Ultra Optics Training and Maintenance Instruction booklet Ultra RX Coating Procedures. SYSTEM INSTALLATION Physical Location
Ultra OpticsTraining and Maintenance Instruction bookletUltra RX Coating Procedures
Choose a physical location with good ventilation and an air exchange rate of 4-5 time per hour. A normal Heating/Cooling A/C system will provide 3-6 air exchange per hour. The Ultra RX has it’s own positive air clean room environment.
The Stand Alone Unit needs only 80” height and has a 25”x30” footprint.
One 115VAC/15 AMP with grounded three-prong receptacle.
Deionized or Distilled water of 1 mega ohm or better is adequate for the cleaning system
80psi (9-10 CFM) minimum of air at constant source. An air regulator is supplied on the system.
INTENDED USE OF MACHINE
The Ultra RX is a backside scratch resistant coating system used for coating optical lenses.
The Ultra RX should not be used for any other purpose other than the process of coating optical lenses. Any other use may result in injury or machine damage.
The Ultra RX machine requires Protective Earth grounding.
The Ultra RX is equipped with 2 outlets on the back of the system. One for main power and One for Foot Pedal.
The Ultra RX has been designed and built in accordance with European and International safety standards. The Ultra RX design is such that it can be used safety.
The Ultra RX should be checked for any visible damage during each shift. Any changes including changes in operation behavior must be reported to supervisors in charge.
The Ultra RX Coating System is intended to have an operator present at all times during operation of the equipment.
Protective Eye Wear
90% or greater IPA and Acetone
Deionized or Distilled water, 1 mega ohm or better
3/8” x 25’ Air Line with a ¼” Female Quip Coupler “Quick Disconnect”
Set-up & Start up procedures:
Slowly turn air pressure on.
Turn power on
Verify there are no coating bubbles in coating filter and correct coating height is achieved.
Prime coating for 5 minutes
Add coating fluid if needed.
Check level of deionized water.
Make sure lens is dry after wash and dry cycle.
Verify positive air flow.
Start Single or Two lens cycle.
Turn vacuum on.
Clean lens with 90% or greater IPA.
Chuck lens on spindle over wash bowl.
Chuck next lens on suction cup over the wash bowl.
Repeat process for next lens.
When the completed lenses comes around, un-chuck by pressing foot pedal to release both lenses.
Continue this process until all trays are complete.
Press ON/OFF button on the Touch Screen to turn vacuum off when last lens is removed.
To adjust coating height:
Press MACHINE SET-UP.
Press COATING ON/OFF. Adjust flow height to top of coating bowl using “Coating Pump” pot.
~Clockwise to increase.
~Counter Clockwise to decrease.
Chuck up a lens on the suction cup located over the wash bowl in the Single Lens or Two Lens Cycle.
Allow the lens to wash and dry.
As soon as the spindles start to come up, press CYCLE STOP.
Un-chuck the lens using the Foot Pedal and ensure the back side of the lens is dry.
*If there is moisture on the backside of the lens, refer to “Priming Your High Pressure Wash” page and ensure your Wash Tip and Screen are free from debris and that the Air Jet Nozzle is correctly aligned.
~ Counter Clockwise to increase
~Clockwise to decrease
Daily Duties Include
Weekly Duties Include
Coating speed 400 RPM
Coat spin off speed 2000 RPM
Wash speed 1800 RPM
Monthly Duties Include
Every 6-8 weeks replace Meissner filters in both coating system and clean water bucket.
Check Capacitor to make sure it is reading 20uf or higher.
Check positive air flow. Using a kimwipe or similar, hold it up to Ultra Optics logo to see the positive air flow. Adjust if needed.
Semi -Annual Duties Include
Replace all 3 air drier filter packs (P/N 1428).
Replace Air jet filter cartridge (if applicable).
Yearly check or replace Hepa filter (P/N 1469).
Detach remaining lenses off the suction cups.
Turn off the power to the machine and disconnect power cord from electrical outlet.
With the power off and disconnected from the outlet, open the lamp doors of the Ultra RX.
Remove the two pan head screws that hold the UV Light in the carriage.
After screws are removed, pull the UV Light Module out of the carriage.
Allow UV Light to cool for 15 minutes or until it reaches room temperature.
Remove the lens from the lamp area.
Check for lens debris on lamp module and if clear then return UV Light to carriage and return to machine operations. If lens debris or burning is present and cannot be removed, replace UV Light Module with a new one and return to machine operations.
Clear Cleated Suction Cup
To prepare the rubber chuck for non-contact measurement of speed, carefully clean an area on the deflector cup of all grease and dirt. Apply approximately a 1/8 inch piece of reflective tape to the deflector cup. Always use the T-5 reflective tape supplies
The ergonomic design of the Pocket-Tach makes the non-contact measurement of speed extremely simple. Aim Pocket-Tach at the reflective target using the sight bars on the top surface on the instrument as an aid in locating the target. A visible light projects from the underside of the Pocket-Tach parallel to the top surface and in line with the sight bars. This design allows you to view the target on the rotating shaft and the display on the instrument simultaneously.
To measure, press and hold the power button on the front panel and aim the instrument at the reflective tape on the deflector cup until a steady illumination of the “bulls eye” symbol in the instruments display indicates you are on target. Once a measurement is completed, released the power button while still viewing the target. Pocket-Tach will continue to display the last reading for approximately 90 seconds and then automatically shut off.
Go intoMachine Set-up screen.
Disconnect the nut on the nylon straight fitting attached to the stainless elbow at the bottom of your reservoir. Point nut and tubing from the filter into a clean container. Press coating ON/OFF button and the coating will pump out of the tubing into the clean container. When the reservoir is empty, press Coating ON/OFF button to turn off coating pump.
If the coating is contaminated, it may be necessary to flush system with Acetone. With the tubing disconnected from the bottom of the reservoir, pour Acetone into the Coating Bowl as you would with coating.
**DO NOT RUN ACETONE THROUGH NEW COATING FILTER. SIMPLY FLUSH INTO WASTE CONTAINER.**
Follow the other black tube from the pump up to the coating reservoir and disconnect. Both coating tubes should now be free.
The coating reservoir can now be unscrewed and removed from the coating bowl for easy cleaning.
Once the coating reservoir is out of the machine flush it out using Acetone and allow to dry. Ensure any debris in the coating reservoir has been removed. Flush again if not. Unscrew elbow from coating filter and save. Unscrew and discard coating filter. Wipe out coating bowl using a clean lint free towel. A coating bowl screen sits on the bottom on the bowl make sure it has been cleaned before reassembling.
Reassemble and either put new coating in or reuse your old coating if it has not been contaminated. Re-prime the system and release any air in the coating filter using the “bleeder” cap. Make sure to use Teflon tape on the new coating filter before reattaching the fittings.
To prime high pressure pump:
Press MACHINE SET-UP.
Chuck lens on spindle over wash bowl.
Press WASH PRIME then DUMP VALVE allow to prime for 45 seconds.
Press DUMP VALVE again to close to ensure constant beat (like a heartbeat).
If wash prime has not been achieved, allow to run with Dump Valve open for another 45 seconds.
After your wash is primed, press DUMP VALVE again and allow to run for 20 seconds. It is important to press WASH PRIME FIRST and then DUMP VALVE LAST when you are finished priming. Following these steps will help keep air out of the system.
To ensure lens is dry before it is coated:
Press PRODUCTION CYCLE
Prepare lens and chuck on spindle over wash bowl. Allow to wash and dry. When spindles start to come up press CYCLE STOP. Release lens and ensure backside is dry. If not dry, ensure wash tip and screen is clean and free of debris and that Air Jet is correctly aligned and is set to correct pressure. Then repeat priming high pressure wash.
To replace Coating Filter:
Disconnect the nut on the elbow at the bottom of your reservoir. Point nut and tubing from the filter into a clean container. Press coating ON/OFF button and the coating will flow out of the tubing into the clean container. When the reservoir is empty, press coating ON/OFF button to turn off coating pump. Disconnect the nut on the elbow at the bottom of your coating filter. Remove both elbows from the old coating filter and save. Discard old filter.
Place Teflon tape on the new coating filter before reassembling. Pour coating back into coating bowl chamber and re-prime system.
To release trapped air during priming, turn “bleeder” cap ¼ of a turn, this will allow air to escape.Always keep ahold of cap to ensure that pressure from priming does not blow cap off.