cleaning Machine.

• Before applying power to the machine isolate the air supply using the valve on the rear of the system.

• Read the below sections 2.5 to 2.9 before powering up the machine.

• See section 4.1 & 4.2.

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2.5 Checking for Water Flow and Bleeding the Cleaning Machine

• The pump should now start to run. This will pump water through the purifying cylinders and the small blue (10inch / 200mm) particulate filter to stages 5 & 6. Air in the system may prevent this happening, so if no water begins to flow after thirty seconds or so, the system probably contains an airlock and will have to be bled. First try switching the machine on and off a few times using the green and red buttons. Allow 5 to 10 seconds between on and off times and look for air bubbles escaping into the tanks.

IMPORTANT: If the pump is left to cavitate (pump air) if will soon fail because water is the lubricant. Make absolutely sure that the system is bled and the pump is running with a steady tone.

• To bleed the system slowly unscrew the bleed screw located on the black connector between the in and out connections on the de-ionising cylinder (right hand cylinder). Do not fully remove this fitting but open it until you hear air escaping. Hold the screw fitting in this position until water flows from the screw thread.

• If there is still no flow into the tanks bleed the small particulate filter. The bleed device is the small red button located on the top of the filter housing. Press this down until water flows from around it.

2.6 Check the Water Levels.

• Stages 5 and 6 will now fill to overflow. If the flow stops it will be because there is insufficient water in the reservoir tank, which has been detected by the reservoir low-level switch. Allow the automatic top-up from the mains supply to catch up with the pump. This will balance itself automatically.

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2.7 Filling the Tanks

• The lid over the top of the coating tank can now be opened using the OPEN / CLOSE switch found on the Manual Menu of the touch screen (see section 5).

• Remove the baffle plate from the base of the tank until after the tank is filled

• Now clean all dust and particulate from all surfaces inside the machine and pay particular attention to the inside of the tanks. We suggest that you use a solvent that is compatible with your hard coat material.

• The tank can now be filled with the hard coat lacquer. Approximately 5 litres will be required to fill the tank and filtration pipes and cartridge. It will not be possible to put all 5 litres in until the system is bled and all of the pipe work is full.

• When the tank has overflowed and the weir trough fills to the same level as the tank, you can open the speed control valve to pneumatic pump until it is pumping rapidly. This should start to drive the air from the system. DO NOT RUN FOR LONG because the overflow trough will quickly empty.

• We suggest that you close the pump speed control valve before the trough empties and then inspect the pump, filter and pipe work for leaks. If there are no leaks refill the over flow trough and run the pump again.

2.8 Degassing the Tanks

• It is important to ensure that there are no small air bubbles in the system. Watch the flow of lacquer streaming up from the inlet to the tank. If you can see small bubbles turn the pump off and bleed the filter cartridge from the blue cap on the top of it – turn it anti-clockwise about half a turn. BE CAREFUL NOT TO COMPLETELY REMOVE THIS because the lacquer will spill from it rapidly.

• Run the machine for about 15 minutes to let it settle and then check again for bubbles. NOTE if you find that it is impossible to eliminate the bubbles, it could be because there is a leak on the suction side of the pump. If this is the case it will necessitate that the system is drained and the pipe work is sealed.

• Clean and refit the baffle plate by lower it into the tank using the hook provided. You can tap the baffle plate on the base of the tank to release bubbles that may have become attached to the inside of the tank whilst the system was being bled.

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Part Part Part Part

3333 Safety

Precautions

• DO NOT put hands or any other part of your body into the ultrasonic tanks when they are in operation.

• DO NOT let the chemicals come in contact with skin – Always handle and use the chemicals in accordance with the manufacturer’s Health and Safety Data Sheets.

• DO NOT open the machine door or panels when the machine is in use.

• DO NOT put your hand or any objects into the gap on the right hand side of the transfer beam. The transfer beam is the device that supports the lens rack during the process.

• Always isolate the machine before any maintenance work on it is performed on the system.

• We recommend that only a qualified electrician work inside the electrical control panel.

• Avoid excessive splashing of water around the top surround. This can cause ingress of water into the automation mechanical components resulting in failure.

• If there is any indication of a problem with the machine isolate it at the mains and contact the supplier.

• DO NOT attempt to process more than one batch of lenses at a time.

IF IN DOUBT ABOUT ANY ASPECTS REGARDING THE SAFE OPERATION OF THE MACHINE PLEASE CONTACT THE SUPPLIER

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PartPartPartPart

4444

About Ultra-Sonics

4.1 Ultra-Sonics

Ultra-sonic energy is energy in the form of sound waves – or mechanical vibrations - at too high a frequency to be heard by the human ear. When present in a tank of cleaning liquid these waves cause each particle of liquid to be alternately stretched and compressed at the frequency of operation. In the UCS 150 this happens between 35-40,000 times each second.

Ultra-sonic waves in this application are produced by means of three transducers bonded to the base of each of the ultra-sonic tanks. These transducers convert the electrical energy supplied by a generator in the control box into ultra-sonic vibratory energy. Ultra-sonic energy produces a number of effects but three of these STREAMING, DEGASSING and CAVITATION are of particular significance in ultra-sonic cleaning.

4.2 Streaming

When the base of the ultra-sonic tank vibrates it produces a force that causes the liquid to flow away from it. This results in a flow of liquid to the surface. This is what causes the waves you see on the surface of the liquid in the ultra-sonic tank. Streaming is useful because it assists in dispersing loosened contaminant from the surface of the lenses.

4.3 Degassing

Most liquids contain dissolved gas. This is in the form of vast numbers of minute finely dispersed bubbles. When these bubbles are exposed to ultra-sonic energy they expand and compress at the applied frequency (in this case 35-40,000 time each second). Bubbles larger that a particular size associated with the operating frequency will allow smaller bubbles to enter them as they expand. These bubbles continue to grow until they are large enough to float to the surface. The liquid is degassed when all of the large bubbles have been released. The water-based chemicals recommended for use in ultrasonic cleaning only take a few seconds to degas. During this start-up part of the process you will see and hear that the ultra-sonic energy is slightly muted.

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4.4 Cavitation

Bubbles smaller than those removed in the degassing phase perform the cleaning. During the stretching phase they grow and during the compression phase they collapse violently. It is millions of these minute bubbles collapsing that cause the contamination to be lifted from the surface of the lens. The lenses do not vibrate – it is the cavitation that scrubs them clean.

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PartPartPartPart

5 5 5 5 Operating

Instructions

5.1 Control Panel & Touch Screen Main Menu Layout & Description

CONTROL

ON

CONTROL

OFF

SYSTEM STATUS

CANOPY OFF ON

LOAD

CYCLE

Emergency Stop Push button

Control on illuminated Push button

Control off illuminated Push button Canopy off / on

selector switch (Machine lighting &

filtration fans off & on)

Touch Screen Main Menu (see below)

System status illuminated Push button

(See Section 5.5)

Load Cycle illuminated Push button

(See Section 5.5)

ETCH

CYCLE

Etch Cycle illuminated Push button

(See Section 5.5)

Run Mode Push button

Stand-by Mode Push button

System Alarm Message display

System Graphical display

• Index Beam status

• Stage Status

Password Log-In & Log-Out Push buttons

Password Indicator

Program Selection Push buttons

(See section 5.7)

Coating Tanks & Tank Speed Selection Push

buttons (See section 5.8)

Select System Data Menu

(See section 5.7)

Select Manual Menu

(See section 7.6) Select Configuration Menu

(See section 7.5)

Select Process Menu

(See section 7.1 to 7.4)

System Status Message display

System Warning Message display

System Alarm mute push button

Select Beam Menu (See section 7.7)

Stage No.1 Etch Cycle timer and countdown

timer (See section 5.6)

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5.2 System Start-up and System Run mode Flow Chart

Connect the 20 Amp 415V 50/60Hz 3 Phase & Neutral supplies.

Turn the Isolators (located at the rear of the machines) on.

The Status Message Display may display: RELEASE E-STOP

Twist the E-stop push button. button release.

The Status Message Display will now display: PRESS CONTROL ON and the red Control Off

button will be illuminated.

YES

NO Check the following:

• 415V Single Phase supplies.

• Circuit breakers tripped.

Press the green Control On button.

The Status Message Display should now display:

STAND-BY MODE SELECTED And the green Control On button will be illuminated

YES

NO Check the following:

• Circuit breakers tripped.

System Control On Run Mode Selected. Although System Run Mode is selected the

system is not ready for operation (see section 5.3 below for further details).

Press the Run Mode button On the Touch screen Main Menu.

The Status Message Display will display: SYSTEM COLD START-UP SEQUENCE

And the Run Mode button on the Touch screen will illuminate green.

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5.3 System Ready and System Start-up

Once System Run Mode has been selected (as above in section 5.2) the system is not ready for operation until the following automatic Start-up sequences have been completed: 1. System Cold Start-Up

The message SYSTEM COLD START-UP SEQUENCE will now be displayed on the System Status (green) message display until the DI water has reached the correct operating temperature. (The system typically requires 60 minutes to achieve operating temperature).

2. Ultra-Sonic De-gas The Message SYSTEM COLD START ULTRA-SONIC DE-GAS will now be displayed on the System Status (green) message display until the Ultra-sonic have run for the defined de-gas period. (The System Default Ultra-sonic De-gas time period is 10 minutes).

Once the Ultra-sonic de-gas sequence has been completed and the System is healthy, the message SYSTEM READY will be displayed on the System Status (green) message display now the system is ready to run (see section 5.6 before loading any carriers into the system). Each of the above sequences is activated when Run mode is selected or when the Start Timer is selected to start the System. The system is not ready for operation until each sequence has been completed (the System start-up sequence can be overridden as below in section 5.4, although this is only recommended during commission). If the System is left in stand-by mode, the System can be set to start automatically via a Start Timer within the System Configuration Menu on the Touch screen (see section 7.5 to set the Start Timer and also to set the real time clock to the correct local time).

5.4 System Start-up Override

The System Start-up can be overridden, once in Run Mode (as above in section 5.2) press and holding down the white System Status push button for a period of 5 seconds, until the white System Status indicator illuminates.

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5.5 System Status Indicator

The white System Status indicator is extinguished or off.

• System not Ready, System Start-up in operation.

• System Ready and Load station is occupied. The white System Status indicator is illuminated.

• System Ready.

• System Ready and the Load station is empty. The white System Status indicator is flashing.

• Do not load any carriers System transfer cycle in operation. The white System Status indicator is flashing with an audible alarm.

• The Unload station is occupied, remove carrier from unload station.

5.6 Stage No.1 Etch Cycle Operation

To operate the Etch cycle the run mode must be selected (as above see section 5.2) and the system cold start must be completed (as above see section 5.3). The Etch cycle is operated by pressing the Blue Etch cycle push button and reset by pressing the blue again or after a predefined time period (which can adjusted see below). During the Etch cycle the lenses will be ultra-sonically cleaned. The water pump will stop & the ultra-Sonics will run, when the time period has expired the ultra-Sonics will switch off and the water pump will start.

\

#

1 2 3

4 5 6

7 8 9

. 0 -

Enter Valve: 0 to 999

Step No.1 To modify the Etch cycle time

press the black display area

showing the current Etch cycle time value.

A numerical keypad will appear on the screen.

Step No.2 Using the numerical keypad

type in the new time value (in seconds) then press the

button.

This display shows the Etch cycle time remaining.

During the Etch cycle this stage No.1 will illuminate yellow.

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5.7 System Program and Coating Data Entry

Before carriers can be placed into the load station the following selections can be made:

• System Process: One of the six System Programs must be selected (the System Program is a predefined sequence of process times used as the carriers are indexed through the Cleaning & Coating Machines).

• Coating Data: If coatings are required the desired coating tanks and tank speeds must be selected. Any combination of Primer Tank & Speed and or Hard Coat Tank & Speed can be selected. If no coatings are selected the Carrier will only be processed by the cleaning Machine.

Once the required System Program & or Coating Data selections have been successfully entered the carrier can be placed in to the load station, then press the yellow Load Cycle push button (which will illuminate) and the carrier will then be automatically indexed through the selected processes. IMPORTANT: If the Load Cycle push button is pressed with no System Program selected, or the incorrect coating data selected the Load Cycle push button will flash, the audible alarm will sound and the System Alarm message display will display INCORRECT PROCESS SELECTION. The Transfer Beam will not index until the carrier has been removed, the Load Cycle push button has been pressed and the illumination has extinguished. The correct System Program and or coating data can now be selected and the carrier can be placed back in the load station and the Load Cycle push button pressed. The System Program & or Coating Data once entered remains valid for all further carriers placed into the load station. Until such a time that the next carrier requires a different System Program & or Coating Data and this is entered. These selections are chosen from the following Push buttons on the Main Menu (See below). Also the System Program & or Coating Data of carriers currently being processed can be viewed (See below).

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Step No.1 System Program selection

When a Program is selected the corresponding button will flash.

To select a new System Program press the current selected Program button, this will extinguish. Now

press the button for the new Program required, this button will now start to flash.

Step No.2 Coating Data selection

When a Primer Tank or Speed is selected the corresponding button will flash.

To select a new Tank or Speed press the current selected Tank or Speed button, this will extinguish. Now

press the button for the new Tank or Speed required, this button will now start to flash.

Step No.3 Coating Data selection

When a Hard Coat Tank or Speed is selected the corresponding button will flash.

To select a new Tank or Speed press the current selected Tank or Speed button, this will extinguish. Now

press the button for the new Tank or Speed required, this button will now start to flash.

Data To view the System Program & or Coating Data of carriers currently

being processed by press this button (See the below example).

Data This Menu shows the following at each

stage of the Cleaning machine:

• System Program

• Primer Tank selected

• Primer Tank speed selected

• Hard Coat Tank selected

• Hard Coat Tank speed selected.

Main Menu Press this button to return to the Main

Menu.

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5.8 Password Entry

Password Entry prevents unauthorised access to secure Menu’s, to gain access to the Secure Menu’s the correct Password must be Logged-In using the Steps 1 to 3 below. There are two levels of password (see below section 5.8). IMPORTANT: When access to secure the Menu’s is no longer required, follow step 4 below to log the Password out, to prevent any unauthorised access.

Step No.1 To gain access to secure

Menu’s, press the Log-In

button. A numerical keypad will appear

on the screen.

Step No.3 Once the correct password word has been successfully entered this indicator will flash, and the

text will prompt logged-In

#

1 2 3

4 5 6

7 8 9

. 0 -


Step No.4 To remove access to secure

menu’s press the Log-Out button.

Step No.2 Using the numerical keypad type in the correct numerical password (the factory default for level No.1 is 1234 and Level No.2 is 2468)

then press the button.

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5.9 Touch Screen Menu’s Security Levels

Main Menu Data Menu No password required

Manual Menu Password level 1 or 2

required

Beam Menu Password level 1 or 2

required

Process Menu Password level 2 only

required

Configuration menu Password level 2 only

required

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Part Part Part Part

6666 Lens

Preparation

6. The key to successful coating is preparation of the lenses.

1. Sharp and brittle edges must be removed from plus lenses using an edging wheel. Sharpe edges will cause: a. The tooling to cut into the lenses and the increase the likelihood of lenses

becoming loose and fall from the tooling.

b. Material from the edges of the lenses to be splintered by the ultrasonic cavitation. This will bond to the optical surface resulting in post-coating surface specs.

2. All traces of manufacturing residues must be removed: cerium oxide, blocking

wax and monomer particulate will cause pits on the lens surface if not totally removed. Blocking wax from the edge of minus lenses can migrate to the lens surface during cleaning resulting in post-coating surface specs.

3. The lenses must be free from existing hard coat so remove this using a suitable caustic stripper.

4. Now clean the lenses by hand using methanol or IPA and an approved soft cloth or disposable lint-free tissue. This will remove alignment ink marks. Before loading the lenses into the coating tooling be sure to inspect to ensure that they are completely free from surface damage or particles.

5. The lenses must be loaded into the lens fixtures by trained personnel to ensure that the correct pressure is applied to them and they are not damaged. If the client has a lens scrubbing machine that uses brushed or sponges, we recommend that this is used to mechanically scrub the lenses prior to hand cleaning with methanol.

Once prepared please process the lenses in accordance with the parameters shown on the process sheet.

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PartPartPartPart

7 7 7 7 Process

& Configuration Menu’s

7.1 Process Menu

The Process Menu can only be accessed once the correct password has been successfully entered (see section 5.7). The Process Menu can be selected from the Touch Screen’s Main Menu (See section 5.1). The Process Menu allows access to each of the six processes for the Cleaning & Coating Machines (See below).

Each System Process consists of a series of process times used in the various stages of the Cleaning & Coating Machines. These process times can be modified from the Process Menu for each individual Program (See below for detailed description of each programmable time).

Process Selected Displays the current Process selected.

Process Menu 2 To gain access to the Coating Machine Process times press

this button.

Main Menu

To return to the Main Menu press this button.

Process Selection To view or edit the times of a particular Process, use the

push buttons to highlight

the desired process, and press the button.

The process times for the selected process will now be displayed, and can also be edited. To select a different Process repeat the above

instructions.

Process Time Displays These display the current

selected process times for each corresponding process stage.

These can be edited (see section

7.4)

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7.2 Cleaning System Process Times

Stage 2 Rinse: This is the time period that the lenses will be rinsed in fresh flowing water. During this period the water top-up solenoid valve for stage 2 will open allowing fresh water to flow through the tank. The lenses will be transferred to the next stage when all other process times have elapsed. This is true for all inter-stage transfers. Stage 3 Sonic: This is the time period that the lenses will be ultra-sonically cleaned. The water pump will stop & the ultra-Sonics will run, when the time period has expired the ultra-Sonics will switch off and the water pump will start. Stage 3 Filter: This is the time period that the lenses will be rinsed in flowing filtered water. Stage 4 Rinse: This is the time period that the lenses will be rinsed in fresh flowing water. During this period the water top-up solenoid valve for stage 2 will open allowing fresh water to flow through the tank. Stage 5 Sonic: This is the time period that the lenses will be ultra-sonically cleaned in Deionised water. The DI water flow solenoid will close & the ultra-Sonics will run, when the time period has expired the ultra-Sonics will switch off and the DI water solenoid will open. Stage 5 Filter: This is the time period that the lenses will be rinsed in flowing filtered Deionised water Stage 6 Rinse: This is the time period that the lenses will be rinsed in flowing filtered deionised water, before the slow drain stage. Stage 6 Drain: This is the time period that the lenses will be slow drained in deionised water. The DI water flow solenoid will close and the two slow drain solenoids will open. The DI water flow solenoid will not open and the two slow drain solenoids will not close until the lenses have started to transfer to the next stage and are well above stage No.7 tank. Stage 7 Dry: This is the time period that the lenses will be dried in the radiant heat dryer. Stage 8 Cool: This is the time period that the lenses will be left in ambient air, if a primer and or hard coat tank has been selected.

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7.3 Coating Program Times

Stage 9 Cool: This is the time period that the lenses will be left in ambient air before being coated (if this coating stage has been selected). Stage 9 Coat: This is the time period that the lenses will be submerged in the coating liquid (if this coating stage has been selected). Stage 9 Dry: This is the time period that the lenses will be left to dry in ambient air before IR drying (if this coating stage has been selected). Stage 10 Cure: This is the time period that the lenses will be dried in the radiant heat dryer or Pre Cure heater. Stage 11 Cooling: This is the time period that the lenses will be left in ambient air before being coated (if this coating stage has been selected). Stage 11 Coat: This is the time period that the lenses will be submerged in the coating liquid (if this coating stage has been selected). Stage 11 Dry: This is the time period that the lenses will be left to dry in ambient air before IR drying (if this coating stage has been selected). Stage 12 Cool: This is the time period that the lenses will be left in ambient air before being coated (if this coating stage has been selected). Stage 12 Coat: This is the time period that the lenses will be submerged in the coating liquid (if this coating stage has been selected). Stage 12 Dry: This is the time period that the lenses will be left to dry in ambient air before IR drying (if this coating stage has been selected). Stage 13 Cool: This is the time period that the lenses will be left in ambient air before being coated (if this coating stage has been selected). Stage 13 Coat: This is the time period that the lenses will be submerged in the coating liquid (if this coating stage has been selected). Stage 13 Dry: This is the time period that the lenses will be left to dry in ambient air before IR drying (if this coating stage has been selected). Stages 14 Cure: This is the time period that the lenses will be dried in the radiant heat dryer or Pre Cure heater.

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7.4 Modifying Process Times

When all required process times have been modified successfully return to the Main Menu and press the Password Log-out button (see section 5.1).

Step No.1 To modify a Process time,

select the time to be modified

and press the black display

area showing the current

process time value. A numerical keypad will appear

on the screen.

#

1 2 3

4 5 6

7 8 9

. 0 -


Step No.2 Using the numerical keypad

type in the new time value (in seconds) then press the

button.

Main Menu To return to the Main Menu

press this button.

WARNING If this text is Red and reads

Warning Do Not Modify

Times. This is because

carriers are currently being processed through the System,

and if Process times are modified this may effect the times of the current carriers

being processed . To modify the times this text

must be Green and read Ok to

Modify Times.

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7.5 Configuration Menu

The Edit Configuration Menu can only be accessed once the correct password has been successfully entered (see section 5.7). The Edit Configuration Menu can be selected from the Touch Screen’s Main Menu (See section 5.1). The following can be modified from the Edit Configuration Menu.

System Water Top-up: This is the time period that the water level in stages 3 and 5 are topped-up for during the System cold start-up sequence.

Ultra-Sonic Degass: This is the time period that the Ultra-sonic are degassed for after System cold start-up sequence.

Stage 6 Fill Timer: This is the time period required to fill Stage 6 after a slow drain cycle, during a automatic sequence this time period is used to ensure that Stage 6 is completely full of water before, starting the Stage 6 Rinse process. Stage 7 Dryer Timers The dryer timers control the duration that the infra-red heater element is either on or off. These timers are factory set and should not be modified without consulting with Optimal Technologies. Stage 10 & 14 Dryer Timers The dryer timers control the duration that the infra-red heater element is either on or off. These timers are factory set and should not be modified without consulting with Optimal Technologies. Coating System Chiller Top-up: This is the time period that the Chiller unit’s water level is topped-up for during System cold start-up sequence.

Coating System Lacquer Pumps Controls: The Lacquer pump for each Coating Stage can be selected to operate in one of the two options:

• Permanent The selected lacquer pump runs constantly.

• Pause The selected lacquer pump runs constantly, but during an automatic cycle the lacquer pump will stop when the lacquer tank reaches it’s top position and will not start again until the tank has reached the bottom position. Current Time & Day: This displays the current time of day and day of week used by the system for the Auto cold start-up times. IMPORTANT: If the Cleaning System is powered down (electrical isolated) the time of day is retained, but the day of the week will require setting on powering up of the cleaning system (see below). Day of Week Number:

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This displays a number which represents the day of the week, example 0 = Sunday, 1 = Monday, etc. The current day of the week is displayed above under Current Time & Day title. Cold Start-Up Times (see section 2.3): These are system start times which can be used to automatically start the system before the system is required for operation. The start-up time is set typically 1 hour before the time that the system is required for operation. There are three sets of start-up times: Monday – Friday Saturday Sunday The system must be left in stand-by mode with the required cold start-up time for the required day of the week enabled for the cold start-up times to automatically start the system. Password Log-in: The password log-in code can be modified see below.


press this button.

Day of Week Number 1. To modify the day of the week,


showing the current value. A numerical keypad will appear

on the screen.

2. Using the numerical keypad

type in the new value then press the button.

Example: 0 = Sunday

Password Log-In To modify the password log-in follow the

following steps:

1. Press the select log-in push button.

2. Press the change log-in push button. A

numerical keypad will appear on the screen.

3. Using the numerical keypad type in the new

value and then press the button.

4. Now press the verify log-in push button.

The password log-in will now have been

modified.

System Timers 1. To modify a System timer,

select the time to be modified and


showing the current time value. A numerical keypad will appear

on the screen.



Lacquer Pump Control Press the selector switch symbol

of the required stage to toggle between permanent and pause lacquer pump operation modes.

Cold Start-Up Times 1. To modify the start-up time,


showing the current value (the hours & minutes are adjusted

separately). A numerical keypad will appear

on the screen.



3. To enable or disable the

required start-up time press the red or green push button, the text will indicate the state of the start-

up time.

Screen Config To gain access to the touch screen configuration menu

press this button. This will gain access to various touch screen settings including time & date, contrast, etc. Do

not modify any of these settings without first contacting

Optimal.

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7.6 Manual Menu’s

The Manual Menu’s 1 and 2 can only be accessed once the correct password has been successfully entered (see section 5.7). Manual Menu 1 can be selected from the Touch Screen’s Main Menu (See section 5.1). Manual Menu’s 1 and 2: Various functions of the Cleaning & Coating Systems can be manual controlled, once manual node has been selected (see below). System Reset Control: The Systems can be reset. Resetting the System will reset all current automatic operations and entered carrier data to zero. When the Reset push button is pressed a warning message is displayed (see example below) if you wish to continue with system reset, Yes or No can be selected. If Yes is selected the System will be reset and the Main Menu will be displayed, if No is selected the display will return to the Manual Menu 1.


press this button.

Manual Menu 2 To gain access to the coating system manual control menu

press this button.

Auto Mode The selected mode’s button will flash, to select auto mode for the cleaning

system press this button. Once in auto mode and the system is

in run mode the above selector switches will be overridden by the

automatic program.

Manual Mode The selected mode’s button will flash,

to select manual mode for the cleaning system press this button.

Warning manual mode can only be

selected if the system is not

occupied. Once in manual mode and the system

is in run mode the above selector switches will be come operational.

Manual Controls These selector switches control various devices on the cleaning system when in manual mode.

Indication Indication of the current status

of each device is displayed.

System Reset Push button.

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Example System Reset Warning Message


press this button.

Manual Menu 1 To gain access to the cleaning system manual control menu

press this button.

Auto Mode The selected mode’s button will flash, to select auto mode for the coating system

press this button. Once in auto mode and the system is in

run mode the above selector switches will be overridden by the automatic program.

Manual Mode The selected mode’s button will flash, to

select manual mode for the coating system press this button.


selected if the system is not occupied.

Once in manual mode and the system is in run mode the above selector switches

will be come operational.

Indication Indication of the current status

of each devise is displayed

Manual Controls These selector switches control various devices on the coating system when in manual mode.

Yes Push button. To select

System reset press this button.

No Push button. To return to

Manual Menu 1 press this button.

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7.7 Beam Menu

The Beam Menu can only be accessed once the correct password has been successfully entered (see section 5.7). The Beam Menu can be selected from the Touch Screen’s Main Menu (See section 5.1). Service Menu: The Function of the Beam main is to enable the commissioning engineer to manual operate the Cleaning or Coating Transfer Beam for fine adjust during testing.


press this button.

Auto Mode The selected mode’s button will flash, to select auto mode for the cleaning

system press this button. Once in auto mode and the system is

in run mode the above selector switches will be overridden by the

automatic program.

Manual Mode The selected mode’s button will flash,

to select manual mode for the cleaning system press this button.


selected if the system is not

occupied.

Once in manual mode and the system is in run mode the above selector switches will be come operational.

Transfer Beam Fault 1. To modify transfer beam fault

time, select the time to be modified

and press the black display area

showing the current time value. A numerical keypad will appear on

the screen.

2. Using the numerical keypad type

in the new value then press the button.

Beam Manual Controls

These push buttons control the transfer beam, when in manual

mode.

CHC60


Part Part Part Part

8888 Maintenance

8.1 Daily Maintenance

• Drain stages 1,2 and 4 by opening the valves located below the tanks. The valves are closed when the text is horizontal.

• Using the hand-held spray gun rinse the tanks out until they are clean. The water supply to the spray gun is via an isolating valve. Open the valve before use and close it after use.

• Close the drain valves below the cleaning tanks and fill the tanks to about 25mm (1”) below their rims. Ensure that the liquid level sensors on the front of the tanks are closed.

• Refill with fresh chemicals. (refer to the recommended process manual)

• Check for any obvious defects and rectify.

• Wipe down surfaces to prevent spilt chemicals crystallising on the surfaces.

• Check the quality of the water in the final stage. The water quality should

always be higher than 1 MΩ/cm or less than 1 µS/cm depending on the type of meter used. If you do not have a suitable meter please contact us for further information.

8.2 Monthly Maintenance

Slides Lubricate the two oscillation slides using light machine oil. These are the slides, which are 160mm long and mounted above the two triangular oscillation fulcrums. Deionised Water System The two large blue cylinders inside the machine purify the water (refer to 2.3 for correct installation procedures). If the contamination in your incoming water is high, and the main reservoir is drained and refilled frequently (say 3 to 4 times) this could exhaust the purifying media inside the cylinders. We recommend that the deionised water is only drained and cleaned when the cylinders are depleted or if the water in the tanks and reservoir has become stagnant Check inside the reservoir monthly for evidence of algae. If evident we recommend that the system be sterilised as follows:

• Isolate the main water supply.

• Drain the reservoir inside the console and wipe it out.

• Should there be any signs of bacterial growth i.e. a slimy film on the side walls of the tank sterilise as follows:

CHC60


• Wipe all residues from side walls

• Fill the tank by opening the mains water isolator valve.

• Add 4 sterilising tablets to the reservoir tank (the type of tablets used to sterilise a baby’s bottle e.g. Milton)

• Leave for one hour and then turn the system on and allow the two rinse tanks to fill.

• Add an additional tablet to each of the rinse tanks and leave for a further 10 minutes with the pump running.

• Drain and refill the system as normal

• Check flow as described in 2,5 and 2.6 above This procedure will reduce the life of the cylinders and should only be carried out if absolutely necessary

8.3 Every Three Months

Replacing the Water Purifying Cylinders. You will have been checking the quality of the water in the final rinse tank daily. We would, however, recommend that the ELGA/Vivendi cylinders be replaced every three months, as they may degrade rapidly thereafter. When replacing the De-ionising cylinders ensure that the particulate filter (Part No.W7-102, 5 micron) is also replaced. After replacing the cylinders check the water flow as described in 2.5 and 2.6 of this manual. IMPORTANT: If the system is not bled and the pump is allowed to cavitate it will self-destruct. Ensure that the correct procedure is followed Slides & Bearings Remove the rear cover from the machine and lightly grease all of the slides associated with the automation.

8.4 Every six Months

Every six months the machine should be serviced. We recommend that a qualified maintenance technician carry out this work.

CHC60


Part Part Part Part

9999 Hard Coat Material

9.1 Solids Checking.

You will require precision scales with a resolution of two decimal places (0.00g) 1. Clean, thoroughly dry and weigh a small disposable container. Note the weight of

the container (A).

2. Take approx. 2ml of lacquer and put it in the container. 3. Weigh the container with the lacquer in it. Now deduct (A) and note the result as

(B). This will be approximately 2g and is the exact weight of the lacquer in the container.

4. Now put the container in an oven at 120°C for 1 hour. 5. After 1 hour weigh the container again and then deduct (A). Note the result as

(C): This is the weight of the solids and will probably be between 0.4 and 0.7 6. Now make the following calculation: (C) divided by (B) them multiply by 100 will

be the percentage solids C / B * 100 = % solids

9.2 Diluting the Lacquer

We recommend that a 80/20 mixture of Methanol and 1-Methoxy-2-propanol (typical 98.5%) is used. So mix 8 parts methanol with 2 parts MP. This is the diluting solvent. Solvent required is (kg(AS – RS)) / RS Kg = weight of the lacquer in the system. When the tank is full this 5 kg AS = Actual Solids RS = Required Solids So if the calculation above shows that the Actual solids content (AS) is 30% and we recommend 24% the calculation would be: 5(30-24) / 24 = 1.25. So we must add 1.25 litres to 5 litres to produce the correct solids content.

CHC60


PartPartPartPart

10101010 Technical

Specification

Electrical Supply:

400 / 415V, 50/60Hz. 3ϕ & Neutral (20A).

Total Power Rating:

8.3kW.

Normal Running:

4.5kW.

Air Supply:

6mm Plastic pipe at 4 Bar

Water Supply:

15mm or ½”BSP female (Speed-fit) connection.

Drain:

Foul Sewer. One 22mm or ¾” BSP female (Speed-fit) Connections: Water & Chemical. One 15mm or ½’’ BSP female (Speed-fit) Connections: De-ionised water.

Fume Extraction:

φ150mm. Duct. 150cfm total

CHC60


PartPartPartPart

11111111 Electrical

Schematics

CHC60


PartPartPartPart

12121212 Plumbing

Schematics

CHC60


PartPartPartPart

13131313 Pneumatic Schematics

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APPENDIX APPENDIX APPENDIX APPENDIX

1111 Temperature

Controller

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1111 Conductivity

Meter

CHC60


Water Quality Meter Calibration Carry out the following procedure to calibrate the meter correctly.

0.00µS AL BH

MODE DISP

AWE Instruments

CAL ENT

Model 7685

CAL MODE: AUTO

Press the CAL button.

CAL MODE: MAN

Press the & buttons to scroll through the various options.

Selected MAN.

0.00µS TR:20°

Press the ENT button the message UPDATE will be

displayed briefly.

0 µSM AL BH

Note: This screen will then be displayed. To indicate Manual has

been selected a flashing M will appear on this screen.

Press the MODE/DISP button.

ZERO COMP: 0.00µ


Note: This screen will then be displayed. Now disconnect the

Conductivity Cell from the back of the display (red wire from terminal

20, blue wire from terminal 22, yellow wire from terminal 23 and

green wire from terminal 24).

CAL ZERO1: µ

Once the Conductivity Cell is disconnected, press the CAL button.

Note: This screen will then be displayed. Wait until the display

has automatically set all five ranges.

SENS: 100.0%

When all five ranges have been automatically set, this screen will

be displayed.

Note: Now reconnect the Conductivity Cell from the back of the display (red wire from terminal

20, blue wire from terminal 22, yellow wire from terminal 23 and

green wire from terminal 24).

0 µSM AL BH

Press the ENT button 2 times.

CAL MODE: AUTO


0 µS AL BH


Selected AUTO. Press the ENT button the message UPDATE will be

displayed briefly.

CHC60


Water Quality Meter Configuration Carry out the following procedure to check configuration of the meter.

0.00µS AL BH

MODE DISP

AWE Instruments

CAL ENT

Model 7685

Configuration

Press the MODE/DISP

button 8 times.

KB UNLOCKED


K Cell: 1.00cm


K Cell: 1.00cm


Selected 1.00cm

C Scale: 20.00µS


displayed briefly.

0 ηS AL BH

Press the MODE/DISP button 3 times to return to the original display,

this will now display ηS or µS.

0 ΜΩ TR:20

Press the MODE/DISP button 2 times to display the water quality

in MΩ or KΩ.

C Scale: 2000ηS


Selected 20.00µS for Micro Siemens or

2000ηS for Mega Ohms

Autoranging:ON


displayed briefly.

CHC60


Mega ΟΟΟΟhms or Micro Siemens Configuration Carry out the following procedure to change the engineering units of water quality meter from micro siemens to Mega Ohms, or from Mega Ohms to Micro Siemens.

0.00µS AL BH

MODE DISP

AWE Instruments

CAL ENT

Model 7685

Configuration

Press the MODE/DISP

button 8 times.

KB UNLOCKED


C Scale: 20.00µS


C Scale: 2000ηS


Selected 20.00µS for Micro Siemens or

2000ηS for Mega Ohms

Autoranging:ON


displayed briefly.

0 ηS AL BH

Press the MODE/DISP button 3 times to return to the original display, this will now

display ηS or µS.

0 ΜΩ TR:20

Press the MODE/DISP button 2 times to display the water quality

in MΩ or KΩ.

CHC60



2222 Message Display

(Trouble Shooting)

Alarm Message Display

Display Message Description & Action to be Taken Type

E-STOP BUTTON OPERATED The Emergency stop button has been pressed. Twist the Emergency stop button clockwise to release.

Alarm

CONTROL OFF The System control is off. To select system control on press the green Control on push button.

Alarm

SYSTEM 3 PHASE SUPPLY FAULT

A fault has been detected on Main 3 Phase electrical supply to the Machine. Check that there is 400-415V Ac between each of the 3 phases and that the phase rotation is correct.

Alarm

INCORRECT PROCESS SELECTION

The yellow Load Cycle push button has been pressed with the incorrect process selected. Either no process has been selected or a coating tank has been selected with no speed selection. Remove carrier from the load station and press the Load Cycle push button, now correct the required process selection. Once the process selection has been corrected, load the carrier back into the load station and press the Load Cycle push button.

Alarm

TRANSFER BEAM FAULT

The Cleaning System Transfer beam could not automatically complete an Index cycle or correct an Index beam error, and has timed out. To reset this fault press the E-stop Button and check the following possible causes: that the air supply is not at approx 4 Bar, Check all pneumatic connection to the transfer beam cylinders, check transfer beam cylinders switches positions & connections, & check Index beam mechanism. Once the cause has been established and cured release the E-stop button, Press the Control On Button and the Run Button.

Alarm

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Warning Message Display


STAGE No.1 LOW WATER LEVEL

Stage No.1 water level float switch has detected a low water level, preventing Stage No.1 heaters and pump from operating, or water level pressure switch has detected a low water level, preventing the ultra-sonics from operating. Check for any water leaks, if there are no leaks top-up the water to the correct level.

Warning



Warning


Stage No.3 water level float switch has detected a low water level, preventing Stage No.1 heaters and pump from operating. Check for any water leaks, if there are no leaks top-up the water to the correct level.

Warning



Warning


Stage No.5 water level pressure switch has detected a low water level, preventing the ultra-sonics from operating. Check for any water leaks, if there are no leaks top-up the water to the correct level.

Warning

DI WATER RESERVOIR LOW WATER LEVEL

DI water reservoir tank water level float switch has detected a low water level, preventing the DI water heater and pump from operating. Check for any water leaks, if there are no leaks top-up the water to the correct level.

Warning

REMOVE CARRIER FROM UNLOAD STATION

A carrier is occupying Coating System Unload station. Remove Carrier from the Coating system Unload Station.

Warning

TRANSFER BEAM ERROR The Cleaning System Transfer beam position is incorrect (not at home position magnetic switch) and the system is automatically correct it’s self.

Warning

CHC60


System Status Message Display


RELEASE E-STOP BUTTON The Emergency stop button has been pressed. Twist the Emergency stop button clockwise to release.

Alarm

PRESS CONTROL ON The System control is off. To select system control on press the green Control on push button.

Alarm

CHECK SYSTEM ELECTRICAL SUPPLY

A fault has been detected on Main 3 Phase electrical supply to the Cleaning Machine. Check that there is 400-415V Ac between each of the 3 phases and that the phase rotation is correct.

Alarm

TRANSFER BEAM FAULT PRESS E-STOP TO RESET

The Cleaning or Coating System Transfer beam could not automatically complete an Index cycle or correct an Index beam error, and has timed out. To reset this fault press the E-stop Button and check the following possible causes: that the air supply is not at approx 4 Bar, Check all pneumatic connection to the transfer beam and dryer stages cylinders, check transfer beam and dryer stages cylinders switches positions & connections, & check transfer beam & dryer stages mechanism. Once the cause has been established & cured release the E-stop button, Press the Control On Button and the Run Button.

Alarm

STAND-BY MODE SELECTED The system is in stand-by mode. To select system run mode, press the green Run Mode push button.

Status

MANUAL MODE SELECTED

The system is in manual mode. Enter required password (see section 5.7) press Manual menu button on the Main Menu, once in the Manual menu press the Select Auto button, and return to the Main Menu.

Status

SYSTEM COLD START-UP SEQUENCE

Wait for System cold start-up sequences to be completed. Status

SYSTEM COLD START-UP ULTRA-SONIC DE-GAS

Wait for System cold start-up ultra-sonic de-gas to be completed.

Status

SYSTEM READY System ready to process carriers. Status

Documents

Manual CHC60-4 Rev1 ING - Tool-Shop-Optic CHC60-4 Rev1_ING.pdfOperator’s Manual CHC60-4 For RXP Oftalmica ... The design is innovative and the process it delivers ... the external