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6ES User Manual Ver 1.082 - National Optronics resources center

1. _ wera Re i 65 55 in 166 50 cm NATIONAL NADONAL SPTRONICS CPTRONICS 54 44 in 138 28 cm WALL 34 in 86 36 cm VACUUM 19 in 48 26 cm LC Tin 17 78 cm General Specifications 29 in 74 cm Cutters Coated carbide Cutter Motor Adjustable speed up to 20 000 RPM DC Brushless 34 Hp Bevel Placement 3 Axis Numerical Control 8 bevel selections with independent point control 1 4 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Vacuum 2 5 HP 109 CFM 9A Lens Materials CR 39 Polycarbonate All High Index Trivex NO GLASS Statement Against Misuse The 6ES edger is designed to edge plastic lenses only Any other use of the machine will compromise its safety protection features The 6ES will edge ONLY PLASTIC LENSES Under no circumstances should any attempt be made to process a glass lens on this unit Rev 1 082 Chapter 1 Before You Begin 1 5 Chapter 2 Section 1 Rey 1 082 Getting Started amp Daily Maintenance Initial Installation National Optronics can provide field technicians who will install your equipment and set up the Optronics 6ES Patternless Edger System to meet the needs of your specific operation You can however perform these tasks yourself Use the information in this chapter as a guide through the initial installation
2. or INC DEC to Change Job Diagnostics Arcnet COM COM2 Load SW Backup Sys NOTE The first three fields Arcnet Connection Machine Node ID and Protocol may display as read only gray background if no Arcnet card is present an Arcnet card is optional equipment Arcnet Connection Specifies the type of Arcnet connection Host 4T Saturn or None Machine 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 Protocol This field disappears when Arcnet Connection is set to None NOP is the protocol being used for each of the following Arcnet connections e A Saturn tracer e 6A4T tracer e A host computer Host Com 1 Connection The choices for Com 1 vary depending on what you have selected in the Arcnet Connection field If you have Host 4T or Saturn selected for the Arcnet Connection field your choice for Com is Bar Code or None If you have None selected for the Arcnet Connection field your choices A 22 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Rey 1 082 Baud Rate Protocol Max TRCFMT OMA Init Level Com 2 Connection Baud Rate Protocol Max TRCFMT OMA Init Level include 4T 3B and Host as well as Bar Code and None You can only have one Bar Code selection This field
3. Seg Depth Segment Depth see drawing below Seg Width Segment Width see drawing below Seg Inset Segment Inset see drawing below Seg Drop Segment Drop see drawing below The following drawing illustrates the concepts of Segment Seg Depth Width Inset and Drop corresponding to fields on the Job Screen Inset or Distance Decentration The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Setup Screen If you are calibrating the machine changing default material or frame settings or cleaning the machine the Setup Screen is often the starting point for your work as suggested by the screen flow graphic on page A 2 the fold out page Screens Left Side of the Setup Screen Cleaning Calibration Blank Materials Frame Servo Burnin Advanced Setup Takes you to the Cleaning Screen to begin cleaning procedures refer to Section 2 of Chapter 2 Getting Started amp Daily Maintenance for step by step instructions Takes you to the Calibration Screen to begin calibration procedures refer to Chapter 5 Calibrating the 6ES for step by step instructions Takes you to the Blank Material Screen for setting up a unique set of speeds etc to be used on certain lenses that is custom materials can be set up for your specific needs Takes you to the Frame Screen for modifying size offset for a specific frame type Takes you to the Serv
4. Names of screens and fields within screens will be placed in Italics for example the Setup Screen Values in a field will be in quotation marks as in The default for the New Code Source field is Floppy Requirements for Use 115 VAC 60 Hz 20A Electrical Supply This is standard outlet power in the United States The Optronics 6ES Patternless Edger System 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 edger including the vacuum is 14 3 amps The 6ES 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 you have power glitches or questions about the power requirements Note The 6ES is available for 230V 50 Hz installations It is also recommended for 230V units to be installed on a dedicated circuit Rev 1 082 Chapter 1 Before You Begin 1 3 Operating Conditions The 6ES edger is designed for indoor use only The edger is designed to operate safely at a temperature range of 5 C to 40 C at altitudes up to 2000 meters General Specifications The following drawing illustrates the general specifications of the Optronics 6ES Patternless Edger System 25 in 63 5 cm A 23 56 in 59 84 cm aos att f 20 44 in 51 92 cm
5. 12 Raise the chip chute cover and wet the sponge to ensure it is secure in the bracket 13 Lower the chip chute cover and turn the cutter motor back on 14 Close the lid of the 6ES Chapter 3 Commonly Performed Tasks 3 7 Verifying Size and Bevel Placement 3 8 Go to the Setup Screen Fs from the Job Screen Press the Calibration function key Fs Press the 58mm Circle function key r Enter a password if prompted Note Pressing the Size Calibration function key Fa causes the Job Screen to choose Job 002 this is the automatic job setup for checking size and bevel placement Load a 6 base plano lens of at least 2 mm thickness by pressing the Chuck button to lock the lens in place Press the Start button on the 6ES When done press the Chuck key 2 to release the lens then remove the lens Using calipers measure from the apex of the bevel to the other apex The distance should be 58 mm If it is not exactly 58 mm adjust Size Offset Visually check to see if the apex of the bevel is in the center of the lens edge If not adjust Bevel Offset The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Changing the Vacuum Bag Rey 1 082 The vacuum bag needs to be changed approximately every 300 cycles There is a Status Indicator in the lower right corner of the Job Screen the Status area lower right of screen that graphically shows how many cycles since the last change
6. Ifthe lens material balls up decrease Wheel 2 Rmls Bev Edge Pres Rey 1 082 8 No further calibration should be required From the Job Screen pull down Job 002 58 mm or internal Job 001 Aviator and edge a Poly lens to verify edge polish If problems are encountered refer back to individual wheel calibration Calibrating CR 39 Rimless Polish 1 Ensure that Wheel 1 and Wheel 2 have been calibrated according to the previous steps 2 Goto the Blank Material Screen press the Materials function key f4 from the Setup Screen and press the CR 39 function key Fz on the Blank Material Screen Ensure that Polish has a check mark and that Wheel 2W is selected This will cause the polish cycle to be wet on Wheel 2 Key Parameter CR 39 Wheel 2W 3 Press the Material2 function key Fs to access the Blank Materials 2 Screen 4 Use the following settings for the material CR 39 Key Parameters CR 39 Takeoff 0 10 Revs 4 Lens rpm 7 Motor rpm 6 and Rmls Bev Edge Pres 0 10 mm 5 Go to the Job Screen and call down the internal 002 circle shape 6 Use the following setting on the Job Screen Key Parameter Material CR 39 7 Set the Rmls Bev Edge Pres by cutting a medium thickness 6 0 base 75 mm diameter or less CR 39 lens e If there are striations on the lens increase Wheel 2 Rmls Bev Edge Pres e Ifthe lens material balls up decrease Wheel 2 Rmls Bev Edge Pres 8 Set the CR 39 Wet Polish Takeoff on t
7. National Optronics Inc Optronics 6E Version2 11 Eye Rignt Job 001 CireSizeJ 000 f Profle Rens Shape oes 508 C 1778 Frame Metal 2 SA Y A Material Poly Bevel Automatic Polish _ Front Back Sfty Bevel Blocking Geometric Center Status Press START to resume cycle A g m z or INC DEC to Change cow cw Apt Front dpt Back Full Front Full Back Profile Bevel The first two function keys from left to right are CCW move the pointer counter clockwise and CW move the pointer clockwise This controls where the pointer is located to be used with the next two function keys The third and forth function keys are pt Front move the bevel in towards the front 1 point at the location where the pointer is located and pt Back which moves the bevel back one point This will position the bevel in the manner shown in the next screen capture The next two function keys Full Front and Full Back lets you move the bevel in a uniform manner around all of the lens not focused at the point where the pointer is located The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Rey 1 082 The final two function keys are Profile showing the mode selected this is a toggle that will take you out of Profile Mode and Bevel which you would press to change the Bevel selection shown here as Automatic for example you could change it to Front which woul
8. ssesssesseeseessessessresseesresresseesresseesseserssressesse A 31 Display Screen Ficlds isc svesisekacceotevau hese aoe A 31 Display Screen Buttons iasissasheccdihsieasdawdatorstedasdsesiaaisneeseauiasinaies A 31 Job Screen Layout Screen icicaiess sce osee ease ieentosscadavo tenia A 32 Job Screen Layout Screen Fields and Buttons 0 cee A 32 Machine Log Screen csiay cseiveiescdaneact a E R a E RA a A 34 CVE ATMO SereeNminn ine a aE N N a a EE A 36 Passwords Seret i vincassit eles Seca heey oe atta er Std a iene Ste A 37 What Happens If I Forget My Password ccccccceesseeseceteceeeeeeeeeeseeeeseens A 37 GES System Messages isccscccesessscsecsssscoosedopnnsesdencsevesestuhedssanseersacnedesnscaracesenandetbesse B 1 Explanation of Numbered Messages Warnings and Errors c cceseeeseeereees B 1 STK OO Messa gts nran a ar e ransanens aba aa Na B 1 100 199 General Warnings nsessssseeseesesseesersseessessessesseeseeseesseesesresseesse B 2 200 299 Physical Machine Limitations c ccccecsseceseeceseceeeeeeeeeeseeesseenes B 4 3002399 Operator Error crimson nroa E AT A Riig B 7 400 499 Communication Error cccccccccessccssscecesscecesececsseeecsseeeesseeeesseeees B 7 500 599 Hardware Brot i iecdecdesstvaudludgsueccovestoeoivagadeegoeteavaasnacens ammeav anaes B 9 600 699 Cycle Errors cenicas aia aise eae caesar aca occa B 11 700 799 Operator Error eenen eases sais vee es ashe de
9. 93071 10 pack 93072 When the indicator turns red it is time to change the cutter blade Note We strongly recommend using the National Optronics cutter blade specified above Using alternative cutter blades may cause size bevel and finish problems To change the blade follow these steps 1 Press the case top release buttons and lift the case top 2 Turn off the power switch on the cutter motor controller far right side of the 6ES Turn this switch OFF before proceeding to the next step Turn switch to cutter motor OFF before pulling the chip chute cover back and touching the cutter blade Rev 1 082 3 1 3 2 3 10 11 12 133 Pull back the plastic chip chute cover The two 6 32 Plastic chip flathead Torx chute cover screws Viewed from Inside Machine Use the Optronics driver labeled Optronics on the handle that came in the 6ES accessory kit to remove the two 6 32 flathead Torx screws holding the clamp in place Note Avoid dropping the two Torx screws down the chip chute into the vacuum bag One method of avoiding that would be to stuff a paper towel or rag into the chip chute opening before removing the screws Remove the clamp If you have trouble getting it to fall out insert the end of the Torx wrench into the holes where the screws had been and lift the clamp out Note that the rounded off end is on the right side you will place it back in the same way in Step 9 be
10. Contents vi Chapter 3 Chapter 4 Chapter 5 OMA Init IEG VEl t2 scsesasacsbevsaceaaeshussbasgs neebunicessansagaabauataaitstonzeshas 2 10 Max TREFMT cainnean crash gt ie aa oA ila ha aa 2 10 Changing Communications Settings ccccesccessceeseecseceeeeeeeeeeeeeeseeneenees 2 10 Section 2 Daily Cleaning amp Other Daily Maintenance of the 6ES 2 11 Daily Cleaning of the GES ccczertsstiasec adv ccsacasasccsboaes eestsaeccnadeesuseesiean Gotetenantanlecs 2 11 Other Daily ait tenance eta ac oat eal os Cound la a toe aoa a St lees ad ce 2 12 Checking the Probe Tip for Wear wisfc seccsstecsccesiucass aiaeecusas see sbermimecseesvacee 2 12 Checking the Clamp Pad csnnnceos ieni e E E AE ERE 2 12 Tne ACCESSORY Kitai a E AE G Ea 2 13 Commonly Performed Tasks eeesooessosssoesssesssocssoossooesssosssoesssesssoossoossssssssesssese 3 1 Cha gi g the Cutten Bladesnseticisir nininini a a a 3 1 Changing the Groover Wheel s sssesesssssessseeseesresseesesrrsseessesrsseessessrssressessessees 3 4 Sponge Replacement i uia a ley ices A EER R EEE RART EER RRi 3 6 Verifying Size and Bevel Placenient 3 s lt ssseseccdestucan sean seestantedtsesdetaueteatacansatvixeieies 3 8 Changing the Vac u m Bag nsnocne cianid E a E i 3 9 Ait Intake Mamtenance casen te tea e Ea a cata ah ER 3 10 Cleaning the Polishing Wheels c sjccs stssalabivsdtastaedvateosnidacsiatesesdtestieotandaatarssaacses 3 11 Backing Up the System seninter
11. Got a Position Error Error 636 Lens is too large to cut Please check size and try again 700 799 Operator Error B 14 Error 703 Must recall job to go back to traced center Error 713 Cannot start calibration from left eye The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rey 1 082 Rey 1 082 Error 714 Need to download job for cycle to be valid Error 715 is invalid Please fix it at host or make it editable Error 716 Cannot load job while calibrating Error 717 Cannot change layout while in recut mode Error 718 Unable to save setup numbers to floppy Please remove diskette from floppy drive Error 719 Unable to restore setup numbers from floppy Please remove diskette from floppy drive Error 720 Chuck pressure is too low to be calibrated Error 721 Chuck pressure is too high to be calibrated Error 722 Please remove lens from chuck Error 723 Out of Range value Valid range is from Error 724 Illegal value Appendix B 6ES System Messages B 15 B 16 Check Value of Error 726 Calibration disk must be chucked to start calibration Error 727 Grooving Spindle Arrangement must be installed before Groove can be calibrated Error 728 Unable to save log to floppy Please remove diskette from floppy drive Error 729 Load aborted Unable to access diskette file Restoring previous main program Please remove
12. If the edger is being installed on a workbench already present in the lab proceed to Preparing the Workbench below for making the necessary cutouts To set up the Optronics workbench follow these steps 1 Remove the cabinet and cabinet top from the box 2 Place cabinet top white side down on floor 3 Place cabinet upside down on cabinet top with the doors on the same side as the cutout in the cabinet top 4 Attach cabinet to cabinet top with screws provided Preparing the Workbench Prepare the bench surface to be used by cutting an opening for the vacuum hose and vacuum power cord if the opening does not already exist as shown below WALL I BENCH bg O MACHINE 8 amp amp Bi 1 a m Zz QQ i ci WE i Yi wy Ws Sage sige les BENCH EDGE i N 23 00 g Note The Optronics cabinet has an additional hole in the back panel approximately six inches from the floor for the vacuum power cord You may need to cut a hole in the cabinet or move the cabinet two inches out from the wall to supply power to 2 2 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 the 6ES itself The power connection for the 6ES is located on the back of the unit Setting Up the Vacuum Unit There are two parts to setting up the vacuum unit assembling the vacuum and setting it up inside the cabinet Assembling the Vacuum To assemble the vacuum
13. Servo Test Screen Fields Graphs The graphs show the power required for each of the servo motors Bevel Axis and Size A number above 50 for linear axes bevel and size or above 70 for axis may indicate some carriage binding or other mechanical problem The red dots represent the first direction of movement usually away from home the green dots represent the movement back toward home position On the bevel the red dots represent the power graph for a movement to the right the green is to the left For the axis the green dots represent the power graph for a clockwise movement when viewing from the back of the lens and the red is counterclockwise On the size the red dots represent the power graph for backward movement the green represents forward movement Home Switch Repeatability This section of the screen displays the repeatability of the home switch A small number is desirable If the average is higher than 50 for the Size or Bevel or higher than 100 for the Axis then you may need to contact National Optronics Power Shows the average minimum and maximum power for each carriage Servo Test Screen Buttons Job Takes you to the Job Screen All Power Runs all three motors one at a time Bevel Power Runs the bevel motor only Axis Power Runs the axis motor only Size Power Runs the size motor only Rev 1 082 Appendix A 6ES Screens Field Definitions A 29 Frame Screen Use the Frame Screen to set defau
14. dimension diameter If the Box Size is greater than 65 mm the lens will be edged to that circumference If this number is 0 00 the edger will cut the shape exactly size on size with the trace The operator may use this feature to manually oversize the first cut or do a light skim cut in the Re cut mode A Size value of 0 10 during a re cut will give a 0 1 mm skim cut Downsizing a re cut by more than 3 mm from the previous size will require re probing for correct bevel placement For Circ Size if the Circ Size is less than 65 mm the size offset will affect the circumference If Circ Size is greater than 65 mm the lens will be edged to that circumference If this number is 0 00 the edger will cut the shape exactly size on size with the trace The operator may use this feature to manually oversize the first cut or do a light skim cut in the Re cut mode Downsizing a re cut by more than 9 mm from the previous size will require re probing for correct bevel placement Note Size adjustments are relative to the original size not the previous cut Frame Specifies whether the frame is metal plastic rimless or a frame that requires a standard groove or a wide groove Metal For metal frames default size offset is 0 00 Plastic For plastic frames automatically defaults to 0 20 but this default oversize may be adjusted on the Frame Screen refer to the Frame Screen field definitions on page A 30 Rimless Cuts a rimless
15. setting up special case frame adjustments 7 4 Frame Screen field definitions A 30 G Groover calibration 5 22 Groover drive belt maintenance replacing 6 4 Groover wheel changing 3 4 H high index with the 6E 1 5 J Job screen pulling down a job 4 1 Job Screen customizing the look 7 6 field definitions A 3 Job Screen Layout Screen field definitions A 32 L lens materials for use with the 6E 1 5 Log Screen field definitions A 34 Machine Log Screen field definitions A 34 Maintenance air intake 3 10 cutter motor replacement 6 1 periodic 3 10 probe tip replacement 6 2 probe vertical alignment 6 3 sponge replacement 3 6 Materials creating customized materials 7 3 N National Optronics contact information 1 1 network LAN ID A 26 New code source updating the software 3 14 O Offsets 5 6 A 21 Operation creating a safety bevel 4 4 edging 4 4 polishing 4 4 pulling down a job 4 1 P Parts ordering 1 1 Password protection 7 1 7 2 A 37 Passwords Screen field definitions A 37 Periodic maintenance probe tip replacement 6 2 probe vertical alignment 6 3 physical specifications 1 4 Polishing 4 4 Polishing wheel calibration 5 6 polycarbonate with the 6E 1 5 power supply 1 3 Power up 2 8 probe calibration 2 8 probe calibration 2 8 5 2 Probe calibration during power up 2 8 Probe calibrations 2 8 5 2 Probe tip replacement 6 2 Probe vertical alignment
16. 4 Remove the probe alignment tool and place it and the hex key set back into the tool kit Rev 1 082 Chapter 6 Performing As Needed Maintenance 6 3 sl Replacing the Groover Drive Belt or Pulley If the Groover Drive Belt breaks the wheel will not turn Replacing the Groover Drive Belt To replace the Groover Drive Belt follow these steps 1 Use the switch on the controller box to turn the motor OFF this is an important safety step Always make sure the controller box switch is OFF before placing your hands near the cutter Remove the three screws Item in the drawing shown below 7 A Wy n Ta W D O 3 Remove cap plate to expose the drive mechanism Item 2 4 Remove the 4 40 socket head cap screw Item 3 to release the pulley from the threaded shaft 5 Remove the groover drive pulley Item 4 also called a sprocket 6 Clean out any debris or build up before replacing the drive belt 7 Remove the old drive belt if broken remove all parts of it and place a new drive belt in its proper place Item 5 8 Reverse Steps 2 through 5 to re install the screws and cap plate 9 Turn the motor back ON 6 4 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Replacing the Groover Drive Pulley s To replace the Groover Drive Pulleys 1 Use the switch on the controller box to turn the motor OFF this is an important safety step A
17. Transfer the trace data to a 6E 3 Edge a lens Ifthe lens fits precisely no adjustments are needed If not perform these steps A Measure the circumference of the lens and calculate the approximate difference between the lens and the size it should be Go to the Advanced Setup Screen Enter a number in the Trace Size field or change the existing number that would be approximately the radius difference for example if the circumference difference is 3 mm enter or change the existing number by 1 e Ifthe lens is too large decrease the number in the Trace Size field e Ifthe lens is too small increase the number in the Trace Size field D Repeat this process until the 6E edges accurately with the trace data received Rev 1 082 Chapter 5 Calibrating the 6ES 5 5 5 6 Calibrating the Polishing Wheels The following pages provide a step by step process for calibrating the polish wheels When you are more familiar with the 6ES screens and terminology you may wish to refer to the 6ES Polish Calibration Quick Reference Guide section on Page 5 24 During the process of calibrating the polishing wheels it is very important that the following steps be performed in order and that each step is completed before moving on to the next step Wheel 2 CR 39 High Index NOP Cutter Dry Rough amp Bevel All Wheel 1 Materials Poly Trivex Note CR 39 and High Index are polished wet on Wheel 2 only The best finis
18. Use the following settings for the material Poly Key Parameters Poly Takeoff 0 10 and Revs 2 5 Goto the Calibration Screen Fs from the Setup Screen 6 From the Calibration Screen move the cursor to 58 mm Circle and press the Ev key or press the 58 mm Circle function key fe This will take you to a modified Job Screen one set up for 58 mm circle calibration 7 Use the following setting on the 58 mm Circle Calibration Screen Barcode or enter Job Number Eye Frame Material Probe Mtd Polish SBevel Advanced Key Parameters Frame Rimless Material Poly 8 Set the Wheel 2 Rimless Size Offset by cutting a medium thickness 6 0 base 75 mm diameter or less Poly lens The polishing wheel should remove material around the lens completely e Ifthe lens is small enter a positive Wheel 2 Rimless Size Offset e If the lens is large enter a negative Wheel 2 Rimless Size Offset Chapter 5 Calibrating the 6ES 5 17 Calibrating Poly Rimless Polish 1 7 5 18 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Go to the Blank Material Screen press the Materials function key F from the Setup Screen and press the Poly function key ffs on the Blank Material Screen Ensure that Polish has a check mark and that Wheel 1D 1W is selected This will invoke a polish cycle on Wheel that is first dry and then wet Key Parameter Poly Wheel 1D 1W Press the
19. is above the line make a negative adjustment to the Axis Offset a positive adjustment if the point is below the line and then recut Repeat the process until the point lines up with the 180 line Note If you prefer to think of moving the line relative to the point of the SBA you can adjust the Axis Offset positive to move the line clockwise negative to move the line counter clockwise 5 4 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 B Check the size Using calipers measure the size across the B dimension on round sides not the point The diameter should be 58 mm If the calipers do not read 58 mm and the lens was cut with a bevel adjust the Size Offset and recut A positive adjustment will increase the size a negative adjustment will decrease it Repeat until the size is 58 mm If the calipers do not read 58 mm and the lens was cut as a rimless adjust the Rimless Size Offset and recut A positive adjustment will increase the size a negative adjustment will decrease it Repeat until the size is 58 mm C Check the bevel It should be centered see drawing BEVEL TOO FAR BEVEL TOO FAR FORWARD MOVE BACK BACKWARD MOVE BY NEGATIVE BEVEL FORWARD BY POSITIVE OFFSET ADJUSTMENT BEVEL OF FSET ADJUSTMENT Calibrate Trace Size Adjustment Perform the following steps if you receive jobs from a tracer 1 Trace a medium weight metal frame on a tracer 2
20. position of the bevel on the lens The proper setting places the center bevel see the Bevel field on the Job Screen described on page A 5 in the center of a pattern or lens Increasing this number will move the bevel towards the front of the lens Decrementing or incrementing this field may be confusing if there are negative numbers For example if the setting is 4 00 mm an increase by 0 50 would be 3 5 mm Defines the cutting radius of the blade or polishing wheel in millimeters mm which will change with blade type These are factory set and should not be altered This value may change with Blade Type Sets the relative angular position of the rotating chuck During calibration this value is used to set the axis of the edger Once set at the factory this number normally should not change except when installing a new axis home switch To adjust when the cut pattern is viewed from the PDA side increasing this value will move the line clockwise Decrementing or incrementing this field may be confusing if there are negative numbers For example if the setting is 4 00 deg an increase by 0 50 would be 3 5 deg Defines the width of the groove in millimeters for the standard or wide groove Defines the depth of the groove in millimeters for the standard or wide groove Adjusts the front to back position of the groove on the lens Increasing this number will move the groove toward the front of the lens Decrementing or incremen
21. that is blank and tells the edger if it should place a safety bevel on the lens To change this value press the S Bevel function key fs key or move the cursor to the field and change its value by pressing the key The Blocking function key Fs allows you to change from Optical Center to Geometric Center from the Job Screen Graphically represents the shape the lens will be cut displays A B C These change appropriately as the size setting is changed In Optical Center mode the decentration will appear in the lower left corner Status Indicators and Fault Indicators display here The warnings appear only if there is a Status or Fault warning The following warnings may appear Status Indicators The bar graphs Groover Blade Sponge and Vac on the Job Screen represents the number of cycles since the last groover blade sponge or vacuum bag replacement This graphic turns yellow at 90 of the life expectancy of each and red when it is time for replacement tefer to Chapter 3 Commonly Performed Tasks for step by step instructions Cutter Fault These words appear when the cutter motor fails to start up at the beginning of the cycle or stops running at any time during the cycle Water Level These words appear when the sensing device on the coolant receptacle indicates that the water level is very low A cycle requiring polishing cannot be started when the Water Level warning is visible Vacuum
22. 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 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Conventions Used in This Manual Wherever possible keys on the 6ES keypad are identified with a graphic representation of the key such as the key The function keys run along the top of the keypad and are associated with buttons on the screen These buttons have different meanings depending on which screen you are viewing Although they are not marked these keys will be identified as FJ through Fe such as the Job function key F Function keys Co C Co C gt Co E through fs CHUCK 7 WLS JUS Jer J 4 3 Jie jee ee START 1 2 3 HELP 7 0 Zx ENTER STOP S I
23. A 12 Default Lens Blocking Multifocal Blocking Progressive Blocking Determines the type of blocking that the 6ES edger will use Geometric Center Traced Center or Optical Center Traced Center is an option to accept the centering of a third party software program You can choose one of the following options for how a lens is blocked for edging Optical Center The block is placed on the optical center of the lens If this option is chosen the operator must also specify bifocal blocking options Traced Center The block is placed on the traced center of the lens shape Geometric Center The block is placed at the geometric center of the frame NOTE If Geometric Center or Optical Center is chosen the options for Multifocal Blocking and Progressive Blocking below will be available Optical Center blocking is the only type that supports full graphical display of the blank and segment Sets the type of optical center decentration to use for multifocal lenses The first option for this field is Segment center which will place the block on the center of the top of the seg MRP The second option is 5 mm down 5 mm in which will place the segment center 5 mm down 5 mm in refer to the drawing on page A 8 for a graphical presentation of these concepts When a single vision lens is blocked it will always be blocked on optical center regardless of the setting in this field S
24. Arcnet connection was found Error 420 Call Host Timeout No response from Host to Gateway Error 421 Job Not Found Check that job number was entered correctly and that job exists at host Error 422 Unknown Error Network detected with no host Error 423 Edger Data NOT Found The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rey 1 082 Error 424 Serial Receive Timeout Check that serial cables are connected from 4T to 6ES and that the communications parameters on both machines are set correctly Error 425 No communication device configured or unsupported protocol Please configure a device and or a supported protocol on the Communications Screen Error 426 Bad trace received 500 599 Hardware Error Rey 1 082 Error 501 Calibration disk not detected PLEASE VERIFY THAT PROBE TIPS ARE PULLED TO THEIR FULL FRONT LIMIT AND RECALIBRATE PROBE Error 503 Possible failure of BEVEL axis home switch detected Check switch and wiring Error 504 Possible failure of SIZE axis home switch detected Check switch and wiring Error 505 BEVEL motor or encoder not responding Make sure motor wiring is intact and carriage rails are clear of debris Error 506 SIZE motor or encoder not responding Make sure motor wiring is intact and carriage rails are clear of debris Appendix B 6ES System Messages B 9 B 10 Error 507 AXIS motor or encoder not responding Mak
25. Carriage option and press the key to move the size carriage Then vacuum the spots you could not reach before Then press the Bevel function key Fs or use the Field Down key to move the cursor to the Move Bevel Carriage option and press the key to move the bevel carriage Then vacuum the spots you could not reach before Press the Home key f4 or move the cursor to the Home Carriages option and press the key to move the carriages back to the home position Reverse steps 2 and 3 to return the vacuum to normal operation that is reconnect the hose and put the switch back to CYCLE position Pull the chip chute cover back and clean around the sponge removing any debris 10 The exterior may be cleaned with a mild non abrasive detergent Note If you bump the probe during cleaning you should perform the probe calibration procedure tefer to Chapter 5 for instructions on calibrating the probe Rev 1 082 Chapter 2 Getting Started amp Daily Maintenance 2 11 Other Daily Maintenance Checking the Probe Tip for Wear If excessive wear is present replace the worn item Run the probe calibration Cut a test lens to verify calibration For information about calibration refer to Chapter 5 Calibrating the 6ES Checking the Clamp Pad If the pad is torn or loose replace with a fresh pad Notice the clamp pad in the picture shown below To replace the pad apply outward pressure to the edge of the pad and pull the
26. Chapter 5 Calibrating the 6ES 5 9 Calibrating Wheel 2 5 10 Calibrating Wheel 2 Bevel Ensure that the dry blade size is calibrated correctly before proceeding with the polish calibration refer to the Calibrating Axis Size and Bevel on Page 5 4 or edge the internal 58 mm shape Job 002 using a medium thickness 6 0 base 75 mm diameter or less Poly lens Go to the Blank Material Screen press the Materials function key f4 from the Setup Screen and press the Poly function key fe on the Blank Material Screen Ensure that Polish has a check mark and that Wheel 2W is selected This will cause the polish cycle to be wet on Wheel 2 Key Parameters Poly Wheel 2W Press the Material2 function key fs to access the Blank Materials 2 Screen Use the following settings for the material Poly Key Parameters Poly Takeoff 0 00 and Revs 2 Go to the Calibration Screen Fs from the Setup Screen From the Calibration Screen move the cursor to 58 mm Circle and press the key or press the 58 mm Circle function key ffe This will take you to a modified Job Screen one set up for 58 mm circle calibration The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 When calibrating Wheel 2 Bevel use Poly as the material with the values shown in this sample screen Use the following settings on the 58 mm Circle Calibration Screen Key Parameter
27. Fault These words appear when the vacuum fails to start up at the beginning of a cycle or stops running at any time during the cycle The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Job Screen with Optical Center Selected Using NOP Protocol If you specify Optical Center for Lens Blocking on the Advanced Setup Screen the Job Screen will have additional fields displaying as shown below National Optronics Inc Optronics 6E Yersion2 1 el Automatic These fields are not shown unless Optical Center is selected DBL Distance Between Lenses value for the frame of the current job Vert Dec Specifies the vertical decentration of the optical center of the lens not typically used for multifocal lens types OC Ht or Seg Ht Segment Height or Optical Center Height of the lens in mm This changes to OC Ht for single vision and progressive lenses Dist PD or Near PD Patient Pupillary Distance in mm This changes to Dist PD Pupillary Distance established when looking in the distance for single vision and progressive lenses Note The PD is considered binocular pupillary distance if the amount is greater than 40 mm If the amount is less than or equal to 40 the 6ES interprets that number as monocular pupillary distance This is a near measurement for all multifocal lenses except Executive segments and a distance measurement for all other lens and segment types Lens Type
28. Job Screen described on page A 5 in the center of the edge of the lens Using a positive number will move the bevel towards the front of the lens a negative number will move it towards the back Axis Offset Sets the relative angular position of the rotating chuck During calibration this value is used to set the axis of the edger Once set at the factory this number normally should not change except when installing a new axis home switch Increasing this value will move the point clockwise when the cut pattern is viewed from the PDA side Rev 1 082 Appendix A 6ES Screens Field Definitions A 21 Communications Screen Use the Communications Screen for the following tasks e To set up communications to the edger and to change communications options refer to the Tnitial Installation section of Chapter 2 for step by step instructions e To load new software refer to Chapter 3 Commonly Performed Tasks for instructions on updating the software e To back up setup numbers and restore them if necessary A sample Communications Screen is provided below Communicatic een EXIT returns to Advanced Setup Screen Comm Settings Software Arcnet Connection None Load Software Backup System Com 1 Connection Host Save Setup Nums Com 1 Baud Rate 19200 Pal aloma Restore Setup From Floppy Max TRCFMT 4 Restore Log From Floppy OMA Init Level None Com 2 Connection None E Start Modem Communications
29. Material2 function key fs to access the Blank Materials 2 Screen Use the following settings for the material Poly Key Parameters Dry Polishing TO 0 30 revs 2 Lens rpm 10 Motor rpm 7 Wet Polishing TO 0 02 revs 4 Lens rpm 10 Motor rpm 10 and Rms Bev Edge Pres 0 10 mm Go to the Calibration Screen 3 from the Setup Screen From the Calibration Screen move the cursor to 58 mm Circle and press the exe key or press the 58 mm Circle function key ffe This will take you to a modified Job Screen one set up for 58 mm circle calibration Use the following setting on the 58 mm Circle Calibration Screen National Optronics Inc Optronics 6ES Version108 EXIT returns to Previous Screen Eyelet Job 002 Box Size 0 00 Lens Shape A 580 B 580 C 1822 Frame Rimless MaterialjPoly Probe Mtd Standard a a Polishh a Sfty Bevel f je f as H r i t 4 A ae A i Calibration Offsets 4 on fi aa Edging Wheeh Wheel2 x A Size Offset 000 oo0 000 S A Rimless Size Offset 0 00 000 0 00 D a Bevel Offset 0 00 000 000 Right 7 Status E L m E Barcode or enter Job Number Eye Frame Material Probe mta Polish S Bevel Advanced Key Parameters Frame Rimless Material Poly Set the Rmls Bev Edge Pres by cutting a medium thickness 6 0 base 75 mm diameter or less Poly lens If there are striations on the lens increase Wheel 2 Rmls Bev Edge Pres
30. P N 90751 eeeesesseeeeeeeeeteeneeenee 6 6 Advanced Configuration amp Special Considerations ssccsscssssssssesseees 7 1 Customizing the 6ES to Meet Your Needs ecceececsceesseceteceeeeeeeeeeeeeeeenteenees 7 1 Password POLS CULO a sitet t gaat Se kta Nhat lan od ad el ac thas 7 1 Changing PASS WN ica cans vi ra a e ne a wad a e a haters 7 2 What Happens If I Forget My Password cccccccceesseeeteceeeceeeeeeseecsaecneenseee 7 2 Defining Customized Materials clecwsccaunsis decades cnsteedunndas ceendaduescnunegeembavecdanes 7 3 Special Charatters res ssri para EE a a a A EE RAS 7 4 Working with the Frame Adjustment Fields 000 0 ccecececeeseeeseeeeeeeteeeees 7 4 Contents vii Contents Collecting and Resetting Statistics 2s xcssscssc0sias dacssesuntssesesnsentarnenearvrstenstanavesataas 7 5 Customizing the Look of Your Job Screen ecceeecccceeceeseeeseceteceeeeeeeeeeeees 7 6 Using Pause Mode and Profile Mode for Bevel Placement cccceeeeeeeeeeee 7 7 When to Use Pause Mode and Profile Mode 0 ccecceescceeceeseeesceeeteeeteeeeees 7 7 Using PAUSE Modestas o cet Gti gets Ges bck dna E EAR RATA EES iTA 7 7 Usime Profle Modes ci 68a os irae tal i e E 7 8 Special Clamps for Thin Lenses with AR Coating ss ssssesessessesessssessesessssesse 7 10 Appendix A 6ES Screens Field Definitions oeosseossesesooesoossoossssesssocssoossoosssossssesssesesoosso A 1 Standard Flow of Work o
31. Reset Vac Reset Wheei Reset Wheel The Cycle Statistics Area The statistics in this area show how many types of cuts have been performed divided up by material The Reset Cycle function button Fe labeled Cycles on the screen zeroes out all the Cycle Statistics values Normally this should only be done at the instruction of a National Optronics service technician These cycles are usually used to record statistics for the life cycle of the 6ES however a lab manager may use them for other accounting analyses The Maintenance Statistics Area This area shows how many cycles of cuts have been performed divided up by material The first button however pertains to the Cycle Statistics area Use the Reset Cycle function button f2 labeled Cycles on the screen as discussed above Reset Buttons Use the maintenance cycle buttons to reset zero out the number of cycles for each of the items listed for example when you have just changed a blade vacuum bag etc Blades Shows the number of cycles the cutter motor has run since this field was reset after a blade change You will need to reset Blades after every cutter change refer to the Changing the Cutter Blade section of Chapter 3 Commonly Performed Tasks for detailed instructions on changing the cutter blade Groover Shows the number of times the grooving wheel was used since last reset Sponge Shows the number of cycles since the sponge was las
32. Thick Poly Same as Poly except for a slower Feed and Lens RPM Use when edging very thin AR coated CR39 or High Index material using the special A R clamps trefer to Chapter 7 for more information Use when edging very thin AR coated Poly or Trivex material using the special A R clamps trefer to Chapter 7 for more information A very fast cycle for cutting a pattern blank to match the job trace When selected the Frame field becomes Rimless because you wouldn t have a bevel or a groove on a pattern Also when the material is Pattern the Bevel Polish and Safety Bevel and fields disappear Note You can add materials to the selections provided This allows you to specify different settings even if the actual material is the same In addition please note that cutting speeds water flow chuck pressure polishing settings and polish safety bevel defaults are controlled with this selection Bevel You can choose from the following options when selecting bevel placement Front Places the bevel along the front surface of the lens Automatic Places the apex of the bevel 1 3 2 3 along the periphery and will automatically center the bevel on those portions of the lens where the edge is thinner than the full bevel This option is recommended for most jobs Center Centers the bevel on all points on the lens edge Back Places the bevel along the back surface of the lens Executive Centers the apex of the bevel along t
33. You are missing information needed for cycle Please fix and try again Error 605 Water level too low to polish or safety bevel Error 606 Block too close to or outside of edge of lens Error 607 Lens too small to probe Error 608 No lens detected Error 609 Cutter Motor Fault Appendix B 6ES System Messages B 11 B 12 Error 610 Vacuum Fault Error 611 Lens hit probe arm You may be in re cut mode using a full blank CAUTION PROBE TIPS MAY HAVE BEEN PUSHED BACK PLEASE VERIFY THAT THEY ARE PULLED TO THEIR FULL FRONT LIMIT Error 614 Door opened before cycle complete Error 615 Lens too large or too decentered to cut Try moving block and Multifocal blocking on Setup Screen to 5mm down 5mm in or changing to Geometric Blocking Error 617 Memory error 2 Error 618 Memory error 3 Error 619 Memory error 4 Error 620 Memory error 5 Error 623 Toolpath alignment error Error 626 Cannot align data The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rey 1 082 Rey 1 082 Error 627 Probe data is irregular Lens may be too small to cut out CAUTION PROBE TIPS MAY HAVE BEEN PUSHED BACK PLEASE VERIFY THAT THEY ARE PULLED TO THEIR FULL FRONT LIMIT Error 628 Not enough information for profile mode Profile cannot be used with back bevel or if back is not probed Error 629 Bevel carriage hit software limit before pro
34. a 28602 Case Bottom s 22608 Display Shield OF e 20648 Door 7 90535 Case Top Latch Assembly 8 77205 PowerSwitch Rev 1 082 C 1 6ES Internal Parts Left Side View View with Axis Gear Box amp Electric Chuck Cover Removed PARTS LIST PART ITEM NUMBER DESCRIPTION Adjustible Axis Assembly 28300 non adjustible shown in picture 2 55322 Axis Servo Motor _ 3 55322 Size Servo Motor _ _ _ 4 65520 Coupler 1 4 x 1 4 Helical Split 3X 5 90373 6ES Solenoid Assembly _ 6 90536 Electric Chuck Leadscrew Assembly 5 08 _ Stabilizer Electric Chuck Ass y Ver 2 8 90543 Size Leadscrew Assembly with Blocks 9 90548 Bevel Leadscrew Assembly with Blocks 10 90767 Reservoir Solenoid Valve Assembly a1 90780 Home Switch Assembly Ver 2 3X 12 94515 Main Ribbon Cable C 2 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 6ES Internal Parts Right Side View PART ITEM NUMBER DESCRIPTION 115V Muffin Fan Assembly 2 90451 230V Muffin Fan Assembly 3 3068 Plastic Fan Grille 2 81 on back of machine 3406 5V Power Supply Assembly 5 3409 24V Power Supply Assembly 6 28111 Home Switch X Y Carriage Vane 7 28320 Axis and EC Motor Cover 8 90872 6ES Small B Spindle Assembly 9 28471 Coolant Reservoir Assembly 10 28560 115V6ES Card Cage Seria
35. a i a a a 3 12 Saving Setup IN UMD S as ccyctcocunicet hovieetnotiataocuhaccnivencetnasenteaundaeesaeasncicannteccauneecs 3 13 Updating SoftWare ce tiaraetet od acne oud Stan Olden atc tena E heen tat RA 3 14 Operating the 6ES Standard Oper ation cccccccsssccsssccsssscsssssescssseseesees 4 1 P lling Down aJobrene ienen a enue aro ea ate aa ee RO EG 4 Job Screen Display Variations js cst ei aes 4 2 Edging Polishing Grooving and Safety Beveling 0 ec eeeeceeeceseceteceeeeeeeneees 4 4 Calibrating the 6ES eossecosssesssossssossosssssosssecssoosssossosossocessossssossoossssessseosssesssss 5 1 Calibrating the Probe Sarcroereeiine ene iiie e E O E sudedtucrunmenst 5 2 Calibration Overview eindar ie araa iaai aaa a i i ia i 5 3 Calibrating Axis Size and Bevel ss ssessesseeseeseosseessesrssseesseserssessessessressessessees 5 4 Calibrate Trace Size Adjustment 25 235 ss cisesssc0995dgccds ah sesowtaazincan dh deccanghegacthauteantlans 5 5 Calibrating the Polishing Wheel seg cctc90t s sakaies atatetevaieisseaadnens aiseishecade eas 5 6 Calibrating Wy Wee lols tact aceasta SoS seta oe Gs cleats cat otek anal Stes 5 7 Calibrating Wheel IMBC Vel cc s5iccs te cchasepaseacsonseeeteWestanneancer eeu eeenavansashs 5 7 Calibrating Wheel 1 Size xis cscee nee oa as iach crs sta cee ah Bled sales 5 9 Calibrating Wheel 2 hernisi t a teat tieces eave vented esta EA iA 5 10 Calibrating Wheel 2 Bevel nsssesssssesessesessssesses
36. an X pattern around the four bolts to ensure even tightening 8 Re tighten the screw holding the coupler in place loosened in Step 2 above 9 Connect the new motor to the controller unit and secure the wire so it will not interfere with other nearby wires Turn the motor ON 10 Go to the Log Screen Fs from the Advanced Setup Screen 11 Press the Reset Motor function key Fe or use the key to move to the Reset Motor field and press the key Probe Tip Replacement Replace the probe tips when bevel placement seems erratic and probe calibration does not fully correct the problem Probe tips should have a fairly distinct point Well worn or rounded tips are a sign for replacement Remove the old tips by following these steps 1 Hold the tip tightly with one hand while performing Step 2 2 Remove the 4 40 screw with a 3 32 inch hexagonal wrench that is an Allen wrench When reinstalling the new tips adhere to the following conditions e Make sure the tips line up e Make sure the tips are pointed at the operator and slightly down from horizontal Note It will be necessary to recalibrate the probe and bevel placement after changing tips trefer to Chapter 5 for calibration instructions The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 L Probe Vertical Alignment Align the probe if you suspect bad bevel placement or if you have replaced the probe or probe C body
37. and daily cleaning To learn about the procedures for changing the cutter blades checking size and bevel position and vacuum bag replacement read Chapter 3 Commonly Performed Tasks To learn about tasks performed while using the 6ES in a standard operation such as pulling down a job edging roughing and finishing polishing and safety beveling refer to Chapter 4 Operating the 6ES Standard Operation To learn about calibration instructions refer to Chapter 5 Calibrating the 6ES There are four phases to setting up the 6ES 1 Setting up the cabinet skipped if you already have one 2 Preparing the work bench 3 Setting up the vacuum unit 4 Setting up the 6ES Edger itself physical setup Within the final phase physically setting up the 6ES there are four main steps 1 Placing the 6ES on the cabinet and connecting the vacuum unit 2 Removing the shipping brackets 3 Connecting the 6ES to your electric outlet 4 Filling the coolant reservoir the water bottle Note These procedures should be followed in sequence the completion of one step may depend on the one previous to it Tools are provided in the accessory kit see the drawing on page 2 13 to aid in both the installation and subsequent operation The 6ES can be shipped with a cabinet which is custom designed for the application The laboratory can either 1 use the custom cabinet or 2 mount the edger on a standard workbench Setting Up the Cabinet
38. cabinet 2 3 Index 3
39. diameter calibration disk and the Pattern Duplicator Adapter PDA in the accessory kit 2 Go to the Calibration Screen 3 Press the Probe button ffs on the Calibration Screen 4 You will see a message box on the initial 6ES screen stating WARNING 101 PLEASE VERIFY THAT PROBE TIPS ARE PULLED TO THEIR FULL FRONT LIMIT Mount probe calibration disk Press Continue to calibrate probe When you see this prompt chuck the probe disk meaning insert the disk and PDA into the Chuck and press the amp 9 button to lock it into place Also verify that the Probe tips are in the correct position see pictures shown below 5 Press the key and wait while the probe calibrates itself 6 When the 6ES is finished calibrating the probe remove the PDA and disk Probe in Correct Position Note that the tips are straight down not slanted as shown below Probe in Incorrect Position Note that the tips are slanted not straight down The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Calibration Overview There are several ways of calibrating the 6ES cutting an SBA Size Bevel Axis shape cutting a circle cutting an aviator and cutting a grooved circle Each has its own advantages and disadvantages e Use the SBA shape with pattern to calibrate everything needed for edging calibration specifically size both bevel and rimless axis and bevel placement e Itis strongly recommend
40. during the cycle Customers using a central vacuum system instead of the National Optronics standard vacuum should turn this feature off Press the Vac Fault function key Fs to turn it off press the Vac Fault function key ffs again to turn it back on When off the words Vacuum Fault display in black typeface and the Vacuum bar is grayed out When on the words Vacuum Fault display in red typeface and the Vacuum bar is visible Rev 1 082 Appendix A 6ES Screens Field Definitions A 33 Machine Log Screen A 34 Use the Machine Log Screen to check maintenance statistics to view statistics on materials edged and to reset statistics when needed and save the log to a CSV file on a floppy disk Machine Log Screen EXIT returns to Advanced Setup Screen rCycle Statistics Abort Recut Full Avg of Safety Polish Polish Material Count Count Count Time Total Beveled Groove Wheel Wheel2 CR 39 24 20 90 01 29 123 67 14 0 0 522 Poly 96 40 624 0117 85 6 28 2 78 n4 18 Hi ldx 0 0 0 00 00 0 0 0 0 0 0 00 0 0 Other 1 0 15 04 31 24 0 0 0 0 00 0 0 Total 121 60 729 01 16 100 0 25 0 15 4 97 8 0 pMaintenance Statistics Vacuum Polish Polish Blades Groover Sponge Bags Wheell Wheel2 Motor Cycles 1028 70 125 193 84 188 n2 Reset Reset Reset Reset Reset Reset Reset Reset Save Log to Floppy CSY Press ENTER to Reset Cycle Statistics Job Reset Cycle Reset Blade Reset GBladd Reset Sponad
41. follow these steps 1 Remove the vacuum from the box 2 Open the vacuum and remove the accessories from inside the canister 3 Install the small motor filter bag and place the large dust collection bag around the inlet 4 Replace the vacuum top making sure the snaps are tight 5 Turn the switch to the ON position its cycling is controlled automatically Setting Up the Vacuum Inside the Cabinet If you are using a different cabinet than the one Optronics provides make sure that you have a hole in the top of the cabinet for the vacuum hose refer to Preparing the Workbench on the previous page To set up the vacuum correctly follow these steps 1 Place the vacuum unit under the workbench so that the short hose can reach from the vacuum inlet to the underside coupling of the edger chip chute refer to the left portion of the drawing shown below 2 Run the power cord through the vacuum power cord hole in the top of the cabinet After you have placed the 6ES on the workbench plug the vacuum power cord into the back of the 6ES refer to the right portion of the drawing shown below ry HOSE FROM CHIP EE CHUTE TO INLET VACUUM POWER TO BACK OF EDGER HOSE FROM OUTLET EDGER POWER TO TO EXHAUST HOLE DEDICATED 20A IN CABINET CIRCUIT VACUUM Rev 1 082 Chapter 2 Getting Started amp Daily Maintenance 2 3 24 Properly ground the vacuum A green yellow striped ground wire extends from the can of the vacuum with
42. frame the 6ES will include standard grooving for the job for example metal 1 If you place a sign within the name for example plastic the 6ES will include wide grooving for the job The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rey 1 082 Calibrating the 6ES Chapter J The 6ES arrives from the factory already tuned and calibrated and ready to go into production immediately You should check the calibration occasionally and adjust it if necessary The table shown below indicates times when calibration should be checked Calibrate Probe Axis Bevel Size Rimless Polish Safety Groove Depth Size Bevel amp Placement Change Bevel Home Switch Size Home Switch Grooving Blade The following procedures should be followed in order to properly calibrate the 6ES It is very important to proceed in order as one step may require previous steps to be completed properly Also note that Probe Calibration is part of the power up process for more information refer to the steps detailed on the following page a ES Rev 1 082 5 1 Calibrating the Probe 5 2 Each time you turn on the power switch for the 6ES you will be prompted to calibrate the probe Follow the prompts If you wish to calibrate the probe after bootup before performing other calibration follow the following steps To calibrate the probe 1 Locate the black 58 mm
43. in safety features the safety switches and the chip chute cover They are in place for operator protection any alteration removal or damage can cause a serious safety hazard Doing so will void your warranty DO NOT attempt changing cutters or any machine maintenance or repair until you have turned the cutter motor switch to OFF ROTATING CUTTERS CAN CAUSE SERIOUS INJURY USE EXTREME CAUTION WHEN WORKING NEAR THE CUTTERS Plug unit into a grounded receptacle ONLY Do not cut off the ground prong or use any cord or adapter without a ground prong Always assume that the power and motor switch are ON do not attempt any cutter change or maintenance until you have verified they are OFF When changing inserts always make sure that the insert clamp s are tight before starting the machine Never turn the machine or the cutter motor on while someone is performing maintenance or repair Always wear safety glasses with side shields when servicing the machinery Never operate this machine while on medication which may affect sight or coordination Under normal operation the 6ES produces sound levels within the requirements of the Occupational Safety and Health Administration Regulations However the use of the 6ES with other noise producing equipment may raise sound levels to a degree where hearing protection should be worn by the user Therefore if the users environmental circumstances cause a projected noise dose of 85 or more appropriat
44. lens roughs the lens out and finishes with a slow finish cut Size overset is done automatically When Rimless is selected the Bevel field changes to Probe Mtd Probe Method see definition on the following page St Groove Cuts a groove 0 5 millimeters wide this is the standard for most grooved lenses W Groove Cuts a groove with a width that is user defined on the Advanced Setup Screen Note If the Frame type is St Groove or W Groove and you have the Grooving spindle arrangement then the cycle will include grooving of the lens In addition if you place an exclamation point within the name of the frame the 6ES will include standard grooving for the job for example metal If you place a sign within the name for example plastic the 6ES will include wide grooving for the job A 4 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Material Specifies the material of the lens to be cut so that the edger can cut it at a specified rate set in the Blank Material Screen refer to the Blank Material Screen field definitions on page A 10 The factory settings are as follows CR 39 Poly HI IDX Trivex Thk Poly AR Resin AR Poly Pattern Fast roughing cut moderately slow finish cut Moderately slow roughing cut slow finish cut For high index materials moderate roughing and finish cuts Fast roughing cut moderately slow finishing cut
45. most common sign for replacement The motor should be replaced following these steps 1 Turn the cutter motor and the edger OFF Unplug the motor from its connection to the controller unit 2 Loosen the screw connecting the coupler to the motor shaft see picture below You can see down into the hole where the hex driver is being used in the picture below before placing the hex driver into the hole manually turn the polishing wheel to make the screw align with the hole Note the 3 32 inch T handle hex driver from the Accessory Kit is being applied to the screw shown below Avoid stripping the hexagonal screw on the coupler in Step 2 above Make sure that the 3 32 inch hexagonal driver Allen wrench you use for the removal of the coupler is not badly worn A new 3 32 inch T handle hex driver is provided in the Accessory Kit Rey 1 082 6 1 3 With the 3 16 inch wrench from the accessory kit unscrew the four bolts on the adapter plate that holds the plate to the wall 4 Remove the adapter plate and motor 5 Remove the four screws that secure the motor to the adapter plate 6 Install the new motor on the adapter plate Make sure that the circular boss on the motor fits into the circular recess in the plate and that the power cord coming out of the motor is at 45 to the right of vertical when viewed from the right hand side of the edger 7 Install the motor adapter plate assembly by re tightening the bolts going in
46. n es B 14 Floating Point Errors 800 899 sec ccsiswte seacoast ees B 17 Referent cicsndezs ch saudcnushececetsvalesceseedetecheucenousbatessesveectonsuscabedlauusecssbadessuseedeneeueateoys C 1 ES External Parts zsnt ene ans auncaeenva tesa tyemen aca ceonalrnnsee E etaeres aeeeo ae C 1 GES Internal Parts Left Side View nish scsi sysaatucstueariendsatn bina metudiesanns C 2 6ES Internal Parts Right Side View cccccccessecsseceseceeseeescecssecesecseeeeeseeeaeeees C 3 Spindle Assembly Exploded View ccsscccssssssscssccesncessssessccssccesncesensessesenes C 4 Statement of Warranty cccssccccsssdsnncaacvccdecevesqocdacesanssackdeseosecscessvoctunevabacesornsecansee D 1 Statement f Warranty cecenii oiei ente ERR EE deme EE ARE D 1 Contents ix Chapter Before You Begin l Before You Begin General Description The 6ES is a state of the art 3 axis Patternless Edger manufactured by National Optronics Inc It will process Polycarbonate Hi index and CR 39 lenses with exceptional accuracy Standard features include pin beveling polishing grooving and automatic decentration The clamping pressure applied by the 6ES s electric chuck is automatically adjusted by the selection of lens material addressing A R crazing issues In addition to its superior mechanics the 6ES s unique software can accumulate statistical lens information that most operators now keep manually Automatic prompts will remind operators to m
47. only appears when the Com Connection has a Barcode Host 3B or 4T configured This field shows the baud rate for the Com 1 Connection The default is 9600 Normally the 6ES software will supply the correct baud rate automatically The edger will not be able to communicate if this parameter is different from the baud rate of the attached device This field only appears when Arcnet Connection is set to None and Com or Com2 has a 4T 3B or Host configured The choices for Host are OMA or GC the choice for 4T or 3B is OMA OMA Trace Format preference 4 is Packed Binary 1 is ASCII Specifies the Initialization Level the communication information available upon initializing communication to another device The default setting is Auto which allows the attached device to specify which data items will be downloaded The other options are Preset which sends the defaults for that type of device or None which means that no data items will be assumed before each time the 6ES communicates with another device None is a slower method of communication but may be necessary depending on the host The choices for Com 2 vary depending on what you have selected in the Arcnet Connection field If you have Host 4T or Saturn selected for the Arcnet Connection field your choice for Com 2 is Barcode or None If you have None selected for the Arcnet Connection field your choices inclu
48. the paper filter and put another one in its place within the steel ring C Squeeze hard on the ring s prongs and slide the filter back into place 10 Reinstall the vacuum head on the can aligning the inlet and exhaust holes Then secure it with the three clamps 11 Close the cabinet 12 Go to the Log Screen Fs from the Advanced Setup Screen 13 Press the Reset Vac function key F7 or use the key to move to the Vacuum Bags field and press the key 14 Type the password if prompted The bag count resets to zero Chapter 3 Commonly Performed Tasks 3 9 Air Intake Maintenance For proper maintenance of your air filter follow these steps 1 Turn off the power switch on the side of the 6ES 2 Mark the top of the air filter cage with either masking tape Scotch tape Liquid Paper or Wite Out or some other method so that you will know which side goes on top when you replace the air filter cage 3 Remove the outer part of the air filter cage as shown below The cage will snap out Note the white dot marking the top of the cage as described in Step 2 4 Remove the filter as shown below 5 Clean the filter with soap and water or replace it with a new filter Part 3069 6 Place the new or cleaned filter back in the air filter cage and snap the outer part of the cage back in place NOTE When performing this step use the mark you placed on the outer part of the cage to ensure that you replace
49. the piece the same as it came out 7 Turn the power switch back on 3 10 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Cleaning the Polishing Wheels Rey 1 082 Clean the Polishing Wheels when experiencing poor polish quality and when there is visual evidence of lens material buildup To clean the Polishing Wheels follow these steps 1 Turn the cutter motor off Remove the cutter but not the clamp Turn the cutter motor back on 2 3 4 Remove the Wire Brush and Cleaning Block from the Accessory Kit 5 Using calipers or a ruler check the diameter of the Wire Brush 6 Attach the Wire Brush to the Cleaning Block then chuck the Wire Brush 1 7 Goto the Cleaning Screen fFe from the Setup Screen 8 On the Cleaning Screen confirm that the Brush Diameter field reflects the actual diameter of the Wire Brush If not type in the correct diameter or use the Up or Down Arrow keys to adjust the diameter setting 9 Press the Clean Wheel function and follow the directions on the screen Pump On a Ss se ae The Wire Brush will make three sweeps across the Polishing Wheel While it is making these sweeps you can adjust the Brush Diameter by pressing the Up Arrow key to increase or Down Arrow key to decrease the Brush Diameter setting When you decrease the Brush Diameter setting the Size Carriage will move towards the wheel which will cle
50. use CR 39 as the material with the values shown in this sample screen LLB BSR TAVASTSTSESTST ST ST Key Parameters CR 39 Grooving Feed 0 02 Lens RPM 10 Motor RPM 10 2 Go to the Calibration Screen Fs from the Setup Screen 3 From the Calibration Screen move the cursor to Groove and press the key or press the Groove function key FJ This will take you to a modified Job Screen 5 22 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 4 Use the following setting on the Groove Calibration Screen National Optronics Inc Optronics 6 EXIT returns to Previous Screen EyefRight Job soos BoxSizef 000 Lens Shape Frame St Groove Material CR 39 Groove Center gE Polish _ a Stty Bevel _ es A 580 B 580 C 1822 H H Groove Zi Standard Wide width 050 075 e A Depthf 000 foo a i Placement 0 00 Right Barcode or enter Job Number Eye Frame Material Groove Polish S Bevel Advanced Key Parameters Size 0 Frame St Groove Material CR 39 Bevel Center Polish No and Safety Bevel No 5 Set the Standard Groove Placement by cutting a 3 5 mm finished edge thickness CR 39 lens The groove should be centered on the lens e Ifthe groove is too far forward use a negative number to adjust the Standard Placement e Ifthe groove is too far backward use a positive number to adjust the Standard Placement Note To con
51. working properly There will not be a continually changing series of numbers if you do not assign a device to COM1 Same as above for Loopback 1 but uses COM2 Indicates whether the 6ES is or is not blank properly connected to a network If there is no checkmark but the edger 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 Switch Diagnostics Section of the Screen Water Level Door Reports the water level in the coolant reservoir Tells you if either the Plexiglas door or the lid is open or ajar Buttons Along the Bottom of the Diagnostics Screen Job Bevel Left Bevel Right Axis CCW Axis CW Size Front Size Back Solenoid Takes you to the Job Screen Moves the bevel one inch to the left The encoder should decrease by 64 000 Moves the bevel one inch to the right The encoder should increase by 64 000 Moves the axis counter clockwise approximately 90 from the keypad side view The encoder should decrease by approximately 60 000 Moves the axis clockwise approximately 90 The encoder should increase by approximately 60 000 Moves the size one inch to the front The encoder should decrease by 64 000 Moves the size to the back The encoder should increase by 64 000 Activates the solenoid on the chip chute which will lower the sponge onto the wheels A 26 The Optroni
52. 0 2004 Remove the unit from its shipping foam and place it on the cabinet or table with all six feet on the bench top and the cutout in the base plate roughly aligned with the cutout in the bench top Plug the vacuum power cord into the back of the edger Attach the vacuum hose from the bottom of the chip chute to the inlet lower hole of the vacuum Rey 1 082 Removing the Shipping Bracket Remove the shipping brackets and the wire tie marked with the yellow tags refer to the picture shown below The brackets can be removed with a 3 16 inch hex wrench found in the hex key set Each Connecting the 6ES to an Electric Outlet As with all electrical equipment you must ensure proper power connection for proper functionality Note The 6ES Edger must be connected to a dedicated 115V 20A circuit Connect the 6ES to power following these steps 1 Before connecting power make sure that the edger ON OFF switch is OFF 2 Plug the female end of the power cord into the back of the unit and the male end into the wall outlet making sure that the connections are secure Rev 1 082 Chapter 2 Getting Started amp Daily Maintenance 2 5 Filling the Coolant Reservoir the Water Bottle The coolant reservoir feeds the coolant to the sponge used for keeping the polishing wheel from overheating Ensure that there is always coolant the mixture of distilled water and Trico s Tri Cool coolant in the reservoir Failure to do so may
53. 10 0 00 0 00 4 7 6 20 7 7 000 000 20 AR Poly 030 2 10 T 0 02 0 00 0 00 4 0 10 20 7 000 000 15 010 000 000 4 7 6 20 rf 7 000 000 20 O10 0 00 0 00 4 7 6 20 7 7 000 000 20 Press CLEAR to edit name Job CR 39 Poly Hi ldx Trivex Thk Poly AR Resin Material Polishing Portion of the Blank Material 2 Screen Dry and Wet Takeoff Tells the edger how large to oversize the lens during the dry cut cycle During polishing this remaining material will be removed by the polishing wheel in millimeters Bev Edge Pres The amount of edge pressure applied when polishing a beveled lens wet Wet Polish Only increases pressure decreases pressure in millimeters Rmls Edge Pres The amount of edge pressure applied when polishing a rimless lens wet increases pressure decreases pressure in millimeters Revs Tells the edger how many revolutions the lens should make during the polishing process This number should be minimized since the greater the number of revolutions the longer the resulting cycle time Revs Tells the edger how many revolutions the lens should make during the polishing process This number should be minimized since the greater the number of revolutions the longer the resulting cycle time Lens rpm The speed at which the lens rotates during the polishing portion of the cycle measured in revolutions per minute Motor rpm Controls the speed of rotation of the cutte
54. 20 Power off cutter motor remove blade and power motor on Mount wire cleaning brush Make sure sponge is damp before cleaning hub Make sure that the lid is closed Press Continue to clean polishing hub 200 299 Physical Machine Limitations B 4 Warning 201 Probe tip fell off lens during probing Lens may be too small to cut out Reprobe lens 2mm smaller CAUTION PROBE TIPS MAY HAVE BEEN PUSHED BACK PLEASE VERIFY THAT THEY ARE PULLED TO THEIR FULL FRONT LIMIT REPROBED LENS CANNOT BE SAFETY BEVELLED NOTE If you receive this error message you will go into Pause Mode refer to the Using Pause Mode section of Chapter 7 beginning in Step 3 Warning 202 Probe tip fell off lens during probing Lens may be too small to cut out Reprobe lens 2mm smaller CAUTION PROBE TIPS MAY HAVE BEEN PUSHED BACK PLEASE VERIFY THAT THEY ARE PULLED TO THEIR FULL FRONT LIMIT Warning 203 Groove can not be placed as far back on lens as specified Warning 204 Lens edge may be too thin to groove The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Rey 1 082 Warning 205 Bevel is too far back to be polished Continuing will move bevel forward on lens Warning 206 Lens is too thick to be polished Continuing will turn polish off Warning 207 Lens is too thick to safety bevel Continuing will turn safety bevel off Warning 208 Half eye clamp and block must b
55. 6 3 Pulling down a job 4 1 R Replacing the coolant filter assembly 90751 6 6 required power supply 1 3 Rimless calibration 5 4 S SAB calibration 5 4 Safety bevel 4 4 Safety bevel calibration 5 20 Saving Calibration Numbers 3 13 Saving Setup Numbers 3 13 Scheduling calibrations 5 1 Security password protection 7 1 7 2 A 37 Servo Screen field definitions A 27 Servo Test Burn in Screen field definitions A 29 setup physical setup of the 6E 2 4 Setup Screen field definitions A 9 shipping brackets 2 5 Size checking 3 8 Size calibration 5 4 Software updating 3 14 Software code updating 3 14 specifications bevel placement 1 4 cutter motor 1 4 general 1 4 physical 1 4 vacuum 1 5 Sponge replacement 3 6 Standard operation creating a safety bevel 4 4 edging 4 4 polishing 4 4 pulling down a job 4 1 Starting the 6E 2 8 probe calibration 2 8 Statistics collecting usage statistics 7 5 T Tecnical support 1 1 temperature ranges acceptable for the 6E 1 4 Thin lenses 7 4 Trace Size Adjustment 5 5 V vacuum initial assembly of the vacuum 2 3 setting up the vacuum inside the cabinet 2 3 Vacuum bag changing 3 9 W water bottle See Coolant reservoir Water flow adjusting 5 21 workbench Index Index creating an opening for the vacuum hose 2 2 initial preparation 2 2 placing the 6E on the cabinet 2 4 setting up the vacuum inside the
56. Calibration Screen O E Job 002 Box Sizej 0 00 Lens Shape f oo A 580 B 580 C 1822 FramefMetal Material CR 39 BevelfCenter ber eee Ea rek A A Sfty Bevel j aor i i b il i E se Calibration Offsets i ee if 5 Edging Wheel Wheel2 N Size Offset 0 00 000 000 oe Pe Rimless Size Offset 000 f 0 00 000 eect Bevel Offset 0 00 000 000 Right Status p 1 H p Barcoce or enter Job Number Eye Frame Material Bevel Polish SBevel Advanced Key Parameter Material Poly Rev 1 082 Chapter 5 Calibrating the 6ES 5 7 5 8 8 Set the Wheel I Bevel Offset by cutting a medium thickness 6 0 base 75 mm diameter or less Poly lens The polishing wheel should lightly touch both the front and the back of the bevel e Ifjust the back is polished enter a negative Wheel 1 Bevel Offset e Ifjust the front is polished enter a positive Wheel 1 Bevel Offset e Ifthe lens is not polished enter a negative Wheel 1 Size Offset e Ifthe lens is completely polished enter a positive Wheel 1 Size Offset e Repeat as necessary until both sides of bevel are lightly touched Try adjusting in 0 05 mm increments Note To conserve lenses the test cuts can initially be oversized and then decreased by 3 mm per iteration For example by setting the Box Size to 6 00 for the first cut it can then be edged at 3 mm then 0 00 3 00 and finally 6 00 mm resulting in 5 test cut
57. D BACK PLEASE VERIFY THAT THEY ARE PULLED TO THEIR FULL FRONT LIMIT Warning 218 Lens shape may be affected by SIZE carriage minimum limit Warning 219 Bevel placement may be affected by BEVEL carriage maximum limit The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 300 399 Operator Error Warning 301 No lens detected Reprobe lens 2mm smaller CAUTION PROBE TIPS MAY HAVE BEEN PUSHED BACK PLEASE VERIFY THAT THEY ARE PULLED TO THEIR FULL FRONT LIMIT REPROBED LENS CANNOT BE SAFETY BEVELLED Warning 302 No lens detected Reprobe lens 2mm smaller CAUTION PROBE TIPS MAY HAVE BEEN PUSHED BACK PLEASE VERIFY THAT THEY ARE PULLED TO THEIR FULL FRONT LIMIT 400 499 Communication Error Rey 1 082 Error 400 No Arcnet Error Error 401 LAN Hardware Failure Make sure the DIP switches on the Arcnet card are all in the same direction Error 402 Duplicate LAN ID This Arcnet ID is already in use by another device Try another ID Error 403 LAN Receive Error Code mismatch in packet series Appendix B 6ES System Messages B 8 Error 404 LAN Receive Error Packet numbers received out of order Error 405 LAN Receive Error HOST ID is not 255 Error 406 LAN Transmit Timeout No Arcnet connection detected Error 407 LAN Receive Timeout Host received request but did not respond in time Error 419 Arcnet Not Connected Tried to call host but no
58. Fault function key F again to turn it back on When off the words Vacuum Fault display in black typeface and the bar is gray When on the words Vacuum Fault display in red typeface and the Vac bar is colored 2 Press the Job key F to go to the Job Screen and save the changes If you are not using the 6ES s polishing feature you may want to disable the Water Level warning to keep the warning from appearing on the screen If you want to disable the Water Level warning use the same type of procedure to enable or disable the Water Level warnings Press the Water function key ffs to turn it off press the Water function key Fe again to turn it back on When off the words Water Level display in black typeface and the Sponge bar will turn gray When on the words Water Level display in red typeface and the Sponge bar is colored 7 6 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Using Pause Mode and Profile Mode for Bevel Placement When to Use Pause Mode and Profile Mode Both Pause Mode and Profile Mode allow you to place the bevel manually rather than using the automated Auto Front Back Center Base Fixed and Percent 6ES bevel placement features Note These two methods also work with the groove cycle that is placement of the groove Use Pause Mode if you want to place the bevel by visually examining at the orange bevel mark on the cutter blade and the lens Pause Mode is also very s
59. Index or CR39 use AR Poly if the lens material is Poly or Trivex 6 Check the Blank Materials Screen to ensure that you are using standard default feedrates and speeds appropriate for the material These settings are listed below Roughing Finishing The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Use NOP Kit Number when ordering these parts and follow these guidelines for choosing the correct half eye blocks when using the A R clamp assembly Blockin Leap Block Leap Block Leap Block S e H 8 Kit Number Intermediate Full Size Full Size ee Lowbase Lowbase Highbase Semi Tech FAN 90068 47 46 42 90071 Shuron Oe 90072 Rev 1 082 Chapter 7 Advanced Configuration amp Special Considerations 7 11 Appendix 6ES Screens Field Definitions Standard Flow of Work on the 6ES The graphical representation on the following pages shows the screens and common patterns of screen usage Although work flow may vary from the graphic these patterns account for the more common tasks Please unfold the next pages We printed them on oversized paper to increase readability of the screen captures These two pages show e Screen flow for standard usage e Screen flow for advanced setup usage usually performed by a lab manager Rev 1 082 A 1 A 2 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rey 1 082 Field Definitions Job Screen Job Screen with Ge
60. LIBRATION DISC P N 87246 CUTTER CLAMP TORX DRIVER P N 87256 NON CONDUCTIVE SLOT SCREW DRIVER P N 87445 INT SIZE RUBBER INSERT P N 73168 QTY 1 HEX KEY SET BALL TIP 1 16 1 4 NOT SHOWN P N 87179 QTY 1 DIAL CALIPER P N 87400 L DIGITAL MULTIMETER MMM LJ L L 20A aa oko TENMA 725095 MULTIMETER DIGITAL P N 87410 GROOVING SPROCKET BELT P N 28436 QTY 1 PLASTIC SQUEEZE WATER BOTTLE P N 75154 CUTTER 5mm SHELF 1 PK P N 93071 QTY 1 PLASTIC BRISTLE BRUSH P N 87201 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Chapter Commonly Performed Tasks 3 To learn about the procedures for changing the cutter blades checking size and bevel position and vacuum bag replacement read this chapter For daily operation procedures refer to Chapter 4 Changing the Cutter Blade The blade needs to be changed approximately every 300 cycles for a carbide blade or every 3 000 cycles for a diamond coated carbide blade There is a Status Indicator in the lower right corner of the Job Screen the Status area that shows how many cycles since the last change This Status Indicator turns yellow at 90 of the blade s life according to the blade type and life specified on the Setup Screen so that you can ensure that you have a replacement blade in stock Coated Carbide Blade Part 93074 Carbide Blade Part
61. Lens Shape A 589 B 510 C 1784 Frame Piastic Material CR 39 Bevel Automatic Polish A Sfty Bevel A a 1 Blocking Geometric Center H r e Right Status E E a E Finishing Lens Eye Frame Material Bevel Polish SBevel Blocking Setup 1 move lens left 2 resume cycle 3 move lens right Chapter 7 Advanced Configuration amp Special Considerations 7 7 7 8 4 Visually examine the location of the bevel by looking at the orange bevel mark on the cutter blade to determine where the bevel will be on the lens If you want to move it to your left or right use the 6ES keypad numbers or 3 to move the bevel placement When it is in the exact location you want press 2 to finish the cycle Using Profile Mode Follow these steps to use Profile Mode 1 Make sure that the field Use Profile Mode on the Setup screen is checked 2 Go to the job screen and set up a job as you would normally do 3 Press the start key then press it again within five 5 seconds When you press the START button the first time you will see the message Press START again to adjust bevel you will have to press the START button within five seconds or the 6ES will proceed in its normal mode After several seconds the message on the screen will change to the words Bevel Adjustment Pending After the probing cycle the screen will display an image representing the lens and bevel looking similar to this
62. NATIONAL oP TRONICS The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Warnings Cautions and Notes as Used in this Publication Warning notices are used in this publication to emphasize that hazardous voltages sharp edges 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 2004 National Optronics All Rights Reserved Safety Reminders DO NOT operate this machine until you have read and understood this manual if operating for the first time ask your supervisor or a qualified operator for help DO NOT attempt to bypass or circumvent the built
63. Specifies the type of lens being edged The choices are Single Vision Bifocal Trifocal Quadrafocal and Progressive If you select Bifocal Trifocal or Quadrafocal several additional fields appear as shown on the following page Note For all five of the fields defined above the information DBL Vert Dec Seg Ht PD and Lens Type will be downloaded to the edger if it is available at the third party computer Rev 1 082 Appendix A 6ES Screens Field Definitions A 7 Job Screen with Optical Center Using OMA Protocol The fields defined below can only be downloaded using OMA protocol and are used to graphically represent the lens block National Optronics Inc Optronics 6E Version2 11 rae Job 001 Cire Sizef 006 Lens Shape Frame Plastic Material CR 39 Bevel Automatic ee ee Polish _ jf PS Sity Bevel N Blocking Optical Center 3 es DeLfi0 0 YF by i f VtDecf 40 H Seg Ht 00 Near Pofsoo pa Lens Tyee a Sea Type Flat Ton 22 ne Left Seg Depth 16 0 i A 587 B 508 C 1779 These fields appear when Lens Type is Seg WWidth 22 0 Status E Bifocal Trifocal ee a E E or Quadrafocal w Blade sponge Vac e or INC DEC to Change Eye Frame Material Bevel Polish S Bevel Blocking Setup Seg Type Type of segment Flat top Round Curve Top Executive choosing a pre set Seg Type will automatically fill in the rest of the fields Seg Depth Width etc
64. TO 0 30 rev 2 e Set Wheel 1 Rimless Size Bias so that 58mm circle is on size e WI Rimless Size Calibrate Wheel 2 Rimless Size e Material Poly Wheel 2D TO 0 10 rev 2 e Set Wheel 2 Rimless Size Bias so that 58mm circle is on size e W2 Rimless Size Calibrate Poly Rimless Polish Material Poly Wheel 1D 1W Dry Cycle TO 0 30 revs 2 Lens rpm 10 Motor rpm 7 Wet Cycle TO 0 02 revs 4 Lens rpm 10 Motor rpm 10 Poly Rmls Edge Pres 0 10mm This will force the wet cycle by that amount Increase or decrease Poly Rmls Edge Pres until 58mm is polished well e Poly Rmls Edge Pres Calibrate CR 39 Rimless Polish e Material CR 39 Wheel 2W TO 0 10mm rev 4 Lens rpm 7 Motor rpm 6 e Increase or decrease CR 39 Rmls Edge Pres until 58mm is polished well e CR 39 Rmls Edge Pres Safety Bevel Calibration Material CR 39 Frame Rimless Safety Bevel Depth 1 00 Safety Bevel Margin 0 0 Increase or decrease the Safety Bevel Depth to obtain the desired safety bevel Material CR 39 Frame Bevel Increase or decrease the Safety Bevel Margin so that the safety bevel just touches the back edge of the frame bevel on a thin lens Rev 1 082 Chapter 5 Calibrating the 6ES 5 25 Chapter 6 Performing As Needed Maintenance Cutter Motor Replacement The life of an electric motor is long but finite Motor bearings are the primary limitation on the motor s life and increasingly loud operation is the
65. This Status Indicator turns yellow at 90 of the vacuum bag life so that you can ensure that you have a replacement bag and filter in stock Bag and Filter 5 Pack Set Part 87142 When it is red it is time to change the vacuum bag and filter This reminder feature can be disabled through the Job Screen Layout field on the Setup Screen Disabling this feature should only be done when using a central vacuum rather than one under the edger Wear an appropriate dust mask and eye protection when changing the vacuum bag especially if you are sensitive to dust particles since the dust is small particles of plastic Change the vacuum bag when it gets full by following these steps 1 Open the cabinet if applicable 2 Make sure the vacuum is turned off 3 Disconnect the vacuum hose from the back of the vacuum 4 Undo the three clamps holding the top on the vacuum 5 Lift the vacuum head out of the vacuum base and set it aside 6 Pull the bag back from the inlet fitting 7 Lift the large bag out and dispose of it 8 Replace it with a new bag The bags and filters are often kept in the cabinet Bag and Filter 5 Pack Set Part 87142 9 Change the paper filter A Examine the top piece that you set aside in Step 5 above There is a steel ring some have a thick rubber band holding the paper filter onto the foam filter Squeeze the prongs on that ring and pull the paper filter off leaving the foam filter in place B Throw away
66. User s Manual October 20 2004 Rev 1 082 Wetting the Sponge for Initial Use For the first time you use the 6ES follow these steps to wet the sponge 1 Go to the Cleaning Screen from the Setup Screen press the Cleaning function key Fe 2 Press the Pump on function key Fs until the sponge is wet 3 Press the Pump off function key Fs after the sponge is completely wet Note Using a water bottle is an alternative way of wetting the sponge but the method described above ensures that the water line is full in addition to wetting the sponge Rev 1 082 Chapter 2 Getting Started amp Daily Maintenance 2 7 Powering Up and Calibrating the Probe 2 8 Each time you turn on the power switch for the 6ES you will be prompted to calibrate the probe Follow the steps discussed below To calibrate the probe 1 Locate the black 58 mm diameter calibration disc and the Pattern Duplicator Adapter PDA in the accessory kit 2 Turn on the power switch 3 You will see a message box on the initial 6ES screen stating WARNING 101 PLEASE VERIFY THAT PROBE TIPS ARE PULLED TO THEIR FULL FRONT LIMIT Mount probe calibration disk Press Continue to calibrate probe When you see this prompt chuck the probe disk meaning insert the PDA and disk into the Chuck and press the Ey key to lock it into place Also verify that the Probe tips are pointed straight down see pictures displayed below 4 Press the Continue key F and wait
67. Wheel 2 Bevelk x stusccclaaien wcdeect inex cc cha decuceataccguneutieatdaacs 5 24 Calibrate Wheel 2 S126 aces anniina ni a eno ah taney 5 24 Calibrate Poly Bevel Polish 3 c dsssccusseccssccssdievicdasecasasareaveatecina ovaks 5 24 Calibrate CR 39 Bevel Polis Macca ole canaces ts slecese mate csaaseo ve sieseast ee 5 25 Rimless Lens Calibration 502 caste ate cask cpa tame a eine ae titer cule cede 5 25 Calibrate Wheel 1 Rimless S126 s icecesiesantguedesedieesdedasnecassessccousevuedes 5 25 Calibrate Wheel 2 Rimless SiZe i295 dase nehesituncdlnalaunwarthen ee 5 25 Calibrate Poly Rimless Polish 2 6 s cc0 sceoccetisese cceaneicasencecdatasese cers 5 25 Calibrate CR 39 Rimless Polish idc scci schedesectcavacenedeccsvceadenacteavas cases 5 25 Safety Bevel Calibratio N essea a eles eves ac Sey 5 25 Performing As Needed Maintenance eeessoessoesssesssecssoossooessoessoesssosesoossosssose 6 1 Cutter Motor Replacement s sseseseseesseseessesseesresresseesessresssesrrsseessesrrssressessessees 6 1 Probe Tip Replacements renens e a EE a E ER R 6 2 Probe Vertical A lenment a gucnnnnnnaniinnea a i R a 6 3 Replacing the Groover Drive Belt or Pulley ec cee ceecceesceeseeeeteceeeeeeeeeeeeenseens 6 4 Replacing the Groover Drive Belt i i cc 2cssiestads sccates eotstacad aici cceddia ees 6 4 Replacing the Groover Drive Pulley S sscissssccsssetssesdeseseccsustsenchoanediasbavensusaens 6 5 Replacing the Coolant Filter Assembly
68. ablish 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 4 National Optronics was notified of the defect within two weeks of the date of discovery Rev 1 082 D 1 A Advanced Setup Screen field definitions A 13 Air intake maintenance 3 10 Axis calibration 5 4 B Backups 3 12 bar code A 3 Bevel calibration 5 4 Bevel Position checking 3 8 Bevel selection A 5 Blade changing 3 1 Blank Material Screen field definitions A 16 Blank Materials creating customized materials 7 3 Burn in Servo Test Screen field definitions A 29 C Calibration axis 5 4 bevel 5 4 rimless 5 4 size 5 4 Calibration Screen field descriptions A 20 Calibrations both wheel and 2 5 13 5 18 general 5 1 Groover 5 22 Grooving mechanism 5 22 polishing hub 5 6 polishing wheel 5 6 Probe 2 8 5 2 safety bevel 5 20 wheel 1 and wheel 2 together 5 13 5 18 when to calibrate 5 1 Changing the blade 3 1 Changing the groover wheel 3 4 Changing the vacuum bag 3 9 Checking and adjusting bevel position 3 8 size 3 8 Cleaning Screen field definitions A 36 code source updating the software 3 14 Collecting statistics 7 5 Commonly performed tasks bevel position checking 3 8 Index blade changing 3 1 cutter blade changing 3 1 g
69. aintain their equipment 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 Parts Order Fax 888 239 0778 General Fax 434 295 7799 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 Rev 1 082 1 1 1 2 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 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 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
70. al October 20 2004 Rev 1 082 Adjusting the Water Flow If you have cut a couple of lenses and the water flow does not seem correct too much flow or not enough you can adjust the water flow by following these steps 1 Go to the Blank Materials Screen from the Setup Screen press the Material function key F4J 2 Move the cursor to the material you are using then move the cursor to the Water Flow field 3 Increase the value in this field to increase the water flow decrease it to decrease the water flow Enter a password if prompted 4 Test the water flow by running another cycle If the water flow is still not adjusted correctly readjust the flow See Note below for an alternative way of testing Note You can also test the water flow on the Cleaning Screen The numbers on the Water Flow field there directly correspond to the numbers on the Blank Materials Screen Rev 1 082 Chapter 5 Calibrating the 6ES 5 21 Calibrating the Groover The process of calibrating the Groover is almost identical to calibrating the Polishing Wheels It is very important that the following steps be performed in order and that each step is completed before moving on to the next step 1 Go to the Blank Material Screen press the Materials function key from the Setup Screen and press the CR 39 function key Fe on the Blank Material Screen and ensure that the CR 39 grooving settings are the same as shown below When calibrating the groover
71. al October 20 2004 Rev 1 082 Spindle Assembly Exploded View Fold open the following page to view a drawing of the 6ES spindle assembly and its components Appendix C Reference C 5 Appendix Statement of Warranty D Statement of Warranty National Optronics warrants the 6ES Patternless Edger 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 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 flutes and clamps 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 to the customer is limited to the exclusive remedies set forth National Optronics 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 est
72. an eyelet attached to its end There are three suggested methods to grounding the vacuum In order of preference these methods are 1 Attach the eyelet directly to the ground frame inside the housing of an electrical outlet preferred or to the faceplate screw on the front of the electrical outlet 2 Attach the eyelet to a grounded metal water pipe Make sure the water pipe is grounded using an ohmmeter to check the continuity between the pipe and earth ground grounding rod 3 Attach the eyelet to the front right bolt of the left spindle support running the ground wire up through the chip chute hole Properly ground the vacuum hose The green yellow striped ground wire attached to the anti static segment of the vacuum hose has an eyelet attached to its end Attach this eyelet to the same ground as the vacuum itself if the wire will reach The three suggested methods to grounding the vacuum are the same as listed above for the vacuum itself in that order of preference Setting Up the 6ES There are four main steps to setting up the 6ES 2 3 4 Placing the 6ES on the cabinet and connecting the vacuum unit Removing the shipping brackets Connecting the 6ES to your electric outlet Filling the coolant reservoir the water bottle Placing the 6ES on the Cabinet To place the 6ES on the cabinet and connect the vacuum correctly follow these steps 1 The Optronics 6ES Patternless Edger System User s Manual October 2
73. an more aggressively 10 Turn the cutter motor off 11 Reinstall the cutter 12 Turn cutter motor back on Chapter 3 Commonly Performed Tasks 3 11 3 12 Backing Up the System National Optronics strongly recommends backing up your system before loading software or make sure that you have a working backup disk before loading new software Try to keep that backup disk up to date with the software that is installed on your 6ES To backup the 6ES s software do the following 1 Go to the Setup Screen from the Job Screen press the Setup function key Fs to select the Setup Screen 2 Press the Advanced Setup Screen function key F7 to go to the Advanced Setup Screen 3 Press the Comm function key Fe or use the Field Down key to move the cursor to the Communications field then press the key 4 Press the Backup Sys function key F7 or use the Field Down key to move the cursor to the Backup System button and press the key 5 Enter the password if prompted Make sure a blank 32 inch disk is in the disk drive 6 Press the key after placing the disk in the disk drive Follow the screen instructions The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Saving Setup Numbers National Optronics recommends that you save all calibration and setup numbers all data saved across power cycles to disk for future retrieval with the Restore Setup from Floppy feature prior to loading new softwar
74. and safety beveling may be affected Adjust this parameter for frame fit after size verification of the internal 58 mm circle job number 002 If the lens for frame fits large decrease this number If the lens is small increase this number Distance in millimeters added to the start position for roughing This is usually set to zero but may be increased to around 5 to help prevent axis slippage Measured offset in mm between or difference between the polishing wheel and the blade radius Set by factory do not change The height of the right probe tip above the center of the cutter Automatically set during Probe Calibration do not change The height of the left probe tip above the center of the cutter Automatically set during Probe Calibration do not change Rev 1 082 Appendix A 6ES Screens Field Definitions A 15 Blank Material Screen When you specify the material on the Job Screen the 6ES edges following the speeds and other data listed on the Blank Material Screen Blank Material Screen Page 1 EXIT returns to Setup Screen Name CR 39 Poly Hi ldx Trivex Thk Poly AR Resin AR Poly Pattern rDefaults rRoughing rFinishing rGrooving Safety Lens Motor Lens Motor Lens Motor Chuck Polish Bevel Wheel Feed rpm rpm Feed rpm rpm Feed rpm rpm O Vv aw 20 6 4 4 p oa 0 v s v YY ww 2 6 16 4 p p 02 0 1 O Vv aw 20 5 6 4 2 SA o n o m VV Dew 20 6 16 4 2 12 o2 0 v EE VY Diw 2 2 ey ry
75. ar 02 0 10 m Jv aw a 8 4 0 2 02 0 10 6 m VY paw 3 4 0 2 02 1 1 ei al m w 8 8 6 4 ee a p p a fl m 2 a 6 4 0 2 02 0 10 15 2 5 6 5 2 12 Press CLEAR to edit name Job CR 39 Poly Hi Idx Trivex Thk Poly AR Resin Materiai2 Defaults Portion of the Blank Material Screen Name Chuck Polish Safety Bevel Wheel The lines of the Name column CR 39 POLY and Pattern cannot be altered except to put a suffix at the end All other lines can be any combination of letters and symbol The main requirement is that they make sense to the operator Each material will appear in sequence on the Job Screen when scrolling through the material selections Refer to Chapter 7 Advanced Configuration for step by step instructions for adding a new material to the list Putting an asterisk anywhere in the name of a material forces rough first particularly useful when dealing with thin lenses see Chapter 7 Advanced Configuration amp Special Considerations The force the machine exerts in clamping the lens For lenses with Anti reflective Coatings AR the pressure can be reduced to prevent cracking or crazing of the lens This value toggles between a checkmark v and no checkmark that is blank and determines if polishing should occur by default If this value is set to v polishing will default to v on the Job Screen If the majority of th
76. aterials function key f4 from the Setup Screen and press the Poly function key ffs on the Blank Material Screen Ensure that Polish has a check mark and that Wheel 1D is selected This will cause the polish cycle to be dry on Wheel 1 Key Parameter Poly Wheel 1D 3 Press the Material2 function key fs to access the Blank Materials 2 Screen 4 Use the following settings for the material Poly Key Parameters Poly Takeoff 0 30 and Revs 2 5 Goto the Calibration Screen Fs from the Setup Screen 6 From the Calibration Screen move the cursor to 58 mm Circle and press the key or press the 58 mm Circle function key ffe This will take you to a modified Job Screen one set up for 58 mm circle calibration 7 Use the following settings on the 58 mm Circle Calibration Screen Optronics BES Version108 E Previous Screen o D Job foo2 5 Lens Shap o a a A 5680 B 580 C 1622 FramejRimless Material Poly Probe Mtd Standara s Pk Polish XN Sity Bevell EA E far i Calibration Offsets ue Edging Wheel Wheel2 k Fa Vi Size Offset 0 00 0 00 J 0 00 Sa ae Rinless Size Onse 000 000 000 OSS ee Bevel Offset 0 00 0 00 J 0 00 Right Status g i H E Barcode or enter Job Number Eye Frame Material Probe Mtd Polish SBevel Advanced Key Parameters Frame Rimless Material Poly 8 Set the Wheel I Rimless Size Offset by cutting a medium thickness 6 0 base 75 mm diameter or
77. be reached target CAUTION PROBE TIPS MAY HAVE BEEN PUSHED BACK PLEASE VERIFY THAT THEY ARE PULLED TO THEIR FULL FRONT LIMIT Error 630 Blocking is invalid Please check blocking parameters Error 631 Axis servo could not maintain correct position during cycle This could be due to one of the following a servo motor encoder or wiring problem a driver chip problem too high a feed rate for the material being cut too high a lens rpm for the material being cut cutter motor never turned on and lens hit arbor Please check your material settings and try again Error 632 Bevel servo could not maintain correct position during cycle This could be due to one of the following Appendix B 6ES System Messages B 13 a servo motor encoder or wiring problem a driver chip problem too high a feed rate for the material being cut too high a lens rpm for the material being cut lens debris blocking carriage Please check your material settings and try again Error 633 Size servo could not maintain correct position during cycle This could be due to one of the following a servo motor encoder or wiring problem a driver chip problem too high a feed rate for the material being cut too high a lens rpm for the material being cut lens debris blocking carriage Please check your material settings and try again Error 634 Lens is too small to cut Please check size and try again Error 635
78. but not when you replace the probe tips Align the probe by following these steps 1 Get the probe alignment tool out of the 6ES toolkit and place it on the two screws as shown below Note that there is a large hole for placing the alignment tool on the screws and a keyhole notch above it Once you M have placed the screws through the Two screws used for 4 holes push the tool down so that the mounting the Probe stem of the screw slides down as far as Alignment Tool Tia it will go and the screw heads fit above 1 the keyhole notch 2 With the probe alignment tool in place tighten or loosen the probe alignment adjustment screw using the 5 64 inch hex driver from the hex key set The lower screwhead of the alignment tool will be flush against the metal of the probe C body when it is perfectly aligned do not over tighten this screw as soon as metal touches metal stop tightening it If you tighten too far the probe will spring outward when you remove the probe alignment tool Tighten or loosen this top screw to align the probe When aligned properly the screwhead will be flush with the metal of the probe C body Note Turning the screw clockwise forces the probe tips toward the back of the 6ES turning them counter clockwise brings the tips in toward the front of the 6ES 3 Pull the probe to the left and ensure it slides to the right past the alignment tool If it doesn t refer back to Step 2
79. cs 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Servo Screen Use the Servo Screen to view gain numbers and set carriage limits Sections Chuck Initial Burst Amount of time to start the chuck motor moving Initial Close Initial closing force of the chuck Chuck Open The force the machine exerts in opening the clamp Limits The travel limits for the bevel and size carriages in encoder counts from the Home position Axis Pos Error The amount of position error in encoder counts that triggers an error on the Axis Linear Pos Error The amount of position error that triggers error on SIZE or BEVEL Repeatability The amount of position error in encoder counts that triggers an error in the linear carriage homing routines This is normally disabled with a value of zero but it may be set to 250 if size or bevel problems appear Servo Gain National Optronics use only Size Decrease Slows down the Axis when the Size goes above this speed in mm second Do not change unless instructed to do so by an Optronics technician Size Increase Speeds up the Axis when the Size goes below this speed in mm second Do not change unless instructed to do so by an Optronics technician Rev 1 082 Appendix A 6ES Screens Field Definitions A 27 A 28 Buttons Along the Side Calibrate Chuck Find Carriage Limits Reset Carriage Limits For National Optronics Use Only Moves carriage
80. ct calibration If the lens is not the correct size recalibrate the size and bevel as discussed in Chapter 5 18 Verify polish calibration Rev 1 082 Chapter 3 Commonly Performed Tasks 3 3 Changing the Groover Wheel The Groover wheel Part Number 93410 needs to be changed when it becomes dull approximately every 3000 cycles To change the Groover blade follow these steps 1 Turn off the motor make sure the switch on the controller box is OFF THIS IS A SAFETY ISSUE Ensure that the switch on the controller box is OFF any time you are touching the cutter blade or groover wheel Failure to do so could lead to serious injury 2 Place a cloth or plastic bag in the top of the chip chute Make this a screw catcher so that if you should drop the screw or washer etc this cloth will catch the screw instead of it falling into the chip chute 3 Take the two 2 supplied 3 16 inch open end wrenches out of the accessory kit 4 Place one 3 16 inch open end wrench on the shaft flats see picture below for location of the shaft and place the other on the screw The shaft use one of the 3 16 inch open end wrenches to hold this while using the other 3 16 wrench to loosen the screw The screw to be loosened 5 Loosen the screw until it is about to come loose 6 Remove the two hex screws securing the plate on the left side of the housing so that you can access the hex screw within the housing as sho
81. d on the blocking mode and protocol 001 Lens Shape A 589 B 5 Rm eon automatic Jm M king Geometric Center The Job Screen for Single Vision Lens with Geometric Center Selected OMA or NOP Protocol The Job Screen looks different when you select Optical Center for Blocking Mode Lens Shape 4 589 B 510 ae Note that the Distance Between Lenses Na i E graphical Height in mm from the top of the segment to the representation of the lens is also different The red cross represents the l A Me ne geometric Pupilary Distance center and the black Cross represents the optical center bottom of the frame Status or INC DEC to C The Job Screen with Optical Center Selected NOP Protocol 4 2 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Additional lens blank information is displayed when you use OMA protocol instead of NOP as shown in the screen shown directly below ae Ta S iE Ee __Freme materia Beva __rotsn __sBevel_ _ Bockin sete The Job Screen Display with Optical Center Selected OMA Protocol Note The Job Screen changes based on lens type as well as protocol Rev 1 082 Chapter 4 Operating the 6ES Standard Operation 4 3 4 Edging Polishing Grooving and Safety Beveling The basic steps involved in edging polishing and safety beveling 1 After pulling down a job put the lens
82. d position the bevel towards the front 4 Make adjustments to the bevel placement using the function keys defined above In the following sample screen we positioned the pointer using CCW the first function key to a thick part of the lens and then placed the bevel using the fourth function key pt Back to the position we believe would be optimal National Optronics Inc Optronics 6E Yersion2 11 EyeJRight Job 001 Cire Sizej 000 Profile rLens Shape mE F FramefMeta 587 B 508 C 1778 Material Poly Bevel Automatic A Polish _ Front Back Sfty Bevel _ Blocking Geometric Center The black ra j Le ae f line shows Note the bevel placement of this i where the screen sample compared to the y X AA bevel will be one on the opposing page rStatus g g E p Done probing cow cw pt Front 1pt Back FullFront_ Full Back Profile Bevel 5 When you have positioned the bevel exactly where you want it press the START button to finish the cycle Press START to resume cycle Chapter 7 Advanced Configuration amp Special Considerations 7 9 Special Clamps for Thin Lenses with AR Coating 7 10 Standard Intermediate Size A R Intermediate Size Standard Clamps Clamp Body Assembly Clamp Body Assembly P N 90076 Vario and qi Special Order P N 90062 Essilor Blocking P N with the appropriate block 90083 vwill work with most A R coated lense
83. damage the machinery To fill the coolant reservoir follow these steps Using the one ounce measuring cup from the 6ES Accessory Kit mix one ounce of Trico s Tri Cool coolant with one gallon of distilled water then fill the reservoir from this mixture This ratio of distilled water to Tri Cool coolant is 128 1 Note If the coolant reservoir is totally empty you may need to prime the pump before it will flow properly The easiest way to do this is to follow these steps 1 10 11 12 Go to the Cleaning Screen from the Setup Screen press the Cleaning function key F2J Move the bevel carriage to the right Fs on the Cleaning Screen to gain access to the solenoid Set the Water Flow field to 20 Down by the solenoid disconnect the water line running from the pump to the solenoid Remove the lid of the water bottle Hold the water line you just connected so that it will squirt water back in the water bottle Press the Pump on function key Fs on the Cleaning Screen Watch the clear tubes to see if water is coming out it should be shooting water into the bottle Ensure that the water is flowing properly then press the Pump off key Fs Reconnect the water line to the solenoid Turn the pump on again and wait for the air to be cleared from the hose leading to the sponge Turn the pump off once the air is cleared and the sponge is saturated 2 6 The Optronics 6ES Patternless Edger System
84. de 4T 3B and Host as well as Barcode and None You can only have one Bar Code selection This field only appears when the Com 2 Connection has a Barcode Host 3B or 4T configured This field shows the baud rate for the Com 2 device Normally the 6ES software will supply the correct baud rate automatically This field only appears when Arcnet Connection is set to None and the Com 2 Connection has a Host 3B or 4T configured If the Com 2 Connection is Host then the protocol choices are OMA and GC If the Com 2 Connection is 4T or 3B then the protocol choices are NOP or OMA OMA Trace Format preference 4 is Packed Binary 1 is ASCII Specifies the Initialization Level the communication information available upon initializing communication to another device The default setting is Auto which allows the attached device to specify which data items will be downloaded The other options are Preset which sends the defaults for that type of device or None which means that no data items will be assumed before each time the 6ES communicates with another device None is a slower method of communication but may be necessary depending on the host Appendix A 6ES Screens Field Definitions A 23 A 24 Buttons Load Software Allows you to load software code using a floppy disk Save Setup Nums Saves all calibration log and setup numbers all data saved across power cycles to dis
85. diskette from floppy drive Error 730 Unable to do download No SETUP program exists Please remove diskette from floppy drive Error 731 Download aborted Unable to copy SETUP program Please remove diskette from floppy drive Error 732 Unable to restore statistics log from floppy Please remove diskette from floppy drive Error 733 Hit maximum software limit on BEVEL carriage The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rey 1 082 Error 734 Hit minimum software limit on BEVEL carriage Error 735 Hit maximum software limit on SIZE carriage Error 736 Hit minimum software limit on SIZE carriage Error 737 Chuck must be closed to find limits Error 738 Wire brush must be chucked to start hub cleaning Floating Point Errors 800 899 Rey 1 082 Error 801 INTO executed with OF flag set Error 802 Integer Divide by Zero Error 803 Invalid Operation Error 804 Division by Zero Error 805 Numeric Overflow Error 806 Numeric Underflow Error 807 Precision Appendix B 6ES System Messages B 17 Error 808 Program Generated Exception Error 809 Stack Ovrflow Error 810 Unknown Error The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rey 1 082 Appendix Reference C 6ES External Parts PART ITEM NUMBER DESCRIPTION 1 94506 Key Pad Assembly 2 90786 Monitor Assembly s 20601 CaseTop
86. e It is also a good precaution to perform this task frequently whether or not you are loading new software To perform this function follow these steps 1 Insert a 3 inch disk into the 6ES s disk drive 2 Goto the Setup Screen from the Job Screen press the Setup function key Fs to select the Setup Screen 3 Press the Advanced Setup Screen function key F7 to go to the Advanced Setup Screen 4 Press the Comm function key Fe or use the Field Down key to move the cursor to the Communications field then press the key 5 Use the Field Down key E to move the cursor to the Save Setup Nums button and press the key 6 Enter the password if prompted and make sure your 3 12 inch disk is in the disk drive 7 Press the key Follow the screen instructions Rev 1 082 Chapter 3 Commonly Performed Tasks 3 13 3 14 Updating Software Update to new software using a 3 42 inch disk through the floppy drive inside the 6ES National Optronics strongly recommends that you back up your system refer to previous page before loading software To update the 6ES s software do the following Go to the Setup Screen from the Job Screen press the Setup function key Fs to select the Setup Screen Press the Advanced Setup Screen function key F7 to go to the Advanced Setup Screen Press the Comm function key FJ or use the Field Down key to move the cursor to the Communications field then press the exer key Back
87. e Wheel 1 Bevel e Material Poly Wheel 1W TO 0 00 rev 2 e Align bevel using Wheel 1 Bevel Bias and Wheel 1 Size Bias just touch e W1 Bevel Bias Calibrate Wheel 1 Size e Material Poly Wheel 1D TO 0 30 rev 2 e Set Wheel 1 Size Bias so that 58mm circle is on size e W 1 Size Bias Calibrate Wheel 2 Bevel e Material Poly Wheel 2W TO 0 00 rev 2 e Align bevel using Wheel 2 Bevel Bias and Wheel 2 Size Bias just touch e W2 Bevel Bias Calibrate Wheel 2 Size e Material Poly Wheel 2D TO 0 30 rev 2 e Set Wheel 2 Size Bias so that 58mm circle is on size e W2 Size Bias Calibrate Poly Bevel Polish Material Poly Wheel 1D 1W Dry Cycle TO 0 30 revs 2 Lens rpm 10 Motor rpm 7 Wet Cycle TO 0 02 revs 4 Lens rpm 10 Motor rpm 10 Poly Bev Edge Pres 0 10mm This will force the wet cycle by that amount Increase or decrease Poly Bev Edge Pres until 58mm is polished well e Poly Bev Edge Pres 5 24 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Calibrate CR 39 Bevel Polish e Material CR 39 Wheel 2W TO 0 10mm rev 4 Lens rpm 7 Motor rpm 6 e Increase or decrease CR 39 Bev Edge Pres until 58mm is polished well e Increase or decrease CR 39 TO if necessary to maintain until 58mm size e CR 39 Bev Edge Pres _ e CR 39 TO Rimless Lens Calibration Calibrate Wheel 1 Rimless Size e Material Poly Wheel 1D
88. e installed to safety bevel this shape Do you want to continue Warning 209 Half eye clamp and block must be installed to cut this shape Do you want to continue Warning 210 Lens edge too thin for base curve bevel If you continue bevel placement will be changed to automatic Do you want to continue Warning 211 Half eye clamp and block must be installed to cut this shape Automatic safety bevel not allowed on lens this small Do you want to continue Warning 213 Probe data is irregular Lens may be too small to cut out Reprobe lens 2mm smaller CAUTION PROBE TIPS MAY HAVE BEEN PUSHED BACK PLEASE VERIFY THAT THEY ARE PULLED TO THEIR FULL FRONT LIMIT Appendix B 6ES System Messages B 5 B 6 REPROBED LENS CANNOT BE SAFETY BEVELLED Warning 214 Probe data is irregular Lens may be too small to cut out Reprobe lens 2mm smaller CAUTION PROBE TIPS MAY HAVE BEEN PUSHED BACK PLEASE VERIFY THAT THEY ARE PULLED TO THEIR FULL FRONT LIMIT Warning 215 Probe appears to be stuck Probe data may be incorrect Warning 216 Bevel carriage hit software limit before probe reached target Reprobe lens 2mm smaller CAUTION PROBE TIPS MAY HAVE BEEN PUSHED BACK PLEASE VERIFY THAT THEY ARE PULLED TO THEIR FULL FRONT LIMIT REPROBED LENS CANNOT BE SAFETY BEVELLED Warning 217 Bevel carriage hit software limit before probe reached target Reprobe lens 2mm smaller CAUTION PROBE TIPS MAY HAVE BEEN PUSHE
89. e lenses of a certain material are to be polished this setting should be set to Vv This value toggles between a checkmark v and no checkmark that is blank and sets the default value for the Safety Bevel on the Job Screen If the majority of the lenses of a certain material are to be safety beveled this setting should be set to v Tells the edger which wheel to use for a specific material refer to the drawing of the wheel in the Calibrating the Polishing Wheel section in A 16 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Chapter 5 for a graphical representation of the wheels The choices are 1D IW 1D 1W 2D 2W or 2D 2W refer to Chapter 5 Calibration for instructions on how to set the 6ES up for using both wheels Roughing Portion of the Blank Material Screen Feed The speed at which the size carriage moves forward during roughing measured in millimeters per lens revolution Lens rpm The speed at which the lens rotates during the roughing portion of the cycle measured in revolutions per minute Motor rpm Controls the speed of rotation of the cutter motor during the roughing cycle measured in thousands of revolutions per minute Finishing Portion of the Blank Material Screen Feed Maximum amount of material to remove per revolution of the lens This value is expressed in millimeters Lens RPM The speed at which the lens rotates during the finish
90. e sure motor wiring is intact and carriage rails are clear of debris Error 508 Unable to detect AXIS home position Check AXIS home switch function and wiring Error 509 False HOME position reading on BEVEL axis Check BEVEL home switch and wiring Error 510 Probe could not detect calibration disk size Probe is probably sticking in left position Error 511 Probe could not detect calibration disk size Probe is probably sticking in right position Error 512 Bevel home switch repeatability error Bevel placement and size may be affected Please call National Optronics Technical Service for help with this error Error 513 Size home switch repeatability error Bevel placement and size may be affected Please call National Optronics Technical Service for help with this error Error 514 Size limit exceeds probe tip location This may indicate missing rear size limit stops or a probe that is too far forward Please call National Optronics Technical Service for help with this error The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rey 1 082 Error 515 False HOME position reading on SIZE axis Check BEVEL home switch and wiring 600 699 Cycle Errors Rey 1 082 Error 601 Lens must be chucked to start cycle Error 602 Door must be closed to start cycle Error 603 Probe not calibrated Please remove lens and calibrate probe before continuing Error 604
91. e testing is recommended the use of hearing protection is highly recommended Further sensitivity to noise levels may depend on the individual user While the 6ES operates within accepted noise standards the use of hearing protection should be considered by the user should the user experience discomfort or abnormal hearing sensations during use The 6ES should be lifted very carefully by two people Before attempting to move or lift the edger ensure that all connections electrical communications and vacuum have been disconnected from the edger To lift the edger each person should carefully lift the edger from the bottom of each edge using both hands THINK SAFETY FIRST ALWAYS PRACTICE SAFE WORK HABITS Preface Content of This Manual Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter Chapter 6 yi Chapter 7 Appendix A Appendix B Appendix C Appendix D Prerequisites Includes National Optronics contact information requirements for use such as electrical supply and operating conditions and general specifications of the Optronics 6ES Patternless Edger System Getting Started Includes instructions on initial installation and daily maintenance Commonly Performed Tasks Includes instructions for changing the blade verifying size and bevel placement updating the software code and changing the vacuum bag and paper filter Operating the 6ES Standard Operation Includes tasks performed while u
92. e this one time A new special password will be required each time you forget your password Special Note The special password is based on the password code and the password code changes on a regular basis so do not exit this screen before receiving and using the special password Press the Change Password button Enter the special one time use password that you received from National Optronics Follow the prompts that appear You will be required to enter a new password and confirm it The 6ES will display a Password has been changed message box 7 2 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Defining Customized Materials The Blank Materials Screen includes all the standard materials used for lenses except glass which the 6ES is not designed to use You may want to create a new Material that has special settings for special need jobs Below is a Blank Materials Screen with the default materials plus a custom material QPOLY m uo m E Ko M wo vow vow fal he lel Ei To add a new Material onto this screen follow these steps 1 2 3 4 Move the cursor to the first blank space in the Name field Press the button Enter the password if prompted Use the key to advance through the alphabet so that you can add a letter Notice that the Increment and Decrement keys eS and move forward or backward through the alphabet Press the key to accept t
93. each cycle The default is unchecked which saves time in the cycle Controls the point at which you receive a warning when grooving a thin lens The range is 1 5 mm to 3 mm with 2 mm as the default Specifies the default distance in millimeters that the apex of a fixed bevel will be from lens front The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Bevel Percent Screen Saver Timeout Blade Life Groover Life Sponge Life Vacuum Bag Life Right Side Clamp Right Recut Cursor Left Recut Cursor Cycle Order Size Dimension Default Lens Material Softkey Use Appendix A 6ES Screens Field Definitions Specifies the location of the bevel apex from front of lens as a percentage of edge thickness Specifies the number of minutes 1 60 of inactivity that will elapse before the screen saver activates A setting of zero 0 deactivates the screen saver Specifies the number of cycles before the 6ES will display a warning that the blade needs to be changed Optronics recommends leaving this number at 300 for carbide cutters 3 000 for diamond coated cutters and 10 000 for diamond cutters Increasing this number from the default may lead to decreased edge quality and axis slippage Specifies the number of cycles before the 6ES will display a warning that the groover needs to be changed Optronics recommends leaving this number at 3 000 Increasing this number from the defa
94. ed to use the circle for polish and groover calibration It can also be used for size and bevel calibration but not axis e Use the aviator shape to calibrate the safety bevel e Use the grooved circle to calibrate groove placement and depth Read this chapter to learn the steps involved in each of the types of calibration Rev 1 082 Chapter 5 Calibrating the 6ES 5 3 Calibrating Axis Size and Bevel As stated earlier use the SBA shape for axis size rimless size and bevel calibration To calibrate using the SBA shape 1 Geta pattern out and ready to use 2 Go to the Calibration Screen 3 Press the SBA function key Fs which takes you to the Job Screen set up for an SBA calibration Note Make sure the Material field says CR39 even though you will be using a pattern ALSO e If you are calibrating the size set the Frame field to Metal e Ifyou are calibrating a rimless set the Frame field to Rimless 4 Chuck the pattern meaning insert the pattern into the Chuck and press the amp 9 button to lock it into place 5 Press the Start button then wait until the cycle ends 6 Remove the pattern and physically examine it A Check the axis The point should be on the 180 line see drawing shown below Check the point to make sure it lines as up with the SO 180 line If the point does not line up with the 180 line adjust the Axis Offset and recut If the point
95. eel 1D 1W is selected This will invoke a polish cycle on Wheel 1 that is first dry and then wet Key Parameter Poly Wheel 1D 1W 2 Press the Material2 function key Fs to access the Blank Materials 2 Screen 3 Use the following settings for the material Poly Key Parameters The Dry Cycle key parameters are Takeoff 0 30 Revs 2 Lens rpm 10 Motor RPM 7 The Wet Cycle parameters are Takeoff 0 02 Revs 4 Lens rpm 10 Motor RPM 10 and Bev Edge Pres 0 10 mm 4 Goto the Calibration Screen Fs from the Setup Screen 5 From the Calibration Screen move the cursor to 58 mm Circle and press the key or press the 58 mm Circle function key FJ This will take you to a modified Job Screen one set up for 58 mm circle calibration 6 Use the following settings on the 58 mm Circle Calibration Screen retiree to Previous Screen gt Job 002 Box Size 0 00 Lens Shape o A 580 B 580 C 1822 When calibrating Poly teria A a Bevel Polish use the s tomatic PA D 7 Polish values shown in this Socom ra Y sample screen Hee is k i i i i Calibration Offsets S J i Edging Wheel Wheel2 AG al f Size Oftset 0 00 f o00 0 00 a bs Rimiess Size Offset 000 000 000 oS a Bevel Oftset 0 00 ig 0 00 ig 0 00 Right Status a E E E Barcode or enter Job Number Eye Frame Material Bevel Polish SBevel Advanced Key Parameter Material Poly Rev 1 082 Chapter 5 Calibra
96. een cut Ifit is blank no checkmark the screen will go to Re Cut mode after Edging the Right Lens and the EYE field must be toggled to LEFT Overrides the material safety bevel default see Material Screen for rimless lenses if checked You may still safety bevel a rimless lens by checking the Safety Bevel box on the Job Screen Overrides the material safety bevel default see Material Screen if checked You may still safety bevel a grooved lens by checking the Safety Bevel box on the Job Screen If unchecked the 6ES will not probe the front of lenses when lens is beveled using Back bevel This will also disable profile mode If unchecked the 6ES will not probe the back of lenses with no Safety Bevel when lens is rimless or beveled using Front or Fixed bevel This will also disable profile mode and the option to turn on safety beveling in recut mode If checked recuts will always start at roughing stage This is useful for cutting multiple lenses of the same type without the need to probe each one If checked the 6ES servos will burn in for 10 minutes on power up If checked bevel adjustment is done using profile window If unchecked the lens will rotate in front of blade during finishing or grooving and the user can adjust bevel placement there If checked leading zeros will be stripped from entered job numbers If not checked the leading zeros will be left to match the HIII If checked the 6ES will home the servos with
97. el Depth 1 00 Safety Bevel Margin 0 0 Note These settings will apply for the material selected and are the same parameters found on the Material Screen Cut a Rimless Lens and examine the safety bevel You should not adjust the margin at this point Adjust the Safety Bevel Depth according to the following guidelines and afterwards cut another lens and re examine it e To increase the depth of the safety bevel increase the number in the Safety Bevel Depth field e To decrease the depth of the safety bevel decrease the number in the Safety Bevel Depth field When you have the Safety Bevel correct for a thick Rimless Lens cut a thin Beveled Lens to calibrate the safety bevel margin A Chuck a thin Beveled Lens B Using the Aviator selection as discussed above cut a lens that will have an edge thinner than the bevel approximately 3mm The safety bevel should lightly touch the back of the frame bevel Adjust the Safety Bevel Margin according to the following guidelines e Ifthe safety bevel cuts too deeply into the frame bevel increase the number in the Safety Bevel Margin field e Ifthe safety bevel is too light decrease the number in the Safety Bevel Margin field Repeat process for each material used You can use the Copy to All Materials button to copy the Safety Bevel Depth and Margin currently displayed to all materials defined on the Materials Screen The Optronics 6ES Patternless Edger System User s Manu
98. en and takes you to the Job Screen Rev 1 082 Appendix A 6ES Screens Field Definitions A 35 Cleaning Screen Use the Cleaning Screen for daily cleaning and cleaning the polishing wheel on the 6ES trefer to the Daily Cleaning and Other Daily Maintenance of the 6ES section in Chapter 2 and the Cleaning the Polishing Wheel section in Chapter 3 returns to Previous Screen Cleaning Wheel Cleaning Move Size Carriage Pump On Move Bevel Carriage Pump Off Home Carriages Water Flow 20 Brush Diameter 70 Clean Wheel Press ENTER to Move Carriages Job Size Bevel Home Pump On Pump Off Clean Wheel Job Returns you to the Job Screen Move Size Carriage Moves the Size carriage so that you can clean underneath it Move Bevel Carriage Moves the Bevel carriage so that you can clean underneath it Home Carriages Returns carriages to Home position after cleaning Pump On Turns the pump on to wet the sponge and the Polishing Wheel for cleaning purposes Pump Off Turns the pump off Water Flow There is a Water Flow field on the Blank Materials screen that specifies the amount of water flow to the sponge needed for the polishing stage for each of the materials CR39 Poly etc Use this field to test the amount of flow The valid range is from 5 to 20 with larger numbers increasing the amount of flow Brush Diameter To be used with the Wire Brush from the Accessory Kit when cleaning the poli
99. et cycle The 1 05 edition includes two new fields on the Advanced Setup Screen and on the Servo Screen neither of which should be adjusted without the advice of an Optronics technician The 1 06 edition includes a correction to the drawing in Appendix C The 1 07 edition includes a new drawing of the Accessory Kit which now includes a one ounce cup to be used when mixing Tri Cool with distilled water prior to filling the water bottle refer to Chapter 2 for more information The 1 08 edition includes a modified drawing of the Accessory Kit in Chapter 2 and new information about A R coating for thin lenses trefer to Chapter 7 for more information There are also three new materials shown on the Blank Materials Screen field definitions supplied in Appendix A In addition this software version includes a new method for cleaning the Polishing Wheel tefer to Chapter 3 for details The 1 081 edition includes a small change to the Blank Materials Screen and the Advanced Setup Screen Previously there was a pressure field on the Advanced Setup Screen This functionality has been moved to the Blank Materials Screen field definitions supplied in Appendix A This change simplifies and improves the calibration of the Polishing Wheel trefer to Chapter 5 for details The 1 082 edition includes a small change to the Accessory Kit drawing in Chapter 2 and additional reference material part lists in Appendix C This manual was released with So
100. ets the type of optical center decentration to use for progressive lenses When a progressive lens is blocked using the optical center blocking method the operator can choose to place the block at the fitting cross or to move the fitting cross 5 above the center of the block The two options are as follows in the field 1 cross this places the block on the fitting cross 2 5 mm up this places the fitting cross 5 mm up from the center of the block The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Advanced Setup Screen The Advanced Setup Screen is often the starting point for a variety of tasks usually performed by a lab manager These tasks include changing the Job Screen layout configuring communications or trouble shooting problems Advanced Setup Screen The Screens Section Communications Takes you to the Communications Screen for setting up or changing the 6ES s communication options tefer to Section 2 of Chapter 2 Getting Started amp Daily Maintenance for step by step instructions Display Adjustment Takes you to the Display Adjustment Screen for changing the system colors the colors used in text boxes etc Job Screen Layout Takes you to the Job Screen Layout Screen for changing the fields to be shown on the Job Screen and making other adjustments to the way the Job Screen will appear by default Note Any chan
101. ftware Version 1 11 Future software upgrades do not necessarily affect the manual Call technical support if you feel you need a newer manual Chapter 1 Chapter 2 Contents B tore You Begin scesssvsnsessadessossecsdoahpecensessedssbesenascensssaodussousinrvbacconaspedasorioncsteutge 1 1 Before You Bef iM aree caret E E a E E E enema EN e a EEE aS 1 1 General Deseripion cau eats Ra ets ue actos a tease Wael ana aee 1 1 Or Further Assistantes oenn tes ascase Seares tees haa n iaae 1 1 TOP OTIS PALS niecki e imate E a E 1 1 For Technical Assistance cis csssxesicdeasta disses taaeas caraneuievsdcna cians 1 2 Conventions Used in This Manual c ccceeseceseceeceeeeeeeeeceseeeeeeeeeeenseeenaeens 1 3 Reguirements for Useni msn enr e E EA A T A 1 3 115 VAC 60 Hz 20A Electrical Supply ssessessessesseessessesseesseesresessee 1 3 Opetating Conditions siistin ai ei a i a R 1 4 General SpecificationS sn nresises iieii i E i RE A RA 1 4 CUtterS iry anotan aeae e aE EA e AEA E EAA AA a A 1 4 Ciitter Motra e E E a E E ER 1 4 Bevel Placementer aiea E E ETER 1 4 NV ACUILIEED sre n a Pata a r A a a N A 1 5 Lens Wate rial Sd i Seain a n a a 1 5 Statement Against Misuse c a Sascic cas ssexetedeses ccaseiosssasebuetetesm ened hiens 1 5 Getting Started amp Daily Maintenance cccssccccsscccssscccssessessescssssceeseseeees 2 1 Section 1 Initial Installation 4 cessccccecccssesacssocscesccsavesescouscecissucssosaedsaadcctadsc
102. function key Fe on the Blank Material Screen Ensure that Polish has a check mark and that Wheel 2D is selected This will cause the cycle to be dry on Wheel 2 Key Parameter Poly Wheel 2D Press the Material2 function key fs to access the Blank Materials 2 Screen Use the following settings for the material Poly Key Parameters Poly Takeoff 0 30 and Revs 2 Go to the Calibration Screen Fs from the Setup Screen From the Calibration Screen move the cursor to 58 mm Circle and press the key or press the 58 mm Circle function key FJ This will take you to a modified Job Screen one set up for 58 mm circle calibration Use the following settings on the 58 mm Circle Calibration Screen Automatic with the values shown in this sample screen 15 Key Parameters Material Poly Set the Wheel 2 Size Offset by cutting a medium thickness 6 0 base 75 mm diameter or less Poly lens The polishing wheel should remove material around the lens completely e Ifthe lens is small enter a positive Wheel 2 Size Offset e Ifthe lens is large enter a negative Wheel 2 Size Offset The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Calibrating Poly Bevel Polish 1 Goto the Blank Material Screen press the Materials function key f4 from the Setup Screen and press the Poly function key ffs on the Blank Material Screen Ensure that Polish has a check mark and that Wh
103. ge to the protocol setting or the Default Lens Blocking field will reset the Job Screen layout Diagnostics Takes you to the Diagnostics Screen for checking servo encoders communications the keypad and the home door and water level switches Servo National Optronics use only Machine Log Takes you to the Machine Log Screen to check the log of various regularly performed maintenance tasks and job statistics Rev 1 082 Appendix A 6ES Screens Field Definitions A 13 Passwords Takes you to the Passwords Screen to set password requirements for different screens The Bias Numbers Section Size Bias Rimless Size Bias Bevel Bias Blade Radius Axis Bias The Groove Section Groove Width Groove Depth Groove Placement Sets the size of the offset for each lens A 58 mm test lens should be cut using 58 mm Circle This lens should be measured and this value should be changed by the difference between the measured amount and 58 mm If the cut lens is larger than 58 mm the difference should be subtracted from this value Decrementing or incrementing this field may be confusing if there are negative numbers For example if the setting is 4 00 mm an increase by 0 50 would be 3 5 mm An adjustment for correctly sizing rimless lenses A round 58 mm rimless test lens should be cut to help in adjusting this value Adjustment is the same as that for the Size Bias setting Adjusts the front to back
104. h for Poly and Trivex requires polishing dry first then wet on Wheel 1 The directions provided on the following pages assume that you are calibrating both wheels and that you begin with Wheel 1 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Calibrating Wheel 1 Calibrating Wheel 1 Bevel 1 Ensure that the dry blade size is calibrated correctly before proceeding with the polish calibration refer to the Calibrating Axis Size and Bevel on Page 5 4 or edge the internal 58 mm shape Job 002 using a medium thickness 6 0 base 75 mm diameter or less Poly lens 2 Go to the Blank Material Screen press the Materials function key F4 from the Setup Screen and press the Poly function key ffs on the Blank Material Screen Ensure that Polish has a check mark and that Wheel 1W is selected This will cause the polish cycle to be wet on Wheel 1 Key Parameter Poly Wheel 1W 3 Press the Material2 function key fe to access the Blank Materials 2 Screen 4 Use the following settings for the material Poly Key Parameters Poly Takeoff 0 00 and Revs 2 5 Goto the Calibration Screen Fs from the Setup Screen 6 From the Calibration Screen move the cursor to 58 mm Circle and press the Ever key or press the 58 mm Circle function key ffe This will take you to a modified Job Screen one set up for 58 mm circle calibration 7 Use the following settings on the 58 mm Circle
105. he Material2 Screen by cutting a medium thickness 6 0 base 75 mm diameter or less CR 39 lens e Ifthe lens is large decrease the CR 39 Wet Polish Takeoff e Ifthe lens is small increase the CR 39 Wet Polish Takeoff Note Steps 7 and 8 are intended to maximize the polish quality while maintaining size These parameters are interrelated and may work best in an iterative application that is after completing Step 7 you may need to repeat Step 6 9 No further calibration should be required From the Job Screen pull down Job 002 58 mm or internal Job 001 Aviator and edge a Poly lens to verify edge polish If problems are encountered refer back to individual wheel calibration Rev 1 082 Chapter 5 Calibrating the 6ES 5 19 Calibrating the Safety Bevel Calibrating the Safety Bevel is generally the last step in calibrating the 6ES polish that is you would generally perform this calibration after you have performed all the other polish calibrations The suggested steps for the process are as follows 5 20 1 8 Prepare a blank lens for cutting Use a lens that has a thick enough edge to leave a 4 Smm edge on a Rimless Lens Go to the Calibration Screen f3 from the Setup Screen Press the Aviator function key F4 which takes you to the Job Screen On the Job Screen make sure the Safety Bevel field has a check mark v in it On the Job Screen use the following values for the initial Safety Bevel cut Safety Bev
106. he color used on the Job Screen to represent the lens blank Lens Block Controls the color used on the Job Screen to represent the block of the lens Segment For representing multi focal lens Controls the colors used to represent the segment Lens Profile Controls the color used on the Job Screen to represent the bevel of the lens when the Profile button is pressed Background Controls the background colors for all screens The default gray is Job Default number 47 If you want to change that color type in a different number Display Screen Buttons Takes you to the Job Screen Reverts to default colors Appendix A 6ES Screens Field Definitions A 31 Job Screen Layout Screen Use the Job Screen Layout Screen to modify the display and edit status of each field on the screen Each field can have one of three settings 1 displaying and editable 2 displaying but read only or 3 hidden does not display on the Job Screen One of the common uses of this screen is to disable warnings such as disabling the vacuum fault warning if a central vacuum is in use see The Status Area below Job Screen Layout Screen Fields and Buttons You can modify each field except the Status area in the following ways e Use the Job button to store changes and go to the Job Screen e Use the Edit button to make the field one that is visible and can be edited by the user e Use the Read Only button to make the field one
107. he letter that is displaying and proceed to the next space to the right The next space to the right will begin with the letter you just entered that is if you are entering the word SPECIAL after entering the S the letter next to it will begin with the letter S and you will need to use the key to go to the letter P If you want to use lower case letters keep pressing the key and lower case letters will display Press the or key to complete the name and leave the field After you have entered the name of the Blank Material you can add the edging and polishing settings Then press the Job key m to go to the Job Screen and save the changes Rev 1 082 Chapter 7 Advanced Configuration amp Special Considerations 7 3 Special Characters If there is an asterisk anywhere within the name of the material the 6ES will rough first then probe to ensure proper bevel placement for very thin lenses that might flex due to clamping For example if you create a custom material called CR39 this technique will be invoked each time you select that material Working with the Frame Adjustment Fields 7 4 You may need to set up unique frame types to accommodate different sizing needs These sizing offsets will automatically be applied to the sizing field on the job screen for the various frame types The default frame types and settings are shown below Name Size Adj Default Bevel Plastic f 020 Automatic Metal f o00 Automa
108. he periphery and will smooth the bevel over an executive shelf Also uses a special probing technique Base This option allows the operator to place a pre selected base curve bevel around the edge for easy fit into frames If selected curve cannot fit the 6ES calculates a range of legal values and prompts you to choose from those values after probing Fixed This option specifies the default distance in millimeters that the apex of a fixed bevel will be from lens front Percent This option specifies the location of the bevel apex from front of lens as a percentage of edge thickness Note Automatic Center Back Base Fixed and Percent placements may be affected by National Optronics cutter geometry specifically the maximum front shelf is 4 mm The front shelf is 3 mm for a polished lens Probe Mtd Appears when Rimless is the frame type There are two selections available Executive and Standard Use Executive for executive lenses Rev 1 082 Appendix A 6ES Screens Field Definitions A 5 A 6 Polish Sfty Bevel Blocking Lens Shape Status Area This value toggles between a checkmark v and no checkmark that is blank and determines if the lens to be edged should also be automatically polished To change this value press the Polish function key Fs key or move the cursor to the field and change its value by pressing the key This value will toggle between a checkmark v and no checkmark
109. her parts of the spindle assembly 3 Pull back chip chute cover and remove manifold screw using a 7 64 inch hex wrench as shown in the picture below The hex key set part number 87178 comes in the accessory kit provided with the 6ES 3 6 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Rey 1 082 4 Remove the sponge and bracket from the assembly Menio Sponge Sponge P N 28450 28450 Sponge Bracket Bracket By h 7 64 inch hex screw head Slide or pull the old sponge out of the sponge bracket noting where it is located so that you can place the new sponge into the same area of the bracket Clean debris from the area around the manifold and sponge bracket Take the new sponge out of its bag Part number 28450 Place the dry sponge in the groove in the sponge bracket where the old sponge came out Make sure that the right side of the sponge is aligned with the right side of the bracket Doing so will align it with the grooves of the hubs 10 Tighten the sponge manifold screw using a 7 64 inch hex wrench and wet a single corner of the sponge with the water bottle as shown below This will allow for any left right adjustment in the next step 11 Lower the chip chute and sponge assembly onto the polishing wheels Make sure that the points of the sponge fit into the bevel grooves of the polish wheels If they do not fit move the sponge until they do fit
110. imilar to the method of adjusting the bevel on a Horizon III Pause Mode provides front to back adjustment to the entire bevel Use Profile Mode if you want precise bevel placement control where you can place the bevel on an image of the lens This also gives you the ability to place the bevel at different positions more towards the front or back at different places along the lens s edge perhaps more useful when you have a lens that is thicker on one side than the other Profile Mode provides point by point adjustments Using Pause Mode Rey 1 082 Follow these steps to use Pause Mode 1 Make sure that the field Use Profile Mode on the Setup screen is unchecked 2 Go to the job screen and set up a job as you would normally do 3 Press the start key then press it again within five 5 seconds When you press the START button the first time you will see the message Press START again to adjust bevel you will have to press the START button within five seconds or the 6ES will proceed in its normal mode Note Pressing START more than once has no effect on Rimless lenses in Pause Mode After several seconds the message on the screen will change to the words Bevel Adjustment Pending Before the finishing cycle the lens will move in front of the bevel part of the blade The words 1 move lens left 2 resume cycle 3 move lens right will then appear on the screen as shown below O Job 001 Box Size 020
111. in and press the Chuck button ES to lock it in place 2 Press the Start button amp to begin the process 3 Wait until the process finishes and remove the lens Depending on the materials and the job there might be a few adjustments The picture shown below illustrates the fields you would be most likely to modify Modify the Frame field press the Frame function key F2 if changing frame To perform grooving choose St Groove or W Groove Modify the Material field press the Material function key Fs if changing material Check this field to polish the lens or uncheck it to skip the polishing use the Polish function key ffs to check or uncheck 4 4 Check this field to create a safety bevel or uncheck it to skip the safety bevel use the SBevel function key Fe to check or uncheck National Optronics Inc Optronics 6E Version2 11 EyefRight joxSizel 020 Frame Piastic Material cR 39 Bevelf Automatic lish fy Bevel Bigcking Geometric Center Job 001 rLens Shape A 589 B 510 C 1784 v Right r Status oem Barcode or enter Job Number Eye Frame Material Bevel Polish SBevel Blocking Setup Note If the Frame type is St Groove or W Groove and you have the Grooving spindle arrangement then the cycle will include grooving of the lens In addition if you place an exclamation point within the name of the
112. ing portion of the cycle measured in revolutions per minute Motor rpm Controls the speed of rotation of the cutter motor during the finishing cycle measured in thousands of revolutions per minute Grooving Portion of the Blank Material Screen Feed The speed at which the size carriage moves forward during grooving measured in millimeters per lens revolution Lens rpm The speed at which the lens rotates during the grooving process measured in revolutions per minute Motor rpm Controls the speed of rotation of the cutter motor during the grooving cycle measured in thousands of revolutions per minute Rev 1 082 Appendix A 6ES Screens Field Definitions A 17 Blank Material Screen Second Part Blank Material 2 When you press the Material2 function key re on the Blank Materials Screen you will see a screen that looks like the one shown below Blank Material Screen Page 2 EXIT returns to Setup Screen rDry Polishing r Wet Polishing Safety Beveling Bey Rmls Nate Take Lens Motor Take Edge Edge Lens Motor Water Lens Motor Water Off Revs rpm rpm Off Pres Pres Revs rpm rpm Flow rpm rpm Depth Margin Flow CR 39 010 0 00 000 4 7 6 20 7 7 000 000 20 Poly 030 2 10 7 002 0 00 0 00 4 0 10 20 7 7 000 000 15 Hi ldx 010 000 000 4 7 6 20 7 7 000 000 20 Trivex 030 2 10 ity 0 02 0 00 000 4 0 10 20 rd 7 000 000 15 Thk Poly o0 2 0 7 002 0 00 0 00 4 10 10 20 7 7 000 000 15 AR Resin 0
113. iseceses 2 1 Setting Up the Cabinets eR eR e a a i n e a a 2 2 Preparing the Workbenchcncneccscsiiiricniinica anini a 2 2 Setting Up the Vacuum Unit eseessesesseeseesesssessessrssessessrssressessrssressessrssresseesees 2 3 Assembling the VACUUMS inoran nia aea i 2 3 Setting Up the Vacuum Inside the Cabinet ssssnssesessesseessesessseessessessressesse 2 3 Setting Up the GES vesacestecensanone sat Eeer n E E A ENESA EEA EARE ET EEN 2 4 Placing the GES on the Cabinet sa cesssideseeciatesvorszeboavdacsieciackiz cans dhdiacdedasvnaaers 2 4 Removing the Shipping Bracket 0 ccccceeccecseesecseceeeeeeeceeseecsseeesaeeneeneaes 2 5 Connecting the 6ES to an Electric Outlets ccccsisicensc tistics 2 5 Filling the Coolant Reservoir the Water Bottle ccecceesceeeteceseeeeeeeeees 2 6 Wetting the Sponge for Initial Use 23 ese cisyeccs yaa nance 2 7 Powering Up and Calibrating the Probe ecceecceesseeeteceteceeeeeesceesaeeneeneees 2 8 Setting Up Communications for Job Information cee eseeeeceseeeeeneeeeeees 2 9 Oyervie Winen na a a aa aaa 2 9 Comm Settings aiea eaa AE a E A EE aE AAR ERER 2 9 Arcnet Connection siusss as iei a E ad A 2 9 Machin Node Dins sanca ienen a e a tees aeS 2 9 Protocol dcosscsstoe nesta tose E E G E E 2 9 Coml and Com2 Connection ss sessssessessesssessessssressessessresseese 2 10 Bad te ao ceea e paris e a E T O 2 10 PROLOG Ol fractals cteuoe hot lar teh tee A E E E A 2 10
114. k for future retrieval with the Restore Setup from Floppy feature Backup System Backs up your complete system recommended before loading software Restore Setup from Floppy Restores from floppy the calibration and setup numbers saved to floppy with the Save Setup Nums feature Restore Log from Floppy Restores Log saved to from floppy with the Save Setup Nums feature The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Diagnostics Screen Use the Diagnostics Screen for checking servo encoders communications keypad and the home door and water level switches D502 Servo Diagnostics Section of the Screen Left Size Right Size Probe Deadband Probe Axis Size Chuck Base MCL HW Ver MCL FW Ver The position of the left probe tip in mm from the Size home switch The position of the right probe tip in mm from the Size home switch Indication of probe movement ability This field should be showing a number less than 50 A value greater than 50 here may indicate a probe that is sticking and could result in probe inaccuracies or probe error messages The Position number represents the encoder count for the probe Used to detect probe movement The Position number represents the encoder count for the axis servo motor Each full rotation of the lens should change the count by 240 000 The At Home checkmark or blank indicates whether the axis is Y o
115. l 11 48561 230v 6ES Card Cage Serial 42 77287 12V Lighted Bodine Controller Switch 13 230V Lighted Bodine Controller Switch 14 80725 Y6 Cutter Motor 15 90236 6ES Chip Chute Assembly 146 90370 6E Slide Probe Assembly 115V Motor Controller Assembly 18 90599 230V Motor Controller Assembly 19 90748 Mercury Relay Assembly 20 90751 Coolant Inline Filter Assembly 21 94499 Display Inverter Cable 22 so Proximity Door Switch Wiring Harness Keypad Wiring Harness a Bevel Servo Motor 25 3 1 2 Floppy Disk Drive Appendix C Reference C 3 Chip Chute Exploded View ITEM P N QTY DESCRIPTION 1 28452 1__ Chip Chute Top 2 28440 1__ Chip Chute 3 28447 1 Chip Chute Splash Guard 4 28451 1__ Splash Guard Nut Plate 5 28441 1__ Hinge 6 28444 1__ Chip Chute Bottom Manifold 7 28449 1__ Sponge Bracket 8 28450 1 Sponge 9 28453 1 Chip Chute Top Manifold 10 74355 1 Straight Fitting 10 32 x 125 11 73061 1 Chip Chute Cover Spring 12 HDWR 2 Stainless Steel Dowel Pin 1 8 x 3 8 13 HDWR 1 Stainless Steel Socket Head Cap Screw 6 32 x 5 8 14 HDWR 4 6 32 x 3 8 SS BHCS 15 HDWR 4 6NYLON WASHER 16 HDWR 2 _ 6 32x 1 4 SS BHCS 17_ HDWR _ 1 __ 250 x 375 SS SHOULDER SCREW 10 24 C 4 The Optronics 6ES Patternless Edger System User s Manu
116. l 1 Key Parameters Poly Wheel 1D 10 Press the Material2 function key Fs to access the Blank Materials 2 Screen 11 Use the following settings for the material Poly Key Parameters Poly Takeoff 0 30 and Revs 2 12 Go to the Calibration Screen Fs from the Setup Screen 13 From the Calibration Screen move the cursor to 58 mm Circle and press the Eve key or press the 58 mm Circle function key ffe This will take you to a modified Job Screen one set up for 58 mm circle calibration 14 Use the following setting on the 58 mm Circle Calibration Screen Op IT ret revi Job oo2 EyefRight i J rLens Shape Bax Size 2 00 A 580 B 580 C 1822 Frame Metal Material CR 39 BevelfCenter Pe j ain X Polish rai aN Sfty Bevell A ae i PT j A i Coen Calibration Offsets we Pi TEN Edging Wheel Wheel2 x P Size Offset 000 000 0 00 S oe Rimless Size Offset 0 00 000 000 Sateen Bevel Offset 000 000 f 000 Right Status E UW T p Barcode or enter Job Number Eye Frame Material Bevel Polish SBevel Advanced Key Parameter Material Poly 15 Set the Wheel I Size Offset by cutting a medium thickness 6 0 base 75 mm diameter or less Poly lens The polishing wheel should remove material around the lens completely e Ifthe lens is small enter a positive Wheel 1 Size Offset e Ifthe lens is large enter a negative Wheel 1 Size Offset Rev 1 082
117. less Poly lens The polishing wheel should remove material around the lens completely e Ifthe lens is small enter a positive Wheel 1 Rimless Size Offset e Ifthe lens is large enter a negative Wheel 1 Rimless Size Offset 5 16 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Calibrating Wheel 2 Rimless Size Rey 1 082 C Job f002 Box Sizef 000 Lens Shape 4 a Frame Rimiess A 580 B 580 C 1822 When calibrating i i ProbeMtdJStendard fee Wheel 2 Rimless Size oS ra a use Poly as the sity Beva F material with the C r Calibration Offsets we ol j values shown in this he T see ie ee Size Offset 0 00 000 000 x sample screen e Ter Bevel Offset 0 00 000 000 Right Status Wo 1 Ensure that the dry blade size is calibrated correctly before proceeding with the polish calibration refer to the Calibrating Axis Size and Bevel on Page 5 4 or edge the internal 58 mm shape Job 002 using a medium thickness 6 0 base 75 mm diameter or less Poly lens 2 Go to the Blank Material Screen press the Materials function key F4 from the Setup Screen and press the Poly function key fe on the Blank Material Screen Ensure that Polish has a check mark and that Wheel 2D is selected This will cause the polish cycle to be dry on Wheel 2 Key Parameter Poly Wheel 2D 3 Press the Material2 function key fs to access the Blank Materials 2 Screen 4
118. low Carefully lift the blade out it may be advisable to wear tight fitting gloves to avoid cutting your fingers Note that the bevel is on the left You will need to place the new blade into place the same way the old one comes out Blow the dust out of the blade and clamp area then clean with alcohol Place the new blade in and slide it to the right away from the hub with the right edge of the blade touching the right edge of the pocket Replace the clamp with the rounded off side on right Replace the screws while holding the blade in place A new blade is V ry sharp Be extremely careful while holding the blade in place in Step 10 above to avoid cutting your finger on the blade Release spring loaded chip chute cover and make sure it springs back into its original position Turn on the motor controller power switch that you turned off in Step 3 above Close the case The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Note If you bump the probe during this process recalibrate the probe before cutting a lens see Chapter 5 for instructions on calibrating the probe 14 Go to the Log Screen Fe from the Advanced Setup Screen 15 Press the Reset Blade function key Fs or use the Field Down key to move to the Reset Blade field and press exter 16 Type the password if prompted The blade count resets to zero 17 Edge a 58 mm circle using internal job 002 to ensure corre
119. lts for size adjustment for each of the frame types listed below or for frame types you name the blank area below Groove in the screen capture shown below n turns to Setup Screen Name Size Adj Default Bevel Plastic ozo Automatic Metal f 000 Automatic Rimless o00 automatic St Groove 000 Center W Groove foo Center oo Automatic Frond automatic fr000 automatic F000 Automatic Press CLEAR to edit name Job Plastic Metal Rimless Frame Screen Fields Name Type of material or other designation for size adjustment purposes Size Adjustment Amount in millimeters to increase or decrease based on the selection For example in operations that use Zyl frames set this value for slightly larger For operations that use cold snap frames the tolerance is much tighter therefore this value should be set to zero or a very small value Default Bevel Shows the default bevel position for each of the frame types listed You can adjust these default settings by moving to the field with the or FE then using the Sor keys to change the selection Frame Screen Buttons Job Takes you to the Job Screen Metal Moves the cursor to the Metal field Plastic Moves the cursor to the Plastic field Rimless Moves the cursor to the Rimless field Note To start the process of adding a name move the cursor to a blank spot and press the Clear button amp J For step by step instructions on this procedu
120. lways make sure the controller box switch is OFF before placing your hands near the cutter Remove the three screws Item in the drawing shown below gt Le gt Ta W gt gt 3 Remove cap plate to expose the drive mechanism Item 2 4 Clean out any debris or build up before replacing the pulley s 5 Remove the 4 40 socket head cap screw Item 3 to release the pulley from the threaded shaft 6 Replace the sprocket pulley or both pulleys with the new one s you have received from Optronics Ts 8 Reverse Steps 2 through 5 to re install the screws and cap plate Turn the motor back on Rev 1 082 Chapter 6 Performing As Needed Maintenance 6 5 s Replacing the Coolant Filter Assembly P N 90751 Approximately every six months or as needed replace the water filter shown below Coolant Inline Filter Assembly P N 90751 Note Small amounts of debris can get into the coolant reservoir during normal use You may need to change the filter more often than every six months if you see a significant accumulation of debris in the filter or notice restricted water flow To change the filter follow these steps 1 Remove lens from the 6ES chuck if you have not already done so Close the chuck by pressing the Chuck button zl Move the bevel carriage over to the right by going to the Diagnostic Screen and pressing the Bevel Right function key Fs the Diagnostics Screen i
121. n A 19 Calibr tion Screenin a Sica e EE areas cae atv EEE RE EE A 20 The Calibration Sect Ons vcs size cs sdasivse cas hiaseeotetiocsastsacaten danas A 20 The Calibration Offsets Section of the Calibration Screen A 21 Communications Sere en s ss ceca stcccsscta tives te essveat deena aecoulaatieen weasels A 22 Diagnostics SCLC 553 cass paaa ear aniar iiaeaa a aE EEEE LAE AEEA a atat A 25 Servo Diagnostics Section of the Screen s sessssessesessssessesee A 25 Communications Diagnostics Section of the Screen A 26 Switch Diagnostics Section of the Screen eeeeeeeeeeteeneeees A 26 ELV SCTE oranan i a aa saa wecsienladehalcatgeeegth doce Ota a e R tees A 27 SECONDS sc ea e a eae tego oust a anna eter aes deceon teanants A 27 viii Appendix B Appendix C Appendix D Contents Buttons Along the Sid6 s 2 sasiccsssassserudevstecstasovsecsae tear tereeialertecas A 28 Buttons Along the Bottom 00 ccccccccecceesseesseceeceseeeeneeeseeeeeens A 28 Servo SUMS SCPC SIS ee e ee iaee aa ae e eA E Eaa A 29 Servo Test Screen Fields onnsnessesseseesseossessssresseesreseesssesess A 29 Servo Test Screen Buttons nc siccsciss agen gids cocesestebesendeteceeeevents A 29 Frame Sereen rco ai ste EK E ER hndcled staat E AER A 30 Frame Screen Fields ncesc nunana a es A 30 Frame Screen Buttons sss ssesssessseseesseessressersseeesseeesseesseesseesseee A 30 Display Adjustment Sereen
122. n be useful in trouble shooting The text in this appendix describes each message and its meaning 51 99 Messages Rey 1 082 Message 51 Please call National Optronics with this code A service technician will give you a temporary password which can be used to change the password to a password of your choice Message 52 Data has been saved Please remove diskette from floppy drive Message 53 Data has been restored Please remove diskette from floppy drive Message 54 Log has been saved Please remove diskette from floppy drive Message 55 New 6ES executable loaded REMOVE FLOPPY DISKETTE 100 199 General Warnings Warning 101 PLEASE VERIFY THAT PROBE TIPS ARE PULLED TO THEIR FULL FRONT LIMIT Mount probe calibration disk Press Continue to calibrate probe Warning 102 You should only turn this fault off if you are using a central vacuum system Are you sure you want to do this Warning 103 Turning off this fault is primarily done by Optronics service technicians Without this warning you might have a situation where you could damage the equipment Are you sure you want to do this Warning 104 Resetting cycle data will erase the entire machine history Are you sure you want to do this Warning 109 Optronics recommends leaving this number at 300 for Carbide cutters and 10 000 for Diamond cutters Increasing this number may lead to decreased edge quality and axis slippage Are you sure
123. n key to move to the field s you want to change and press the increment LS or decrement keys to change the selection Refer to the field definitions above and on the previous page 4 Enter the password if prompted Note If you receive job numbers using a barcode reader or use a computer connected through a serial port use the Communications Screen to set up the COM ports 2 10 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Section 2 Daily Cleaning amp Other Daily Maintenance of the 6ES Daily Cleaning of the 6ES Keeping the 6ES clean is the largest single component in proper maintenance Thorough daily cleanings are strongly recommended and will prevent many service problems and greatly extend the service life of the edger To clean the interior 1 2 9 Go to the Setup Screen and select the Cleaning Screen function key Fe Remove the 14 inch hose from the vacuum canister s inlet and install the 14 inch hose fitted with the crevice tool Move the rocker switch on the front left side of the center wall to CLEAN position see label next to the switch This will turn on the vacuum independent of the 6ES s operation Vacuum the debris from the inside of the 6ES 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 Size function key Fe or make sure the cursor is on the Move Size
124. n the GES ssssesssesssesessseessesessssesseserssressessreseesseesesressee A 1 Field Definitions st i e e ac tac ech a e e a eases a ens A 3 VOD SCPCCH rn raaa aa aa Da E ESARTE AREARE EO E AERDEN RERS A 3 Job Screen with Geometric Center Selected 0 cee eeeeeeeeeee A 3 Job Screen with Optical Center Selected Using NOP Protocol A 7 Job Screen with Optical Center Using OMA Protocol A 8 SEUD SCPC IN id der Canary e ma cath ada dee A dae uaacah E RE A 9 Screens Left Side of the Setup Seren ssjecsscsie dis raed nccakaens A 9 Helpers aenea Mateo tins E T AR A 10 AANA A E AE E A 10 Advanced Setup ScreeM kienes a a E a E A 13 The Screens SCCtothy ais casieiscte an initia uteadartous A 13 The Bias Numbers Secon icsssci tisdausvcaitics tas cnacialasnnatis A 14 The Groov Sectioias nam Calas ca slate elves that nea suse A 14 The Settings SECON s 6A isccse tulad Calas cede geans seasetsCadaecsiaeeacaees A 15 Blank Material Sere ite consens a a idea tet aoe A 16 Defaults Portion of the Blank Material Screen eee A 16 Roughing Portion of the Blank Material Screen eee A 17 Finishing Portion of the Blank Material Screen eee A 17 Grooving Portion of the Blank Material Screen cee A 17 Blank Material Screen Second Part Blank Material 2 A 18 Polishing Portion of the Blank Material 2 Screen Dry and Wet A 18 Safety Beveling Portion of the Blank Material 2 Scree
125. n will be measured using both the right and the left probes This information will be used by the 6ES to determine size and bevel location Refer to the Calibrating the Probe section of Chapter 5 for step by step instructions The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 The Calibration Offsets Section of the Calibration Screen This section is used to add offsets to the current calibration numbers which are stored as bias numbers on the Advanced Setup Screen These are intended to be a way of quickly making slight adjustments to your calibration without having to worry about absolute calibration numbers For example if your unpolished size is too large by 0 1 mm you would set your Size Offset for Edging to 0 10 Use the minus sign to decrement the size Note After editing these values and leaving the screen the numbers will be zero 0 when you come back to this screen however the bias numbers on the Advanced Setup Screen will be adjusted correctly Size Offset Adjusts the 6ES for size differences between cutting surfaces To increase the size increase this number units in mm Rimless Size Offset Adjusts the 6ES for size differences for rimless and grooved lenses To increase the offset increase this number units in mm Bevel Offset Adjusts the front to back position of the bevel on the lens The proper setting places the center bevel see the Bevel field on the
126. o Burnin Screen to warm up the servo motors and check burn in range and other information Takes you to the Advanced Setup Screen which allows a lab manager to perform more advanced tasks such as changing the Job Screen layout configuring communications or trouble shooting problems Rev 1 082 Appendix A 6ES Screens Field Definitions A 9 A 10 Help Help Graphics Error Text Preferences Rough First Eye Toggle Rimless SB Override Grooved SB Override Probe Front Probe Back Rough Recut Initial Burnin Use Profile Window Strip Leading Zeros Home Servos Thin Groove Edge Fixed Bevel Distance When performing maintenance or trouble shooting you may work with different pieces of the internal equipment To assist you in these tasks Optronics provides 3D drawings of several parts To scroll through the names of each drawing move the cursor to the Help Graphics field and press the Increment J or Decrement keys Press the key to display Press any key to return to the Setup Screen Enter error number in this field and the 6ES will display the text of the message for that error number If checked lens will be probed after roughing for better bevel placement The default is checked Determines whether the job screen will automatically toggle to the Left Eye after the Right has been cut If set to y checkmark then it will automatically toggle to the Left Eye after the Right has b
127. old one out Press the new one in its place 2 12 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 2 14 The Accessory Kit Use the accessories provided to perform setup and other tasks such as daily cleaning The drawing shown below identifies the accessories that are usually shipped with the 6ES ePinowies Optronics GES Backup Disk Veni SYSTEM DISK BACKUP DISK P N 3319 PN 3325 Na A PROBE TIP TEFLON P N 27092 QTY 2 INT SIZE ASS Y CLAMP BODY RUBBER INSERT P N 90076 STD LENGTH QTY 1 aes 15 AMP FUSE w CONTROLLER P N 77320 PATTERN DUPLICATOR ADAPTOR PDA CALL FACTORY FOR PART NUMBER CLEANING BLOCK CALL FACTORY FOR PART NUMBER Ww RUBBER PLUG TAPERED P N 73166 QTY 1 GRAPHICS HELP DISK P N 3322 3 16 LONG HANDLE BALL DRIVER P N 87450 3 16 HEX T HANDLE P N 87452 HEX T HANDLE 87462 OR P N 90083 SHORTENED VARIO BLOCKING WRENCH 3 16 OPEN END THIN P N 87227 QTY 2 x REPLACEMENT CHIP CHUTE SPONGE P N 28450 QTY 2 Q MEASURING CUP OZ P N 85098 QTY 1 WHEEL BRUSH BRASS P N 65411 QTY 1 T 15 6 32 x 3 8 Lg FHCS eal Cah E P N 65232 QTY 4 PATTERN BLANK RECTANGLE P N 87605 QTY 5 C BODY SETTING GAUGE P N 87261 HUB CLEANING BRUSH P N 87200 CA
128. ometric Center Selected The Job Screen for a single vision lens with Geometric Center selected displays the fields shown below eometric Center ei fre eee veterea Bevi poin _sBevi _ stocking setup Job Job number may be entered with the keypad or with a barcode wand Barcode requires 8 Bits 1 Stop Bit and No Parity also CR or LF must be sent after the code when configuring for a bar code reader Baud rate can be set on the Communications Screen Eye Denotes the eye for which the lens will be cut Right or Left Note If you check place a checkmark v in the Eye Toggle field on the Advanced Setup Screen under Settings once you finish edging the lens for the right eye it will automatically switch to the left eye Rev 1 082 Appendix A 6ES Screens Field Definitions A 3 Box or Cire Size This field will appear as Box or Circ Size circumference size based on the Size Dimension field on the Setup Screen For either Box or Circ Size this field specifies a size correction if the size of the frame to be used is different from the size used when performing the trace or a size adjustment to the downloaded shape for any other reason A setting of 0 00 mm means that the frame to be used is the exact same size as the one that was traced to create the specific job that is no increase or decrease needed For Box Size if the Box Size is less than 65 mm the size offset will affect the A
129. place you can finish tightening with the two 3 16 inch open end wrenches Note There is a small rim on the inside of the shaft flat Make sure you have the wheel resting on the small rim prior to final tightening You will probably need to lift it slightly to place it on there Using the two 3 16 inch open end wrenches hand tighten the screw until it is very snug Remove the cloth you placed in the chip chute during Step 2 Turn the motor back on Go to the Log Screen Fe from the Advanced Setup Screen Press the Reset GBlade function key F4 or use the Field Down key to move to the Reset Groover field and press Type the password if prompted The groover count resets to zero Recalibrate the groover refer to Chapter 5 for directions Rev 1 082 Chapter 3 Commonly Performed Tasks 3 5 Sponge Replacement The sponge should be replaced when it wears thin or becomes non functional approximately every 300 cycles This will vary from one machine to another depending on the amount of usage Cleaning debris from the sponge may help extend the sponge life and ensure a consistent lens polish Note that the manifold is attached to the plastic cover Before you begin retrieve the water bottle from the 6ES Accessory Kit To replace the sponge follow these steps 1 Open cover of the 6ES 2 Turn motor switch Off Make sure the switch to the cutter motor is turned OFF when handling the sponge the hubs and ot
130. place an exclamation point within the name of the frame the 6ES will include standard grooving for the job for example metal If you place a sign within the name for example plastic the 6ES will include wide grooving for the job Collecting and Resetting Statistics You can use the Machine Log Screen to collect statistics about the 6ES including number of cycles since the last maintenance etc You will also use this screen immediately after replacing the vacuum bag the cutter blade etc Refer to Chapter 3 Commonly Performed Tasks for instructions on vacuum bag and cutter blade replacement refer to Chapter 6 Performing Periodic Maintenance for instructions on motor replacement For all other replacements call National Optronics Note National Optronics Service Technicians use the Cycle Statistics for data analysis and troubleshooting and for that reason we recommend that resetting Cycle Statistics be performed or authorized by a manager or other authorized personnel Rev 1 082 Chapter 7 Advanced Configuration amp Special Considerations 7 5 Customizing the Look of Your Job Screen You can control many of the fields that display on the Job Screen as well as the warnings for Vacuum fault etc through the Job Screen Layout Screen shown below National Optronics Inc Optronics 6E Version2 11 EXIT returns to Previous Screen 5 b a Re Cut Jo Box Size rLens Shape Frame oo Ma
131. r is not blank in the home position The Position number represents the encoder count for the size servo motor Each full rotation of the servo coupler should change the count by 8 000 The At Home box indicates whether the axis is in home switch or is not blank in home switch For Optronics use only Motion Control Library hardware version Motion Control Library firmware version Rev 1 082 Appendix A 6ES Screens Field Definitions A 25 Bevel The Position number represents the encoder count for the bevel servo motor Each full rotation of the servo coupler should change the count by 8 000 The At Home checkmark or blank indicates whether the axis is or is not blank in home switch Communications Diagnostics Section of the Screen Keypad Serial Com 1 Serial Com 2 Arcnet Connected Allows you to test the keypad to determine if each key is working This field indicates the last key or button pressed If you assigned a device to COM1 the continually changing series of letters numbers and symbols indicates what is being sent out of the serial port The serial port can be tested by placing a jumper across pins 2 amp 3 of COM1 on the back of the 6E 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
132. r motor during the polishing cycle measured in thousands of revolutions per minute Wet Polish Only lt Water Flow Adjusts the flow of water from the pump onto the sponge Increase the number to increase the flow decrease the number to decrease the flow Water flow for Wheel 1 is also used during safety beveling Also see note on the following page A 18 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Safety Beveling Portion of the Blank Material 2 Screen Lens rpm The speed at which the lens rotates during the safety beveling portion of the cycle measured in revolutions per minute Motor rpm Controls the speed of rotation of the cutter motor during the safety beveling cycle measured in thousands of revolutions per minute Depth Determines how much material in millimeters to remove when cutting the safety bevel The larger the number the deeper the lens will come into the hub during safety beveling and hence the safety bevel will be larger Margin Influences the relationship between the safety bevel and the back of the lens bevel This number in millimeters should be adjusted so that the safety bevel does not cut into the bevel of a thin lens Increasing this number will increase the margin between the bevel and the safety bevel Water Flow Adjusts the flow of water from the pump onto the sponge Increase the number to increase the flow decrease the number to decrease the flo
133. rd The screen capture below shows the default settings white background indicates password protected screens assword Screen EXIT returns to Advanced Setup Screen Screens Passwords Setup Change Password Calibration Forgot Password Blank Materials Frame Advanced Setup Display Adjustment Communications Machine Log Password Screen Job Protect Unprotect Change Forgot You can change the default settings by following these steps 1 Goto the Advanced Setup Screen F from the Setup Screen 2 Goto the Password Screen F7 from the Advanced Setup Screen Rev 1 082 7 1 Move the cursor to the button of the screen you want to password protect or unlock and press the Protect F2 or Unprotect fks function key Enter the password if prompted Press the Job key FJ to go to the Job Screen and save the changes Changing Password To change your password press the Change Password button and follow the prompts The password must be 6 digits in length What Happens If Forget My Password If you forget the current password follow these steps 1 2 3 5 6 Press the Forgot Password button then call National Optronics Technical Service Provide them with the password code displayed in the message box They will provide you with a special one time use password that can be used in place of the current password Note This special password is only valid for us
134. rd press this Change button and follow the prompts Forgot If you forget the password follow the directions shown below What Happens If Forget My Password If you forget the current password follow these steps 1 Press the Forgot Password button then call National Optronics Technical Service 2 Provide them with the password code displayed in the message box 3 They will provide you with a special one time use password that can be used in place of the current password Rev 1 082 Appendix A 6ES Screens Field Definitions A 37 Note This special password is only valid for use this one time A new special password will be required each time you forget your password Special Note The special password is based on the password code and the password code changes on a regular basis so do not exit this screen before receiving and using the special password 4 Press the Change Password button 5 Enter the special one time use password that you received from National Optronics 6 Follow the prompts that appear You will be required to enter a new password and confirm it The 6ES will display a Password has been changed message box A 38 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Appendix 6ES System Messages B Explanation of Numbered Messages Warnings and Errors There is a number attached to most system messages and all errors These numbers are significant and ca
135. re refer to Chapter 7 Advanced Configuration In addition if you place an exclamation point within the name of the frame the 6ES will include standard grooving for the job for example metal If you place a sign within the name for example plastic the 6ES will include wide grooving for the job A 30 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Display Adjustment Screen Use the Display Adjustment Screen to change the default colors for fields and displays within the 6ES software Display Adjustment Screen EXIT returns to Setup Screen Active Field Magentas Inactive Field Buet Field with ErrorfLt Red 2 General informationfLt BlueS HelpText cyen3 Lens Front Reas Lens BlankjBlue 1 Lens BlockjBlack 7 Segment Lt Sues Lens ProfilefBlack7 Background 47 Cs i or INC DEC to Change E E Display Screen Fields Active Field Controls the colors used in the field where the cursor is located that is the active field Controls the colors used in fields where the cursor is not located that is the inactive fields Inactive Field Field with Error Controls the colors used to accentuate an error General Information Controls the colors used for information boxes Help Text Controls the colors used for help text Lens Front Controls the color used on the Job Screen to represent the front of the lens Lens Blank Controls t
136. roover wheel changing 3 4 size checking 3 8 vacuum bag changing 3 9 Communications Screen field descriptions A 22 contact information for National Optronics 1 1 coolant 2 6 Coolant filter assembly 90751 replacing 6 6 Coolant reservoir 2 6 adjusting the water flow 5 21 filling it 2 6 wetting it for initial use 2 7 CR 39 with the 6E 1 5 Custom materials thin lenses bevel placement 7 4 customized materials 7 3 Customizing the 6E 7 1 creating special frame adjustments 7 4 defining customized materials 7 3 frame adjustment 7 4 Job Screen 7 6 password protection 7 1 7 2 A 37 Cutter motor replacement 6 1 D Diagnostics Screen field definitions A 25 Display Adjustment Screen field definitions A 31 Drive belt maintenance replacing 6 4 E edger setup physical setup of the 6E 2 4 Edging 4 4 electrical supply 1 3 F Field definitions Advanced Setup Screen A 13 Blank Material Screen A 16 Burn in Servo Test Screen A 29 Cleaning Screen A 36 Diagnostics Screen A 25 Display Adjustment Screen A 31 Frame Screen A 30 Job Screen A 3 Job Screen Layout Screen A 32 Log Screen A 34 Machine Log Screen A 34 Index 1 Index Index 2 Passwords Screen A 37 Servo Screen A 27 Servo Test Burn in Screen A 29 Setup Screen A 9 Field descriptions Calibration Screen A 20 Communications Screen A 22 Filter coolant filter assembly 90751 replacing 6 6 Frame adjustments
137. rrssessessrssressessessees 5 10 Calibrating Wheel 2 Size accesses cata eae wlan ua ers 5 12 Calibrating Poly Bevel Polish s4 22 sccsCocasustesecess denasesocesastavedisd peguares aoceusuaees 5 13 Chapter 6 Chapter 7 Contents Calibrating Bevel Polish for CR 39 ti ss cisiccsdcastsrontecssesaiaaranvesealaiatenststentertes 5 15 Riml ss Lens Calibr ann css cctciss adstiinceecisdowiss batasibadatncackemwas eatin ts 5 16 Calibrating Wheel 1 Rimless Size co kaiccsescdccda testa kaa neatiniatasmmatiaasace 5 16 Calibrating Wheel 2 Rimless Size ssc cccitecsis aedcrastsaaevistadsna ase tiecescieass 5 17 Calibrating Poly Rimless Polish i sjsc2issesedgdeddeattazdccstatadabartaesdearnetasiieeiatoas 5 18 Calibrating CR 39 Rimless Polshive cesacaccuny es cosscaivtenisaee cate aa 5 19 Calibrating the Safety Bevel icccaxtenes cece reeds tieedeccusteeanerees oeonnaerowiare dea seveanuankes 5 20 Adjusting the Water FOW usecase oceans asa it oo pce cadea sue ceattagt nano ar eas ans 5 21 Cai tb TATOO VT cnra oA cp Seizes vs Wades ae aes cc obs tus mame weeds 5 22 6ES Polish Calibration Quick Reference Guide cecceceesccesscecesseessseeeesaes 5 24 Beveled Lens Calibration ct eetunced cote sents teaicce cates uectunccateae qeouatugaacdee ve deeapenasees 5 24 Calibrate Wheel 1 Bevel sis 2 eistesarsdenststaadsuhelecdsabistasaedansviasdates 5 24 Calibrate Wheel 1 Si s lt casac ccs tesaatty cdvneptacactisastecngedatadkieeededeites 5 24 Calibrate
138. s Material Poly Set the Wheel 2 Bevel Offset by cutting a medium thickness 6 0 base 75 mm diameter or less Poly lens The polishing wheel should lightly touch both the front and the back of the bevel e Ifjust the back is polished enter a negative Wheel 2 Bevel Offset e Ifjust the front is polished enter a positive Wheel 2 Bevel Offset e Ifthe lens is not polished enter a negative Wheel 2 Size Offset e If the lens is completely polished enter a positive Wheel 2 Size Offset e Repeat as necessary until both sides of bevel are lightly touched Try adjusting in 0 05 mm increments Note To conserve lenses the test cuts can initially be oversized and then decreased by 3 mm per iteration For example by setting the Box Size to 6 00 for the first cut it can then be edged at 3 mm then 0 00 3 00 and finally 6 00 mm resulting in 5 test cuts per lens Once adjustments are close enough that the lens touches the Polishing Wheel do not use re cut mode this will result in inaccurate bevel placement If you use Circ Size instead of Box Size you can accomplish the same thing by downsizing the Circ Size by 10 00 mm each time Rev 1 082 Chapter 5 Calibrating the 6ES 5 11 5 12 Calibrating Wheel 2 Size 10 11 12 13 14 When calibrating Wheel 2 Size use Poly as the material Go to the Blank Material Screen press the Materials function key f4 from the Setup Screen and press the Poly
139. s Standard Full Size Clamp Body Assembly P N 90077 Vario and Essilor Blocking P N 90089 will work with most A R coated lenses A R Full Size Clamp Body Assembly Special Order Vario P N 90061 and Essilor Blocking P N 90086 with the appropriate block 3M AIT Blocking System shown above To edge AR coated thin lenses follow these steps 1 Ensure that your cutter blade is in good condition 2 Select the correct A R clamp assembly depending on the size of the lens being edged e Ifthe shape of the lens has a 23 B or higher use the full size A R clamp e Ifthe shape of the lens has a B size lower than 23 use the intermediate A R clamp 3 For 3M blocking select the correct block depending on the clamp selection e When using the full size clamp body use only eight base blocks regardless of lens curvature e When using the intermediate size clamp body use only two base blocks regardless of lens curvature e Ifa half eye block is needed and you are using the 3M blocking system use National Optronics modified half eye 3M blocks see table on the following page for part numbers e Do not use a six base block for any A R work For Vario blocking use a solid block and match the block curve with the lens curve 4 Use 3M Blue Chip or equivalent protective tape on both sides of the lens 5 On the Job Screen set the material to AR Resin if the lens material is High
140. s an option from the Advanced Setup Screen Turn off the 6ES s power switch Press and hold the top part of the top Quick Release fitting and pull the hose away from the filter Repeat with the bottom Quick Release fitting Squeeze the top part of the Quick Release fitting down while lifting the tube out The tube should come out easily 6 6 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 L 6 Discard the used filter 7 Using the Quick Release fittings on the new filter install the new filter into the place where the one was removed NOTE There is a water flow indicator arrow on the filter The water flow indicator should be pointing down The water flow indicator should be pointing down 8 Turn the power back on and check for leaks by going to the Cleaning Screen and turning on the pump If there are any leaks push the tube farther into the Quick Release fittings Rev 1 082 Chapter 6 Performing As Needed Maintenance 6 7 Chapter Advanced Configuration amp Special 7 Considerations Customizing the 6ES to Meet Your Needs There are several ways you can customize the 6ES software to meet the needs of your organization Customizing tasks tend to be performed by lab managers or supervisors Password Protection Certain screens are password protected by default meaning that a user cannot change the settings on a given screen without typing in the passwo
141. s per lens Once adjustments are close enough that the lens touches the Polishing Wheel do not use re cut mode this will result in inaccurate bevel placement If you use Circ Size instead of Box Size you can accomplish the same thing by downsizing the Circ Size by 10 00 mm each time In addition please note that setting the Offset is a quick and easy way of adjusting the bias When you enter an Offset the 6ES automatically adjusts the bias numbers on the Advanced Setup Screen If this is changed on the Calibration Screen when you return to this screen later you will see that the Offset is zero 0 rather than the number you have entered That shows that it has made the adjustment on the bias numbers the bias numbers will change by the amount positive or negative that you enter in the Offset If you change this on the Job Screen the special one set up for 58 mm circle calibration the Offset will change to zero when you press the Start button Alternatively you can press the Advanced Setup function key fs and modify the Bias numbers directly The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Calibrating Wheel 1 Size 9 Goto the Blank Material Screen press the Materials function key f4 from the Setup Screen and press the Poly function key Fs on the Blank Material Screen Ensure that Polish has a check mark and that Wheel 1D is selected This will cause the polish cycle to be dry on Whee
142. s to find their limits Sets the carriages range of motion to zero used primarily by National Optronics This will force the machine to find limits on the next boot up Buttons Along the Bottom Job Find Limits Reset Limits Axis Motor Bevel Motor Size Motor Takes you to the Job Screen Moves carriages to find their limits Sets the carriages range of motion to zero used primarily by National Optronics This will force the machine to find limits on the next boot up Moves the cursor to the top of the Axis column Moves the cursor to the top of the Bevel column Moves the cursor to the top of the Size column The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Servo Burn In Screen Use the Servo Burn In Screen to burn in the servo motors or to view the power graphs for each servo motor and to monitor the Home switch repeatability It can also be used to warm up the servo motors after a period of shut down for example after a weekend of non use This type of warm up is not required but some operations consider it a good practice pHome Switch Repeatability Power Last Average Min Max Passes Average Min Max Passes Axis 121 121 121 121 4 Axis 65 9 19 83 4 Size 20 20 20 20 1 Size 375 29 46 J Bevel 25 25 25 25 1 Bevel 425 36 53 1 Job All Power Axis Power Size Power Bevel Power
143. selected for the Arcnet Connection field your choices include 4T 3B and Host as well as Barcode and None You can only have one Barcode selection Baud Rate This field only appears when the Com 1 Connection has a Barcode Host 3B or 4T configured This field shows the baud rate for the Com 1 or Com2 Connection The default is 9600 or 19 200 if the Protocol is GC Normally the 6ES software will supply the correct baud rate automatically The edger will not be able to communicate if this parameter is different from the baud rate of the attached device Protocol This field only appears when Arcnet Connection is set to None and Com or Com2 has a 4T or Host configured The choices for Host are OMA or GC the choice for 4T or 3B is OMA OMA Init Level This field allows you to set the level of OMA initialization to Auto Preset or None Auto is the best choice most of the time Max TRCFMT This field allows the operator to set the highest trace format used by the 6ES for OMA communications This field defaults to 4 for Packed Binary communications A value of 1 should be used when communicating with 4Ts earlier than Version 1 23 Changing Communications Settings To change the current communications settings follow these steps 1 From the Setup Screen press the Advanced Setup function key 2 Press the Communications function key Fe 3 From the Communications Screen use the Field Dow
144. serve lenses the test cuts can initially be oversized and then decreased by 3 mm per iteration For example by setting the size to 6 00 for the first cut it can then be edged at 3 mm then 0 00 3 00 and finally 6 00 mm resulting in 5 test cuts per lens Do not use re cut mode this will result in inaccurate bevel placement If you use Circ Size instead of Box Size you can accomplish the same thing by downsizing the Cire Size by 10 00 mm each time 6 Set the Standard Groove Depth using the following procedure e Ifthe groove is too deep use a negative number to adjust the Standard Depth e Ifthe groove is too shallow use a positive number to adjust the Standard Depth 7 Set the Wide Groove Placement and Depth in the same manner as Steps 6 and 7 8 Set the Wide Groove Width using the following procedure e Ifthe groove is too wide enter a smaller number to adjust the Wide Groove Width e Ifthe groove is too narrow enter a larger number to adjust Wide Groove Width 9 Ifyou made any adjustments re cut a lens to test the calibration Rev 1 082 Chapter 5 Calibrating the 6ES 5 23 6ES Polish Calibration Quick Reference Guide After you have performed calibration several times and are fully familiar with the process you can use this Quick Reference Guide to perform calibration If you forget a step in the process refer back to the detailed steps in the previous 23 pages Beveled Lens Calibration Calibrat
145. shing wheel see Clean Wheel below Clean Wheel Use this function with the Wire Brush from the Accessory Kit when experiencing poor polish quality and when there is visual evidence of lens material buildup on the polishing wheels Refer to the Cleaning the Polishing Wheel section in Chapter 3 for step by step instructions Note For step by step instructions for the cleaning functions mentioned above refer to Section 2 Daily Cleaning and Other Daily Maintenance of the 6ES in Chapter 2 of this manual A 36 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Passwords Screen The Passwords Screen allows the lab manager to determine which screens require passwords to change settings and values The sample Passwords Screen shown below has the default settings Notice that the bottom four buttons appear different for example they are white buttons and look pressed in indicating that they are Protected see button definitions of Protect and Unprotect below Fram Advanced Setup Display Adjustment Machine Log Job Saves the changes and takes you to the Job Screen Protect When you Protect a screen for example the Communications Screen as shown above the 6ES requires a password to change any value on that screen Unprotect To Unprotect a screen means that the 6ES no longer requires a password to change values Change To change the passwo
146. sing the 6ES in a standard operation such as pulling down a job edging roughing and finishing polishing grooving and safety beveling Calibrating the 6ES Includes instructions on all aspects of calibration Performing As Needed Maintenance Includes instructions for performing non daily maintenance tasks For daily maintenance tasks refer to Chapter 2 Advanced Configuration amp Special Considerations Includes instructions on less commonly performed tasks with the 6ES Edger System such as changing display options on the Job Screen creating alternate selections on the Blank Materials screen reading and interpreting data collected in the Log Screen and using less common calibration settings These tasks are generally performed by a lab manager or a National Optronics technician and are password protected Screen Field Definitions Includes reference information including definitions of the fields on the screens you will see on the 6ES s monitor 6ES System Messages Describes and gives more detail about the messages you will see on the 6ES s monitor warnings information etc Spindle Assembly Shows an exploded view of the spindle Assembly Statement of Warranty Includes the Warranty Statement for the 6ES iii Preface Changes from the Previous Edition The 1 04 edition includes a change to the takeoff value when calibrating the Wheel 2 Size Bias The suggested takeoff is now 0 30 since this is what we use in the dry w
147. t reset You will need to reset these cycles after replacing the sponge Refer to the Replacing the Sponge The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 section of Chapter 3 Commonly Performed Tasks for detailed instructions on changing the sponge Vacuum Bags Shows the number of times the vacuum started since last reset You will need to reset these cycles after every vacuum bag change tefer to the Changing the Vacuum Bag section of Chapter 3 Commonly Performed Tasks for detailed instructions on changing the vacuum bag Polish Wheel 1 Shows the number of times the polish cycle started when using Wheel 1 since last reset You will need to reset these cycles after changing Polishing Wheel 1 Polish Wheel 2 Shows the number of times the polish cycle started when using Wheel 2 typically Wheel 2 as defined in the Blank Material screen since last reset You will need to reset these cycles after changing Polishing Wheel 2 Motor Shows the number of times the motor started since last reset You will need to reset these cycles after every cutter motor change trefer to the Cutter Motor Replacement section of Chapter 6 Performing Periodic Maintenance for detailed instructions on changing the motor Save Log to Floppy CSV Saves the log to disk in Comma Separated Variable format In addition note that the Job function key stores the changes made on this scre
148. terial Bexa Polish Stty Bevel Blocking 7 Opt son Into DBL Diameter Vt Dec Seg Ht Dist PD Lens Type Base Curve Cross Curve Center Thk Cylinder Axis Prism Seg Type Seg Depth Prism Dir Seniai rStatus Seg Inset mobe Cutter Fault Seg Drop Front Gure Water Level Bevel Adjustment Pending vr lade ponge ac Vacuum Fault Barcode or enter Job Number Job Edit Read only Hidden cut Fault Water vac Fault Each field can have one of three settings 1 displaying and editable 2 displaying but read only or 3 hidden does not display on the Job Screen Prism Axis To modify the settings of fields on this screen follow these steps 1 Move the cursor to the field whose display or edit characteristics you want to modify 2 Press the Edit button Fe if you want to make a field editable and displaying on the Job Screen Press the Read Only button if you want to make a field non editable read only but displaying on the Job Screen Press the Hidden button F if you want to make a field hidden not displaying on the Job Screen 3 Then press the Job key Fi to go to the Job Screen and save the changes One of the common uses of this screen is to disable warnings such as disabling the vacuum fault warning if a central vacuum is in use To modify the Vacuum fault warning follow these steps 1 Press the Vac Fault function key F7 to turn it off press the Vac
149. that is visible but cannot be edited by the user that is to make it a read only field Read only fields will display with a gray background e Use the Hidden button to make the field disappear from the Job Screen A 32 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 The Status Area The following buttons are used only for the display in the Status area of the Job Screen Cut Fault Used to turn off or turn on the cutter motor fault during a cycle In the default setting on if the cutter motor does not come on when you try to cut a lens the cycle aborts and a cutter motor fault is displayed Caution Turning off the Cut Fault is used primarily for diagnostics purposes by National Optronics service technicians Without this warning you might have a situation where you could damage the equipment Water Used to turn off or turn on the refill water reminder feature Operations that never use the Polish or Safety Bevel feature of the 6ES may want to turn this feature off Press the Water function key Fs to turn it off press the Water function key fes again to turn it back on When off the words Water Level display in black typeface and the Sponge bar is grayed out When on the words Water Level display in red typeface and the Sponge bar is visible Vac Fault Used to turn off or turn on the vacuum bag replacement reminder feature as well as the fault indicator if the vacuum does not start
150. tic Rimless feoo0 Standard St Groove ooo Automatic WN Groove 000 Automatic ooo Automatic _ joo automatic _ ooo Automatic _ f 000 automatic _ ooo Automatic _ Press CLEAR to edit name Job Plastic Metal Rimless To add a new frame type add a new Name in the Name field by following these steps 1 Move the cursor to the first blank space in the Name field 2 Press the button 3 Enter a password if prompted 4 Use the Ls key to advance through the alphabet so that you can add a letter Notice that the Increment and Decrement keys amp and move forward or backward through the alphabet Press the key to accept the letter that is displaying and proceed to the next space to the right The next space to the right will begin with the letter you just entered that is if you are entering the word SPECIAL after entering the S the letter next to it will begin with the letter S and you will need to use the key to go to the letter P If you want to use lower case letters keep pressing the Iz key and lower case letters will display 5 Press the or key to complete the name and leave the field The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 6 After you have entered the name of the Frame you can add the size adjustments settings Then press the Job key F to go to the Job Screen and save the changes Note In addition if you
151. ting the 6ES 5 13 5 14 7 Set the Poly Edge Bev Pres by cutting a medium thickness 6 0 base 75 mm diameter or less Poly lens e If there are striations on the lens return to the Materials 2 Screen and increase the Poly Edge Bev Pres e Ifthe lens material balls up return to the Materials 2 Screen and decrease the Poly Edge Bev Pres 8 No further calibration should be required From the Job Screen pull down Job 002 58 mm or internal Job 001 Aviator and edge a Poly lens to verify edge polish If problems are encountered refer back to individual wheel calibration The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Calibrating Bevel Polish for CR 39 i Go to the Blank Material Screen press the Materials function key f4 from the Setup Screen and press the CR 39 function key Fz on the Blank Material Screen Ensure that Polish has a check mark and that Wheel 2W is selected This will cause the polish cycle to be wet on Wheel 2 Key Parameter CR 39 Wheel 2W Press the Material2 function key fs to access the Blank Materials 2 Screen Use the following settings for the material CR 39 Key Parameters CR 39 Takeoff 0 10 Rev 4 Lens rpm 7 Motor rpm 6 and Bev Edge Pres 0 10 mm Go to the Job Screen and call down the internal 002 circle shape Use the following setting on the Job Screen Key Parameter Material CR 39 Set the CR 39 Edge Bev Pres by cutting a medi
152. ting this field may be confusing if there are negative numbers For example if the setting is 4 00 mm an increase by 0 50 would be 3 5 mm Groove Blade Radius Defines the cutting radius of the grooving blade in millimeters This is factory set and should not be altered A 14 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 The Settings Section Chuck Type Blade Type Blade Material Spindle Arrangement Probe Speed Calib Disk Thk Trace Size Adjustment Rough Offset Blade Offset Right Probe Height Left Probe Height Sets the type of chuck used to hold block Since the size varies from brand to brand it is important to specify the type that you are using When changing chuck types follow these steps 1 Update this field 2 Reset the Front Size Stop 3 Find the servo limits 4 Recalibrate the probe 5 Check size and bevel calibration Specifies the type of blade you are using Specifies that you are using a carbide blade coated carbide or diamond This affects the number of jobs required for the blade status indicator on the Job Screen Specifies the type of spindle Speed or Groove Set by factory do not change Specifies how fast the lens turns during probing Set by factory do not change Thickness of the calibration disk in millimeters Note You will have to recalibrate your probe if you change this number and both bevel bias
153. ult may lead to decreased edge quality and axis slippage Specifies the number of cycles the 6ES will run before showing a warning to change the sponge National Optronics recommends 300 Specifies the number of cycles the 6ES will run before showing a warning to change the vacuum bag National Optronics recommends 300 Options are Standard and Half Eye Set to Half Eye if you do not want to see the Half eye warning appear and a half eye clamp is installed Controls where the cursor goes when doing recuts on the right eye lens Your choices are Job or Size referring to going to the Job field or going to the Size field Controls where the cursor goes when doing recuts on the left eye lens Your choices are Job or Size referring to going to the Job field or going to the Size field On jobs requiring both grooving and polishing use this field to control which is done first the grooving or the polishing Specifies whether the Job Screen will include the field Box Size or Circ Size Circumference Size used for manually adjusting the size offset Specifies the material from the list on the Material Screen to use if the Lens Material is not provided by the 4T or host computer Specifies whether the f7 key on the Job Screen toggles Blocking or Probe Order If you choose for it to toggle Probe Order then the softkey label on the Job Screen will toggle between Rough First and Probe First
154. um thickness 6 0 base 75 mm diameter or less Poly lens Ifthere are striations on the lens return to the Materials 2 Screen and increase the CR 39 Edge Bev Pres e If the lens material balls up return to the Materials 2 Screen and decrease the CR 39 Edge Bev Pres Set the CR 39 Wet Polish Takeoff on the Material2 Screen by cutting a medium thickness 6 0 base 75 mm diameter or less CR 39 lens e Ifthe lens is large decrease the CR 39 Wet Polish Takeoff e Ifthe lens is small increase the CR 39 Wet Polish Takeoff Note Steps 6 and 7 are intended to maximize the polish quality while maintaining size These parameters are interrelated and may work best in an iterative application that is after completing Step 7 you may need to repeat Step 6 No further calibration should be required From the Job Screen pull down Job 002 58 mm or internal Job 001 Aviator and edge a CR 39 lens to verify edge polish If problems are encountered refer back to individual wheel calibration Rev 1 082 Chapter 5 Calibrating the 6ES 5 15 Rimless Lens Calibration Calibrating Wheel 1 Rimless Size 1 Ensure that the dry blade size is calibrated correctly before proceeding with the polish calibration refer to the Calibrating Axis Size and Bevel on Page 5 4 or edge the internal 58 mm shape Job 002 using a medium thickness 6 0 base 75 mm diameter or less Poly lens 2 Go to the Blank Material Screen press the M
155. up the System if needed Press the Load SW function key fe or use the Field Down key L to move the cursor to the Load Software button and press the key Enter the password if prompted If loading from a diskette make sure it is in the disk drive Press the key after placing the update disk in the floppy drive Follow the screen instructions The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Chapter Operating the 6ES Standard Operation 4 This chapter includes directions for standard tasks performed while using the 6ES in a standard operation such as pulling down a job edging roughing finishing and grooving polishing and safety beveling For calibration instructions refer to Chapter 5 Pulling Down a Job For standard operations there are only two steps to this part of the process 1 Go to the Job Screen which is where the 6ES will go automatically if you just started it up 2 Type in the number of the job to pull down from a Tracer Blocker or Host computer Note Another way of pulling down a job is to scan the job tray with the bar code reader Bar code readers are optional accessories call National Optronics technical support if you want information about this The Job Screen parameters can be tailored to meet the specific needs of the user Rev 1 082 4 1 Job Screen Display Variations The three screens displayed in this section show the default parameters base
156. w Water flow for Wheel 1 is also used during safety beveling Note You can test the water flow numbers by adjusting them on the Cleaning Screen Refer to page A 36 for information about the Water Flow field in the Cleaning Screen Rev 1 082 Appendix A 6ES Screens Field Definitions A 19 Calibration Screen Use this screen to perform size bevel axis probe and polish calibration refer to Chapter 5 Calibrating the 6ES for step by step instructions The Calibration Section 58 mm Circle Size Bevel Axis Aviator Groove Probe A round 58 mm diameter shape will be cut so that the Size Offsets and Bevel Offsets can be adjusted and set as required The Job Screen will display with Job 002 this is the internal job setup for checking size and bevel placement Refer to Chapter 5 for step by step instructions Cuts an internal shape that allows the user to calibrate all of the edging offsets Refer to Chapter 5 for step by step instructions Cuts an internal shape for calibrating the safety bevel Activates the procedure for calibrating the groover Refer to the Calibrating the Groover section of Chapter 5 for step by step instructions Activates the procedure for calibrating the probe The 6ES edger will automatically measure the 58 mm calibration pattern to determine the relative locations of the probe tip and the bevel and size carriages The diameter of the 58 mm calibration patter
157. while the probe calibrates itself 5 When 6ES is finished calibrating the probe remove the PDA and disk Probe in Correct Position If the probe tips are NOT straight down manually pull them forward into position Probe in Incorrect Position Note that the tips are slanted not straight down The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Setting Up Communications for Job Information Comm Settings Rev 1 082 Overview The settings on the Communications Screen are shown in the screen sample below and discussed in the sections that follow Communication Arcnet Connection Optional Equipment Specifies the type of Arcnet connection Host 4T Saturn or None Machine Node ID This field disappears when Arcnet Connection is set to None Specifies the Node ID of the Arcnet connection Protocol This field disappears when Arcnet Connection is set to None NOP is the protocol being used for each of the following job sources e A Saturn tracer e A 4T tracer e A host computer Host Chapter 2 Getting Started amp Daily Maintenance 2 9 Com1 and Com2 Connection The choices for Com1 and Com2 vary depending on what you have selected in the Arcnet Connection field If you have Host 4T or Saturn selected for the Arcnet Connection field your choice for Com1 or Com2 is Barcode or None If you have None
158. wn in the picture below Note that you can remove two screws and swing it open see picture below 7 To avoid dropping the screw hold the screw with a pair of needle nosed pliers to hold the screw and turn the other end with a 3 32 hex driver one is available in the toolkit s hex tool cluster At this point in the process it is better to use a 3 32 hex driver to loosen the screw the rest of the Notice that we have removed two of the hex screw holding this plate Step 6 so that it can way until the screw with i swing open the washer and groover wheel disconnects from the assembly 3 4 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 10 11 12 14 16 17 18 20 Remove the washer and groover wheel from the screw and set the washer and screw aside The old groover wheel should be marked as used or thrown away Clean debris from around the bearing and shaft before installing the new grooving wheel Take new groover wheel P N 93410 out of the shipping bag Assemble the screw placing the washer and groover wheel onto the screw in the same manner as they came off To avoid dropping the screw hold the screw with a pair of needle nosed pliers to hold the screw and turn the other end with a 3 32 hex driver this is the same as done in Step 7 on the previous page except that you are now tightening instead of loosening After you have the screw secured in
159. you want to do this Warning 110 Optronics does not recommend changing the vacuum bag life from the default of 300 Increasing this number may lead to decreased machine performance or life Are you sure you want to do this B 2 The Optronics 6ES Patternless Edger System User s Manual October 20 2004 Rev 1 082 Rey 1 082 Warning 111 Has the machine been cleaned Warning 112 Insert diskette into floppy drive Warning 113 Check that floppy is inserted in drive Warning 114 Insert System Diskette or other diskette with new software CAUTION File transfers may require several minutes DO NOT insert or remove floppy diskette unless prompted DO NOT turn off system power unless prompted If system shows NO activity for 3 minutes remove diskette turn off power restart system again Warning 115 Cycle will pause during finishing to allow for bevel adjustment Warning 116 Cycle will pause during grooving to allow for groove adjustment Warning 117 Optronics does not recommend changing the groover life from the default of 3000 Increasing this number may lead to decreased machine performance or life Are you sure you want to do this Warning 118 Optronics does not recommend changing the sponge life from the default of 300 Increasing this number may Appendix B 6ES System Messages B 3 lead to decreased machine performance or life Are you sure you want to do this Warning 1

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