Ultra OpticsTraining and Maintenance

Instruction booklet

Ultra RX Coating Procedures

ULTRA RX COATING SYSTEM

SYSTEM INSTALLATION

Physical LocationChoose a physical location with good ventilation and an air exchange rate of 4-5 time per hour. A normal Heating/Cooling A/C system will provide 3-6 air exchange per hour. The Ultra RX has it’s own positive air clean room environment.

Space RequiredThe Stand Alone Unit needs only 80” height and has a 25”x30” footprint.

Hook-Ups

Electrical One 115VAC/15 AMP with grounded three-prong receptacle.

WaterDeionized or Distilled water of 1 mega ohm or better is adequate for the cleaning system

Compressed Air80psi (9-10 CFM) minimum of air at constant source. An air regulator is supplied on the system.

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WARNING! NEVER CHANGE OR DEACTIVATE SAFETY SWITCHES OR

PROTECTIVE DEVICES IN ANY WAY

INTENDED USE OF MACHINEThe Ultra RX is a backside scratch resistant coating system used for coating optical lenses.

RISK-REDUCTION PROCEDURESThe Ultra RX should not be used for any other purpose other than the process of coating optical lenses. Any other use may result in injury or machine damage.

PROTECTIVE EARTHINGThe Ultra RX machine requires Protective Earth grounding.

ADDITIONAL ACCESSORIESThe Ultra RX is equipped with 2 outlets on the back of the system. One for main power and One for Foot Pedal.

GENERAL SAFETY•The Ultra RX has been designed and built in accordance with European and International safety standards. The Ultra RX design is such that it can be used safety.•The Ultra RX should be checked for any visible damage during each shift. Any changes including changes in operation behavior must be reported to supervisors in charge.•The Ultra RX Coating System is intended to have an operator present at all times during operation of the equipment.

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SUMMARY

Safety Requirements:

Protective Gloves

Protective Eye Wear

Equipment Requirements:

90% or greater IPA and Acetone

Coating Solution

Deionized or Distilled water, 1 mega ohm or better

3/8” x 25’ Air Line with a ¼” Female Quip Coupler “Quick Disconnect”

Set-up & Start up procedures:

Slowly turn air pressure on.

Turn power on

Verify there are no coating bubbles in coating filter and correct coating height is achieved.

Prime coating for 5 minutes

Add coating fluid if needed.

Check level of deionized water.

Make sure lens is dry after wash and dry cycle.

Verify positive air flow.

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PROCEDURE SUMMARY

Start Single or Two lens cycle.

Prioritize trays.

Turn vacuum on.

Clean lens with 90% or greater IPA.

Chuck lens on spindle over wash bowl.

Chuck next lens on suction cup over the wash bowl.

Repeat process for next lens.

When the completed lenses comes around, un-chuck by pressing foot pedal to release both lenses.

Continue this process until all trays are complete.

Press ON/OFF button on the Touch Screen to turn vacuum off when last lens is removed.

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SET-UP & START UP PROCEDURES

Powering up Ultra RX coating machine

Slowly press the air valve down to raise spindles. This valve is located on the right side of the Ultra RX.

Press the Red Power Button on the front of the machine to the ON position.

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SET-UP & START UP PROCEDURES

Bleeding Coating filter

Open the front door of the Ultra RX. Look at the coating filter to ensure there are no air bubbles. If so, refer to the “Operation Tips” page.

Check the level of the clean deionized water bucket and fill if needed. (Remember to clean out the buckets if algae and/or debris are visible.) Check to make sure your waste bucket is empty.

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SET UP & START UP PROCEDURE

Checking the Coating Fountain height

To adjust coating height:

Press MACHINE SET-UP.

Press COATING ON/OFF. Adjust flow height to top of coating bowl using “Coating Pump” pot.

~Clockwise to increase.~Counter Clockwise to decrease.

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SET-UP & START UP PROCEDURES

How to check if a lens is dry before production.

Chuck up a lens on the suction cup located over the wash bowl in the Single Lens or Two Lens Cycle.

Allow the lens to wash and dry.

As soon as the spindles start to come up, press CYCLE STOP.

Un-chuck the lens using the Foot Pedal and ensure the back side of the lens is dry.

*If there is moisture on the backside of the lens, refer to “Priming Your High Pressure Wash” page and ensure your Wash Tip and Screen are free from debris and that the Air Jet Nozzle is correctly aligned.

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SET-UP & START UP PROCEDURES

Adding coating fluid to reservoir

When coating needs to be added, pour the coating directly into the coating bowl. There is no need to wait for the coating to mix. Ensure there are no air bubbles in the coating filter before starting production.

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SET-UP & START UP PROCEDURES

Verifying positive air flow

Using a tissue, hold it above the window opening. If the tissue flows outward at a 45 degree angle or more, the flow is good. If the tissue flows inward, the Hepa Filter needs to be adjusted higher.

To adjust the Hepa Filter, turn the knob located on the upper right side of the Hepa Filter unit.

~ Counter Clockwise to increase

~Clockwise to decrease

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PROCEDURES FOR COATING A LENS

Cleaning your lens before placing it in the Ultra RX

Holding the lens concave side up, trying to keep your fingers only on the edges, squirt a dime size amount of IPA on the backside.

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PROCEDURES FOR COATING A LENS

Cleaning your lens before placing it in the Ultra RX

Swirl the IPA around the lens starting in the center and moving to the outside edge.

Holding the lens in a vertical position, rinse the lens off into a waste container. This will ensure the lens is as clean as possible.

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PROCEDURES FOR COATING A SINGLE LENS

Single Lens Cycle

Press SINGLE. Press ON/OFF button on Touch Pad. Chuck the lens on the suction cup located above the wash bowl.

The machine will run the lens through the entire cycle. When the lens comes back over the wash station, the lens will be completed.

Press the foot pedal, this will release the lens.

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PROCEDURES FOR COATINGTWO LENSES

Two Lens Cycle

Press TWO LENS. Press ON/OFF button on the Touch Pad. Chuck the first lens on the suction cup above the wash bowl. When the second spindle is over the wash station, chuck the next lens on the suction cup over the wash bowl.

Reach into the machine

and hold onto both lenses (One above the wash bowl, and one located above the Coating bowl) Press the foot pedal, this will release BOTH lenses at the same time.

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Coating Cover Cycle

When the machine is not being used for 90 seconds or more, the coating cover cycle activates and covers the coating and wash bowls.

Coating cover cycle will not activate in the machine set-up screen.

This is done to prevent coating from curing and prevent contaminants from entering the coating bowl.

Press Resume to continue production.

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PREVENTATIVE MAINTENANCE Daily

Daily Duties Include

Wipe wash bowl and deck area with IPA and a clean damp cloth.

Wipe out inside of Coating Bowl with a lint free rag slightly dampened with Acetone or IPA.

Clean Coating Bowl screen.

Check the level of deionized or Distilled water, refill as needed. Empty waste water pail.

Check coating level in reservoir, refill as needed.

Check coating fountain height, level should be even with top edge of coating bowl.

Check lamp hours (Replace at 1,000 hours).

Check that the lens is dry after wash and air-dry cycle (Check by pushing CYCLE STOP after air jet turns off).

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PREVENTATIVE MAINTENANCE Weekly & Monthly

Weekly Duties Include Visual check suction cups for deterioration replace as necessary.

Check spindle speeds: Coating speed 400 RPMCoat spin off speed 2000 RPMWash speed 1800 RPM

Check that the lamp cycle time is at 16 seconds.

Check regulator PSI @ 80

Wipe clean water bucket with IPA

Clean out top Hepa unit and replace top Pre-Filter as needed using a 10x10x2 furnace filter.

Check vacuum pressure using the digital Convum gauge located on the right side door.

Inspect complete vacuum chuck assembly for any dried coating and/or debris. Clean as needed.

Check Air Drier Filter gauge and filters. Replace all three if needle points to “Change” or if filters are moist/dirty, or every 6 months.

PREVENTATIVE MAINTENANCEWEEKLY & MONTHLY

CONT.

Monthly Duties Include

Every 6-8 weeks replace Meissner filters in both coating system and clean water bucket.

Check Capacitor to make sure it is reading 20uf or higher.

Check positive air flow. Using a kimwipe or similar, hold it up to Ultra Optics logo to see the positive air flow. Adjust if needed.

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Semi -Annual Duties Include

Replace all 3 air drier filter packs (P/N 1428).

Replace Air jet filter cartridge (if applicable).

Yearly check or replace Hepa filter (P/N 1469).

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TROUBLE SHOOTING

Figure 1: Wagon wheel effect may be caused from the coating fountain height. The coating fountain should be even with the top edge of the top of the bowl.

Figure 2: One or two streaks across the lens may be caused from air in the coating filter. While pump is running, crack the bleed valve on the Meissner Filter ¼ turn. This will allow the air to escape.

Figure 3: Tiny pits that appear to have indented the lens. If these pits are always in the same position check to ensure spindle is spinning at the correct speeds and or even spinning at all. The indentations may be caused from the wash tip always returning to the same position on the lens while spindle is not spinning.

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TROUBLE SHOOTING

Figure 4: Pits on the outer edge of the lens and or in clumps may be caused by either the Air jet pressure, dirty wash tip or poor prime on the wash pump. Clean tip, run wash pump prime for 30 seconds to purge out air bubbles. If problems still exists adjust the air flow from air jet nozzle. Make sure lens is dry after wash and dry cycle are completed.

Figure 5: Large pits with runs behind streak: if you can feel the pit with your finger it is most likely debris on the lens. Check your cleaning procedures, ensure wash tip is free and clear of debris.

Figure 6: Glob of coating left on the center of the lens; maybe caused from spindle not spinning. Check for loose wires on spindle motor. Check and or replace bearings in vacuum chuck assembly.

ULTRA RX LENS RETRIEVAL FROM UV LIGHT MODULE

1) Detach remaining lenses off the suction cups.

2) Turn off the power to the machine and disconnect power cord from electrical outlet.

3) With the power off and disconnected from the outlet, open the lamp doors of the Ultra RX.

4) Remove the two pan head screws that hold the UV Light in the carriage.

5) After screws are removed, pull the UV Light Module out of the carriage.

6) Allow UV Light to cool for 15 minutes or until it reaches room temperature.

7) Remove the lens from the lamp area.

8) Check for lens debris on lamp module and if clear then return UV Light to carriage and return to machine operations. If lens debris or burning is present and cannot be removed, replace UV Light Module with a new one and return to machine operations.

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DEFLECTOR CUP ASSEMBLY

1. Chuck Assembly

2. Deflector Cup

3. Retaining Ring

4. Clear Cleated Suction Cup

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ULTRA RX POCKET-TACHINSTRUCTIONS

PreparationTo prepare the rubber chuck for non-contact

measurement of speed, carefully clean an area on the deflector cup of all grease and dirt. Apply approximately a 1/8 inch piece of reflective tape to the deflector cup. Always use the T-5 reflective tape supplies

AimingThe ergonomic design of the Pocket-Tach makes the

non-contact measurement of speed extremely simple. Aim Pocket-Tach at the reflective target using the sight bars on the top surface on the instrument as an aid in locating the target. A visible light projects from the underside of the Pocket-Tach parallel to the top surface and in line with the sight bars. This design allows you to view the target on the rotating shaft and the display on the instrument simultaneously.

MeasuringTo measure, press and hold the power button on the

front panel and aim the instrument at the reflective tape on the deflector cup until a steady illumination of the “bulls eye” symbol in the instruments display indicates you are on target. Once a measurement is completed, released the power button while still viewing the target. Pocket-Tach will continue to display the last reading for approximately 90 seconds and then automatically shut off.

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FLUSHING COATING SYSTEM INSTRUCTIONS

Go into Machine Set-up screen.

Disconnect the nut on the nylon straight fitting attached to the stainless elbow at the bottom of your reservoir. Point nut and tubing from the filter into a clean container. Press coating ON/OFF button and the coating will pump out of the tubing into the clean container. When the reservoir is empty, press Coating ON/OFF button to turn off coating pump.

If the coating is contaminated, it may be necessary to flush system with Acetone. With the tubing disconnected from the bottom of the reservoir, pour Acetone into the Coating Bowl as you would with coating.

**DO NOT RUN ACETONE THROUGH NEW COATING FILTER. SIMPLY FLUSH INTO

WASTE CONTAINER.**

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COATING FLUSHING INSTRUCTIONS

continued

Follow the other black tube from the pump up to the coating reservoir and disconnect. Both coating tubes should now be free.

The coating reservoir can now be unscrewed and removed from the coating bowl for easy cleaning.

Once the coating reservoir is out of the machine flush it out using Acetone and allow to dry. Ensure any debris in the coating reservoir has been removed. Flush again if not. Unscrew elbow from coating filter and save. Unscrew and discard coating filter. Wipe out coating bowl using a clean lint free towel. A coating bowl screen sits on the bottom on the bowl make sure it has been cleaned before reassembling.

Reassemble and either put new coating in or reuse your old coating if it has not been contaminated. Re-prime the system and release any air in the coating filter using the “bleeder” cap. Make sure to use Teflon tape on the new coating filter before reattaching the fittings.

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OPERTION TIPS

Priming the High pressure pump

To prime high pressure pump:

Press MACHINE SET-UP.

Press VACUUM.

Chuck lens on spindle over wash bowl.

Press WASH PRIME then DUMP VALVE allow to prime for 45 seconds.

Press DUMP VALVE again to close to ensure constant beat (like a heartbeat).

If wash prime has not been achieved, allow to run with Dump Valve open for another 45 seconds.

After your wash is primed, press DUMP VALVE again and allow to run for 20 seconds. It is important to press WASH PRIME FIRST and then DUMP VALVE LAST when you are finished priming. Following these steps will help keep air out of the system.

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OPERATION TIPS

To ensure lens is dry before it is coated:

Press PRODUCTION CYCLEPress OFF/ONPrepare lens and chuck on spindle over wash bowl. Allow to wash and dry. When spindles start to come up press CYCLE STOP. Release lens and ensure backside is dry. If not dry, ensure wash tip and screen is clean and free of debris and that Air Jet is correctly aligned and is set to correct pressure. Then repeat priming high pressure wash.

To replace Coating Filter:

Disconnect the nut on the elbow at the bottom of your reservoir. Point nut and tubing from the filter into a clean container. Press coating ON/OFF button and the coating will flow out of the tubing into the clean container. When the reservoir is empty, press coating ON/OFF button to turn off coating pump. Disconnect the nut on the elbow at the bottom of your coating filter. Remove both elbows from the old coating filter and save. Discard old filter.

Place Teflon tape on the new coating filter before reassembling. Pour coating back into coating bowl chamber and re-prime system.To release trapped air during priming, turn “bleeder” cap ¼ of a turn, this will allow air to escape. Always keep ahold of cap to ensure that pressure from priming does not blow cap off.