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2G Manual 3-14-06 - National Optronics resources center

1. NATIONAL 5 E N TE INCORPORATED 2G SCREEN FLOWCHART SOFTWARE VERSION 3 29 Center Removal Press READY to Load Data enter removal edge removal curve in diopters None Last Enter Blank Front in Diopters s READY to enter menu Lens Material Screen P to exit arriage Limits 1 1 1 1 1 SPINAL Y to enter menu pphack2 nnected None and close lid Host 9600 OMA Barcode Comm Software totor Other Counters Interrupt Events Ax Setup from Floppy READY to Continue Chapter 4 Setting Up the 2G 4 3 4 4 Calibration Screen This screen contains values for the Axis Bias Thickness Bias Lens Curve Bias Lap Curve Bias Lens Range Correction and Lap Range Correction See Chapter 5 Calibration for more a more detailed discussion of how to set the following values This screen can be accessed from the Setup Screen by moving the cursor to the Calibration Screen line and pressing the READY key Figure 2 illustrates the layout of the Calibration Screen followed by an outline of each entry Calibration Screen Press SET UP to Exit Calibrate Axis READY Calibrate Thickness READY Calibrate Lens Curve READY Calibrate Lens Curve Carbide READY Axis Bias Thickness Bias Lens Curve Bias Lap Curve Bias Lap Holder Thickness Lenses 6 00D Correction 1 00D Correction 12 00D Correction Laps 6 00D Co
2. Servo Motors AXIS DEPTH RADIUS Position 0 0 Home No No Z O Start Switch Off Start Lamp Off Emergency Loop No Keypad Serial Loopbackl Serial Loopback2 gt Arcnet Connected Yes Special Options Press 09 for Servo Diagnostics Figure 4 Diagnostic Screen This screen will initiate a continuing series of steps to check the functioning of the various electronic controls and sensing devices in the machine Axis Depth Radius The Axis Depth and Radius Carriages are static This allows the operator to move the carriages and check for varying position rate speed and home switch operation The corresponding home switch should indicate YES when the operator moves any carriage into its home position and NO when the carriage is away from its home position The number of the counts is relatively unimportant but the count should move smoothly when a coupler is rotated without any large jumps These can be jogged by pressing 0 then 9 and following the instructions Start Switch This should say ON when the green start switch is depressed otherwise it should read OFF Chapter 4 Setting Up the 2G 4 13 4 14 Start Lamp The reading here should correlate with the start switch lamp Emergency Loop This field will display the state of the Emergency loop This will read Yes when the lid is down the Chuck is pressed and the STOP is released Keypad
3. Setup numbers are invalid Please verify and correct This indicates that a value entered in one of the Setup Screens is out of range C 2 Communication Errors LAN Hardware Failure gt ARCNet hardware failure No reconfigurations were detected Normally when a machine joins a network it causes a network reconfigurations so it will be included in the network If no reconfiguration is detected then the Server Down 1 message is displayed A possible cause of this condition is the ARCNet Hybrid driver located on the controller board no responding to the ARCNet controller chip A defective hybrid driver chip or the power supply s 12 Volt could cause this problem Duplicate LAN ID Duplicate ID Detected If changing the ID doesn t fix this problem then there may be a hardware failure with the ARCNet controller LAN Receive Error Code mismatch Wrong information was received from what seemed the correct source Scrambled data in the ARCNet packet Try downloading again If the problem persists then there may be a hardware failure LAN Receive Error If a packet was received from a node ID that doesn t math the one contained in the packet then this error Occurs LAN Transmit Timeout Transmit packet failure This is caused by an ARCNet packet time out This indicates that the Server could not be reached LAN Receive Timeout Receive packet failure This is caused by an AR
4. Accessories Cutters 93743 6 Flute Carbide Cutter 93761 Polycrystalline Diamond Cutter Collet Assembly 9017 Collet Insert Assembly 2145 Collet Locating Pin 2030 Collet Adapter Plate 9018 Collet Insert Assembly LOH The 2G Generator User s Manual June 23 2005 Appendix Control Panel amp Monitor Descriptions A Control Panels There are two front control panels on the 2G the right side and the left side see Figure 1 CHUCK E STOP START i 4 NA l 000000 000000 F D E B A Figure 1 Control Panels Right Side panel A On Off Switch with Internal Circuit Breaker This switch controls line power to the generator and vacuum It contains an integral 20 amp resettable circuit breaker for overload protection Start Button Green This button begins the generating cycle Stop Button Red This is a Panic Button Pressing this button at any time will abort the cycle and return the carriages to their start positions Left Side panel D Cumulative Cycle Counter The first counter will register the total number of cycles on the generator It should initially read 20 100 cycles as the generator was tested prior to shipment This counter will count the total number of lenses generated NOT the number of jobs A 1 A 2 Keypad Monitor SLE E Resettable Cycle Counter The next cycle counter is resettable simila
5. 2 Loose connection on the interface board Check the wire connections on the interface board mounted on the back of the keypad under the keypad cover 3 Contrast control malfunction Contact the factory for service Invalid Value message appears at the bottom of screen Job Entry Screen data must fall within certain parameters for each entry An Invalid Value message at the bottom of the screen indicates that one or more of the entries are outside of these parameters The cursor will move to the entry in question Cross Curve 1 Incorrect Cross Curve entry The entry for the lens Cross Curve must be equal to or of a greater minus value than the Base Curve 2 Incorrect Blade Radius entry Ensure the Set Up Screen entry for Blade Radius is set in accordance with the tool being used Center Thickness 1 Incorrect Center Thickness entry The entry for Center Thickness must be greater than 1 0 mm There is no provision for entering the decimal point on the keypad the decimal point is an automatic entry Therefore if a center thickness of 2 0 mm is desired a 2 would be entered followed by a 0 2 Incorrect lens blank data The 2G s software uses the entries in the lens blank data area to determine if the requested center thickness can be obtained An entry error in the lens blank data can result in a correct Center Thickness entry as being deemed invalid Edge Thickness Incorrect Edge Thickness entry This is the edge t
6. Sep Feed For Bck PBW Ring 158 4 6 66 1 538 5 1 66 1 538 1 66 1 538 1 66 1 538 1 66 1 538 1 66 1 538 1 66 1 538 1 66 1 538 1 66 1 538 1 66 1 538 Trivex 6 1 5 5 1 5 5 5 5 5 5 5 5 5 5 5 5 5 Press for next screen name Final Pass is Skim Cut name Gentle Entry into Lens name Variable Spiral Separation Spiral Sep For Forvard Crib Feed Rate Bck Backward Crib PBW Pin Bev Width Ring Ring Index CLEAR to modify name For This is the maximum number of millimeters the 2G can crib while moving forward into the lens Bck This is the maximum number of millimeters that the 2G will go for each pass while moving backwards PBW This is width in mm of the Pin Bevel Ring Index This is the index of refraction on which the Rx computer prism calculations are based It should be set to the same index upon which your prism rings are based if you are using rings for other generators and should be in agreement with the ring index in the Rx calculation software Note Ring Index is for calculation only it is not recommended to use prism rings with the 2G Generator 4 10 The 2G Generator User s Manual June 23 2005 Lap Material Screen This screen allows the adjustment of the cutting parameters including Spiral Separation Feed Rate Takeoff Pad Thickness Skim Cut and Tool Index for various materials Lap Material Screen Press SET UP to exit Sep FR Sep FR TO PT
7. spiral separation feed rate and takeoff Cycle times too long 1 Incorrect Lens Material Screen settings Verify that the Lens Material Screen settings Spiral Separation Axis Speed Pass Depth are set to minimize cycle time for the materials to be processed See Lens Material Screen field descriptions in Chapter 4 2 Incorrect blank data Verity that the actual lens blank data for the lens being processed is being entered in the blank data area of the Job Screen 3 Incorrect End Mill Flute Length Verify that the entry for End Mill Flute Length in the Set Up Screen is correct for the cutting tool being used Use a PD stick to measure from the tip of the cutter to the end of the cutting flutes Chapter 6 Periodic Maintenance and Troubleshooting 6 9 6 10 Carriages move into cutting position however neither cutter motor nor vacuum operate Mercury Relay not functioning A Using a voltmeter verify the output voltage of the relay by attaching one lead of the meter to the white violet wire at the top of the relay and the other lead to any large white neutral wire close the case top and cycle the 2G When cycled 110 Volts AC 230 VAC where applicable should be read at the meter if so check the white violet output wires for breaks Check the input voltage by attaching one meter lead to the red wire at the base of the relay and the other lead to any large white neutral wire 110 Volts AC 230 VAC where applicable should be
8. steps 1 through 7 Note It should crib on all sides If it does not repeat steps 1 through 7 with a smaller diameter Chapter 5 Calibration 5 3 Verify the Lens Curve Bias Setting 1 2 4 Change the 6 00D Correction to a setting of 0 00 In the Calibration Screen select the Cut Test Lens option Cut a 6 00D sphere curve on the back of a lens When the cycle is complete the unit will return to the Calibration Screen Using a sag gauge measure the curve for variances from center to within 5 mm of the edge If the curve varies from center to edge change the Lens Curve Bias setting to correct any inconsistencies If the lens measures flatter in the center make the Lens Curve Bias setting more positive to remove the high spot If the lens measures steeper in the center make the Lens Curve Bias setting more negative to remove the low spot Initial adjustments should be made in increments of 0 02 mm If the 2G will be utilized for lap cutting the following procedure should be followed to ensure accurate plus curves Lap Curve Bias The Lap Curve Bias Correction creates an offset to the Lens Curve Bias to produce accurate laps as well as lenses 3 In the Calibration Screen select the Cut Test Lap option At the Lap Screen cut a 6 00D sphere lap When the cycle is complete the unit will return to the Calibration Screen Using a sag gauge measure the curve for variances from center out If t
9. 20 Volts DC adjust according to the instructions on Page 15 B If voltage is greater than 20 Volts DC by a margin of more than 10 i e 22 Volts DC damage to the driver chips may have occurred If voltage cannot be adjusted to within acceptable limits replacement of the power supply is required Excessively high voltages may cause damage to the processor board in which case replacement of the Electronics Enclosure may be necessary Checking and Adjusting Voltages Extreme care should be exercised when checking and adjusting voltages 115 VOLTS AC 230 VAC where applicable is present at the transformer Remove all jewelry and use insulated tools and test equipment DO NOT LET HANDS COME INTO CONTACT WITH ELECTRICAL COMPONENTS For accuracy it is recommended that a good quality digital voltmeter be used for measuring voltages The 2G Generator User s Manual June 23 2005 Preparation 1 Switch the power to the OFF position 2 Remove the electronics enclosure cover 3 Inspect the wires within the electronics enclosure for breaks and loose connections 4 Close the case top 5 Switch the power to the ON position Checking and Adjusting the 5 Volt DC Processor Voltage I 2 Locate the 5 Volt DC test points Ensure that the meter is set to the DC voltage scale and place the red meter lead on the red wire and the black meter lead on the black wire on the back plane Read the voltage from the meter when proper
10. Block Diameter could lead to a situation where the cutter crashes into the block which might ruin the cutter blade This parameter refers to the physical diameter of the block not the Sag diameter 2 Press the READY key to orient the collet so that you can mount the lens 3 Properly mount the lens Refer to the Mounting the Lens Blank section of Chapter 3 Generating a Lens for directions on mounting the lens 4 Close the 2G s lid 5 Press the Start button 6 After removing the lens move the cursor down to the Cut Matching Lap field and press Ready key to begin the process of cutting a lap Refer to the Lap Cutting section of Chapter 3 Generating a Test Lens for information about this part of the process Job Screen Input of data on the Job Screen is required for each lens to be generated The Job Screen will display two jobs The job on the right hand side is either the one currently being generated or the job that has just finished The job on the left hand side is the next lens to be run The data for the next job can be entered while the machine is running A representation of the Job Screen is shown below Job Screen Job Number Next Base Curve 0 000 Cross Curve 0 000 Center Thickness 0 0 Crib Diameter Off Pin Bevel Off Layout Axis Prism Prism Axis Prism Direction Blank Data Front Curve Back Curve Edge Thickness Diameter Material Block Diameter Cut Matc
11. Cycle will not start switches and servo encoders Check Electronics Enclosure indicator lights Check power supply fuses Carriages stop mid cycle Verify that servo encoders and home switches operate properly i Check line voltage Verify that unit is on a dedicated circuit Check board Unit resets mid cycle voltages and power supply fuses Check mercury switch position Check Lens Cuve Bias setting Check Compensation Radius 6 00D Curves incorrect setting Check Curve Correction 1 00D and 12 00D values Clean and check home switches Verify that servo encoders count properly Clean support rods and lead screws Check Depth Bias setting Check Block Diameter for Sag setting Verify Thickness incorrect that Front Curve value is accurate Clean support rods and lead screws se fe Check Axis Bias setting Clean and check axis home switch Check axis Axis incorrect servo encoder Before taking lens measurements the Spiral Separation for CR 39 should be changed to a setting of 0 63 this will provide a smoother surface for measuring with a gauge Alternatively all lenses generated during testing could be run on the POLY setting Once measurements are satisfactory a lap to lens curve comparison should be made This is performed by cutting a test lens and fining for approximately 15 seconds after which the lens is examined to ensure it is being fined consistently throughout its entire surface If not minor calibration adjustm
12. SC Tool other 1 00 60 1 20 100 6 0 46 Y 1 530 Coburn 1 00 60 1 20 100 6 0 46 Y 1 530 DAC 1 00 60 1 20 100 6 0 46 Y 1 530 OWC 1 00 601 20 100 6 0 46 Y 1 530 PSI 1 00 60 1 20 100 6 0 46 Y 1 530 Salem 1 00 60 1 20 100 60 46 Y 1 530 GCFoam 1 25 150 2 50 200 17 0 46 N 1 530 PSISnap 1 25 150 2 50 200 17 0 46 N 1 530 Sep Spiral Sep PT Pad Thickness FR Feed Rate SC Skim Cut TO Pass Takeoff Tool Tool Index Sep Finish amp Rough This parameter determines the distance between each sequential circular sweep of the tool as it moves across the lap during the cutting pattern The smaller the spiral separation the smoother the surface finish Reducing the spiral separation though will increase the cycle time as the cutter requires more time to sweep the lap Also the increased time that the cutter is in contact with the lap can cause premature wear of the cutter The boundaries of this parameter are 0 32 mm to 2 54 mm Feed Rate This parameter controls the lap feed rate which in turn defines the surface cutting speed of the cutter The larger the feed rate the faster the cycle time Increasing feed beyond the cutter s ability to cleanly remove material though could result in an unacceptable finish This should be set taking into account both surface finish and the cycle time The boundaries of this parameter are 1 mm sec to 200 mm sec Note The feed rate is the most important setting that affects cycle time and thus should be max
13. This field will indicate the last key or button pressed The number keys are indicated as numbers and the other key are denoted as follows SETUP s plus minus p READY r 7 up arrow u CLEAR c down arrow d Serial Loopback The continually changing series of letters numbers and symbols indicates what 1s being sent out of the serial ports The serial ports can be tested by placing a jumper across pins 2 amp 3 of the serial port connection on the back of the 2G for COMI For COM2 place a jumper across pins 1 amp 14 of the serial port connection on the back of the 2G If the serial port is working properly the display should change from a single character to the same character being printed twice For example the display should change from A B C to AA BB CC if the serial port is working properly ARCNet Connected This will indicated whether or not the 2G is connected to a network If this reads NO but the 2G is physically connected to a network it indicates a problem with the network Possible causes are a bad co axial coax cable or a duplicate LAN ID or no Arcnet card present To exit the Diagnostic Screen press the SET UP key IF THE UNIT WILL NOT BOOT UP The operator may get to this screen by pressing and holding down the any key while turning the machine on The machine will go directly to this screen without going through the usual boot up procedures The 2G Generator User s Manual Ju
14. any of these additional screens move the cursor using lt gt or lt d gt to the line which denotes the screen you want to access and press the READY key The flowchart on the following page is provided for easy reference and clarification of the various screens The second section of the Setup Screen contains data pertinent to the proper operation and calibration of the 2G Once set changes to this section should rarely if ever need to be made Setup Screen Field Descriptions 4 2 Block Brand Select the type of blocking system being used To change the value in this field press the key to scroll through the list of common block types Any changes to this value may also change the Block Diameter for Sag and Block Thickness values Block Diameter for Sag This is the diameter in mm of the surface blocks or blocking ring being used This information is only used in calculating center thickness The accuracy or this value is critical for obtaining accurate center thickness The allowable range of this parameter is 25 to 75 mm The factory default value is 50 mm The follow table shows common B ock Diameter for Sag values Brand Block Diameter for Sag Coburn 50 PSI 50 Optek 58 may vary Others Contact Factory Blade Radius This is the blade radius of the tool being used It is changed only during calibration if a different size cutting tool is installed For the Y diameter carbide cutting tool the setting is 6 350
15. be measured across the white and red wires on the input side of the transformer Ensure the meter is set to the AC voltage scale and place one lead on the red wire and the other lead on the white wire The meter should read approximately 115 volts AC 230 VAC where applicable 24 Volt AC 4 AMP Output The 24 volt 4 amp supply voltage can be measured across the violet and the white violet wires Ensure the meter is set to the AC voltage scale and place one meter lead on the violet wire and the other lead on the white violet wire The meter should read 24 volts AC 10 volts AC 8 Volt AC Output The 8 volt supply voltage can be measured across the red and blue Ensure the meter is set to the AC voltage scale and place one meter lead on the red wire and the other lead on the blue wire The meter should read 8 volts AC 10 volt AC 24 Volt AC 0 2 AMP Output The 24 volt 0 2 amp supply voltage can be measured across the orange and white orange wires Ensure the meter is set to the AC voltage scale and place one meter lead on the orange wire and the other meter lead on the white orange wire The meter should read 24 volts AC 10 volts AC The 2G Generator User s Manual June 23 2005 Parts Replacement Replacing the Cutter Motor 1 2 Switch the POWER to the 2G to the OFF position Remove the cutting tool from the motor Unplug the motor s power connection Remove the three screws securing the chip chute
16. be rounded using the same method explained above under the description of Base Curve Prism Axis Enter the orientation of the prism power in degrees referenced from the layout 0 180 axis The 2G Generator User s Manual June 23 2005 Prism Direction This is used in conjunction with the prism axis to determine the direction of prism This parameter is used for labs using a 0 180 degree up and down notation Labs using a 0 360 degree notation will always leave this parameter UP The next 5 data fields describe the physical characteristics of the lens blank being used These parameters allow the machine to calculate the number of passes required for efficient material removal and the distance the cutter should sweep in order to completely cover the lens face Front Curve Enter the blank s true front curve in diopters Two decimal place values are required in this field For example to enter a front curve of 6 12 diopters enter the sequence 6 1 2 The front curve must be between 30 00 and 430 00 diopters This value will NOT be rounded It is very important that this number be accurate since any error will cause an error in the center thickness Back Curve Enter the back curve in diopters In this field two decimal places are required For example to enter a back curve of 6 25 enter the sequence 6 2 5 The back curve must be between 30 00 and 30 00 diopters This value will NOT be rounded Edge Thickness Ente
17. diopters The entry must be between 6 00 and 30 00 diopters This field requires the entry of two decimal place values For example to enter a curve of 6 125 enter the sequence 6 1 2 or to enter a curve of 6 00 enter the sequence 6 0 0 See the note below on how this number is rounded Note This value will be rounded to the either nearest eighth of a diopter ex 0 125 0 250 or the nearest sixteenth of a diopter ex 0 0625 0 1875 Ifa value is entered in tenths ex 0 10 0 20 the value will be left as entered Since only two decimal places may be entered to enter 6 1875 enter the sequence 6 1 8 To enter a diopter value of 6 20 enter the sequence 6 2 0 Cross Curve Enter the desired cross curve in diopters The entry must be between 6 00 and 30 00 diopters and must have greater curvature than the base curve For more information refer to the Saddle Back Lenses section of Appendix D Specialty Lenses The above note on rounding will also apply to the cross curve Chapter 2 Entering a Job 2 3 2 4 Center Thickness Enter the final center thickness before fining and polishing in millimeters One decimal place value must be entered in this field For example to enter a center thickness of 2 5 enter the sequence 2 5 or to enter 2 0 enter 2 0 Crib Diameter Enter the desired crib diameter in millimeters A value of 0 in this field will set crib diameter to Off Val
18. in software versions 2 55 and 3 15 The fields are similar to those found on the NOP 6E and 4T For more details refer to the end of Chapter 4 In Version 3 29 there are also changes on the both Lens Material Screens formerly called the Blank Materials Screens as well as a new screen the Lap Material Screen In the 3 291 edition of the manual was released with Software Version 3 29 Future software upgrades do not necessarily affect the manual Call Technical Support 434 295 9126 if you feel you need a newer manual This edition of the manual 3 292 includes a General Specifications section in Chapter 1 Related Publications The Optronics 4T User s Manual The Optronics 6E User s Manual iii Preface Chapter 1 Chapter 2 Chapter 3 Contents Before You Beet ocn eiii yer trt A El Before You Begin iue eerie eed i e AA I rede e uie tet showed feeds 1 1 For Further ASsistanCe cidade 1 1 To Ord r ARE EE EE EE EE EE 1 1 For Technical Assistance 5 GER VEG GER GEES Ge GER Tee E e Ges ee ee ek ed 1 2 R quirements Tor Use o gir Pergit EE E E Ai 1 2 115 VAC 60 Hz 20A Electrical Supply iese ese se see ee ee ee ae ee ee GR ee GR ee Ge ee ee ee ee ee ee ee 1 2 Operating Conditions sse eere ener nnne 1 2 General Specifications sse GR AR enne TE nnne 1 3 Dimensions eo Ree RR RAE D RU e ARR e DB 1 3 enr EE EE EE EE ER OE N N 1 3 Cutter Motor AE ER tarta GE EE N EE antri hes
19. is used in the case of a very high minus prescription This procedure is done to create a more cosmetically appealing lens to simplify fitting into the frame and to prevent the lens from contacting the patient s face When lenses of a very high minus power are produced usually the curves required are of a lesser diameter then the lens blank Due to this the unfinished portion of the lens will be 14 to 18 millimeter in thickness The following outlines the procedure for producing a myodisc e Using your Rx calculation software determine the correct curves for power Block and generate the necessary curves Do not complete the fining and polishing at this time e Determine the secondary curve that will produce the desired edge thickness e Generate the secondary curve on the lens If a minus lens is used for this purpose care should be taken to not destroy the curves required to obtain the proper power e Fine and polish the secondary curve before the power curves This will ensure that the finished power curves are not damaged during the fining and polishing process e Care must be taken during the fining and polishing process not to mar the finished surfaces or to tear the fine and polish pads Off Center Blocking Progressive Saddle Back Although this method of blocking is not recommended certain precautions must be taken when attempting to cut a lens using a method of blocking which places the block in a location different tha
20. lens on the concave surface as indicated by the Job ticket Enter the surfacing data into the 2G as usual No other adjustment are needed assuming that the following data is entered correctly e The Block Diameter for Sag corresponds to the outside diameter of the block or fiber ring e The Front Curve is set to the correct minus value e The Back Curve is set to the correct plus value e The Block Diameter on the Job Screen corresponds with the Block Diameter for Sag Two main factor must be considered when cutting lenticulars 1 The type of blocking system 2 The Rx calculation software D 2 Because of multiple combinations of the above factors the following guidelines will only cover precautions to take to prevent inaccuracies e Ensure that the Ry calculation software is properly setup for the type of surfacing blocks being used e Verify that accurate data regarding bowl diameter and carrier base is entered into the Rx calculation computer e Determine the appropriate Front Curve entry on the Job Screen This should be between the true curve of the bowl or carrier This value is critical for accurate center thickness e Enter the data from the job ticket as indicated There should be no need to make any adjustments to the center thickness The 2G Generator User s Manual June 23 2005 Myodisc Myodisc lenses are produced by cutting two independent sets of curves on the back of the lens This type of lens
21. mm For diamond cutters refer to the accompanying tag usually this value will be around 10 000 mm End Mill Flute Length This is the length of the cutting surface on the cutting tool For the standard diameter carbide endmill cutter the setting is 26 mm for a 6 fluted carbide ball 17 mm and an extended flute diamond cutter is 22 mm If in doubt measure the flute length from the tip to the very back of the cutting flute Prism Arrow Location By individual lab preference either the apex or the base direction of the prism arrow is marked during surface layout This entry allows a lab to configure the generator to its particular convention Utilizing this parameter the generator will automatically orient the collet for the labs method of marking prism Three choices are valid in this field Base Apex and None With Base the prism base will always be up With Apex selected the prism apex will always be up With None selected the bifocal will always be down which eliminates the need to mark lenses The 2G Generator User s Manual June 23 2005 Default Pin Bevel This sets the Pin Bevel field on the Job Screen default to On Off or the same as the value for the last job The default can be overridden by a host computer or the operator Screen Flowchart Refer to the screen flowchart on the following page for an overview of the different patterns of screen access when using the 2G software
22. on the final pass The units are in millimeters It is used during calibration to set center thickness Lens Curve Bias This is initially set using the Calibrate Lens Curve It controls the relative position of the lens drive table to the depth carriage This aligns the cutter blade with the center of the lens The units are in millimeters Lap Curve Bias This is a corrective offset to the Lens Curve Bias used to ensure true curves when cutting laps Lap Holder Thickness This is the thickness of the lap holder used to ensure accurate stock removal when cutting laps This number will always be a positive number 6 00D Correction This is used to adjust the curves for accuracy at 6 00D the approximate mid point for the most commonly cut lenses 6 00D Correction This is used to adjust the curves for accuracy at 6 00D the approximate mid point for the most commonly cut laps Range Calibration The curves can also be adjusted at 1 00D and 12 00D if the operator needs to compensate at these extremes See Adjusting the Curves in Chapter 5 Calibration for proper calibration techniques The units are in millimeters Note Range Calibration is optional and may not be necessary to adjust for proper operation Many operators will find that the 6 00D Correction and 6 00D Correction will bring in all curves with sufficient accuracy A negative number will produce a steeper curve and a positive value will
23. present as soon as power is switched on it is not necessary to cycle the 2G to check input power if no voltage is present check the red wire for breaks If input voltage is present check the DC trigger voltage to the relay by attaching one meter lead to the orange wire at the base of the relay the other meter lead to the white orange wire also at the base of the relay close the case top and cycle the 2G When cycled 18 Volts DC should be read at the meter If no voltage is present check both wires for breaks and loose connectors If both input and trigger voltages are present and no output voltage is measured replacement of the mercury relay is required The 2G Generator User s Manual June 23 2005 Cutter Motor Motor does not run Cutter motor mercury switch malfunction The cutter motor mercury switch is located inside the case top secured to the right hand side near the wiring harness A Ensure the switch is tied securely to the inside of the case and is parallel with the case top B Inspect the switch leads for breaks and make sure the connector is firmly in place C Verify the switch operation by unplugging the switches amp style connector and placing a jumper wire across its wiring harness receptacle If the motor runs when the 2G is cycled replacement of the mercury switch is required Note Bypassing the mercury switch 1s performed solely for diagnostic purposes and is NOT intended for operation SERIOUS INJURY cou
24. used by cutting an opening for the vacuum hose and power cord per Figure 2 REAR OF BENCH 28 INCHES 30 INCHES MIN GENERATOR BASE PLATE 10 INCHES 7 INCHES BENCH 3 INCHES FRONT OF BENCH Figure 2 Work Bench Cutout 3 Unpacking the Generator and Vacuum Remove the generator from its wooden shipping pallet by removing the two bolts found on the pallet s underside with a 13 16 box wrench Remove the vacuum unit from its carton Remove the accessories from the inside of the canister and install the large vacuum bag Place the vacuum under the workbench aligning its inlet with the bench opening Feed the vacuum power cord through the bench opening and lay it towards the rear of the bench as 1t will be plugged into the rear of the generator Turn the power switch on the vacuum to the ON position as its cycling is automatically controlled by the 2G Place the generator on the bench cabinet aligning the vacuum coupler on the underside of the generator with the right side of the bench opening Chapter 1 Before You Begin 1 5 1 6 4 Removal of Shipping Bolts The cutter motor carriage and the lens drive carriage are secured for shipping To release the lens drive carriage remove the shipping bracket that is bolted to the base and the carriage plate To release the cutter motor carriage remove the bolt in the block on the right side of the carriage After removing the bol
25. with the Curve Corrections a Bring a 6 00 lap to the proper sag with the 6 00D Correction adjustment to 6 00D Correction if curve is steep adjustment to 6 00D Correction if curve is flat Adjust in increments of 0 010 mm and re cut 0 5 mm thinner to check b Bring a 12 00 lap to the proper sag with the 12 00D Correction adjustment if too steep adjustment if too flat c Bring a 1 00 lap to the proper sag with the 1 00D Correction adjustment if too steep adjustment if too flat The 2G Generator User s Manual June 23 2005 Appendix Error Codes C Job Data Errors Legal Range This indicates that the value entered for a field is outside the allowable range for that field The legal range of values will follow the words Legal Range Invalid Value This indicates that the job contains some invalid data A value in one or more of the fields will cause the lens to not be cut properly The cursor will return to the suspect field so that it can be re entered WARNING Blade will contact the block This message indicates that the blade will cut into the block holding the lens NOTE The 2G will still allow the lens to be cut with the entered values if this message appears WARNING Blade will be within 0 5mm of block Proceed with caution The indicates that the blade will cut to within 0 5 mm of the block NOTE A job can still be run if this warning appears
26. would be indicated by the M20VDC light NOT being illuminated on the power supply LEDs see Figure 1 below To check the fuse perform the following steps 1 2 Turn the 2G s power switch to the OFF position Remove the acorn nuts from the Electronics Enclosure and remove the cover The power supply board will be on the right hand side of the box Locate the fuse labeled F2 item 16 and remove it from the socket Using an ohmmeter test for continuity through the fuse Reversing steps through 3 either replace the blown fuse or return the good fuse into the socket labeled F2 ensuring that the pins on the fuse properly line up with the socket Note The 20 Volt LED is the Top LED which may or may not be labeled correctly on your box Figure 1 LEDs Home Switch Malfunction 1 Failure in the closed mode Open the case top and examine the carriages if one of the carriages is slowly creeping forward locate the corresponding home switch A Check the switches connector to ensure it is firmly in place B Using a soft dry cloth or the air gun supplied in the accessory kit clean the opening in the switch C If the switch still malfunctions replacement of the switch is required Failure in the open mode If the switch fails in the open mode the corresponding carriage will run past the home position and bottom out against its stop plate This can be detected by a humming of th
27. your equipment from National Optronics there is no charge for telephone support If however you purchased your Optronics equipment elsewhere you will be charged for telephone support at the rate of 47 50 per half hour If you would like to schedule an on site Technical Service visit please call Technical Support at 800 247 9796 ext 314 Please know the serial number of your machine and Customer Account Number for requesting a Technical Service visit There is no charge for warranty service visits If your machine is out of warranty there is a charge of 55 00 per hour for travel to and from the equipment location and 125 00 per hour two hour minimum for the Technician s time at the location Any additional travel expenses incurred such as airline tickets hotel rooms etc are billed to the customer The rates published above may be subject to change without notice Requirements for Use 1 2 115 VAC 60 Hz 20A Electrical Supply This is standard outlet power in the United States The Optronics 2G generator should be on a dedicated circuit no other electrical loads connected to the same circuit to ensure a uniform consistent power supply The maximum continuous power consumption of the generator including the vacuum is 14 3 amps The 2G must be properly grounded do not use any adapter that will bypass the grounding plug Power fluctuations can adversely affect production and machine integrity Please contact the factory if
28. 0 POLY 0 63 601 00 80 7 80 0 1 530 Hi Idx 1 00 60 1 00 60 9 80 0 1 530 Trivex 0 63 60 1 00 80 7 80 0 1 530 1 00 60 1 00 60 9 80 0 1 530 1 00 60 1 00 60 9 80 0 1 530 1 00 60 1 00 60 9 80 0 1 530 1 00 60 1 00 60 9 80 0 1 530 1 00 60 1 00 60 9 80 0 1 530 1 00 60 1 00 60 9 80 0 1 530 SFINAL 1 00 60 1 80 0 Press for next screen S in name Final Pass is Skim Cut in name Gentle Entry into Lens amp in name Variable Spiral Separation Sep Spiral Sep RPM Max Axis RPM Feed Feed Rate Tool Tool Index TO Pass Takeoff Figure 3 Lens Material Screen Finish and Rough The Lens Material Screen has two forms the one shown above for Finish and Rough material settings and one for Cribbing The Cribbing form is discussed after the Finish and Rough form and can be accessed by pressing the key The following is a description of each entry Chapter 4 Setting Up the 2G 4 7 4 8 Lens Material Screen Finish and Rough Material This is a description of the material being processed that is CR 39 POLY etc and will appear in the Material field on the Job Screen The first two lines are reserved for CR 39 and POLY Polycarbonate and cannot be erased but can have a suffix added The third line defaults to Hi Idx high index the fourth to Trivex but can be erased or modified The remaining lines may be customized with any names and feed rates To create a custom material place the cursor in a blank
29. 0 40 LEVEL SURFACE Figure 1 Measuring a Lap Center Removal Enter the desired amount of removal of material from the center of the lap Usually this number is small 1 2 mm This field expects one decimal place value to be entered For example for a center removal of 1 0 mm enter the sequence 1 0 This can be supplied automatically by the 2G software when you enter data in the Lap Manufacturer field and either change or accept the recommended lap type in the Lap Type field The removal measurement here may be rounded up slightly from the amount shown in the center removal field discussed below to prevent overcutting center removal and edge removal at bottom Display only fields that show the values calculated by the 2G software based on the manufacturer and type specified in the in the Lap Manufacturer and Lap Type fields Center removal is always 1 0 mm or more When the required data is entered press the READY key to load the data Place the lap into the lap holder and tighten the bolt with a small amount of pressure Overtightening can cause the lap to deform producing inaccurate curves At this point the lap is ready to be mounted inside the 2G To start cutting the lap press the START button HELPFUL HINT Should the next lap to be cut be similar to the one currently running the operator can move the cursor to the Repeat Last Lap line on the top of the screen and press the REA
30. 0 60 1 20 100 0 46 Y 1 530 00 60 1 20 100 6 0 46 Y 1 530 00 60 1 20 100 6 0 46 Y 1 530 00 60 1 20 100 6 0 46 Y 1 530 00 60 1 20 100 6 0 46 Y 1 530 00 60 1 20 100 6 0 46 Y 1 530 25 150 2 50 200 17 0 46 N 1 530 25 150 2 50 200 17 0 46 N 1 530 Spiral Sep PT Pad Thickness Feed Rate SC Skim Cut Pass Takeoff Tool Tool Index The following is a description of the fields used when cutting a lap Base Curve Enter the base curve of the lap to be generated The allowable range for this value is between 6 000 and 30 000 See the following note Chapter 3 Generating a Lens 3 3 3 4 Note The 2G expects a base and cross curve value of three 3 decimal places and will not round off any entered values For example to enter a base curve of 6 500 enter the series 6 5 0 0 Cross Curve Enter the cross curve of the lap to be generates The allowable range for the cross curve is 6 000 to 30 000 See note above on rounding Pad Thickness If laps are used that are compensated enter the amount of compensation in mm The allowable range for the pad thickness is between 0 00 and 3 00 mm Two decimal place values are required in this field The following chart shows some common pad compensation values 0 018 0 022 0 028 0 032 Lap Manufacturer Select the manufacturer for the lap you are using Every time a lap is to be cut the 2G will select the chosen manufacturer s best fit lap to cut the desired curves
31. 2G Remove one of those fuses and return the bag with extra fuses to the clip The fuse holder is on the side of the Electronic Enclosure below the ribbon cable labeled Line Power The fuse holder is also labeled For the 115 Volt 2G use your hands to twist off the fuse For the 230 Volt 2G use a flat head screwdriver to press in and loosen the fuse holder top The fuse will probably fall out If not pull the fuse holder top out then remove and discard the old fuse Place the new fuse in the fuse holder and tighten the fuse holder top Replace the Servo Motor Cover and the Electronics Enclosure Cover and reinstall the nuts and screws securing them Plug the 2G back in close the case top and turn the power switch to ON to determine if replacing the fuse fixed the problem The 2G Generator User s Manual June 23 2005 Troubleshooting Quick Reference Lens Quality Following is a quick reference of the most commonly encountered problems The next sections contain more detailed descriptions of problems If you have any further questions with a service issue please contact the National Optronics Service Department Problem Suggested Action i Check line voltage for 120V Verify that unit is on a dedicated circuit Unit does not boot up Check Electronics Enclosure indicator lights Check board voltages Check cable connections inside machine Verify position of mercury switches Verify correct operations of home
32. 5 volt fuse can be found on the power supply board inside the Electronics Enclosure It will be labeled F1 The following steps should be followed to check the fuse 1 Turn the 2G s power switch to the OFF position 2 Remove the acorn nuts from the Electronics Enclosure cover and then remove the cover The power supply board will be on the right hand side of the box 3 Locate the fuse labeled F1 and remove it from the socket 4 Using an ohmmeter test for continuity through the fuse 5 Reversing steps 1 through 3 either replace the blown fuse or return the good fuse into the socket labeled F1 ensuring that the pins on the fuse properly line up with the socket Encoder and Home Switch Diagnostics A further diagnostics of the encoders and home switches can be performed through the 2G s software To access the Diagnostic Screen switch the power to the 2G to the OFF position After waiting 10 seconds switch the power back ON When the message Press any key for Immediate Diagnostics appears at the bottom of the screen press and hold the lt 1 gt key until the Diagnostic Screen 1s accessed see field descriptions in Chapter 4 Rotating the depth or radius carriage servo motor couplers so that the carriage moves forward away from the home position the corresponding encoder should count upwards or positively and HOME should read NO when the carriage is moved away from the home position When the coupler
33. As mentioned in a previous Note press the READY key between steps The following steps are the same as what displays on the screen 1 Open Lid and Turn Cutter Motor Off 2 Insert Calibration Plug into Chuck After Step 2 the depth carriage will move to the left and the radius carriage will move forward 3 Manually Turn Servos so that Blade Just Touches Nylon Insert Note on Step 3 Move the servos in similar manner to what is described in the Note on page 5 2 4 Remove Calibration Plug 5 Turn Cutter Motor Back On The 2G Generator User s Manual June 23 2005 Calibrating the Axis To calibrate the axis 1 2 B ck gy SOM Go to the Axis Calibration Screen from the Calibration Screen Enter appropriate data for the blank Chuck the lens Press the START button When prompted mark the vertical axis with a Magic Marker or other permanent marker Press the READY key Wait until prompted to proceed Remove the lens and visually inspect the axis Adjust Axis Bias if needed Press a key to return to the Calibration Screen Chapter 5 Calibration 5 7 Chapter 6 Periodic Maintenance and Troubleshooting Periodic Maintenance Daily Cleaning the Interior The interior of the 2G should be cleaned on a daily basis using the vacuum to remove debris that escapes the chip chute during normal operation A 1 x 6 flexible hose and crevice tool are provided with the vacuum for this purpose To clean the i
34. CNet packet time out This indicates that the Server heard but did not respond correctly to the request in time The 2G Generator User s Manual June 23 2005 Appendix Specialty Lenses D Bi Concave Lenses Bi concave lenses are produced by cutting a concave curve on both sides of a lens To cut this type of lens both surfaces need to be finished independently Normally the surface to be used on the front of the lens is finished first If cylinder power is desired on the front of the lens it is suggested that the back surface be finished first The following is the recommended procedure for cutting bi concave lenses Lenticular Determine the front curve you wish to produce Some experimentation with your Ry calculation software may be required to determine the curves that will provide a cosmetically appealing lens Select the best lens blank to cut the curves This will be a judgment call based on the lenses available in stock Block the lens on the convex side and generate the new front curve first Remove only enough material to finish the lens across its entire surface Fine polish and inspect the lens for defects Produce a work ticket indicating the newly cut front curve as the true front or base curve of the lens Change the Block Diameter for Sag on the Set Up Screen to represent the outside diameter of the block or ring being used This value can be measured with a PD stick Mark tape and block the
35. Curves tee tt ee ee dep nth e E e de e Ee a 5 5 Adjusting Lap CUVE S aida 5 5 Tl ckness e iecit etiem O O dedican ds 5 6 To Calibrate the Thickness sess 5 6 Calibratin amp ER EO etr EE Re eb eerte EE ER id 5 7 Chapter 6 Periodic Maintenance and Troubleshooting eere O71 Periodic Maintenance sa AA GR Re Ge eene nre erre Re ee Re ee ee ee ee 6 1 Daily i52 EE oia Bas 6 1 Cleaning the Interior ee ee ee ae RR RR RA nennen 6 1 Drain the Air Filter eee eee ER Re e e tees 6 1 Check the Air Pressure neea a a RA ener enne enn 6 2 Every 200 t0 300 Cycles se SE dianas eee eti RE fak ERA ge Re See GR e AR DEd Ese Es 6 2 Contents vii Contents viii Change the Vacuum B bsins cenorias iiia ener ennt 6 2 Every Two Weeks xtd rere etre sde 6 2 Clean the Collet Assembly and Cutter Motor essen 6 2 Clean the Electronics Enclosure Fan Filter iese sesse esse ee ee ee ee Ge Re ee ee ee ee 6 3 AS Needed mi o eerte eie pe Hi kde aaa tae eae 6 3 Change the Cutting Tool sess 6 3 Every Cutter Change ln to e D UON e 6 3 Clean the Collet and Collet Nut 6 3 Changing the Electronics Enclosure FUSE esse see see ee se ee ae ee ae Gee Re Ge ee ee ee ee ee 6 4 Troubleshooting asan pe E EE EE 6 5 QUICK Reference ses rire aem doe vou IE EER 6 5 Unit does riot boot UP c pi Rr er RA EN wed eet see e dba 6 5 Cycle mill not Statt eser Sat RE eA ee ae ee e
36. DY key This will recall the data from the previous job so that only the fields to be changed need to be reentered Chapter 3 Generating a Lens 3 5 Chapter Setting Up the 2G 4 Setup Screen Calibration of the 2G generator is accomplished through variables in the software accessed via the unit s Setup Screen The 2G is designed to retain all the set up data when the power to the unit is switched off This allows the generator to be ready to run when turned on Figure 1 illustrates the layout of the Setup Screen This is an example only not all values will be the same for all machines setup Screen Press SET UP to exit Software Version 3 29 Calibration Screen READY Servo Screen READY Lens Material Screen READY Lap Material Screen READY Diagnostics Screen READY Servo Burn In Screen READY Move Carriages for Cleaning READY Communications Screen READY Statistics Screen READY Block Brand COBURN ALUM Block Diameter for Sag 50 0 Block Thickness 9 0 Blade Radius 10 200 End Mill Flute Length 20 Prism Arrow Location None Default Pin Bevel Last Press READY to enter menu N y Figure 1 Setup Screen To access this screen from the Job Screen press the SET UP key on the keypad Please ensure that all Setup Screen entries are correct before proceeding to any subsequent screens 4 1 The first section of the Setup Screen provide access to additional screens To access
37. GRA GRA GR Re RA Ge Re ee Re ee 4 11 Sep Finish amp Rough ecce eie ete eite ti ee ertet 4 11 Feed Rate etiaai ete bet ees 4 11 T ke Off 4 ie 4 12 Pad Thickness oreet etm EE i EE 4 12 Ski Cut 4 12 Tool Tool Index ie EE SE GEES t ti 4 12 DiagniosticSere n EE EE OE N ee de EE Ee Se Ge AE Gee De DO Re SO 4 13 AXIS DEP ERAS SE niin etu te V o DoD brain 4 13 Start Switch 2 sd eda P EE N EEN 4 13 Start Ee AREA EET 4 14 Emergency Loopie sern rei ect eerte EL e irl Ge ee Fete i il 4 14 Keypad eei ER EER EE EN 4 14 Serial Loopback incio 4 14 ARCNetConnected ii EE ES EE tede eire eee eee 4 14 Communications Screen ed ee P ere Rede OE EE 4 15 Statistics E ME Ne GE A ER Ee Ge EG ee GE ee OS 4 17 Cycle Statsz sienten ee qam d d e a ee 4 17 Maintenance Stats acoso ee tea ee ee t eed tede Gute 4 17 Servo Burn In Screen oot er eee vec eri re er eee euis 4 18 Move Carriages for Cleaning sees ener enne 4 19 Chapter 5 A O A Calibration eenn A IO Bo US 5 1 To Calibrate the 26 EE tos de e li tego et 5 1 Lenses Lens Curve Bias 42 2 2 n drei e eL RE E LI e AGE NR GREG AE 5 2 Calibrate Lens Curve Procedure sess 5 2 Verify the Lens Curve Carbide Setting esse 5 3 Verify the Lens Curve Bias Setting ee sa ea ae ae ee ee ee ee ee ee ee ee ee 5 4 Lap Curve BidS 41 vet A ae teet eie etia 5 4 Adjusting the Lens
38. NATIONAL SPTRONICS The 2G Generator User s Mnai Rev 322 J une 23 2005 Warnings Cautions and Notes as Used in This Publication Warning notices are used in this publication to emphasize that hazardous voltages currents temperatures or other conditions that could cause personal injury exist in this equipment or may be associated with its use In situations where inattention could cause either personal injury or damage to equipment a Warning notice is used Caution notices are used where equipment might be damaged if care is not taken Note Notes merely call attention to information that is especially significant to understanding and operating the equipment This document is based on information available at the time of its publication While efforts have been made to be accurate the information contained herein does not purport to cover all details or variations in hardware or software nor to provide for every possible contingency in connection with installation operation or maintenance National Optronics assumes no obligation of notice to holders of this document with respect to changes subsequently made Copyright 1998 2005 National Optronics Inc All Rights Reserved Preface Revisions to This Manual Software versions 3 xx and 4 xx reflect internal hardware differences that are transparent to the user that is screen appearance and machine operation is identical The Communications Screen changed
39. T ede der Ctt es E Es ede se ee Toad 3 1 Blocking OE i ase uted a tds 3 1 SETUP CE ts DE E cR SE OA E eei tete Ee 3 1 Contents Job Input 4 235 ete one pet rd qose tiers tem a DHT es 3 1 Mounting the Lens Blank ese se ee ee ener enne nennen 3 2 R nnitig a Bens sg es GER EG De Ee ee een ide e M fas eg ee ista cederent 3 2 Lap Guten alista 3 3 Proc ss OVAs 3 3 Ese RO EE ERE N se 3 3 BELIG OE OR OE N es EE EO aae 3 3 CO CU A bee Ge GEE ge EE ta 3 4 Pad Thin iii ea nea been NT I PE E ea d 3 4 Lap Manufacturer i s Se EER ede atada 3 4 Lap TYPE RE MEN A ehe re eee te Hee e eee ede 3 4 Blank Base Clive EE HE teas 3 4 Blank Gross Gury 6 22 i acidos 3 4 Diametet utente a avi gee es 3 4 Genter Thickness eren ee D acidos 3 5 Center Removal esten aee ee bete T a e eds 3 5 center removal and edge removal at bottom esse ese ee ee ee Re ee Re ee Re 3 5 Cutting Lap ete metti rete eb ege TE RS EA her TE M GE Ge oe ere Se ego 3 5 Chapter 4 SECC Up CHE C AOU SCP S ER ER EE AE ME Ee 4 1 Setup Screen Field Descriptions essen 4 2 Block Brand re e Em S Eee t d diode 4 2 Block Diameter for Sag ee ee ee Re RR RR RA RA GRA ee eene 4 2 Blade Radius vii asse iom ER E TREE nee ition Sr Ae 4 2 End Mill Flute Length uuo co eet eer e Re ote ean a 4 2 Prism Arrow Location epe aucun nt andere te EE e Reed s 4 2 Default Pin Bevel eerte edet e e e e Re
40. The 2G Toric Generator is optionally shipped with a cabinet which is custom designed for the application The laboratory can either 1 Use the custom cabinet or 2 Mount the generator on a standard workbench mm COLLET WRENCH 24mm ARMATURE WRENCH 11 16 ARGOS ow P N 87490 P N 87495 15 AMP FUSE 3 0 AMP FUSE P N 87260 P N 77320 P N 77318 y EN P N 77317 FOR 230V QUICK DISCONNECT HEX KEY SET 2 5 AMP FUSE gt P N 74262 P N 87178 P N 77324 3 16 HEX T HANDLE P N 87452 3 16 L ALLEN WRENCH T 10 TORX WRENCH Za FILTER e 3 PN ASS Y BALL END MILL 3 8 SHAFT BALL END MILL 3 8 SHAFT N P N 93743 NEWER UNITS ONLY P N 93741 OLDER UNITS ONLY 2 M N SPTRONICS sPiRONICS o he M N PC Generator System Disk PC Generator Backup Disk Version AN N W NS d Se v d 4 n CALIBRATION PLUG LAP HOLDER SYSTEM DISK BACKUP DISK P N 87248 P N 2108 P N 3311 P N 3306 1 Custom Cabinet Assembly Figure 1 Accessory Kit Remove the cabinet and cabinet top from box Place cabinet top white side down on floor Place cabinet upside down on cabinet top with doors on same side as cutout in the cabinet top Attach cabinet to cabinet top with screws provided Proceed to Step 3 The 2G Generator User s Manual June 23 2005 2 Work Bench Preparation Prepare the bench surface to be
41. The 2G will use the cutting parameters as defined on the Lap Material Screen for that manufacturer Lap Type Shows the recommended lap for the manufacturer selected in the Lap Manufacturer field This lap type recommended is the lap that requires the least amount of stock removal to be able to cut the curves specified in the Base Curve and Cross Curve fields Blank Base Curve Enter the existing base curve of the lap to be used in diopters Two decimal place values are expected in this field For example to enter a blank base curve of 6 25 enter the sequence 6 2 5 This entry must be between 30 00 and 30 00 Blank Cross Curve Enter the existing cross curve of the lap to be used in diopters Two decimal place values are required This entry must be between 30 00 and 30 00 Diameter Enter the diameter of the lap in mm A whole number value between 20 and 100 is required for this field The 2G Generator User s Manual June 23 2005 Cutting a Lap Center Thickness Enter the actual center thickness of the lap A whole number value between 10 and 100 must be entered in this field NOTE It is very important that the center thickness be measured from the very base of the lap to the top of the lap See Figure 1 for further instructions on measuring the center thickness PD RULER Millimeters OVERALL HGT_____ 10 20 3
42. ameters depend on the accuracy of the Block Diameter settings and the center thickness calibration discussed above Cut Matching Lap Press the READY key to take you to the Lap Screen Refer to the Lap Screen section of Chapter 3 Generating a Lens for field definitions The 2G Generator User s Manual June 23 2005 Chapter Generating a Lens 3 Process Overview The steps in generating a lens are as follows 1 Enter a job covered in Chapter 2 2 Generate a lens 3 Cut a matching lap for polishing if you do not have one Generating a Lens Blocking Center blocking is the recommend blocking method for use in the 2G Prism rings should not be used with the 2G since it is capable of automatically generating prism Setup Screen During final testing at the factory the 2G was fully calibrated with machine specific entries Unless the parameters must be changed the operator need only work with the Job Screen to begin generating lenses If changes are necessary see instructions in the Setup Screen section Job Input You must enter job data on the Job Screen as the initial step Refer to Chapter 2 Entering a Job if you need to review that part of the process or for an explanation of each field After entering the data move the cursor to the next field by pressing the up arrow 17 key or down arrow s4 key which will automatically store the data in the previous field If the data 1s out of the al
43. and spacer to the front motor bracket Loosen four 4 20 inch socket head screws on the motor bracket Three of these are 4 20 x 3 4 inch one of them is shorter and goes into the counterbore Make sure that you reinstall the shorter screw in the top hole from where it came Slide the motor out Place the new motor in and reverse the steps described above Replacing the Cutter Motor Controller Turn the power to the 2G OFF There are the two 2 4 20 x inch socket head screws on the controller with two 2 1 4 inch hi collar lock washers holding them in place Remove those two screws Disconnect the controller from the cutter motor Disconnect the power to the controller Remove the old controller Mount the new controller into the space from which the old controller was removed The controller can only mount one way Reverse the process of removing the controller that 1s replace the screws reconnect power etc Chapter 6 Periodic Maintenance and Troubleshooting 6 17 a 6 18 Replacing the Electronics Enclosure 1 10 11 If possible use the Save Setup to Floppy option on the Communications Screen to record the entries from each of the setup screens If not possible manually record the entries from the each of the setup screens Switch the power to the 2G to the OFF position and disconnect the power plug from the rear of the machine Disconnect all the leads from the left side of the Electr
44. ar Install the regulator filter assembly found in the accessory kit by inserting it into the quick connect bulkhead fitting The assembly will snap in place Attach the quick disconnect onto the end of the air line to be used The air line can then be pushed on the male fitting of the regulator filter assembly Verify that the regulated line pressure is 80 psi which is the necessary operating pressure for the collet If the pressure is not 80 psi adjust the knob on the top of the regulator filter assembly 7 Electrical Connections Plug the vacuum cord that was laid on the rear of the bench into the socket on the back of the generator Verify that all panel switches are in the out rather than the in position Also verify that the power switch on the right side of the control panel is in the OFF position Connect the power cord for the cabinet exhaust fan to a dedicated 115 VAC wall Connect the power cord supplied from the back of the generator to a dedicated 115 VAC wall receptacle of at least 15 amp capacity Note Proper operation requires that no other equipment be on the same power feed circuit breaker as it could cause nuisance drop outs of the processor FILTER REGULATOR J ES BE AIR LINE WITH E E ur Er QUICK DISCONNECT pa Pd FITTING VACUUM POWER TO BACK OF GENERATOR HOSE FROM OUTLET TO EXHAUST HOLE EDGER POWER TO WORKBENCH IN CABINET DEDICATED 20A
45. ar sequentially on the screen To proceed to the next step press the READY key Note After each of the following steps press the READY key to proceed to the next step Think of the READY key as a way of saying that this step is done and you are ready for the next step Calibrate Lens Curve Procedure As mentioned in the Note above press the READY key between steps The following steps are the same as what displays on the screen 1 Open Lid and Turn Cutter Motor Off 2 Insert Calibration Plug into Chuck After Step 2 the depth carriage will move to the left and the radius carriage will move forward 3 Manually Turn Servos to Insert Cutter into Calibration Plug Note on Step 3 Manually advance the cutter by rotating the rubber coupler on the depth carriage lead screw assembly If necessary rotate the rubber coupler on the radius carriage until the cutter is aligned to go into the circular cut out in the center of the calibration plug Completely center the cutting tool in the calibration plug cutout by rotating the rubber couplers on both the radius and depth carriages lead screw assemblies If you are using a diamond cutter be careful not to nick the cutter edge on the calibration plug Try moving the radius coupler back and forth while moving the depth carriage forward until making full contact inside the calibration plug then center the play remaining in the radius coupler Manually spin the collet nut in the direction of nor
46. correct Repeat the above procedure Adjusting the Curves for 1 00D and 12 00D curves utilizing the 1 00D Correction and 12 00D Correction to adjust the curves for accuracy It is very important that the 6 00D Radius be set accurately first since the curve corrections are adjustments from this number Adjusting Lap Curves If the 2G will be utilized for lap cutting use the following procedure adjust the lap curves for accuracy 1 In the Calibration Screen select the Cut Test Lap option 2 Cuta 6 00D sphere lap When the cycle is complete the unit will return to the Calibration Screen 3 Measure the curve with a sag gauge If the curves are off use the 6 00D Correction to adjust the curves for accuracy as follows e Ifthe curve measures too flat make the 6 00D Correction value more negative Chapter 5 Calibration 5 5 5 6 Thickness e Ifthe curve measures too steep make the 6 00D Correction value more positive e The initial adjustment should be no more than 40 01 mm Repeat the procedure until the curves are correct Repeat the above procedure for 1 00D and 12 00D laps utilizing the 00D Correction and 12 00D Correction to adjust the curves for accuracy if so desired The 6 00D Correction must be set accurately first since the curve corrections are adjustments from this number From the Calibration Screen move the cursor to Calibrate Thickness and press the READY key To Calibrate the Thickness
47. e white bag Clean or replace if necessary To change the bags I 2 Every Two Weeks Remove the head of the vacuum unit by releasing the three restraining clips Slide the old collection bag off of the inlet fitting and dispose of properly Slide the fresh collection bag s rubber hole guard over the inlet fitting inside the canister Expand the bag around the inside of the canister Squeeze the ends of the spring clamp securing the white filter bag to the inlet cage on the underside of the vacuum head and slide it off the inlet cage Remove the white filter bag from the inlet cage and dispose of properly Inspect the foam filter sleeve for tears or holes Clean or replace as necessary Place a fresh filter bag completely over the foam filter on the inlet cage to the vacuum motor Slip the spring clamp over the inlet cage completely to secure the filter bag in place Place the head of the vacuum back on the canister aligning the exhaust port on the head with the inlet of the canister Secure the three clamps to attach the head to the base Clean the Collet Assembly and Cutter Motor Using the safety air gun supplied in the accessory kit thoroughly blow out the vents in the collet drive and cutter motor The 2G Generator User s Manual June 23 2005 As Needed Ls Clean the Electronics Enclosure Fan Filter The Electronics Enclosure fan pulls fresh air into the Electronics Enclosure to help protect the components
48. e servo motor or a twitching of the servo motor coupler If the axis home switch fails in the open mode the collet will begin rotating and not stop When a switch fails in the open mode switch replacement is required The 2G Generator User s Manual June 23 2005 Ls Servo Motor Encoder Malfunction The servo motor encoders are an integral part of the servo motors themselves Failure of an encoder would reguire replacement of the entire servo motor The servo encoders report the exact position of the radius and depth carriages and axis location of the lens chuck to the main processor The blue ribbon cable extending from the rear of the motors carry the encoder signals Depth or radius carriage encoder failure will be indicated by the corresponding carriage running forward at a rapid rate If the axis encoder fails the 2G will initialize normally however once a job is entered and the lt READY gt key is pressed the collet will begin rotating at a rapid rate and not stop Locate the appropriate cable and ensure its connectors are firmly in place If so replacement of the servo motor is required Blown 5 Volt Fuse If the 2G does not go through its normal boot up routine and no text is present on the display The 5 volt power supply fuse may be blown A blown 5 volt fuse would be indicated by the 5 VDC light NOT being illuminated on the power supply LEDs which are located on the front of the electronics enclosure See Figure 1 The
49. en 3c 1 3 TODA LA d IM E 1 3 Lens Material GE one Ihe eR Es 1 3 CT M Me DE sae 1 3 Statement Against MisuS Gates aie seta D utei gi DTE Nes 1 3 Installation Procedures ti UHR RR PORTER EC REI ERA 1 4 2G BoOt Up Sequence nici ertet ete he d era cokes mee Tene cin ee eed ERG id 1 8 The First Time After a Black Box Is Installed oooonoccnnonononnnoonccconaconnnonnos 1 8 Entering a Po osse ee NE CN Process OVervIe wi tas fem aient iem eG adeb T nee ce E ab ads count dus 2 1 Entering a JOD RO EE We eerie 2 1 Entering a Job Direct without a Host Computer Server sse 2 2 Job Screen oro rectis RE secant PT EE ER Ue E eo e LP edes Eee T LR PE ee 2 2 Job Number oec ete tere reet et Ere t E eg DE O Ge EE Res 2 3 Base EUIVE ER oO ae ee 2 3 Disi Rc 2 3 Center Thickness AE EE AE D EE Dee OE N reve edges 2 4 Grib Diamet amp r mn tete te AE eere YO 2 4 A 2 4 LAMAS E 2 4 Ra T E NC ITEM 2 4 died ie dl a E E EEEE ti AE eed eee Suen ea teo N 2 4 Pism Diere GO OR eet OO t teu ets 2 5 Front CU Sui 2 5 EET dd He EO do l 2 5 Edge Thickn s8 soi eot dte ar ls N 2 5 Diameter zt tete em la m detecte 2 5 Material be elu 2 5 Block Diameters EE etat i e trees 2 6 Cut Matching Laps iu tette ROSEO EROR RD EE N is 2 6 Generating Eo Ee I L Process OVervIeW a dedere beet gittis em etie P AA e re rude tete epi funde 3 1 Generating g LENS irta etie
50. enerate a desired lens This is the only screen needed for routine operation when no calibration or set up is required 2 The Set Up Screen is used for system calibration and configuration All of the five remaining screens are accessed directly from the Set Up Screen 3 The Calibration Screen allows the operator to calibrate the 2G for proper curves axis and center thickness Also a test lens can be generated from this screen to test settings 4 The Servo Screen allows you to find the carriage limits 5 The Lens Material Screen contains information to configure the generator for different lens materials The 2G Generator User s Manual June 23 2005 6 The Lap Material Screen contains information to configure the generator for different lap materials 7 The Diagnostic Screen initiates a series of system checks on the generator 8 The Servo Burn In Screen exercises the 2G servo motors for break in warm up and test 9 The Move Carriages for Cleaning Screen will help simplify the cleaning process 10 The Communications Screen allows you to set you communications options usually performed during initial setup only 11 The Statistics Screen allows you to check various counts and cycles You can also reset cycle information after replacing vacuum bags blades etc Note Cleaning the 2G is an essential part of the maintenance process and should be performed on a regular basis Monitor Contrast Control The monit
51. ents should be made until this is accomplished Note Recommendations made in this section are done under the assumption that the cylinder machines have been checked for correct axis and pressure and that the laps have been checked for curve accuracy Chapter 6 Periodic Maintenance and Troubleshooting 6 5 6 6 Unfined or gray areas toward the outside edge of the lens Curves are too flat fining from the inside out Unfined or gray areas at the center of the lens Curves are too steep fining from outside in Unfined area resembling an hour glass or off axis condition 1 Incorrect Axis Bias setting Follow the procedures in Chapter 5 Calibration for setting the Axis Bias 2 Incorrect Lens Curve Bias setting Follow the procedures in Chapter 5 Calibration for setting the Lens Curve Bias Hump or depression at or near the center of the lens Incorrect Lens Cuve Bias setting Follow the in Chapter 5 Calibration for setting the Lens Cuve Bias Excessive chatter This is indicated by large pit marks or a tearing away of the lens material requiring prolonged fine times 1 Incorrect Lens Material Screen settings Ensure that the Spiral Separation and Axis Speed are set within the acceptable ranges for the material being surfaced 2 Dull cutting tool Follow the procedures on Page 3 for changing the cutter tool 3 Motor bearing failure Wear in the cutter motor bearing will cause the cutting tool to vib
52. erify that all entries in the lower half of the screen are correct refer to Chapter 4 Setting Up the 2G for more detail Then move the cursor to the line titled Lens Material Screen and press the READY key After entering the Lens Material Screen change the spiral separation for CR 39 to a setting of 0 63 this will provide a smooth surface for taking measurements note the original setting so it can be reset after calibration Alternatively all lenses generated during the calibration process could be cut using the POLY setting Note Remember after you have set or verified the numbers in the first Lens Material Screen Finish and Rough press the key to go to the next Len Material Screen Cribbing Once the change is made press the SET UP key once to return to the Setup Screen Move the cursor to the line titled Calibration Screen and press the READY key Lenses Lens Curve Bias 5 2 Note The Calibrate Lens Curve procedure WILL NOT need to be performed with each cutter change The Lens Curve Calibration procedure will need to be performed when e A new cutter motor is installed e The RADIUS home switch is replaced The Calibrate Lens Curve function automatically calibrates the Lens Curve Bias The Lens Curve Bias setting is the relative position of the lens drive table to the cutter It is used to align the center of the cutter with the center of the lens The units are millimeters The following steps appe
53. from over heating The filter prevents dirt from being pulled in with the fresh air Failure to clean the filter will affect the fan s performance The filter which is located under the right rear corner of the unit can be removed by lifting the right side of the machine one to two inches and sliding the filter towards the right Cleaning can be accomplished using the safety air gun provided in the accessory kit shipped with the machine Change the Cutting Tool The need to change the cutting tool will be indicated by a deterioration in the surface quality of the lens The tool should be changed when surface finish requires extended fining times Extreme care should be exercised when changing the cutting tool Turn the cutter motor OFF before proceeding Read the directions completely before proceeding and follow them step by step The carbide cutter is sharp and may cause hand and finger lacerations if not handled carefully The diamond cutter s edge is sharp and is fragile handle with great care To change the cutting tool 1 Open the lid and switch the cutter motor contoller s toggle switch to the OFF position 2 Using the wrenches provided loosen the collet nut and carefully remove the cutter 3 Remove the collet nut and collet and clean thoroughly see the section titled Clean the Collet and Collet Nut below reinstall the collet and collet nut 4 Insert the exposed cutter shank into the cutter motor until the col
54. g 6 5 Garriages stop mid cycle 3E SEE ane eee iaa 6 5 Unit resets mid cycle x ER EE A Ee 6 5 CULVES 1eorf eet er coin ec hui Sled eek es hte E d o e tek 6 5 Th ckness Incottect nsi Re a eter o Ei aie tie ees 6 5 ARIS COLT CE sas cesa ion bid 6 5 Lens QUito 6 5 Unfined or gray areas toward the outside edge of the lens 6 6 Unfined or gray areas at the center of the lens sse 6 6 Unfined area resembling an hour glass or off axis condition 6 6 Hump or depression at or near the center of the lens sss 6 6 oi di n EE EE MR EE EE ER 6 6 Center thickness is inconsistent essen 6 6 Prism ditection CO iii dee p Te E Hg e TES ieu 6 7 Prism amount CO tuo ta 6 7 JoD Ertry Screen eee eee oret in s er Lent ddes Lege tede Ped netter Lee Ede Eee Round 6 8 Screen entries are barely visible sese 6 8 Invalid Value message appears at the bottom of screen ees se se ee eke 6 8 Cross CUEVE eere ee cei p Io eee tede e eee 6 8 Center Thickness ie eene eo d ea 6 8 Edge Thickness hen eet Eee ate atiis 6 8 Cycle Irregularities rnor d ne rte ett de e e en a adu det reise dde 6 9 Job entry data is accepted however cycle won t start sesse se ee ee ke ee 6 9 Collet appears to stutter or stall during the cutting cycle sesse see sek ee ke 6 9 Cycle times too long ees EE EE EE e eee EE N 6 9 Carriages move into cutting posit
55. he curve varies from center to edge change the Lap Curve Bias setting to correct any inconsistencies If the lap measures flatter in the center make the Lap Curve Bias setting more positive to remove the flat spot If the lap measures steeper in the center make the Lap Curve Bias setting more negative to remove the high spot Initial adjustments should be made in increments of 0 02 mm The 2G Generator User s Manual June 23 2005 Adjusting the Lens Curves 1 In the Calibration Screen select the Cut Test Lens option 2 Cuta 6 00D sphere curve on the back of the lens When the cycle is complete the unit will return to the Calibration Screen 3 Using a sag gauge measure the curve If the curves are incorrect use the 6 00D Correction to adjust the curves for accuracy as follows e If the curve measures too flat make the 6 00D Correction value more negative e Ifthe curve is too steep make the Correction value more positive e The initial adjustment should be no more than 40 01 mm Note By depressing the key marked lt _ gt the value can be changed from a positive to a negative value EXAMPLE 1 EXAMPLE 2 Desired curve 6 00 Desired curve 6 00 Measured curve 5 92 Measured curve 6 10 Present Correction 0 000 Present Correction 0 002 Setting after initial adjustment 0 010 Setting after initial adjustment 0 012 Repeat the above procedure until the curves are
56. hickness of the lens blank to be surfaced and is a whole number there is no provision for a decimal point Therefore if the edge thickness measures 8 5 the entry should be rounded to 9 mm an entry of 85 would be seen as invalid The 2G Generator User s Manual June 23 2005 Cycle Irregularities Job entry data is accepted however cycle won t start Main mercury switch malfunction The main mercury switch is part of the 2G s control loop circuitry a malfunction of the mercury switch will disable the cycle start switch 1 Check the position of the switch The mounting collars tab should be aligned in the cut out of the plexiglas shield stop bracket and secured with the mounting screw and nut 2 Inspect the switch leads for breaks and the connector to ensure it is firmly in place 3 Verify the switch operation by unplugging the switches amp style connector and placing a jumper wire across its wiring harness receptacle If the 2G cycles normally replacement of the mercury switch is required Note Bypassing the mercury switch 1s performed solely for diagnostic purposes and is NOT intended for operation SERIOUS INJURY could result from operating the 2G in this manner Collet appears to stutter or stall during the cutting cycle 1 Low servo voltage Follow the procedures on page 6 15 for checking and setting the 20 Volts DC Processor Board voltage 2 Material removal 1s too aggressive Check the Lens Material Screen settings
57. hing Lap Barcode or Enter Job Number 2 2 The 2G Generator User s Manual June 23 2005 The data is shown line by line as entered The following is a description of each entry Job Number This field is used in installations where the job entry data is entered at a remote location By typing in the Job Number or Tray and pressing down arrow V or the READY key the complete job entry data is automatically downloaded to the generator After pulling down a job from a server or host computer verify all entries before pressing the Ready key Pay close attention to the Block Diameter field using the wrong block diameter could ruin your blade HELPFUL HINT Should the next lens to be generated be similar to the one running the operator can move the cursor to the upper most field Job Number and enter 0 as the job number When the cursor is moved down J to store the entry or the READY key is pressed the data fields on the right side will automatically be duplicated on the left Then only the fields that need to be changed must be re entered Barcode Reader Users The 2G will interface with most barcode readers to provide fast job data entry into the Job Screen Contact the factory for interface specifications and compatible product recommendations The first 4 data fields relate to the base curve cross curve center thickness and crib diameter of the finished lens Base Curve Enter the desired base curve in
58. id crib diameters are whole numbers between 50 and 80 mm If this value is smaller than the Block Diameter Page 6 the 2G will automatically crib the lens 2 mm larger than the Block Diameter The next 4 data fields specify information about the prism to be generated The 2G s software automatically programs the cutter to generate prism eliminating the need for prism rings or blocking Note Center blocking is the recommended blocking method for the 2G Care must be taken when using any other method of blocking Prism is always entered as actual rather than compensated as no compensation is necessary due to the accuracy of the 2G s cutting action Pin Bevel This value will toggle between Off and On and tells the 2G if it should place a bevel on the lens to reduce the possibility of cutting your fingers when handling the lens and to increase coolant flow between the lens and the lap during fining Layout Axis Enter the axis from the seg line to the cylinder line in degrees Depending on lab convention this may be referred to as cylinder axis Prism Enter the actual uncompensated prism power in diopters This field will require entry of three decimal place values For example to enter a prism amount of 2 000 prism diopters the sequence 2 0 0 0 must be entered or to enter 1 750 diopters the sequence 1 7 5 0 must be entered The amount of prism must be between 0 00 and 20 00 prism diopters This value will
59. il 0 0 0 RESET E Press READY to reset data Cycle Stats Displays the relevant statistics pertaining to each of the different types of lens generated Maintenance Stats Displays the number of cycles and passes since the last vacuum bag blade or motor change When you change one of these parts come into this screen move the cursor down to the appropriate field and press the READY key to reset the statistics Chapter 4 Setting Up the 2G 4 17 4 18 Servo Burn In Screen Here the 2G operates its servo motors for break in and test Figure 5 illustrates the layout of the Servo Burn In Screen The Servo Burn In Screen can be accessed from the Setup Screen by pressing the READY key after moving the cursor to the Servo Burn In Screen line Servo Burn In Screen Press any key to Exit DO NOT LEAVE COMPLETELY UNATTENDED Time Elapsed 0 00 00 of 4 00 00 Depth Velocity 20 0 mm sec Axis Velocity 25 0 rev min Radius Velocity 20 0 mm sec Depth Home 0 000 mm Axis Home 0 000 deg Radius Home 0 000 mm Depth Figure 5 Servo Burn In Utility Entering the Servo Burn In Screen begins a series of exercises that measure servo velocities and tests the home switches This exercise is primarily for factory burn in but may be used as a diagnostic procedure Acceptable values for the servo velocities are 15 to 30 If any of the values fall outside this range it may indicate problems that would require factory assistance The h
60. imized Chapter 4 Setting Up the 2G 4 11 4 12 Take Off This is the maximum depth of material that can be taken off TO Take Off in one pass The valid range is to 17 mm This value along with the End Mill Flute Length on the Setup Screen will determine the amount of material removed in a single pass Pad Thickness If laps are used that are compensated enter the amount of compensation in mm The allowable range for the pad thickness is between 0 00 and 3 00 mm Two decimal place values are required in this field The following chart shows some common pad compensation values 0 018 0 022 0 028 0 032 Skim Cut When set to Y this will provide a final skim pass on all laps being surfaced ensuring the best possible surface finish and curve accuracy Tool Tool Index This is the Index of Refraction that was used as the basis for cutting the laps being used for fining and polishing It should be set to the lap manufacturer s specifications and should be in agreement with the Tool Index in the Rx calculation software The 2G Generator User s Manual June 23 2005 Diagnostic Screen On this screen the 2G performs a series of tests to its hardware with readouts to the operator Figure 4 illustrates the layout of the Diagnostic Screen The Diagnostic Screen can be accessed from the Setup Screen by pressing the READY key when the cursor is on the Diagnostic Screen line Diagnostics Screen Press SET UP to exit
61. ing to the Diagnostics Screen The message Press any key for Immediate Diagnostics will appear at the bottom of the screen If the 2G will not complete its boot up due to a problem press any key at this time to enter the Diagnostics Screen The First Time After a Black Box Is Installed All of the above occurs plus the following A message Remove lens if present and press READY will appear After removing a lens if present from the chuck press the READY key The 2G now will display the message Discovering Limits and move its carriages to determine its full range of motion First the radius carriage will come forward and the depth carriage will move to the left Caution It is very important that no lens is present in the chuck when the 2G is discovering its limit If a lens is present it could cause permanent damage to the cutter The carriages will then move to home and the Job Screen will be displayed signaling that power up is complete It is also very important not to drop the 2G as it is not built to withstand dropping The 2G Generator User s Manual June 23 2005 Chapter Entering a Job 2 Process Overview The steps in generating a lens are as follows 1 2 3 Enter a job Generate a lens covered in Chapter 3 Cut a matching lap for polishing if you do not have one covered in Chapter 3 There are two ways of entering a job 1 from a host computer or Optronics server described o
62. ion however neither cutter motor nor vacuum ODOT ALC uites ete pete Ee HE OR ERE EE COR ARR PERRO e DOUG EE EE NO AGE EE EE a 6 10 Mercury Relay not functioning ee ee se ee RR GR nene 6 10 Cutter Motors AE E 6 11 Motor do s Tot r n si a e nt rd 6 11 Motoras NOISY n rad timuit esee E tut esed t ees 6 11 Processor Initialization Failure Start Up Failure sse 6 12 Blown 20 Volt Power Supply Fuse 6 12 Home Switch Malfunction essere 6 12 Servo Motor Encoder Malfunction seseseeeeeeennene 6 13 Blown 3 Volt Else ci eR Pe OR EO EE RE OE HE 6 13 Encoder and Home Switch Diagnostics sss 6 13 Servo Motor Malfunction ee ee se se se RR RA GRA GRA eee 6 14 Checking and Adjusting Voltages sese ener 6 14 2G User s Manual June 23 2005 Contents Preparations oes ue Ro seek ees ess 6 15 Checking and Adjusting the 5 Volt DC Processor Voltage 6 15 Checking and Adjusting the 20 Volt DC Processor Voltage 6 15 Checking the Power Supply Input Voltages iese se ee RA RA RA Re Re ee 6 15 Transformer Supply Voltage ees es ee Re GR E GRA Re ee ee ee R 6 16 24 Volt AC 4AMPOUDU reses eerte ig reete tee eire yere ee 6 16 8 Volt AC OULDUL erre REESE E PH ey 6 16 24 Volt AC O2AMP OUDUE Ses EG SEG rere te eite iy eee ES eg apa 6 16 Parts Replacement ieii ann a RA GRA RA ener enn nn
63. is rotated so as to move the carriage towards the home position the encoder should count downwards or negatively and once back in the home position HOME should read YES Rotating the collet towards the front of the 2G the chuck must be closed the encoder should count upwards or positively and HOME should change from NO to YES each time the actuator vane passes through the switch Rotating the collet towards the rear of the 2G the encoder should count downwards or negatively Chapter 6 Periodic Maintenance and Troubleshooting 6 13 6 14 Servo Motor Malfunction Failure of a servo motor can be attributed to 1 of 3 things The servo motor itself the power supply or the servo motor driver chips If failure of a servo motor is suspected it can be isolated as follows 1 Switch the power to the OFF position 2 Rotate the servo s couplers and collet so as to move all three carriages away from their home position 3 Observing the carriages and collet switch the power ON During the initialization process the servos will search for their home position Failure of one of the carriages or collet to find its home position will indicate the location of the malfunction 1 Servo motor connector Locate the corresponding servo motor power connector and ensure that it is firmly in place 2 20 Volt DC Supply Voltage Follow the procedures on Page 14 Checking and Adjusting Voltages A If voltage is less than
64. l R tige EE ED ic C 1 Inveni C 1 Blade will contact the block 5 5 eer ettet ee ge ee Ree C 1 Blade will be within 0 5mm of block Proceed with caution C 1 Please wWerity and COffect oet ete eect oe ee C 1 Communication Errors ccccccccesccccesssscececssccececscececssecececssseececssseesecssseeeeesssseecenseaeees C 2 LAN Hardware Failure i s esse degie esse eed eers see Ged GE ee ee eed ee Ee ge ee Gede eek C 2 Duplicate LAN ID EE EE eie eee He e die eed C 2 LAN RECEIVE BrtOt ie ie teet tti ste ee ee lee roads C 2 Contents ix Contents LAN Transmit Timos EE RE C 2 LAN Receive Timeout sie REEN Ges Ese EG RE GR Se Ke GE Bee gee be seep ed C 2 IS A I IU D 1 ES MA ESE SR RR RE OE RE OE E D 1 bentiedlaf MA EIE t EE ID N VO ER ME Oe AA EK Pe at D 1 dtm D 3 Off Center Blocking ies se ee ener enne enne nennen ee ee RA D 3 ProgresSlye 2x5 ue A Ge Gee ge D 3 Saddle Back d HR RETE DRE NT d Pe Erg of D 3 Appendiv E Warranty eee reco RR CHE NAMES Ee nEn VM EVE ER GO ee PEE E 1 x 2G User s Manual June 23 2005 Chapter 1 Before You Begin Before You Begin The 2G is a state of the art 3 axis toric generator manufactured by National Optronics Inc It will process Polycarbonate Hi index and CR 39 lenses with exceptional accuracy A unique cutting tool is used to dry cut the back of plastic prescription lenses with no elliptical error The removed material is drawn into a vacuum uni
65. lar bottoms out against the collet nut 5 Tighten the nut with the wrenches provided in the accessory kit Make sure that the cutter nose is still projecting 38 mm from the collet nut for a carbide end mill cutter and at 43 mm for a diamond two fluted or carbide cutter 6 The cutter position should be close to the old cutter position It is advised however to perform a full calibration setting the curves and thickness Proceed to the section on Calibration Page 5 Every Cutter Change Clean the Collet and Collet Nut While the cutter has been removed also remove the collet nut and collet from the nose of the motor Clean with alcohol or acetone and dry with the air gun before reinstalling Chapter 6 Periodic Maintenance and Troubleshooting 6 3 6 4 Changing the Electronics Enclosure Fuse Change the fuse after a sudden power loss that is not related to the power supply or the power source To change the fuse 1 Turn the power switch to OFF unplug the 2G and open the case top Using a 5 16 inch nut driver or an adjustable wrench remove all acorn nuts and screws securing the Servo Motor Cover and the Electronics Enclosure Cover Then remove the Servo Motor Cover and the Electronics Enclosure Cover There will be a small plastic bag with fuses clipped to the base plate 2 AMP 250 Volt Time Delay fuses Part Number 77327 for the 230V 2G and 3 AMP 250 Volt Fast Acting fuses Part Number 77318 for the 115V
66. ld result from operating the 2G in this manner Motor or Controller failure Using a voltmeter verify the motor controller supply voltage by attaching one lead of the meter to the white wire and the other lead to the white orange wire at the motors amp style connector Close the case top and cycle the 2G When cycled 110 Volts AC 230 VAC where applicable should be read at the meter If no voltage is present check the wiring harness leads for breaks If 110 Volts AC 230 VAC where applicable is present at the connector replacement of the cutter motor and or the controller is required Follow the procedures on page 6 17 for changing the cutter motor controller Motor is Noisy Nose bearing failure If the motor is making a grinding squealing sound it is an indication the nose bearing is going bad Follow the procedures on page 6 17 for replacing the cutter motor Chapter 6 Periodic Maintenance and Troubleshooting 6 11 a 6 12 Processor Initialization Failure Start Up Failure When the power switch is first turned ON the 2G performs a series of system checks A failure of any of the checks will prevent the 2G from continuing the initialization process The screen freezes at this point and you will not be able to exit by pressing the SETUP key Blown 20 Volt Power Supply Fuse Two fuses are used on the power supply board inside the electronics enclosure to prevent electrical damage to the processor board A blown 20 volt fuse
67. lock Diameter for Sag on the Set Up Screen e Generate the lens e If desired enter the Lap Screen and surface the desired tool in a similar fashion e Ifa knocking or banging sound is produced during fining and polishing set the cylinder machines to low speed if available and increase fining times slightly The 2G Generator User s Manual June 23 2005 Appendix a Warranty Statement of Warranty National Optronics Inc warrants the 2G Generator to be in good and serviceable condition upon shipment from the plant in Charlottesville VA The customer s sole remedy is to have defective parts replaced or repaired according to the following General Warranty For a 1 year period from the date of shipment National Optronics Inc will replace or repair all defective parts Replacement parts supplied under this Warranty will be covered for the remainder of the initial warranty period Exempted from this General Warranty are perishable tools and wear parts specifically covering but not limited to cutting tools These tools are warranted to meet normal operating specifications when shipped they will be replaced or a credit issued if found to be defective upon return to the plant These warranties set forth are made in lieu of all other warranties including merchantability expressed or implied The liability of National Optronics Inc to the customer is limited to the exclusive remedies set forth National Optronics Inc
68. lowable range an Invalid Value message will be displayed at the bottom of the screen After entering the data on the Job Screen press the READY key to load the data The data will transfer to the right column and the job will be ready to run If prism has been entered the chuck will automatically orient itself as defined in Prism Arrow Location refer to the Prism Arrow Location section of Chapter 4 Setup Screens for more information If no prism is entered pins will rotate to a vertical position Mounting the Lens Blank Running a Lens 3 2 1 Mount the lens with your right hand while depressing the CHUCK button with the left 2 Make sure the lens is pushed as far into the chuck as possible and is properly located on the two pins and seated on the collet face 3 Press the CHUCK button Note Center blocking is the recommend blocking method for use in the 2G Prism rings should not be used with the 2G since it is capable of automatically generating prism After mounting the lens close the Plexiglas lid and depress the start button The 2G will automatically generate the lens After completion of the cycle the operator should lift the Plexiglas shield and holding the lens in the right hand release the CHUCK button with the left The chuck will not release until the lens collet carriage returns to its home position NOTES AND HINTS The software is configured so the operator can input the next job to be
69. ly adjusted the meter should read between 4 95 and 4 99 volts DC If adjustment is needed locate the 5 Volt DC adjustment potentiometer and using a small insulated screwdriver adjust until the voltage is within the limits specified above Checking and Adjusting the 20 Volt DC Processor Voltage l 2 Locate the 20 Volt DC test points Ensure that the meter is set to the DC voltage scale and place the red meter lead on the white orange wire and the black meter lead on the white yellow wire on the I O board Read the voltage from the meter when properly adjusted the meter should read between 19 95 and 20 10 volts DC If adjustment is needed locate the 20 volt DC adjustment potentiometer and using a small insulated screwdriver adjust until the voltage is within the above limits Checking the Power Supply Input Voltages The power supply input voltages are provided by the transformer Three separate voltages are supplied to the power supply Voltage measurements can be made either at the transformer or the power supply connector Note Output of the transformer to the power supply is the side of the transformer with 6 wire leads the input side of the transformer has 2 wire leads Chapter 6 Periodic Maintenance and Troubleshooting 6 15 6 16 Transformer Supply Voltage In order for the transformer to supply the correct voltages to the power supply the correct input voltage must be present The transformer supply voltage can
70. mal cutting backing the cutter around may damage the diamond edge to check cutter clearance The 2G Generator User s Manual June 23 2005 RE Wg PS 1 o D mar O30 i 1 I 1 T I 1 1 b o lo gt ss oM Qc c o c Le 6 e gt RADIUS SERVO COUPLER DEPTH SERVO COUPLER e Oe pas J lt TTD dl D o Hi A T Aa los 6 ms gt o o DEPTH CARRIAGE MOTION IS MOTION d vmm VIDA o e m TES B O o HEE E lo o 1 1 S i 1 E 2 Ta I la CALIBRATION PLUG MANUALLY SPIN CUTTER AND ADJUST RADIUS SERVO COUPLER TO os eo IS los 20 CENTER CUTTER BALL IN PLUG HOLE Figure 1 Setting Lens Curve Bias Remove Calibration Plug Turn Cutter Motor Back On Press the READY key to return the unit to the Calibration Screen Verify the Lens Curve Carbide Setting 1 Go to the Calibration Screen and move cursor to Calibrate Lens Curve Carbide then press the READY key Select a blank lens Enter the information as prompted and press the READY key Chuck the lens Push the START button and wait until the 2G stops Then remove the lens Using calipers measure the diameter and enter that measurement on the screen in the blank provided Press the READY key and wait The 2G will adjust itself and it will display the message Lens curve bias adjusted If you wish to verify that the 2G has now adjusted itself repeat
71. material field and press the CLEAR key The cursor will move just to the right of the field name press the lt 1 gt key to scroll up through upper and lower case letters and symbols if the desired letter or symbol is bypassed the lt 2 gt key will scroll back down through the available characters After the appropriate character has been selected press the lt 3 gt key to move to the next character position Select the next character of the name with the 1 and lt 2 gt buttons Press the 17 or lt gt Arrow key to end the entry To erase an existing custom entry move the cursor to the desired entry location and press the CLEAR key followed by the lt gt or lt gt If one of the following ASCII characters or amp is anywhere in the material name the software will automatically add the associated feature s These characters can be scrolled to with the 1 or x27 key as described above They may even be added to the CR 39 and POLY settings press the CLEAR key while in one of these fields and the cursor will jump to the end without deleting the name The operator may then add the custom feature Sep Finish amp Rough This parameter determines the distance between each sequential circular sweep of the tool as it moves across the lens during the cutting pattern The smaller the spiral separation the smoother the surface finish Reducing the spiral separation though will increase the cycle time as the cutter requires
72. more time to sweep the lens Also the increased time that the cutter is in contact with the lens can cause premature wear of the cutter The boundaries of this parameter are 0 32 mm to 2 54 mm Feed Finish amp Rough This parameter controls the lens feed rate which in turn defines the surface cutting speed of the cutter The larger the feed rate the faster the cycle time Increasing feed beyond the cutter s ability to cleanly remove material though could result in an unacceptable finish This should be set taking into account both surface finish and the cycle time The boundaries of this parameter are 1 mm sec to 200 mm sec Note The feed rate is the most important setting that affects cycle time and thus should be maximized TO This is the maximum depth of material that can be taken off TO Take Off in one pass The valid range is 1 to 17 mm This value along with the End Mill Flute Length on the Setup Screen will determine the amount of material removed in a single pass The 2G Generator User s Manual June 23 2005 RPM Maximum RPM for the Axis This is generally set to 80 rpm but may be slowed to 60 if you notice pitting toward the center of the lens Tool Tool Index This is the Index of Refraction that was used as the basis for cutting the laps being used for fining and polishing It should be set to the lap manufacturer s specifications and should be in agreement with the Tool Index in the Rx calculation soft
73. n this page or 2 by entering data directly into the fields on the Job Screen described on the following page The process is slightly different depending on which approach you are using Entering a Job The 2G is designed to provide easy job data entry for lens generation Entering a Job from a Host Computer Server 1 2 Type in the number or use the barcode reader to enter a number into the Job Number field Verify the information on the screen Pay close attention to the Block Diameter field An incorrect Block Diameter could lead to a situation where the cutter crashes into the block which might ruin the cutter blade This parameter refers to the physical diameter of the block not the Sag diameter Press the READY key to orient the collet so that you can mount the lens Properly mount the lens Refer to the Mounting the Lens Blank section of Chapter 3 Generating a Lens for directions on mounting the lens Close the 2G s lid Press the Start button After removing the lens move the cursor down to the Cut Matching Lap field and press Ready key to begin the process of cutting a lap Refer to the Lap Cutting section of Chapter 3 Generating a Lens for information about this part of the process Entering a Job Direct without a Host Computer Server 1 Enter data for each field tefer to Job Screen field descriptions that follow Pay close attention to the Block Diameter field An incorrect
74. n inner enne 6 17 Replacing the Cutter Motor sese 6 17 Replacing the Cutter Motor Controller essere 6 17 Replacing the Electronics Enclosure esse see see see se ee ee ee ee GRA ener 6 18 Replacing a Servo Motor 5t t be cett tibia 6 19 Replacing the Home Switches esse sae ss sk Re ee Ge ee ee ee Re GR ee GRA RA ee ee eek ee 6 19 Replacement Parts List esses GR AA ee RA GRA GRA GRA ener 6 20 Chip Chute issue EE EE OR IRURE EET 6 20 Case TODD de te wee EE ae Sita ERR Qe stum ed 6 20 A ER ERR M ent Pa e ee ee E ee oe 6 21 azul AR 6 21 Cutter Motor es ae Sei amie EE EE a 6 21 VACUUM cic E 6 21 Motion Controla ias DIS eb RU EE RE 6 21 ACCESSOMES R da lt ce Dee es oUt 6 22 BEA ER ie elfe rei ett eU qo 6 22 Collet Assembly ER RE EE RE OR OE 6 22 Appendix A Control Panel Monitor Descriptions ee sssees esse esse sesse ee se ee se see eene sees essee AT Control Panels NE AE aon ainia NN A 1 Right Side pamela aa aida A 1 Lett Side parla eo ette tu den atea da de dd oe da a A 1 VEE il A A N EE A A 2 MOntOE A A i TEE I Eo EE T Ts A 2 Monitor Contrast Control is E ie ei e ids A 3 Appendix B Summary of Calibration Process ee ee esee ee eene ee ee se ae es sees see B L Calibration Summary y iese sees ee ee ae RA RA RA GRA eene enne nennen nnne enne enne enne B 1 Appendix E Error Codes sis oe cento A Job DUA EOS rette OR N OO EE e t ee OE OE C 1 Lega
75. n the geometric center of the lens Adjustments must also be made to the blank Diameter and the Crib Diameter 1f cribbing is desired The new Diameter should be adjusted by adding two times the decentration to the physical diameter of the lens For example A 70 mm blank decentered by 5 mm should have an entered Diameter value of 80 mm 70 2 5 The Crib Diameter must also be adjusted in a similar fashion With the accuracy of the 2G generator and today s Rx calculation programs progressive lenses can be blocked on geometric center to be cut accurately During cutting the 2G will accurately move the OC from the geometric center of the lens to the MRP This is done by using the prism calculated by the Ry calculation software Saddle backs are produced by simultaneously producing both a minus and a plus curve on the back ofalens A saddle back is usually produced due to a limited availability of lenses in stock or for cosmetic reasons The 2G generator will produce saddle back curves in combinations from 6 00D to 6 00D Laps can also be produced for fining and polishing saddle backs The following outlines the recommended procedure for generating such a lens Appendix D Specialty Lenses D 3 D 4 e Mark tape and block the lens as usual e Enter the surfacing data into the 2G Job Screen e Change the Block Diameter on the Job Screen to match the outside diameter of the surfacing block or fiber ring There is no need to change the B
76. ne 23 2005 Communications Screen Use the Communications Screen to set up communications to a host computer or a barcode scanner Communications Screen Press SET UP to exit Comm Settings Arcnet Connection None Coml Connection Host Coml Baud Rate 9600 Coml Protocol OMA Com2 Connection Barcode Com2 Baud Rate 300 Comm Software Manage Code READY Save Setup to Floppy READY Restore Setup from Floppy READY Comm Settings Arcnet Connection Requires optional equipment Specifies the type of Arcnet connection Host or None Arcnet Node ID This field disappears when Arcnet Connection is set to None Specifies the Node ID of the Arcnet connection The value can be 1 249 Arcnet Protocol This field disappears when Arcnet Connection is set to None NOP is the only protocol selection Coml1 Connection Specifies the device connected to from the COM 1 port choices are Host Barcode or None Com1 Baud Rate Specifies the baud rate used for communications to the COM 1 device If the Com Connection field is set to None this field will not appear COMI Protocol Under Coml Baud Rate ONLY when Coml Connection is Host This field only appears when Arcnet Connection is set to None and Com1 has a Host configured OMA is the only selection Com2 Connection Specifies the device connected to from the COM 2 port choices are Host Barcode or None Chapter 4 Setting U
77. nterior J 2 6 Enter the Set Up Screen and select the Move Carriages for Cleaning option Remove the 2 inch hose from the vacuum canister s inlet and install the 14 inch hose fitted with the crevice tool Move the toggle switch on the back left corner of the 2G to the down position This will turn on the vacuum independent of the 2G s operation Vacuum the debris from the inside of the 2G with the crevice tool being careful not to disturb the control wiring When ready to move on to the next stage of cleaning press the READY key to move the carriages Reverse steps 2 and 3 to return the vacuum to normal operation The exterior may be cleaned with a mild non abrasive detergent Drain the Air Filter The filter regulator assembly 1s located on the left side of the 2G towards the rear of the machine Any moisture that has accumulated should be drained by pressing up on the valve stem located at the bottom of the bowl 6 2 Check the Air Pressure The 2G depends on air pressure to open the chuck The gauge on the regulator should be maintained at 80 psi for proper operation Every 200 to 300 Cycles Change the Vacuum Bags Both the large collection bag and the small filter bag should be changed together To insure proper operation the bags should be changed when the large collection bag has reached two thirds of its capacity While the white filter bag is removed inspect the foam filter sleeve located beneath th
78. ome switch tests indicates the change from the baseline home position to the home position of the current pass The difference should be small Consult the factory if this is not the case The Servo Burn In Utility will continue until time has expired four hours or when the operator holds any key to exit The 2G Generator User s Manual June 23 2005 Move Carriages for Cleaning When you activate this procedure from the Setup Screen the screen shown below appears Follow the steps shown on the screen The carriages will move to a cleaning position and then remain stationary until you press the READY key This allows for a more thorough cleaning behind the carriages Cleaning is a very important maintenance procedure that should be performed on a regular basis Move Carriages for Cleaning Screen 1 Open lid and turn cutter motor Off Vacuum Position 1 2 Vacuum Position 2 3 Vacuum Position 3 4 Turn cutter motor on and Close Lid Press READY to Continue IMPORTANT NOTE To store any changes made in any of the screens discussed in this chapter the SET UP key must be pressed while in the Setup Screen This will store the changes in the 2G s internal storage device When the Job Screen returns this will be your indication that the values were completely stored Chapter 4 Setting Up the 2G 4 19 Chapter J Calibration Calibration To Calibrate the 2G 1 Press the SET UP key Once in the Setup Screen v
79. onics Enclosure Remove the mounting screws and washers from the tabs at each end of the electronics enclosure Carefully remove the Electronics Enclosure from the 2G Place the new electronics enclosure into place in the 2G taking care not to trap any wires beneath the enclosure Install the mounting screws and washers Reconnect the leads to the left side of the electronics enclosure Insert the power plug at the rear of the 2G and switch the power to the ON position If you used the Save Setup to Floppy option on the Communications Screen use the Restore Setup from Floppy to recover the Setup numbers If the Set Up Screen entries were recorded in step 1 re enter the values at this time If it was not possible to record these entries and they were not previously recorded in the manual refer to Chapter 5 for settings and calibration Cut a test lens and calibrate as necessary The 2G Generator User s Manual June 23 2005 Ls Replacing a Servo Motor 1 2 Switch the power to the 2G to the OFF position Loosen the 2 set screws securing the servo motor s shaft to the servo motor coupler Omit this step for the axis servo motor Disconnect both the power and the encoder plugs Loosen the two clamping screws securing the motor in its mount Slide the new motor into the mount taking care to align the flat on the motor s shaft with one of the set screws on the servo motor coupler For the axis servo take care
80. or contrast can be adjusted by turning the knob that is mounted on the inside of the unit on the left hand side of the monitor keypad dust cover The monitor is configured for white lettering on a blue background Appendix A A 3 Appendix Summary of Calibration Process B Calibration Summary Pre calibration Checklist e Correct Blade Radius e Review Blank Material Screen Depth Carriage Stop Sete End Mill Flute length LENSES Center Cutter with the Calibrate Lens Curve Procedure a b Use the Calibrate Lens Curve procedure refer to Chapter 5 for details to Rough in the Lens Curve Bias Cut a 6 00 lens and check sag consistency across entire surface adjustment to Lens Curve Bias if lens is flat in the center adjustment to Lens Curve Bias if lens is steep in the center Adjust in increments of 0 010 mm and re cut 0 5 mm thinner to check e Perfect sag not necessary adjust to get curve consistent 2 Calibrate Curves with the Compensation Radius and the Curve Corrections a Bring a 6 00 lens to the proper sag with the 6 00D Correction adjustment to 6 00D Correction if curve is steep adjustment to 6 00D Correction if curve is flat Adjust in increments of 0 010 mm and re cut 0 5 mm thinner to check Bring a 12 00 lens to the proper sag with the 12 00D Correction adjustment if too steep adjustment if too flat Bring a 1 00 lens to the proper sag with the 1 00D Correc
81. p the 2G 4 15 4 16 Com2 Baud Rate Specifies the baud rate used for communications to the COM 2 device If the Com2 Connection field is set to None this field will not appear COM2 Protocol Under Com2 Baud Rate ONLY when Com2 Connection is Host This field only appears when Arcnet Connection is set to None and Com2 has a Host configured OMA is the only selection Comm Software Manage Code Allows you to load the new code from a floppy drive Save Setup to Floppy Saves all calibration setup numbers and statistics all data saved across power cycles to disk for future retrieval with the Restore Setup from Floppy feature Restore Setup from Floppy Restores from floppy all the numbers saved to floppy with the Save Setup to Floppy feature The 2G Generator User s Manual June 23 2005 Statistics Screen Use the Statistics Screen to review various types of machine cycles Also when you change the vacuum bag cutter blade or motor reset the cycles to zero counts Statistics Screen Press SET UP to exit Cycle Stats avg avg of Count Pass Time Total PB Crib CR 39 0 0 0 0 00 0 0 POL 0 0 0 0 00 0 HI IDX 0 0 0 0 00 0 0 0 LAP 0 0 0 0 00 0 Total 0 0 0 0 00 Reset Cycle Data RESET Maintenance Counters Cycles Passes Vac Bags 0 0 RESET Blades 0 0 RESET Motor 0 0 RESET Other Counters Interrupt Events 0 RESET Axis Depth Radius Home Fail 0 0 0 RESET Servo Fa
82. produce a weaker curve If in doubt about how to use these values or whether you need to leave them at the factory settings Chapter 4 Setting Up the 2G 4 5 4 6 Axis Calibration Screen When you press the READY key while on the Calibration Axis field you go to the Axis Calibration Screen Calibration Screen Press SET UP to Exit Blank Front Curve 0 0 Blank Back Curve 0 0 Edge Thickness Blank Diameter Material Block Diameter Press READY for next step Press SET UP for next exit Enter Blank Front in Diopters The fields are self explanatory For instructions on calibrating the axis refer to Chapter 5 Calibration The 2G Generator User s Manual June 23 2005 Lens Material Screen This screen allows the adjustment of the cutting parameters including Spiral Separation Feed Rate Takeoff Axis Velocity and Tool Index for various materials The Lens Material Screen see Figure 3 can be accessed from the Setup Screen by pressing the READY key when the cursor is on the Lens Material Screen line The parameters entered in the fields control the speed and surface finish during the generating cycle and can be changed within specific limits To exit the Lens Material Screen and return to the Setup Screen press the SET UP key Lens Material Screen Press SET UP to exit Finish Rough sep Feed Sep Feed TO RPM Tool CR 39 1 00 100 2 00 100 10 80 0 1 53
83. r the initial blank edge thickness in millimeters Only whole number values are accepted This value must be between 1 and 30 mm Note This is NOT the final edge thickness that might be indicated on the lab ticket Diameter Enter the blank diameter in millimeters A whole number value between 25 and 99 must be entered in this field If cribbing 1s desired the maximum value for this field is 81 mm due to the physical characteristics of the 2G and the cutting tool Material Select the material type This selection determines the axis speed spiral separation and index from the Lens Material Screen refer to parameters The field will automatically default to the same material as the previous job To change the material press the lt _ gt key The unit is initially configured with three lens materials CR 39 POLY and HI IDX High Index Depending on lab preference you can add up to seven additional materials see Lens Material Screen section of Chapter 4 Chapter 2 Entering a Job 2 5 2 6 Block Diameter This is the outside diameter of the lens block The valid range is 40 to 99 mm and must be a whole number The default value is 50 mm This number is used to determine if a cutter crash will occur Note The software is programmed to handle unreasonable data entry to prevent the cutter from cutting into the block This protection can be overridden but a warning will be given to the operator The protection par
84. r to a trip odometer in an automobile The counter is provided for scheduling maintenance or measuring operator performance To prevent accidentally resetting it during operation you can insert a small pin wire or nail in the hole in the reset button F Chuck Button Blue This button opens and closes the chuck which holds the lens block of epi Figure 2 Keypad The keypad on the right side of the generator controls the data input for the lens being generated See Figure 2 for the layout of the keypad lt P gt lt gt The up arrow and down arrow keys are used to move the cursor on the screen SET UP The SET UP key is used to transfer between the Set Up Screen and the Job Screen To transfer to the Set Up Screen the operator will be asked to enter a 6 digit security code number READY The READY key is used to accept the complete job data and prepare the machine to cycle This key is also used to enter various screens from the Set Up Screen CLEAR The CLEAR key is used to erase data on a line to re enter new data lt _ gt This key is used to change the sign on any of the data fields It is also used to scroll though a set of predefined choices in the appropriate fields The monitor mounted in the case top on the right is used to display the various screens associated with the 2G generator There are multiple screens available 1 The Job Screen is used to enter the data necessary to g
85. rate against the lens producing excessive chatter Follow the procedures on Page 17 for changing the cutter motor Center thickness is inconsistent 1 Incorrect Block Diameter for Sag Ensure the Set Up Screen entry for Block Diameter for Sag is correct for the type of blocking system being used see Chapter 5 Calibration 2 Incorrect blank Front Curve Verify that the value entered for the Front Curve on the Job Screen is accurate and correct 3 Loose or damaged depth servo coupler Ensure the four set screws securing the coupler to the servo motor and lead screw are tight and the coupler is intact Replace the coupler if necessary The 2G Generator User s Manual June 23 2005 Ls Prism direction incorrect Incorrect prism arrow location Ensure the Set Up Screen entry for Prism Arrow Location is set in accordance with lab procedures for locating prism see Chapter 5 Calibration Prism amount incorrect 1 Incorrect Ring Index Ensure the Lens Material Screen entry for Ring Index is set in accordance with the lab s Rx calculation computer This can be verified through your system manager 2 Lens blocked off center Ensure lenses are blocked on geometric center Chapter 6 Periodic Maintenance and Troubleshooting 6 7 a Job Entry Screen 6 8 Screen entries are barely visible 1 Contrast control out of adjustment Adjust the contrast knob located on the keyboard cover inside the case top for best clarity
86. rrection 1 00D Correction 12 00D Correction Cut Test Lens Cut Test Lap Press READY to enter menu Figure 2 Calibration Screen Note These are default values Each machine will have unique values for proper calibration which will not necessarily match the above values The Cut Test Lens feature will automatically bounce between the Calibration Screen and the Job Screen during the fine tuning of curves center thickness etc The Cut Test Lap feature will automatically bounce between the Calibration Screen and the Lap Screen during the fine tuning of curves center thickness etc Special Note The values on the Calibration Screen are only temporarily saved during this procedure while the operator is fine tuning It is necessary to press the SET UP key once to exit the Calibration Screen and again to exit the Setup Screen and return to the Job Screen to permanently save the calibration values Axis Bias This controls the relative angular position of the rotating chuck assembly It is used during calibration to adjust axis position The units are degrees Normally this value is between 0 0 and 5 0 Once set at the factory the only time that this number should change is when a new home switch or a collet assembly is installed The 2G Generator User s Manual June 23 2005 Thickness Bias This is the distance from the initial home position of the cutter to the plunge depth of the cutter into the lens
87. run in the left column while the machine is running After the cycle is completed the READY key can then be pressed to transfer the new job over so that it can be generated The machine will then be ready to accept new data in the left column Should the next lens be similar to the one running the operator can move the cursor to the upper most field Job Number enter 0 in the field and press arrow down 4 This procedure will duplicate the data fields of the right side into the left side so that any necessary changes can be made from the previous job This can also be done while a lens 1s running The 2G Generator User s Manual June 23 2005 Lap Cutting Lap Screen Process Overview l 2 Fill in data on the Lap Screen Press the Ready key to position the collet preparatory to loading the lap Place the lap into the lap holder and tighten the bolt with a small amount of pressure Overtightening can cause the lap to deform producing inaccurate curves Load the lap into the Chuck Press the CHUCK button to grip the lap holder Press the START button to begin cutting the lap Enter the Lap Screen from the Job Screen by pressing the READY key from the Cut Matching Lap field See the figure shown below for the layout of the Lap Screen other Coburn DAC OWC PSI Salem GCFoam PSISnap 1 Sep FR TO Lap Material Screen Press SET UP to exit Finish Rough Sep FR Sep FR TO PT SC Tool 1 0
88. t allowing lenses to be generated without liquid coolant Its fully automatic cutting operation can generate base and cross curves from 30 to 30 diopters in a nominal 45 to 90 second cutting cycle time Prism power and direction are also computer executed eliminating the need for prism blocking or prism rings Collet adapters are available for all standard surface blocking systems For Further Assistance If you should require any further assistance National Optronics can be contacted directly between 8 30 AM and 5 00 PM ET Monday through Friday National Optronics 100 Avon Street P O Box 1547 Charlottesville Virginia 22902 Toll free 800 247 9796 Tel 434 295 9126 Fax 434 295 7799 Parts Order Fax 888 239 0778 To Order Parts Please call our Customer Service Department at 800 247 9796 ext 317 Please know your part number serial number of the machine and Customer Account Number If you do not know the part number of the part you need to order you will need to talk with Technical Assistance The following guidelines for Technical Assistance will apply in that circumstance If you need to return a part the Customer Service Department will issue a Return Authorization Number to you and explain the procedure for returning parts 1 1 For Technical Assistance Please call our Technical Service Department at 800 247 9796 ext 314 and know the serial number of your machine and Customer Account Number If you purchased
89. t remove the spacer between the block and cutter motor carriage Leave the block in place as it acts as a carriage stop during operation See Figure 3 Figure 3 Shipping Bolts Attempting to operate the machine without removing the shipping bolts could cause significant damage 5 Attaching the Vacuum System Insert the end of the 2 flex vacuum hose into the coupler on the bottom of the generator from below the bench This connects the hose to the chip chute Maintaining a gentle curve between the chip chute and vacuum connect the other end of the 27 hose to the vacuum inlet Note The vacuum inlet is the lower hole in the vacuum canister The 24 hose should be cut to the shortest length possible with a utility knife The shorter the hose the more effective the suction The excess hose can be used to direct the heated exhaust of the vacuum away from the machine The 2G Generator User s Manual June 23 2005 Connect the additional large hose from the outlet of the vacuum canister to the boot on the lower left side of the rear of the cabinet This hose is used to exhaust the hot air from the cabinet To protect your hearing ensure that the vacuum is either in a cabinet such as the one supplied by Optronics or that it is located at least one meter away from the operator s ears 6 Attaching the Compressed Air Line The compressed air connection is on the left side of the generator towards the re
90. tede 4 3 Screen FLOW liart ertet et ott een n e C PEE ve ek 4 3 Calibration Screen ee ee RA Re RA RA GR AR Ge ee ee ee ee ee ee ee GRA ee ee 4 4 Akis Bl ce 4 4 Thickness Blas eene deret He He ien 4 5 Lens Curve Bias esce dde e teet e hee edd 4 5 Lap Curve Bias N EE N RE EE eH Ee e IR ien 4 5 Lap Holder Thicktess izo 4 5 6 00D Come EE ette et ee ae LEO EE ee 4 5 6 00D Corrections eR Se eee ed 4 5 Range Calibration tre RR ee OR ER ie 4 5 Axis Calibration Screen e Rea eR as 4 6 Lens Material Screen ote diia aeos aa 4 7 Lens Material Screen Finish and Rough sese 4 8 Material entiende e eH ERREUR Oe TE RE Tete 4 8 Sep Finish amp Rough edes itti iere er e 4 8 Feed Finish amp Rough esie edm eer eere detis 4 8 jo ER 4 8 lug 4 9 Tool Tool Ide ccoo ida 4 9 Final Pass Is Skim Clinic aaa 4 9 Gentle Entry into ens EE Ed 4 9 amp Variable Spiral SeparatiOn ees se RA RA Re ae ee ee ee ee ee ee ee ee ee 4 9 vi 2G User s Manual June 23 2005 Contents Lens Material Screen Cribbing eese eene 4 10 lod 4 10 j E 4 10 PB WEE M GE ee 4 10 Ring Tid SA LA IR EE AE 4 10 Lap Material Screen sse Re ee Re ee AA
91. tion adjustment if too steep adjustment if too flat 3 Calibrate thickness with the Depth Bias a b C Use the Calibrate Thickness procedure refer to Chapter 5 for details then verify that the correct Block Diameter for Sag is entered Cut a 6 00 lens and check cut thickness against desired thickness adjustment to Depth Bias 1f lens is too thick adjustment to Depth Bias if lens is too thin Re cut 6 00 lens until thickness is correct verify with another curve 4 Check axis with Axis Bias set at factory should not vary a b c Cut a high cylinder lens for which you have an accurate lap Fine the lens for 20 seconds pull off and check for off axis marks If marks exist adjust Axis Bias 1f necessary also verify cylinder machine axis B 2 LAPS optional Verify lap thickness adjust with the Lap Holder Thickness a Verify that the correct Lap Holder Thickness is entered b Cut a 6 00 lap and check thickness adjustment to Lap Holder Thickness if lap is too thick adjustment to Lap Holder Thickness if lap is too thin Achieve lap consistency with the Lap Curve Bias a Cut a 6 00 lap and check sag consistency across lap adjustment to Lap Curve Bias if lap is flat in the center adjustment to Lap Curve Bias if lap is steep in the center Adjust in increments of 0 01 mm and re cut 0 5 mm thinner to check e Perfect sag not necessary adjust to get curve consistent Calibrate Curves
92. to align the teeth of the Delron gear with the gear at the rear of the chuck assembly Tighten both set screws securing the motor to the coupler Tighten the clamping screws securing the motor in its mount Do not over tighten as this could bind the motor Reconnect both the power and the encoder plugs Follow the procedures beginning on Chapter 5 to recalibrate the 2G Replacing the Home Switches l 2 Locate the wiring connector and taking note of its orientation disconnect it from the switch Remove the 2 screws securing the rectangular switch cover Remove the 3 screws securing the switch to its mount Taking care to align the switch with its vane mount the new switch using all 3 screws Do Not Overtighten Remount the switch cover Reconnect the wiring connector Cut a test lens and calibrate as necessary Chapter 6 Periodic Maintenance and Troubleshooting 6 19 a 6 20 Replacement Parts List Chip Chute 90231 Chip Chute Assembly 2257 Chip Chute Cutter Shield 2254 Top Cutter Shield Hinge 2259 Top Cutter Shield Latch 2263 Chip Chute Gasket Case Top Light Bulb U Lamp The 2G Generator User s Manual June 23 2005 Pneumatic 74203 Filter Regulator 74302 Bulkhead Fitting Female Electrical Cutter Motor Collet Vacuum Vacuum Hose 24 X 6 Vacuum Hose 1 2 X 12 Chapter 6 Periodic Maintenance and Troubleshooting 6 21 6 22 Motion Control
93. urve 2 3 6 8 for laps 3 4 cut test lens 4 4 cutter motor 6 2 collet nut 6 3 replacing 6 17 cutting tool changing 6 3 6 4 cylinder axis See layout axis D depth bias 4 5 diagnostic screen 4 13 A 3 diameter 2 5 for laps 3 4 E edge thickness 2 5 6 8 electrical connections 1 7 electrical supply 1 2 electronics enclosure replacing 6 18 encoder 6 13 end mill flute length 4 2 F fan filter 6 3 final skim cut 4 9 front curve 2 5 fuse 20 volt 6 12 5 volt 6 13 G gentle entry 4 9 H high index with the 6E 1 3 home switch 6 12 6 13 home switches replacing 6 19 Index 1 Index Index 2 J job entry 3 1 job screen 2 2 A 2 Job Screen 3 1 K keypad 4 14 A 2 L Lap curve bias 5 4 lap holder bias 4 5 lap screen 3 3 layout axis 2 4 lens materials for use with the 6E 1 3 lens quality 6 5 lenticular D 1 material 2 5 mercury relay 6 10 mercury switch cutter motor 6 11 monitor A 2 monitor contrast A 3 move carriages for cleaning 4 19 A 3 myodisc D 3 N network LAN ID 4 14 O off center blocking D 3 P pad thickness 3 4 4 12 pass depth 4 8 4 10 4 12 physical specifications 1 3 polycarbonate with the 6E 1 3 power supply 1 2 prism 2 4 axis 2 4 direction 2 5 prism arrow location 4 2 4 3 progressive D 3 The 2G User s Manual June 23 2005 R radius bias 4 5 radius bias correction 4 5 Radi
94. us lens curve bias 5 2 range calibration 4 5 5 5 recutting laps 3 5 lenses 2 3 remote job entry 2 3 required power supply 1 2 running a lens 3 2 S saddle back D 3 serial loopback 4 14 servo burn in 4 18 A 3 servo motor 6 13 replacing 6 19 set up screen 3 1 4 1 A 2 shipping bolts 1 6 specifications cutter motor 1 3 general 1 3 physical 1 3 vacuum 1 3 spiral separation 4 8 4 11 start switch 4 13 Statistics Screen 4 17 T temperature ranges acceptable for the 6E 1 2 tool index 4 9 4 12 V vacuum 1 5 bags 6 2 varied spiral separation 4 9 voltages 20 volts DC 6 15 24 volts AC 0 2 amp 6 16 24 volts AC 4 amp 6 16 5 volts DC 6 15 8 volts AC 6 16
95. w CUTOUT VACUUM Figure 4 Setup Diagram THE GENERATOR IS NOW SET UP TO OPERATE Chapter 1 Before You Begin 1 7 2G Boot Up Sequence 1 8 During the boot up process the 2G will perform a series of self diagnostic tests that can prove valuable in troubleshooting problems The following steps are performed during boot up First the 2G will sound a series of 4 beeps and then two short beeps If the 2G continuously sounds a short beep it indicates a problem in the Electronics Enclosure This problem has many possible causes including low voltage Contact the factory for further assistance in diagnosing this problem The 2G will display a series of short messages indicating a normal boot up process for example it will display Loading Setup Values Loading Statistics Loading Menus and Install Serial Ports Next the 2G will check for internal LAN communications which requires optional specialized hardware It will set the LAN ID as specified in the Communications Screen The message Network LAN ID XX will appear on the bottom line of the display where XX is the LAN ID The type of ARCNet card will also be identified If there is no ARCNet card in your 2G or if the ARCNet card is nonfunctional the 2G will display the words No ARCNet Card found Unable to Initialize ARCNet After the 2G checks for a network and installs Servo software it will give the option of immediately go
96. ware Final Pass Is Skim Cut This feature will allow the cutter to rough cut a lens and finish up with a light smooth pass It is invoked by including a dollar symbol as any character in the material name on the Lens Material Screen When the material with the symbol is chosen all but the final pass will run at the settings for that material The final pass will be cut at the SFINAL settings The final pass can be used on any material and the may be anywhere in the name This can be configured for a final pass takeoff of 1 or 2 mm under the SFINAL material settings Note This feature will increase cycle time for those lenses that are currently being generated with a single pass since this feature requires a second pass Gentle Entry into Lens This will provide an especially gentle entry in the lens at the beginning of the cut It is useful for thick polycarbonate or maintaining sharp knife edges The feature is invoked by including a pound symbol as any character in the material name POLY for instance amp Variable Spiral Separation This option will increase Spiral Separation up to 2 50 mm at the center of the lens Chapter 4 Setting Up the 2G 4 9 Lens Material Screen Cribbing The Sep and Feed fields are the same as defined above only applied to the Cribbing part of the process The other fields are defined below Lens Material Screen Press SET UP to exit Cribbing
97. will not be held responsible for loss of use or any indirect or consequential damage As a general condition to recover in the General Warranty the customer must establish that 1 He is the original purchaser of the machine or part 2 The unit was maintained in accordance with the instructions in the Manual provided with the unit 3 The unit was operated under normal conditions and National Optronics Inc was notified of the defect within two weeks of the date of discovery See gentle entry See final skim cut amp amp See varied spiral separation A accessory kit 1 4 air filter 6 1 air pressure 6 2 ARCNet 4 14 automatic lap skim cut 4 12 axis bias 4 4 Axis calibration 5 7 axis speed 4 8 4 11 B back curve 2 5 Bar code Reader 2 3 base curve 2 3 for laps 3 3 bi concave lenses D 1 blade radius 4 2 blank base curve 3 4 blank cross curve 3 4 blank material screen 4 7 A 2 block diameter 2 6 block diameter for sag 4 2 blocking 3 1 C cabinet 1 4 calibration plug procedure 5 2 5 6 calibration screen 4 4 A 2 center removal 3 5 center thickness 2 4 6 8 for laps 3 5 cleaning the interior 6 1 collet assembly 6 2 Communications 4 15 compressed air 1 7 control panels A 1 chuck button A 2 on off switch A 1 Index start button A 1 stop button A 1 counter cumulative A 1 resettable A 2 CR 39 with the 6E 1 3 crib diameter 2 4 cross c
98. you have power glitches or questions about the power requirements Note The 2G is available for 230V 50 Hz installations It is also recommended for 230V units to be installed on a dedicated circuit Operating Conditions The 2G is designed for indoor use only The 2G is designed to operate safely at a temperature range of 5 C to 40 C at altitudes up to 2000 meters The 2G Generator User s Manual June 23 2005 General Specifications Dimensions Height 19 48cm Width 30 64cm Depth 25 64cm Weight 110lbs S0Kg Cutters Carbide endmill Two fluted diamond Cutter Motor 20 000 RPM DC Brushless 4 Hp Vacuum 2 5 HP 109 CFM 9A Lens Materials CR 39 Polycarbonate All High Index Trivex NO GLASS Certifications Conforms to UL Std 61010 1 C Conforms to EN 61010 1 Model 60124 only Statement Against Misuse The 2G generator is designed to edge plastic lenses only Any other use of the machine will compromise its safety protection features The 2G will edge ONLY PLASTIC LENSES Under no circumstances should any attempt be made to process a glass lens on this unit Chapter 1 Before You Begin 1 3 1 4 Installation Procedures Note These procedures should be followed in sequence as the proper completion of a given step may depend on the one previous to it Tools are provided in the accessory kit See Figure 1 to aid in both the installation and subsequent operation

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