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1 PATTERNLESS EDGER Model SERVICE MANUAL December 2008 Pages in total: 190 LLE13ARDA001D/E

2 NIDEK CO., LTD. : 34-14, Maehama, Hiroishi-cho, Gamagori, Aichi , Japan (Manufacturer) Telephone: Facsimile: NIDEK CO., LTD : 3F Sumitomo Fudosan Hongo Bldg., , Hongo, (Tokyo Office) Bunkyo-Ku, Tokyo , Japan Telephone: Facsimile: NIDEK INCORPORATED : Westinghouse Drive, Fremont, California 94539, U. S. A. (United States Agent) Telephone: Facsimile: NIDEK SOCIETE ANONYME : Europarc 13, rue Auguste Perret, CRETEIL, France (EU Authorized Representative) Telephone: Facsimile:

3 Table of Contents 1 INTRODUCTION SAFETY PRECAUTIONS PRODUCT OUTLINE Quality Standard Configuration Wheel Configuration Labels ASSY Layout Electrical Component Layout Replacement Parts List TROUBLESHOOTING REMOVING PROCEDURES Prior to Removal Work Abbreviations for Screws Opening Top Cover ASSY Removing Covers REPLACEMENT PROCEDURES Rocker Switch Main Board Inverter TFT color LCD Trace SW Board Setting SW Board Main SW Board Cover Relay Board USB Board Wheel Grooving Wheel and Safety Bevel Finishing Wheel Stylus Tracing Unit ASSY Feelers Feeler ASSY Lens Measurement Unit ASSY Lens Measurement Board Pulse Motor (40340-E033) Encoder Cables (40340-CA31, CA32, CA33) I

4 6.21 Safety Beveling and Grooving ASSY Spindle ASSY Pulse Motor (40340-E035) Sensor Cable (44001-CA42) LED Cable Spindle Motor Guide Processing Chamber ASSY Lower Processing Chamber ASSY Carriage ASSY Chuck Axis Motor ASSY Y axis motor ASSY Y axis stepping motor DC Motor θ Axis Stepping Motor Carriage Relay Board Sensor Cables (44001-CA27, CA29) Sensor Cables (44001-CA26, CA28) X axis motor ASSY Pulse motor (44001-E037), sensor cable (44001-CA17) Feedwater ASSY Lid ASSY Sensor Cable (44001-CA37) Pulse Motor (44001-E038) DC Fan Communication Connector Board Cables (44001-CA07) Fuse Holders Inlet Reactor Regenerative Resistor for BL Motor Mains Part ASSY Inverter for BL Motor Switching Regulator Motor Drivers SSR Board Line Noise Filter SETTING/ADJUSTMENT Notes for Proper Setting and Adjustment Utility Program Upgrading Lex 1000 main program Backing up parameter settings Restoring parameter settings Copying parameter settings to USB flash drive Writing program to tracing unit CPU Setting parameters Displaying parameter setting screen Displaying wheel parameter screen II

5 Parameter list Machine Test program Ethernet settings Mechanical Components Carriage ASSY Adjusting movement of carriage ASSY bearing Engagement of X axis motor ASSY motor gear Adjusting height of carriage ASSY Y axis Adjusting θ axis of carriage ASSY Y axis Adjusting position of carriage ASSY left/right shaft Lens measurement unit ASSY Height of feeler ASSY Initial position of feeler ASSY Voltage of lens measurement unit ASSY Safety beveling and grooving ASSY Position of safety beveling and grooving ASSY arm Chuck pressure Tentative chuck pressure Chuck pressure Tracing unit Adjusting tilt of tracing unit stylus Adjusting position of cable CA Cleaning pattern tracing pin Electrical Components Parameters of BL motor inverter Parameter table of BL motor inverter Trip table of BL motor inverter Calibration Displaying calibration screen Attaching calibration jig Calibration of safety beveling and grooving ASSY Full calibration Bevel calibration Wheel calibration Calibration of lens measurement unit ASSY θ axis autognosis Calibration of lid ASSY Torque calibration of tracing unit Frame auto calibration of tracing unit Pattern auto calibration of tracing unit Full calibration of tracing unit Processing Adjustment Feeler axis Finish size Bevel position Lens axis Polish (differential and polish wheel height, bevel, axis) Polish (differential and polish wheel height) Bevel position to be polished III

6 Polish axis Polish size Groove depth Groove position Groove axis Safety bevel Safety bevel axis (bevel) Safety bevel axis (flat) High base curve processing Wheel position (HCrvFr) Wheel position (HCrvRe) Size adjustment for high base curve processing Bevel height (HCrv) Axes (HCrvFr and HCrvRe) Other Setting and Adjustment Dressing wheels Setting and operation of Print screen SUPPLEMENT Wiring Diagram Connector Cable Main Board (BA01) Grease Grease MSDS NIPPECO LLP BE SHV NBU Troubles and Measures Jigs Tools Consumables Annex Upgrade to MAIN V1.01 and wheel cover replacement Modification procedure of chuck axis motor ASSY Procedure for upgrade to MAIN V Nozzle replacement procedure Change of Lex 1000 tracer measurement range Upgrade to MAIN V Remedies for EEPROM error Remedies for failures of control panel buttons VCA conformance statement Built-in barcode scanner MAIN V1.04 upgrade MAIN V1.05 upgrade IV

7 1 INTRODUCTION This Service Manual is for the NIDEK PATTERNLESS EDGER, Lex For correct service, thorough understanding of the contents of this manual is required prior to the service. This manual mainly describes easy remedies by part replacement. Disassembly or repair must be performed by NIDEK service persons or other qualified personnel. Refer to the Operator s Manual, Parts List, and Installation Manual for the Lex Refer to the Service Manual Annex for important changes. In case the system cannot be repaired according to the procedures described in this service manual, please report the serial number of the system, version of the software, and details of the symptom or symptoms. 1-1

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9 2 SAFETY PRECAUTIONS <General precautions> Servicing must be performed by NIDEK service persons or other qualified personnel. Perform all servicing according to the procedures described in this manual. Failure to do so may cause accident or malfunction. Always have two or more people to move the Lex Failure to do so may result in injury or accident. When performing maintenance work, turn off the power switch and disconnect the power cord from the wall outlet unless the power needs to be on. Never wipe the covers using an organic solvent such as a paint thinner. Doing so may ruin the surface and impair the appearance of the system. <Maintenance precautions> In case of system malfunction, check the symptom and turn off the power. Do not drop parts or screws inside the system, nor bump it against surrounding objects. Prepare storage cases so as not to lose the removed parts or screws. Tighten or loosen screws with proper tools. After loosening the screws fixed by a threadlocking adhesive, be sure to reapply the threadlocking adhesive to the screws when retightening them. After replacing parts, confirm that they are fixed in their original positions securely before turning on the power. Should you observe smoke or strange odors being issued from the system, immediately turn off the power switch, disconnect the power cord from the outlet, and investigate the cause. If the system is powered in abnormal conditions, fire, electric shock, or total loss of the system may result. See Wiring Diagram and Connecting Cable for checking cable breaks as described in TROUBLESHOOTING. In addition, check the following: 1. Connectors are connected and crimped securely. 2. No contact failure occurs after re-connection of connectors. 3. Cables are soldered properly. Do not yank the cables with excessive force. Doing so could cause cable breakage. Do not perform servicing with wet hands. Doing so could cause electric shock or malfunction. Prevent water seepage into the system. Do not apply excessive force to the stylus of the tracing unit. Doing so could cause deformation or malfunction of the stylus. Make a lens material selection correctly according to the lens to be processed. If an improper material is selected, the lens may break or the lifetime of processing wheels may be shortened substantially. Never open the processing chamber door while the wheel is rotating. Spray containing processing waste may come into your eyes. Keep hands and face away from the rotating wheel. Replace the wheel with gloves on after cleaning the wheel and inside of the processing chamber. Bare hands can be hurt by glass-processing waste. Safety bevel the front and rear surfaces of glass lenses after processing. Subtle burrs may damage one s skin. Never use the adjustment jigs for purposes other than those intended. 2-1

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11 3 PRODUCT OUTLINE 3.1 Quality Standard Classification Configuration Item Checkpoint Measurement method/tool Standard configuration Main body 1 unit Accessories Operator s Manual 1 volume Installation Manual 1 volume Pliable cup 10 units Pliable cup for high base curver 6 units Double-sided adhesive pad (100sheets) 1 set Cup remover 1 unit Dressing stick for finishing wheel of glass 1 unit lenses (WA320K) Dressing stick for finishing wheel (WA320K) 1 unit Compound kit 1 unit Pattern setting unit 1 unit Standard frame 1 unit Standard pattern 1 unit Hexagonal screwdriver (2.5 mm) 1 unit Drain hose adapter set 1 set Power cord 1 unit Spare fuse 2 units Visually check the contents and numbers. Appearance Packaging unit Gap between cover juncture Appearance of formed part Color and polish of formed part 1 per 1 product unit Gap in juncture between covers is ±1.2 mm or less and level difference is 1 mm or less. No scratches or chips No stains, discolorations, or dents Color tone, grain, and polish are equivalent to those of the sample. Visually check the contents and numbers. Visual check Measure if necessary. (Scale) According to Appearance Acceptance Criteria (QIK106) Not discernible by visual check According to Appearance Acceptance Criteria (QIK106) Exterior burrs No burrs in metal or resin formed parts Visual and tactile check Printing No blurred letters or ink stains Visual check Compare with Labeling Name plates and labels follow instructions. Instruction and check Name plate/ According to Appearance label No stains or scratches Acceptance Criteria (QIK106) No peeling, curled edges, or wrinkles Visual and tactile check Power cord No stains or scratches Visual check Characters are legible. Visual check LCD display No stains or scratches Visual check 3-1

12 Classification Item Checkpoint Measurement method/tool Motorized cover When it closes, it attaches to the top cover securely. Visual check Function Cooling water volume adjustment Button function The volume of water can be adjusted when the flow control is turned. Pressing a button produces a beep and starts the corresponding operation (including LED lighting). Visually check the volume of water. Visual check Interface Data can be transmitted and received between a PC and the system. Data can be transmitted and received between the system and connected blocker (Ice 1000, ICE-9000, ICE mini). Connect a PC and a blocker to check data transmission/reception. The tracing unit lid is smoothly opened and closed. Tactile check Operation Mechanical operation Tracing speed: Frame tracing takes 30 seconds or less (both-eye tracing). Pattern tracing takes 20 seconds or less. Use a stopwatch to time from when the tracing start button is pressed until when a beep sounds to indicate tracing completion. Lens shape measurement takes 15 seconds or less, or 25 seconds or less when safety beveling is set. Use a stopwatch to time from when the feelers go down until when they come out. Water leakage from No water leaks from the juncture of the processing chamber cover. processing chamber Feedwater/drain/ No water leakage exhaust hose Maximum lens size: φ85 mm or less (within the range of φ110 mm) Minimum lens size (horizontal x vertical) Visual check Visual check Processing performance Processing performance Pliable cup Nano cup Without safety beveling With safety beveling Flat edging Beveling Flat edging Beveling φ32.0 x 19.5 φ20.0 x 15.5 φ33.0 x 21.0 φ21.0 x 16.5 φ34.5 x 21.5 φ23.0 x 18.5 * φ21.0 x 17.5 for type PL-8 Minimum lens size in an 8-base curve processing Pliable cup: φ39.0 x 26.0 Nano cup : φ27.0 x 22.5 φ35.5 x 22.5 φ24.0 x 19.5 According to Lex 1000 processing accuracy data (LLE13ARTA001) 3-2

13 Classification Item Checkpoint Measurement method/tool Processing accuracy Beveling Size accuracy Call up φ45 internal data and bevel a CR-39 lens in the Auto processing mode. The diameter is within φ45 ±0.1 mm. Axis angle Call up 45 internal data and bevel a glass/cr-39/polycarbonate lens in the Auto processing mode. The axis angle is within ±1. Flat edging Size accuracy Call up φ45 internal data and flat-edge a CR-39 lens. The diameter is within φ45 ±0.1 mm. Axis angle Call up 45 internal data and flat-edge a glass/cr-39/polycarbonate lens. The axis angle is within ±1. Measure lens outer size horizontally and vertically with a vernier caliper/ measuring jig. Processing performance Safety beveling Grooving (except for glass) Width accuracy: Call up φ45 internal data and flat-edge a CR-39 lens with safety Check by measuring with beveling selected. The width is within the set value ±40% or a vernier calipter etc. ±0.2 mm, whichever is larger. Width and depth accuracy: Call up φ45 internal data, select Nylor, and process a CR-39 Check by measuring with lens. The groove width is within the set value ±0.1 mm and a vernier calipter etc. groove depth is the set value ±0.15 mm. Retouching Size accuracy Call up φ45 internal data and bevel a CR-39 lens in the Auto processing mode. Retouch the lens with the size set to 0. The reduced size amount is within 0.15 mm. Check by measuring with a vernier calipter etc. Beveling position accuracy Keeps the ratio of 5 : 5 for a 1 mm-thick lens in the Auto processing mode. Visual check Type PLB: A CR39 lens is entirely polished after retouched for a tear drop frame when beveling/flat edging is selected. Visual check Polishing ability Type PL8: A CR39 lens is entirely polished after retouched for a tear drop frame when flat edging is selected. Visual check Type PLB-G: A CR39 lens is entirely polished after retouched for a tear drop frame when beveling/flat edging is selected. Visual check High curve beveling A lens can be securely mounted into an 8-base curve metal frame. Visual and tactile check [In-process product]: Tracing unit ASSY ( ) Specified items about in-process product: Not applicable Service life of the product: 8 years (No applied regulation) * Service life means the period during which the instrument can perform properly after newly purchased, not the warranty period. Service life of main components: Not applicable Maintenance parts and retention period: Not applicable 3-3

14 3.2 Configuration 8. Tracing unit 1. Notch for pattern setting unit 7. Display Control panel 2. USB port 6. Barcode scanner 5. Flow control 3. Tray 4. Processing chamber 1. Notch for pattern setting unit The provided pattern setting unit is placed here when not in use. 2. USB port Used to upgrade the software. 3. Tray Holds a lens or lens cup. 4. Processing chamber Processes lenses here. 5. Flow control Controls the flow volume of the cooling water poured over the wheels. 6. Barcode scanner Scans barcodes. This barcode scanner is optional. 7. Display Shows lens shapes and layout data. 8. Tracing unit Frames or lens shapes are measured here. 3-4

15 Rear view Power switch 8. Vent 1. Outlet for Pump 1 2. Outlet for Pump 2 Cooling fan 3. Outlet for vacuum cleaner Inlet Fuses 7. Ethernet port 6. RS-232C port (Drill) 5. RS-232C port (COM2) 4. RS-232C port (COM1) 1. Outlet for Pump 1 (Pump 1) Connects with the power cord of the pump for cooling water control. 2. Outlet for Pump 2 (Pump 2) Connects with the power cord of the pump for wash water control. 3. Outlet for vacuum cleaner Connects with the power cord of the vacuum cleaner LED RS-232C port (COM1) Communication port for connection with a computer or an optional intelligence blocker 5. RS-232C port (COM2) Communication port for connection with a computer or an optional barcode scanner 6. RS-232C port (Drill) Communication port for connection with an optional auto drilling unit (in preparation) 7. Ethernet port (LAN) Ethernet communication port 8. Vent Connects to the duct of the vacuum cleaner LED

16 Processing chamber 4. Nozzle for water curtain Feelers (for lens shape measurement) 5. Lens chunk 1. Cup holder 6. Wheels 2. Feedwater nozzles 7. Grooving wheel 3. Safety beveling wheel 1. Cup holder This part holds a lens blocked with a pliable cup. 2. Feedwater nozzles Supply cooling water to the edging area of a lens being processed. 3. Safety beveling wheel Safety bevels lenses. 4. Nozzle for water curtain Discharges the water curtain (wash water) to keep the processing chamber clean. 5. Lens chunk Presses against a lens set in the cup holder to secure it. 6. Wheels Multiple lenses are provided (see 3.4 Wheel Configuration ). 7. Grooving wheel Grooves lenses for nylor frames. 3-6

17 Tracing unit 4. Rim clips 1. Upper slider 5. Pattern tracing pin 6. Stylus 2. Lower slider 3. Pattern setting unit support 4. Rim clips Upper slider 2. Lower slider Frames are fastened between these sliders. 3. Pattern setting unit support Mounts the pattern setting unit set with a pattern or demo lens. 4. Rim clips Holds the rim of frames. 5. Pattern tracing pin Traces a pattern or demo lens to measure its shape. 6. Stylus Traces a frame groove to measure its frame shape. 7. button Starts left-eye tracing. 8. button Starts both-eye tracing. 9. button Starts right-eye tracing. 3-7

18 Control panel (1) S T P O S TA R T button Displays the retouch menu. 2. button Switches safety beveling on or off. 3. button Secures a lens to or releases a lens from the lens chunk. 4. button Opens or closes the processing chamber cover. 5. button Starts processing. 6. button Stops processing. 3-8

19 Control panel (2) 7. Frame button 6. Lens button 8. Mode button 9. Polish button 10. FC button 11. R/L button S T P O S TA R T button Switches the screen between the layout and menu. 2. button, button Moves the highlight on the screen. 3. button, button Enters the data such as prescription. 4. button Changes the layout entry method. 5. button Calls up the data measured by the tracing unit on the display. 6. Lens button Used to select the lens material among CR39 (plastic), Hi-index (high index plastic), Polyca. (polycarbonate), Acrylic (acrylic resin), Trivex, Urethane (polyurethane), and Glass. (Glass cannot be selected in type PLB-8.) In addition, extended pressing of this button switches soft processing on and off. 7. Frame button Used to select processing mode. Extended pressing of this button switches 8-base curve processing on and off. 8. Mode button Used to select processing mode. Extended pressing of this button switches nano cup processing on and off. 9. Polish button Switches polishing on and off. 10. FC button Switches frame changing mode on and off. 11. R/L button Used to select the side of a lens to be processed, right (R) or left (L). 3-9

20 3.3 Wheel Configuration PLB-G ( ) Roughing wheel for plastic lenses Finishing wheel ASSY Finishing wheel for glass lenses Roughing wheel for glass lenses 77 mm Motor side Marking on wheel Rotation direction Part No. Rotation direction 13mm 12mm 17.5mm 17.5mm 17mm Marked surface side PL-8 ( ) Roughing wheel for plastic lenses Finishing wheel ASSY 8-base curve wheel Roughing wheel for glass lenses 76.5mm Motor side Rotation direction 13mm 17mm 17.5mm 12mm 17mm Marked surface side PLB-8 ( ) Roughing wheel for plastic lenses 8-base curve wheel Finishing wheel ASSY 69mm Motor side Rotation direction 17.5mm 17.5mm 17mm 17mm Marked surface side 3-10

21 3.4 Labels Indicates that caution must be taken. Refer to the operator s manual before use. Indicates that caution must be taken to avoid cutting fingers. Indicates that the instrument must be supplied only with alternating current. Fuse. Indicates that the state of the power switch. When the symbol side of the switch is pressed down, the power is on. Indicates that the state of the power switch. When the symbol side of the switch is pressed down, the power is off. Indicates the date of manufacture. Indicates the date of manufacturer. Indicates that this product shall be disposed of in a separate collection of electrical and electronic equipment in EU. Rotating direction (EU area only) 3-11

22 S T A R T S T P O LLE13ARDA001D/E (EU area only) or CAUTION Pump1 MAX.1A Pump 2MAX.1A 3 MAX.1A 230V Pump1 MAX.1A 230V Pump 2MAX.1A 230V Vacuum3 MAX.1A or 3-12

23 3.5 ASSY Layout V A00 230V V A0 230V PART NO. DESCRIPTION 3-13

24 3.6 Electrical Component Layout BA07 CA38 E38 CA17 BA02 E69 BA04 E66 E67 100V 200V E37 BA03 E108 E107 CA34 E58 SYM. PART NO. DESCRIPTION 3-14

25 E33 E43 CA50 CA31 BA01 BA09 CA42 E35b E35b CA28 CA29 E35a CA34 SYM. PART NO. DESCRIPTION 3-15

26 BA03 BA05 BA06 E105 E16 2 E36 E106 BA08 CA26 E43 E42 CA27 3 CA07 E104 E103 2 E100 SYM. PART NO. DESCRIPTION 3-16

27 3.7 Replacement Parts List * : Needs adjustment after replacement : Needs confirmation after replacement 3-17

28 3-18

29 4-1 LLE13ARDA001D/E 4 TROUBLESHOOTING

30 4-2

31 5.1 Prior to Removal Work 5 REMOVING PROCEDURES 1. The assembly procedure after part replacement is generally not described as it is basically the reverse of the disassembly procedure. However, in exceptional cases, the assembly procedure is specified. 2. Each number in exploded diagrams indicates Removal order Part number removal order or part number as shown to the right. Numbers of removal order correspond to those of steps. 3. The mark in exploded diagrams indicates a threadlocking adhesive. 5.2 Abbreviations for Screws 5-1

32 5.3 Opening Top Cover ASSY 1. Remove the set screws [SB4 10 (n = 2)] of the top cover ASSY ( ). 2. Raise the top cover until the notch of the stay (44001-M245) fits on the rear panel ( M169) to lock it SB Removing Covers 1. Turn off the power switch and disconnect the power cord. 2. Open the top cover ASSY ( ) and lock it (see 5.3). 3. Disconnect connector J1 (P701) from the cover relay board (44001-BA07). 4. When the tracer ASSY ( ) is attached, disconnect connector J1 (P201) from the tracer SW board (44001-BA02). 3 BA07 4 BA02 5-2

33 5. Removing the top cover ASSY ( ) Raise the top cover ASSY ( ) to release the lock. Slide it to the left to release the hinge (40350-M180). 6. Removing the left side cover (44001-M204) and right side cover (44001-M205) Open the top cover ASSY ( ) (see 5.3) or remove it. Then remove the left side cover (44001-M204) and right side cover (44001-M205). 7. Removing the rear cover (44001-M203) Remove the tie wrap ( ) fixing the duct (44001-M084). Unscrew SB4 10 (n = 4) to remove the rear cover (44001-M203) SB

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35 6 REPLACEMENT PROCEDURES Processing adjustment Where there is an indication that readjustment is necessary after part replacement, perform processing adjustment after standard adjustment. See 4.7 Replacement Parts List for the parts which need adjustment. 6.1 Rocker Switch Replacement part: Rocker switch ( ) 1. Remove the top cover ASSY ( ) (see 5.4). 2. Disconnect all cables from the terminal of the rocker switch ( ). 3. Remove the rocker switch while pressing its clasps, then replace it. 4. Reassemble the parts in the reverse order. Be careful not to reverse the left side ( and right side ( ) of the rocker switch (see the right figure) Clasps 6.2 Main Board Replacement part: Main board (44001-BA01) 1. Save the parameters to the compact flash memory card (40273-E030) (see 7.2.2). * This step is for minimizing the system readjustment work after the main board replacement. When the inside parameters are not saved or restored, all parameters of the Lex 1000 must be adjusted (see 7.2.6). 2. Remove the top cover ASSY ( ), left side cover (44001-M204), right side cover (44001-M205), rear cover (44001-M203) (see 5.4). 3.Remove the compact flash memory card (40273-E030). 4. Unscrew BS4 10 (n = 3) to remove the board holder (4001-M172) and main board ( BA01). 172 BA01 E030 SB SB

36 5. Disconnect all cables from the connector of the main board and unscrew BS3 6 (n = 4) to replace the main board. 6. Insert the compact flash memory card. 7. Restore the parameters saved in the compact flash memory card to the main board (see 7.2.3). 6.3 Inverter Replacement part: Inverter ( ) 1. Remove the top cover ASSY ( ) (see 5.4). 2. Disconnect the cable (44001-CA31) from the CN1 connector of the inverter ( ), and disconnect the LCD supplied cable from the CN2 connector (see the figure below). (High Voltage) The inverter ( ) is high voltage. Be sure to turn off the power while handling. 3. Unscrew N3 (n = 2) to replace the inverter N CA CA BA04 J4 CN1 LCD supplied cable E BA

37 6.4 TFT color LCD Replacement part: TFT color LCD ( ) 1. Remove the top cover ASSY ( ) (see 5.4). 2. Disconnect the LCD supplied cable from the CN2 connector of the inverter ( ). (High Voltage) The inverter ( ) is high voltage. Be sure to turn off the power while handling. 3. Unscrew PT3 6 (n = 4) to remove the display holder (44001-M278) along with the TFT color LCD ( ). 4. Unscrew SB3 6 (n = 4) and PW3 (n = 4), and disconnect the cable (44001-E020) from the CN1 connector of the TFT color LCD to replace it PT PW3 4 SB Trace SW Board Replacement part: Trace SW board (44001-BA02) 1. Remove the top cover ASSY ( ) (see 5.4). 2. Disconnect connector J1 (P201) from the trace SW board (44001-BA02). 3. Unscrew PT3 6 (n = 4) to replace the trace SW board PT3 6 4 BA02 6-3

38 6.6 Setting SW Board Replacement part: Setting SW board (44001-BA03) 1. Remove the top cover ASSY ( ) (see 5.4). 2. Remove the inverter ( ) (see 6.3). (High Voltage) The inverter ( ) is high voltage. Be sure to turn off the power while handling. 3. Disconnect all cables from the connector of the setting SW board (44001-BA03). 4. Unscrew PT3 6 (n = 5) to remove the setting SW board BA03 PT Remove M260, M261, SB3 6 (n = 2), and B305R (n = 2) from the removed setting SW board to replace it. 2 BA B305R SB

39 6.7 Main SW Board Replacement part: Main SW board (44001-BA04) 1. Remove the top cover ASSY ( ) (see 5.4). 2. Disconnect connector J1 (P401) from the main SW board (44001-BA04). 3. Unscrew PT3 6 (n = 5) to remove the main SW board PT3 6 5 BA04 4. Remove M254, M255, M256 from the removed main SW board, then replace it. 256 BA

40 6.8 Cover Relay Board Replacement part: Cover relay board (44001-BA07) 1. Remove the top cover ASSY ( ) PT3 6 (see 5.4). 2. Disconnect all cables from the connector of the cover relay board (44001-BA07). 3. Unscrew PT3 6 (n = 4) to replace the cover relay board. 4 BA BA USB Board Replacement part: USB board (43501-BA03) 1. Remove the top cover ASSY ( ) (see 5.4). 2. Disconnect connector J1 (P301) from the USB board (43501-BA03). 3. Unscrew PT3 6 (n = 2) to remove the USB board along with the USB board holder (44001-M282). 4. Remove the screws (43501-M109 [n = 2]) from the USB board holder to replace the USB board PT3 6 2 BA03 BA

41 6.10 Wheel Replacement part: Wheel Jig: Wheel removal jig ( ) 1. Removing the wheel <When the wheel removal jig ( ) is not available> * The hexagon bolt may not be loosened without using the wheel removal jig ( ) as the bolt is screwed so tight. 1) Open the top cover ASSY ( ) (see 5.3). 2) Attach the long offset wrench ( M603) to the hexagon bolt (40340-M722). 3) Loosen the hexagon bolt by turning the long offset wrench toward the back of the system while holding the wheel by hand. 4) Remove the hexagon bolt, wheel retainer, and wheel. <When using the wheel removal jig ( )> * Note: Be careful not to contact the wheel removal jig ( ) to the wheel. 1) Open the top cover ASSY ( ) (see 5.3). 2) Attach the wheel removal jig ( ) while aligning it with the groove of the wheel retainer (40347-M721). 3) Attach the long offset wrench ( M603) to the hexagon bolt (40340-M722). 4) Turn the long offset wrench toward the back of the system to loosen the hexagon bolt. 5) Remove the hexagon bolt, wheel retainer, and wheel

42 2. Attaching the wheel * See 3.4 Wheel Configuration for the attachment procedures and wheel configuration. 1) Apply the grease (NIPPECO LLP) to the motor shaft. 2) Apply the grease (NIPPECO LLP) to each wheel surface to which the motor shaft contacts. 3) Attach the wheels to the motor shaft seeing 3.4 Wheel Configuration. * Make sure that the marked surface orientation and rotation direction of the wheel are correct (see 3.4). 4) Loosely attach the hexagon bolt ( M722) and wheel retainer (40347-M721) by hand. 5) Attach the long offset wrench to the hexagon bolt. 6) Turn the long offset wrench toward the front of the system while holding the wheel by hand to tighten the hexagon bolt. * Torque the wheel fixing screw to 12 Nm. 7) Perform the bevel calibration (see 7.5.5). 8) Perform the wheel calibration (see 7.5.6). 9) Perform the processing adjustment (see 7.6). 6-8

43 6.11 Grooving Wheel and Safety Bevel Finishing Wheel Replacement parts: Grooving wheel (44001-M689), Safety bevel finishing wheel ( M693) 1. Open the top cover ASSY ( ) (see ) Unscrew SB3 8 (n = 2) to remove the wheel cover (44001-M691). SB Unscrew SB4 10 and remove the wheel retainer (44001-M611), grooving wheel (44001-M689), spacer (44001-M685), and safety bevel finishing wheel (44001-M693). 4. Replace the grooving wheel and safety bevel finishing wheel. 1) Calibrate the safety beveling and grooving ASSY (see 7.5.3) SB Stylus 474 Replacement part: Stylus (40340-M474) 1. Open the top cover ASSY ( ) (see 5.3). 2.With the system turned off, turn the measurement part of the tracing unit counterclockwise by hand to direct the stylus (40340-M474) as shown in the right picture. 3. Pull up the stylus (40340-M474) by hand and unscrew CK2 3 (n = 2) to replace the stylus. 4. Reassemble the parts in the reverse order. 1) Adjust the tilt of the stylus (see ). 2) Perform the torque calibration of the tracing unit (see ). 3) Perform the frame auto calibration of the tracing unit (see ) CK

44 6.13 Tracing Unit ASSY Replacement part: Tracing unit ASSY ( ) 1. Remove the top cover ASSY ( ) (see 5.4). 2. Disconnect connectors J2 (P1502) and J7 (P1507) from the tracing unit board ( BA15). BA15 CA12 CA Loosen SB4 8 (n = 2). 4. Unscrew SB4 8 (n = 2) to replace the tracing unit ASSY ( ). 5. Reassemble the parts in the reverse order. 1) Write to the tracing unit CPU (see 7.2.5). 2) Perform the torque calibration of the tracing unit (see ). 3) Perform the frame auto calibration of the tracing unit (see ). SB SB

45 6.14 Feelers Replacement part: Left feeler (40340-M983), Right feeler (40340-M984) * Replace the feelers when the lens-contact surfaces of the left and right feelers obviously wear out and correct measurement values are not obtained. * Even though the lens-contact surface of the feeler wears out from use, the other surface can be used. Remove the machine screws and turn the feeler 180º. 1. Open the lid ASSY 2. Lay a cloth inside the processing chamber beforehand so as not to lose the machine 983 screws or feelers while handling. 3. Remove the machine screws (40340-M994 [n 2 = 4]) from the feeler ASSY ( ) Remove the feeler retainers (40340-M985 [n = 2]), left feeler (40340-M983), and right feeler 984 (40340-M984) Turn each feeler 180º to use the other surface. If the both surfaces of the feeler wear out, replacement is necessary. 6. Reassemble the parts in the reverse order. 1) Calibrate the lens measurement unit ASSY (see 7.5.7)

46 6.15 Feeler ASSY Replacement part: Feeler ASSY ( ) 1. Remove the top cover ASSY ( ) and left side cover (44001-M204) (see 5.4). 2. Turn manually the arrow-indicating area of the lens measurement unit ASSY ( ) in the right figure so that the set screws (40340-M291 [n = 2]) of the feeler ASSY ( ) can be seen. 3. Loosen the set screws (40340-M291 [n = 2]) Remove the Allen screw (40340-M293) and 3PW4 to replace the feeler ASSY ( ). 5. Reassemble the parts in the reverse order. 1) Adjust the height of the feeler ASSY (see ). 2) Adjust the feeler initial position (see ). 3) Calibrate the lens measurement unit ASSY (see 7.5.7). 4) Adjust the feeler AXIS (see 7.6.1) PW

47 6.16 Lens Measurement Unit ASSY Replacement part: Lens measurement unit ASSY ( ) 1. Remove the top cover ASSY ( ) BA06 and left side cover (44001-M204) (see 5.4). 2. Remove the feeler ASSY ( ) (see 6.15). SB Remove the tie wrap ( ) to the processing chamber side and move the duct (40350-M084) aside as shown to the right. 4. Disconnect connector J1 (P601) from the 84 board (40340-BA06). 5. Unscrew SB6 20 (n = 2) and remove the positioning pins (40340-M112 [n = 2]) to replace the lens measurement unit ASSY ( ) Reassemble the parts in the reverse order. * The sleeve (40340-M995) of the lens measurement unit must be below the processing chamber door. 1) Adjust the height of the feeler ASSY (see ). 2) Adjust the feeler initial position (see ). 3) Calibrate the lens measurement unit ASSY (see 7.5.7). 4) Adjust the feeler AXIS (see 7.6.1) Lens Measurement Board Replacement part: Lens measurement board (40340-BA06) 1. Disconnect all cables from the connector of the lens measurement board (40340-BA06). 2. Unscrew PT3 6 (n = 2) to replace the board (40340-BA06). 3. Reassemble the parts in the reverse order PT3 6 2 BA

48 6.18 Pulse Motor (40340-E033) Replacement part: Pulse motor (40340-E033) 1. Remove the lens measurement ASSY ( ) (see 6.16). 2. Disconnect connector J2 (P602) from the board (40340-BA06). 3. Unscrew SB3 10 (n = 4) and HH4 6 to replace the pulse motor (40340-E033). 4. Reassemble the parts in the reverse order. * Readjustment is necessary (see 6.16). E33 HH SB Encoder Replacement part: Encoder (40340-E043) 1. Remove the lens measurement ASSY ( ) (see 6.16). 2. Disconnect connector J6 (P606) from the board (40340-BA06). 3. Unscrew SB3 6 (n = 2) and PW3 (n = 2) to remove the encoder holder (40340-M288) and encoder (40340-E043). 4.Unscrew CK2 5 (n = 2) to replace the encoder (40340-E043). 5. Reassemble the parts in the reverse order. * Readjustment is necessary (see 6.16) CK E43 PW3 2 SB Cables (40340-CA31, CA32, CA33) Replacement part: Cables (40340-CA31, CA32, CA33) 1. Open the top cover ASSY ( ) (see 5.3). 2. Replacing the cable (40340-CA31) 1) Disconnect connector J3 (P603) from the board (40340-BA06). 2) Unscrew SB2 10 (n = 2) and 3PW2 (n = 2) to replace the cable (40340-CA31). CA32 CK CA33 CK2 5 2 CA31 3PW2 2 2 SB

49 3. Replacing the cable (40340-CA32) 1) Disconnect connector J4 (P604) from the board (40340-BA06). 2) Unscrew CK2 5 (n = 2) to replace the cable (40340-CA32). 4. Replacing the cable (40340-CA33) 1) Disconnect connector J5 (P605) from the board (40340-BA06). 2) Unscrew CK2 5 (n = 2) to replace the cable (40340-CA33). 5. Reassemble the parts in the reverse order. * Readjustment is necessary (see 6.16) Safety Beveling and Grooving ASSY Replacement part: Safety beveling and grooving ASSY ( ) 1. Remove the top cover ASSY ( ) Tape (white) and left side cover (44001-M204) (see 5.4). 2. Remove the tie wrap ( ) to the processing chamber side and remove the duct (40350-M084). 3. Remove the tape (white) and guide ( M931). 4. Disconnect the connector (CN03) of the motor cable (40340-CA34), the connector (CN04) of the pulse motor(40340-e035), and the connector (CN05) of the sensor cable ( CA42). 5. Unscrew SB6 20 (n = 2) and remove the 84 positioning pins (40340-M112 [n = 2]) to replace the safety beveling and grooving ASSY ( ). 6. Reassemble the parts in the reverse order. 1) Adjust the position of the safety beveling and grooving ASSY arm (see ). 2) Calibrate the safety beveling and grooving ASSY (see 7.5.3) Tape (white) 2 SB6 20 BA

50 6.22 Spindle ASSY Replacement part: Spindle ASSY ( ) 1. Remove the safety beveling and grooving ASSY ( ) (see 6.21). 2. Unscrew SB3 8 (n = 2) to remove the wheel cover (44001-M691). 3. Unscrew SB3 8 (n = 2) to replace the spindle ASSY ( ). 4. Reassemble the parts in the reverse order. 5.Apply the gasket (1211) material to the underside of the screw heads (SB3 8 [n = 2]) for fixing the spindle ASSY. 6. Reassemble the parts in the reverse order Apply gasket material (1211) SB3 8 2 SB Pulse Motor (40340-E035) Replacement part: Pulse motor (40340-E035) 1. Remove the safety beveling and grooving ASSY ( ) (see 6.21). 2. Unscrew SB3 6 (n = 4) to remove the pulse motor (40340-E035) along with the motor support (44001-M661). 3. Loosen HH3 4 (n = 2) and unscrew FC3 8 (n = 4) to replace the pulse motor ( E035). 4. Reassemble the parts in the reverse order. 1) Calibrate the safety beveling and grooving ASSY (see 7.5.3). E SB3 6 4 FC HH Sensor Cable (44001-CA42) Replacement part: Sensor cable (44001-CA42) 1. Open the top cover ASSY ( ) (see 5.3). 2.Disconnect the connector (CN05) of the sensor cable (44001-CA42). 3. Unscrew CK2 4 (n = 2) to replace the sensor cable (44001-CA42). 4. Reassemble the parts in the reverse order. 1) Calibrate the safety beveling and grooving ASSY (see 7.5.3). CA42 CK

51 6.25 LED Cable Replacement part: LED cable (44001-CA50) 1. Open the top cover ASSY ( ) (see 5.3). 2. Disconnect the connector (CN07) of the LED cable (44001-CA50). 3. Remove the tape (white) to replace the LED cable (44001-CA50). CA50 Tape (white) CN07 CA Spindle Motor Replacement part: Spindle motor (40347-E058) 1. Remove the top cover ASSY ( ) and right side cover (44001-M205) (see 5.4). 2. Manually raise the carriage ASSY ( ) in the direction of the arrow as shown to the right. 3. Remove the wheel (see 6.10). 4.Disconnect the cable connectors (CN01, CN02) of the spindle motor. 5. Remove the colloar (40347-M717) by hand. 6. Unscrew SB6 20 (n = 4) to remove the motor ASSY ( ) SB Unscrew SB5 18 (n = 4) to replace the spindle motor (40347-E058). 8. Reassemble the parts in the reverse order. * Attach the spindle motor (40347-E058) so that the cables point back and down as shown to the right. E58 SB

52 6.27 Guide Replacement part: Guide (44001-M931) 1. Open the top cover ASSY ( ) (see 5.3). 2. Disconnect the connector (CN07) of the LED cable (44001-CA50). 3. Remove the tape (white) fixing the guide (44001-M931). Tape (white) (CN07) Tape (white) 4. Remove the tie wrap ( ) to the processing chamber side, duct (40350-M084), and guide (44001-M931) Processing Chamber ASSY Replacement part: Processing chamber ASSY ( ) 1. Remove the top cover ASSY ( ), left side cover (44001-M204), and right side cover (44001-M205) (see 5.4). 2. Remove the guide (44001-M931) (see 6.27). 3. Remove the tube (44001-M083) from the two positions. 4. Remove the tube (43101-M441). 5. Remove the safety beveling and grooving ASSY ( ) (see 6.21)

53 6. Loosen HH4 4 (n = 4). 7. Unscrew SB4 10 to replace the processing chamber ASSY ( ). 8. Reassemble the parts in the reverse order. 1) Adjust the position of the safety beveling and grooving ASSY ( ) arm and calibrate the ASSY (see , 7.5.3). SB HH Lower Processing Chamber ASSY Replacement part: Lower processing chamber ASSY ( ) 1. Remove the top cover ASSY ( ), left side cover (44001-M204), and right side cover (44001-M205) (see 5.4). 2. Remove the guide (44001-M931) (see 6.27). 3. Remove the feeler ASSY ( ) (see 6.15). 4. Remove the safety beveling and grooving ASSY ( ) (see 6.21). 5. Remove the motor ASSY ( ) (see 6.26). 6. Remove the processing chamber ASSY ( ) (see 6.28). 7. Remove the inner guards (44001-M621 [n = 2]), guard R (40340-M923), and guard L (40340-M924). 8.Unscrew SB4 10 to replace the lower processing chamber ASSY ( ). 9. Reassemble the parts in the reverse order. 1) Adjust the position of the safety beveling and grooving ASSY ( ) arm and calibrate the ASSY (see , 7.5.3). SB

54 6.30 Carriage ASSY Replacement part: Carriage ASSY ( ) 1. Remove the top cover ASSY ( ), left side cover (44001-M204), and right side cover (44001-M205) (see 5.4). 2. Remove the guide (44001-M931) (see 6.27). 3. Remove the feeler ASSY ( ) (see 6.15). 4. Remove the safety beveling and grooving ASSY ( ) (see 6.21). 5. Remove the motor ASSY ( ) (see 6.26). 6.Remove the processing chamber ASSY ( ) (see 6.28). 7. Remove the lower processing chamber ASSY ( ) (see 6.29). 8. Disconnect connector J1 (P501) from the carriage relay board (44001-BA05). 9. Unscrew SB6 20 (n = 2) and remove the shaft retainers (40340-M108 [n = 2]) to replace the carriage ASSY ( ). 10.Reassemble the parts in the reverse order. 1) Adjust the carriage ASSY (see 7.3.1). 2) Adjust the position of the safety beveling and grooving ASSY ( ) arm and calibrate the ASSY (see , 7.5.3). 3) Adjust the height of the feeler ASSY (see ). 4) Adjust the feeler initial position (see ). 5) Adjust the chuck pressure (see 7.3.4). 6) Calibrate the lens measurement unit ASSY (see 7.5.7). 7) Adjust the feeler axis (see 7.6.1) Chuck Axis Motor ASSY SB6 20 Replacement part: Chuck axis motor ASSY ( ) 1. Remove the top cover ASSY ( ), left side cover (44001-M204), and right side cover (44001-M205) (see 5.4). 2. Remove the guide (44001-M931) (see 6.27). 3. Remove the feeler ASSY ( ) (see 6.15). 4. Remove the safety beveling and grooving ASSY ( ) (see 6.21). 5. Remove the motor ASSY ( ) (see 6.26). 6. Remove the processing chamber ASSY ( ) (see 6.28). 7. Remove the lower processing chamber ASSY ( ) (see 6.29)

55 8. Remove the carriage ASSY ( ) (see 6.30). 9. Disconnect connector CN06 from the DC motor (44001-E042) and connector J3 (P503) from the carriage relay board (44001-BA05). 10. Unscrew SB6 40 (n = 2) to replace the chuck axis motor ASSY ( ). 11. Reassemble the parts in the reverse order. 1) Adjust the chuck pressure (see 7.3.4) Grease (SHV-2) SB Y axis motor ASSY Replacement part: Y axis motor ASSY ( ) 1. Remove the top cover ASSY ( ), left side cover (44001-M204), and right side cover (44001-M205) (see 5.4). 2. Disconnect connector CN02 from motor driver MD01 (44001-E036) and connector J5 (P505) from the carriage relay board (44001-BA05). 3. Unscrew SB6 10 to replace the Y axis motor ASSY ( ). 4. Reassemble the parts in the reverse order. 1) Adjust the carriage ASSY (see 7.3.1). 2) Adjust the position of the safety 544 beveling and grooving ASSY ( ) arm and calibrate the ASSY (see , 7.5.3). 3) Adjust the height of the feeler ASSY (see ). 4) Adjust the feeler initial position (see ). 5) Calibrate the lens measurement unit ASSY (see 7.5.7). 6) Adjust the feeler axis (see 7.6.1). SB Y axis stepping motor Replacement part: Stepping motor (44001-E035) 1. Remove the Y axis motor ASSY ( ) (see ). 2. Unscrew SB4 6 (n = 2) to remove the cable clamp (44001-M574). 6-21

56 3. Unscrew HH4 3 (n = 2) and SB3 8 (n = 4) to replace the stepping motor (44001-E035). 4. Reassemble the parts in the reverse order. 1) Calibrate the safety beveling and grooving ASSY (see 7.5.3). 2) Calibrate the lens measurement unit ASSY (see 7.5.7). E DC Motor Replacement part: DC motor (44001-E042) 1. Remove the top cover ASSY ( ), left side cover (44001-M204), and right side cover (44001-M205) (see 5.4). 2. Disconnect connector CN06 from the DC motor (44001-E042). 3. Unscrew HH4 6 (n = 2), BS4 10 (n = 3), and 3PW4 (n = 3) to replace the DC motor (44001-E042). 4. Reassemble the parts in the reverse order. 1) Adjust the chuck pressure (see 7.3.4). SB3 8 4 HH SB4 6 2 E PW4 3 SB HH θ Axis Stepping Motor Replacement part: θ axis stepping motor (44001-E035) 1. Remove the top cover ASSY ( ), left side cover (44001-M204), and right side cover (44001-M205) (see 5.4). 2. Disconnect connector CN02 from motor driver MD02 (44001-E036). 3. Unscrew BS4 10 (n = 2) to remove the motor holder (44001-M516) along with the θ axis stepping motor (44001-E035). 4. Unscrew HH4 4 (n = 2), BS3 8 (n = 4), and 3PW4 (n = 3) to replace the θ axis stepping motor. 5. Reassemble the parts in the reverse order. 1) Calibrate the safety beveling and grooving ASSY (see 7.5.3). 2) Calibrate the lens measurement unit ASSY (see 7.5.7). E35 2 SB SB3 6 4 HH

57 6.35 Carriage Relay Board Replacement part: Carriage relay board (44001-BA05) 1. Remove the top cover ASSY ( ), left side cover (44001-M204), and right side cover (44001-M205) (see 5.4). 2. Disconnect connector J1 (P501) from the carriage relay board (44001-BA05). 3. Unscrew BS3 6 (n = 4) to replace the carriage relay board (44001-BA05). SB3 6 4 BA Sensor Cables (44001-CA27, CA29) Replacement parts: Sensor cables (44001-CA27,CA29) 1. Remove the top cover ASSY ( ), CK2 4 2 left side cover (44001-M204), and right side cover (44001-M205) (see 5.4). 2. Disconnect connectors J4 (P504) and J6 (P506) from the carriage relay board ( BA05). 3. Unscrew CK2 4 (n = 2 for each) to replace the sensor cables (44001-CA27, CA29). CA27 CK2 4 2 CA Sensor Cables (44001-CA26, CA28) Replacement parts: Sensor cables (44001-CA26, CA28) 1. Remove the top cover ASSY ( ), left side cover (44001-M204), and right side cover (44001-M205) (see 5.4). CA28 2. Disconnect connectors J3 (P503) and J5 (P505) from the carriage relay board ( BA05). CK Unscrew SB2 3 (n = 2), 3PW2 (n = 2), and SB2 8 (n = 2) to replace the sensor cable (44001-CA26). 4. Unscrew SB2 4 (n = 2) to replace the sensor cable (44001-CA28). SB2 8 2 CA26 SB PW

58 X axis motor ASSY Replacement part: X axis motor ASSY ( ) 1. Remove the top cover ASSY ( ), left side cover (44001-M204), and right side cover (44001-M205) (see 5.4). 2. Disconnect connectors J9 (P109) and J10 (P110) from the main board (44001-BA01). 3. Unscrew SB6 15 (n = 2) to replace the X axis motor ASSY ( ). 4. Reassemble the parts in the reverse order. 1) Adjust the engagement of the X axis motor ASSY motor gear (see ). SB Pulse motor (44001-E037), sensor cable (44001-CA17) Replacement part: Pulse motor (44001-E037), sensor cable (44001-CA17) 1. Remove the X axis motor ASSY ( ) (see ). 2. Unscrew SB4 10 (n = 4) to replace the pulse CA17 motor (44001-E037). CK Unscrew CK2 5 (n = 2) to replace the sensor cable (44001-CA17) E37 SB

59 6.39 Feedwater ASSY Replacement part: Feedwater ASSY ( ) 1. Remove the top cover ASSY ( ) and right side cover (44001-M205) (see 5.4). 2. Remove the motor ASSY ( ) (see 6.26). 3. Remove the tubes (44001-M080, M081) from the elbow (41274-M262). 4. Loosen the crescent clamps (40340-M960 [n = 2]) to remove the tubes (44001-M081, M082) Loosen HH4 6 to remove the knob ( M165). 6. Unscrew AS4 10 (n = 2) to replace the feedwater ASSY ( ). 7. Reassemble the parts in the reverse order. 1) Apply the gasket material (1211) to the joint (44001-M866). 2) Insert the tube (44001-M080) into the elbow (41274-M262). Make sure that it cannot be pulled out. 2 AS HH Lid ASSY Replacement part: Lid ASSY ( ) 1. Open the lid ASSY ( ). 2. Unscrew SB4 10 (n = 3) and remove the retainer (44001-M287) to replace the lid ASSY 3. Reassemble the parts in the reverse order. 1) Perform the cover calibration (see 7.5.9) SB

60 6.41 Sensor Cable (44001-CA37) Replacement part: Sensor cable (44001-CA37) 1. Remove the top cover ASSY ( ) (see 5.4). 2. Disconnect connector J4 (P704) from the cover relay board. 3. Unscrew SB2 10 (n = 2) and 3PW2 (n = 2) and remove the mount (44001-M247) to replace the sensor cable (44001-CA37). 4. Reassemble the parts in the reverse order. 1) Perform the cover calibration (see 7.5.9) SB2 10 3PW CA Pulse Motor (44001-E038) Replacement part: Pulse motor (44001-E038) 1. Remove the top cover ASSY ( ) (see 5.4). 2. Disconnect connector J3 (P703) from the cover relay board (44001-BA07). 3. Move the gear (44001-M246) and unscrew SB3 6 (n = 4) to remove the pulse motor (44001-E038). E38 SB Grease (SHV-2) Loosen HH4 4 (n = 2) and remove the gear (44001-M239) to replace the pulse motor (44001-E038). 5. Reassemble the parts in the reverse order. 1) Perform the cover calibration (see 7.5.9). 2 HH4 4 E

61 6.43 DC Fan Replacement part: DC fan (40350-E016) 1. Remove the top cover ASSY ( ) and rear cover (44001-M203) (see 5.4). 2. Disconnect connector CN08 from the DC fan (40350-E016). 3. Unscrew PC4 30 (n = 4) to remove the DC fan (40350-E016). 4. Reassemble the parts in the reverse order. * Attach the DC fan so that the hole for the cable is oriented as shown to the right. E16 PC Communication Connector Board Replacement part: Communication connector board (44001-BA08) 1. Remove the top cover ASSY ( ) BA08 and rear cover (44001-M203) (see 5.4). 2. Remove the tracing unit ASSY ( ) (see 6.13). 3.Disconnect all connectors from the communication connector board ( BA08). 4. Remove the connector locks (n = 6) to replace the communication connector board ( BA08) Cables (44001-CA07) Replacement parts: Cables (44001-CA07) 1. Remove the top cover ASSY ( ) and rear cover (44001-M203) (see 5.4). 2. Remove the tracing unit ASSY ( ) (see 6.13). 3. Disconnect connectors J6 (P906), J7 (P907), and J8 (P908) from the SSR board ( BA09). 4. Pull out the cables (44001-CA07) respectively while pressing the three clasps for each. 3 CA

62 6.46 Fuse Holders Replacement part: Fuse holders ( [n = 2]) 1. Remove the top cover ASSY ( ) and rear cover (44001-M203) (see 5.4). 2. Remove the tracing unit ASSY ( ) (see 6.13). 3. Remove all cables from the fuse holders ( [n = 2]). 4. Remove the supplied nuts (n = 2) to replace the fuse holders ( [n = 2]). 5. Reassemble the parts in the reverse order. * Attach the fuse holder so that P on the fuse holder terminal appears as shown to the right. Supplied nuts Inlet Replacement part: Inlet ( ) 1. Remove the top cover ASSY ( ) and rear cover (44001-M203) (see 5.4). 2. Remove the tracing unit ASSY ( ) (see 6.13). 3. Remove the cable from the inlet ( ). 4.Remove the inlet ( ) while pressing its clasp and replace it. 5. Reassemble the parts in the reverse order. * Attach the inlet so that the GND terminal is oriented as shown to the right

63 6.48 Reactor Replacement part: Reactor (40350-E043) 1. Remove the top cover ASSY ( ), rear cover (44001-M203), and right side cover (44001-M205) (see 5.4). 2. Remove the tracing unit ASSY ( ) (see 6.13). 3. Disconnect connector DC BUS (PD/P) from the inverter for the BL motor (40347-E066 for 100 V or E067 for 230 V). 4. Unscrew SPC4 6 (n = 2) to replace the reactor (40350-E043). SPC4 6 2 E Regenerative Resistor for BL Motor Replacement part: Regenerative resistor for BL motor (40340-E069) 1. Remove the top cover ASSY ( ), rear cover (44001-M203), and right side cover SPC4 6 (44001-M205) (see 5.4). 2. Remove the tracing unit ASSY ( ) (see 6.13). 3. Disconnect connector BREAK (P/PB) from the inverter for the BL motor (40347-E066 for 100 V or E067 for 230 V). 4. Unscrew SPC4 6 (n = 2) to replace the regenerative resistor for the BL motor ( E069). 2 E

64 6.50 Mains Part ASSY Replacement part: Mains part ASSY ( for 100 V or 12A0 for 230 V) 1. Remove the top cover ASSY ( ), 100V 230V rear cover (44001-M203), left side cover BA A0 (44001-M204), and right side cover ( or M205) (see 5.4). 2. Remove the tracing unit ASSY ( ) (see 6.13). 3. Unscrew SB4 10 (n = 3) to remove the board mount (44001-M172) along with the main board (44001-BA01). 4. Unscrew SB4 10 (n = 5) to replace the mains part ASSY ( for 100 V or 12A0 for 230 V). 5. Reassemble the parts in the reverse order. 3 SB SB Inverter for BL Motor Replacement part: Inverter for BL motor (40347-E066 for 100 V or E067 for 230 V) 1. Remove the top cover ASSY ( ), rear cover (44001-M203), left side cover (44001-M204), and right side cover ( M205) (see 5.4). 2. Remove the mains part ASSY ( for 100 V or 12A0 for 230 V) (see 6.50). 3. Disconnect all connectors and cables from the inverter for BL motor (40347-E066 for 100 V or E067 for 230 V). 4. Unscrew AS4 10 (n = 2) to replace the inverter for BL motor (40347-E066 for 100 V or E067 for 230 V). 5. Reassemble the parts in the reverse order. * Set the parameters of the inverter for the BL motor (see 7.4.1) V or A0 230V E66 E67 or 100V 230V 2 AS

65 6.52 Switching Regulator Replacement part: Switching regulator ( ) 1. Remove the top cover ASSY ( ), rear cover (44001-M203), left side cover (44001-M204), and right side cover ( M205) (see 5.4). 2. Remove the mains part ASSY ( for 100 V or 12A0 for 230 V) (see 6.50). 3.Remove all terminals from the switching regulator ( ). 4. Unscrew AS4 10 (n = 2) to replace the switching regulator ( ) AS Motor Drivers Replacement parts: Motor drivers (44001-E036 [n = 2]) 1. Remove the top cover ASSY ( ), rear cover (44001-M203), left side cover (44001-M204), and right side cover ( M205) (see 5.4). 2. Remove the mains part ASSY ( for 100 V or 12A0 for 230 V) (see 6.50). 3. Disconnect all connectors from the motor drivers (44001-E036 [n = 2]). 4. Unscrew SB3 12 (n = 4) to replace the motor drivers (44001-E036 [n = 2]). 2 E36 4 SB SSR Board Replacement part: SSR board (44001-BA09) 1. Remove the top cover ASSY ( ), rear cover (44001-M203), left side cover (44001-M204), and right side cover ( M205) (see 5.4). 2. Remove the mains part ASSY ( for 100 V or 12A0 for 230 V) (see 6.50). 3. Disconnect all connectors from the SSR board (44001-BA09). 4. Remove the SSR board (44001-BA09). BA

66 6.55 Line Noise Filter Replacement part: Line noise filter ( ) 1. Remove the top cover ASSY ( ), rear cover (44001-M203), left side cover (44001-M204), and right side cover ( M205) (see 5.4). 2. Remove the mains part ASSY ( for 100 V or 12A0 for 230 V) (see 6.50). 3. Remove all terminals from the line noise filter ( ). 4. Unscrew SPC4 6 (n = 2) to remove the board mount (44001-M194). 5. Unscrew SPC4 6 (n = 4) to replace the line noise filter ( ) SPC SPC

67 7 SETTING/ADJUSTMENT 7.1 Notes for Proper Setting and Adjustment 1. Prepare jigs necessary for adjustment and measurement (see 8.7). 2. See TROUBLESHOOTING or use the Lex 1000 internal data φ45 or 45 to determine from which the trouble results, the tracing unit or processing chamber. 3.When the trouble results from the processing chamber, select Machine Test in the parameter screen to specify further the malfunction or maladjustment spot (see 7.2.7). 4. In the beginning of setting and adjusting work, thoroughly confirm and perform the adjustments of finishing size, height of the SFB arm, and height of the feeler for lens measurement as they become the standards for adjustments. If they are not fully adjusted, accuracy in grooving and safety beveling or processing quality using lens shape is not stabilized even though other adjustments are performed. 5. After completing the lens size adjustment, mechanical adjustment of the SFB arm height, and height adjustment of feeler for lens measurement, perform settings and adjustments of polishing, grooving, safety beveling, and others. 6. Chuck pressure cannot be measured correctly without the measurement jig. Use the chuck pressure measurement jig LEDJ-11 ( ) to obtain accurate result as chuck pressure does not vary linearly according to the adjusted value. 7-1

68 7.2 Utility Program Upgrading Lex 1000 main program Purpose: Writing upgrade program from the USB flash drive to the master CPU (approx. 10 seconds) <Prior to upgrade> 1. Preparation 1) USB flash drive (43501-E032) * Format the USB flash drive in FAT. If it is formatted in FAT32, it may not operate properly. 2) Main program * The extension is.mot. 3) Resource file * Resource file is a text file necessary to display multiple languages. It can be provided as necessary. The extension is.txt. 2. Copying program Copy the main program to the prepared USB flash drive. At this time, be sure to copy it to a root folder. If it is copied to a sub folder, it cannot be recognized. In addition, begin the name of main program file with E13_. 3. Copying resource file Make a res folder in the prepared USB flash memory. Copy the resource file to the res folder. Name the file freely. However, when the file name is too long, it is displayed in a short name. <Upgrade> 1. Main program 1) Turn off the Lex ) Open up the USB port cover to insert the USB flash drive. 3) While pressing, turn on the main body. Press and hold the button until a beep sounds. USB port cover USB flash drive 7-2

69 4) When the files in the USB flash drive are listed on the display, select the copied main program with or, then press. 5) When the confirmation message appears, press. If a wrong file is selected, press. 6) When Please turn off power and remove the USB memory. appears, turn off the power and remove the USB flash drive. Note: Never remove the USB flash drive nor turn off the Lex 1000 while upgrading. The USB flash drive may be damaged or the Lex 1000 may not start. 2. Resource file 1) Confirm that the USB flash drive is not inserted in the Lex ) Turn on the Lex ) After the Lex 1000 starts, press to switch to the Menu screen. 4) Open up the USB port cover and insert the USB flash memory. Select Update string info. and press. 7-3

70 5) After the files in the res folder are listed on the display, select the copied resource file with or, then press. * To cancel, press. To display the Menu screen again, remove the USB flash drive once, then insert it again. 3. Confirmation 1) After upgrade is completed, check the version information. While pressing, press to switch to the Parameter screen. The version information is displayed to the left of the screen. 2) Main program To check the version of the main program, see the version of Master. 3) Resource file To check the version of the resource file, see the version of Resource. If the version of Resource is not displayed, press Language to switch the language. 7-4

71 7.2.2 Backing up parameter settings Purpose: Backing up parameter settings to the compact flash memory card (40273-E030) (approx. 3 seconds) 1. Turn on the main body. 2. While pressing, press to display the Parameter screen. 3. Press to select EEPROM, and press. 4. Press to select Backup, and press. 5. The dialog box appears. Press to select OK. 6. Pressing backs up the parameter settings to the compact flash memory card ( E030). 7-5

72 7.2.3 Restoring parameter settings Purpose: Restoring the parameter settings to the main board from the compact flash memory card (40273-E030) (approx. 3 seconds) 1. Turn on the main body. 2. While pressing, press to display the Parameter screen. 3. Press to select EEPROM, and press. 4. Press to select Restore, and press. 5. The pop-up menu appears. Press to select the desired software version. 6. Pressing displays the dialog box. Select OK with,,, or, then press. The parameter settings are restored to the main board from the compact flash memory card (40273-E030). 7-6

73 7.2.4 Copying parameter settings to USB flash drive Purpose: Copying the parameter settings to the USB flash drive (approx. 3 seconds) Note: Be sure to back up the parameter settings before copying them to the USB flash drive (see 7.2.2). Jig: USB flash drive 1. Turn on the main body. 2. While pressing, press to display the Parameter screen. 3. Open up the USB port cover to insert the USB flash drive. USB port cover USB flash drive 4. Inserting the USB flash drive displays the popup menu. 5. Press to select Obtain machine info. 6. Press to copy the parameter settings to the USB flash drive. 7-7

74 7.2.5 Writing program to tracing unit CPU Purpose: Writing program to tracing unit CPU (approx. 3 minutes) 1. Connect one end of the RS232C cross cable for the tracing unit to the PC COM1 port. 2. Open the Lex 1000 main body cover (see 5.4). 3. Turn off the Lex 1000, connect the conversion cable (40390-CA01) to J4 of the tracing unit (on the left side of the unit), and connect the other end of the above RS232C cross cable to the conversion cable. 4. Release the protection by sliding PROGRAM of the tracing unit protect SW to the ON position (lower). 5. Turn on the Lex The Lex 1000 main body is initialized, but the tracing unit is not. If the protect SW is not released in Step 4, the tracing unit starts ordinary operation. 6. Activate Flash Writer PRO. 7. Click Setting and set the following items as shown to the right. Click Setting. 1. Select CPU 2. CPU operation clock 3. COM Port Setting 8. Click File Open to select the file to be written (ex. Le10_Tracer_V101.mot). 9.The dialog box confirming the start of Select. download appears. Clicking OK starts the Select. download and displays the window indicating the download status. Click Apply. 10.Writing will be completed in approx. 3 minutes and the window indicating the download status closes. Click OK. If writing is not completed properly, a message appears. 11. Exit Flash Writer PRO. 12.Turn off the main body. 13.Release the protection by sliding PROGRAM of the protect SW to the OFF position (upper). 14.Disconnect the cable. 15.Close the Lex 1000 main body cover. 16.Turn on the Lex 1000 to confirm the version No. in the Menu screen or Parameter screen. 7-8

75 7.2.6 Setting parameters Displaying parameter setting screen 1. Turn on the power switch. 2. While pressing, press to display the Parameter screen. 3. Press to select Parameter Setting, and press. 4. Press Prev page or Next page to display the desired page (1/16 to 16/16). 5. Press to select the desired item Displaying wheel parameter screen 1. Turn on the power switch. 2. While pressing, press to display the Parameter screen. 3. Press to select Wheel Parameter, and press. 4. Press or to display the desired wheel type. 5. Press to select the desired item. 7-9

76 Parameter list Parameter Default Setting Range Lex Drill Adjustment Size Differential (Glass) Axis Bevel Position (Auto) Groove Position (Auto) Groove Depth Hole diameter Hole depth PD offset PD correction in Passive Exec None Exec Rimless frame angle Default Setting FPD [mm] DBL [mm] PD [mm] Optical center height [mm] Groove width Groove depth Front SFB size (Bevel) Rear SFB size (Bevel) Front SFB size (Flat) Rear SFB size (Flat) Grinding Setting Plastic frame preset Plastic frame preset (Glass) Measurement for flat edging Exec None Exec R/L reverse reference R R L Bifocal offset (V) Bifocal offset (H) Tilt function None None Exec Measurement after rough None None Exec SFB mode (Bevel) F & R R F & R Default setting for Soft grinding None None Exec Additional SFB None None Exec Maintenance message Exec None Exec Wheel Pump Auto passive mode None None Exec Vacuum None None Exec Vacuum timer [s] Jewel 1 outer hole diameter [mm] Jewel 1 outer hole depth [mm] Tool length Jewel 1 inner hole diameter [mm] Jewel 1 inner hole depth [mm] Tool length Jewel 2 outer hole diameter [mm] Jewel 2 outer hole depth [mm] Tool length Jewel 2 inner hole diameter [mm] Jewel 2 inner hole depth [mm] Tool length Jewel 3 outer hole diameter [mm] Jewel 3 outer hole depth [mm] Tool length Jewel 3 inner hole diameter [mm] Jewel 3 inner hole depth [mm] Tool length Year Unset Month Unset 1 12 Day Unset 1 31 Hour Unset 0 23 Minute Unset 0 59 Second Unset 0 59 Date format yyyy/mm/dd yyyy/mm/dd dd/mm/yyyy mm/dd/yyyy 7-10

77 7-11

78 7-12

79 7-13

80 7.2.7 Machine Test program Purpose: Specifying the malfunction or maladjustment spot with Machine Test when the trouble results from the processing chamber. 1. Turn on the main body. 2. While pressing, press to display the Parameter screen. 3. Press to select Machine Test, and press. 4. Press or to select the desired test item. 5. [X Axis] 1) Displays the X axis origin sensor between ON and OFF. (ON: blue, OFF: white) 6. [Y Axis] 1) Displays the Y axis origin sensor between ON and OFF. (ON: blue, OFF: white) 2) Displays the output value of the Y axis encoder. (Pressing Enclear sets the output value to 0.) 3) Displays the output value of the Y axis motor. (The output value is adjusted with Power Down or Power Up.) 7. [θ Axis] 1) Displays the θ axis origin sensor between ON and OFF. (ON: blue, OFF: white) 2) Displays the output value of the θ axis encoder. (Pressing Enclear sets the output value to 0.) 3) Displays the output value of the θ axis motor. (The output value is adjusted with Power Down or Power Up.) 7-14

81 8. [Chuck] 1) Displays the chuck open/close sensor. 2) Pressing Close closes the chuck axis. (ON: blue, OFF: white) 3) Pressing Open opens the chuck axis. (ON: blue, OFF: white) 9. [SFB] 1) Displays the SFB ASSY origin sensor between ON and OFF. (ON: blue, OFF: white) 2) Pressing Init sets the SFB ASSY in the standby position. Pressing Down sets the SFB ASSY in the processing position. 3) While Wheel On is pressed, the motor rotates and the output value of the SFB ASSY motor is displayed on the Cur field. 10.[LMU] 1) Displays the LMU ASSY origin sensor between ON and OFF. (ON: blue, OFF: white) 2) Pressing Init sets the LMU ASSY in the standby position. Pressing Down sets the LMU ASSY in the measurement position. 3) Displays the output value of the LMU ASSY encoder. (Pressing Enclear sets the output value to 0.) 4) When the feeler ASSY is in the default position (UP), the Lift value is around 740. When the ASSY is in the measurement position (DOWN), the value is around [Cover] 1) Displays the lid ASSY open/close sensor between ON and OFF. 2) Pressing Close closes the lid ASSY (ON: blue, OFF: white) 3) Pressing Open opens the lid ASSY (ON: blue, OFF: white) 7-15

82 12.[Spindle] 1) Displays the rotation number of the spindle motor. (The output value is adjusted with Speed Down or Speed Up.) 2) Displays the output value of the spindle motor. (The output value is adjusted with Speed Down or Speed Up.) 3) The output value of the spindle motor is displayed in the Cur field. 13.[Others] 1) Pressing SSR1 activates the Pump 1 outlet. 2) Pressing SSR2 activates the Pump 2 outlet. 3) Pressing SSR3 activates the VACUUM outlet. 4) Pressing Lamp illuminates the LED lamp of the processing chamber. 7-16

83 7.2.8 Ethernet settings Purpose: Describing the Lex 1000 setting procedures necessary when it communicates with an intelligent blocker or PC through the Ethernet port * Note: This step applies to V1.02E1 or later. 1. Setting procedures according to the LAN environments The setting procedures to configure a small-scale network with an intelligent blocker (ICE- 9000, ICE mini, Ice 1000, etc.) are as follows: The set up is easy when the network is comprised only of an edger, blocker, tracing unit, or PC with a server software such as irx Server installed, and when it is not directly connected to an intranet or the Internet. [For Mini Lab system] This is the setting procedure for configuring a system when an intelligent blocker is used as a server. 1) Set the IP address of the intelligent blocker to the initial value. 2) Set the transport protocol of the intelligent blocker to TCP. 3) Press to switch to the Menu screen. 4) Select Communication Setting and press. 5) Change System to Mini Lab. At this time, select the system configuration illustration which matches to the actual equipment configuration. 6) Specify the IP address of the intelligent blocker in the Host IP address field. 7) Specify a value that is unique and not used by any other equipment within the network in the IP address field. 7-17

84 8) Specify the ID number of the intelligent blocker in the ID field displayed above the server. ID number Ice ) Specify a value that is unique and not used by any other equipment within the network in the ID field displayed above the Lex ID number Lex 1000 Ethernet Ethernet [For Lab system] This is the setting procedure for configuring a system when a PC is used as a server. 1) Set the IP address of the PC to ) Press to switch to the Menu screen. 3) Select Communication Setting and press. 4) Change System to Mini Lab. At this time, select the system taking the intelligent blocker as the PC. 7-18

85 5) Specify the IP address of the PC in the Host IP address field. 6) Specify a value that is unique and not used by any other equipment within the network in the IP address field. 7) Specify 32 in the ID field displayed above the server. 8) Specify a value that is unique and not used by any other equipment within the network in the IP field displayed above the Lex Do not use the Lex 1000 in a network connected to an intranet or the Internet. Doing so may result in a communication error. Set up must be performed by personnel with sufficient knowledge of networks. 2. Setting procedure according to the WAN environment The setting procedure to configure a system network using a corporate intranet is as follows: For the IP address of each equipment and subnet mask, ask your network administrator. 1) Press to switch to the Menu screen. 2) Select Communication Setting and press. 3) Change System to Mini Lab. At this time, select the system taking the intelligent blocker as the PC. 4) Specify 32 in the ID field displayed above the server. 5) Specify a value that is unique and not used by any other equipment within the network in the ID field displayed above the Lex

86 6) Press and to switch to the Layout screen. 7) While pressing, press to switch to the Parameter screen. 8) Select Network and press. 9) Specify the IP address allocated by the network administrator in the IP address field. 10) Specify the network subnet mask in the subnet mask field. 11) Specify the IP address of the PC in the Host IP address field. Be sure to specify the IP address and subnet mask allocated by the network administrator. Failure to do so may result in a communication error. Set up must be performed by personnel with sufficient knowledge of networks. * Configure a possible independent network. Do not connect to an intranet or the Internet. 7-20

87 7.3 Mechanical Components Carriage ASSY Adjusting movement of carriage ASSY bearing Purpose: Smoothening the movement of carriage ASSY bearing (40340-M556) 1. Open the top cover ASSY ( ) to remove the left side cover (44001-M204) and right side cover (44001-M205) (see 5.3 and 5.4). 2. Move the carriage ASSY ( ) to left or right so that the bearing (40340-M556) can be seen properly. 3. Loosen the fixing screw (SB5 25) on the bushing (40340-M571) of the carriage ASSY 4. Turn the bushing (40340-M571) of the carriage ASSY with a pair of long-nose pliers, adjust the position of the bearing (40340-M556), and tighten the screw (SB5 25) on the bushing (40340-M571). 5. While holding the carriage ASSY by hand so that it does not move to left or right, turn the bearing. Confirm that it turns smoothly. If it does not, restart from Step Apply CRC to the shaft (40340-M104) Apply CRC. SB

88 Engagement of X axis motor ASSY motor gear Purpose: Adjusting the engagement of the X axis motor ASSY ( ) motor gear 1. Open the top cover ASSY ( ) to remove the left side cover (44001-M204) and right side cover (44001-M205) (see 5.3 and 5.4). 2. Move the carriage ASSY to left or right so that the motor gear of the X axis motor ASSY ( ) is centered between the screws securing the rack (44001-M568) of the carriage ASSY 3. Loosen the screws (SB4 10 [n = 2]) securing the rack. Move the X axis motor ASSY to the rack and fix it. 4. While pressing the rack against the motor gear, retighten the screws (SB4 10 [n = 2]) securing the rack. 5. Move the carriage ASSY to left and right to confirm that the rack moves smoothly without play on both ends. If the rack does not move smoothly, restart from Step Apply the grease (SHV-2) to the rack and motor gear of the X axis motor ASSY Move the carriage ASSY to left and right so that the grease is evenly applied. * After applying the grease, confirm the movement of carriage ASSY Grease (SHV-2) SB SB

89 Adjusting height of carriage ASSY Y axis Purpose: Adjust and calibrate the height of the carriage ASSY Y axis using the Y axis adjustment jig Jig: Y axis adjustment jig LEDJ-16 (40396-M002) Note: Perform this adjustment along with that of θ axis of the carriage ASSY Y axis (see ) in order to insert the pin (44001-M551) into the notch of the Y axis adjustment jig (40396-M002). Left shaft 1. Display the Calibration screen and enter the Carriage Free mode (see ). 2. Open the top cover ASSY ( ) (see 5.3). 3. Remove the wheel (see 6.10). 4. Set the Y axis adjustment jig (40396-M002) to the shaft of the motor ASSY ( ). 5. Move the carriage ASSY in the direction of X axis by hand and adjust the height of Y axis to insert the left shaft into the notch of the Y axis adjustment jig. (40396-M002) Loosen HH4 4 (n = 2) and move the shaft (44001-M593) up and down to change the height of the shading plate. 7. Loosen HH4 4 (n = 2). 8. Press. Initialization occurs and the setting for the height of Y axis is changed. 9. Remove the Y axis adjustment jig. Shading plate

90 Adjusting θ axis of carriage ASSY Y axis Purpose: Performing adjustment and calibration of the θ axis of the carriage ASSY Y axis using the Y axis adjustment jig Jig: Y axis adjustment jig LEDJ-16 (40396-M002) Note: Perform this adjustment along with that of the carriage ASSY Y axis height (see ) in order to insert the pin (44001-M551) into the notch of the Y axis adjustment jig (40396-M002). 1. Display the Calibration screen and enter the Carriage Free mode (see 7.5.1). 2. Loosen HH6 6 (n = 2) of the large pulley (44001-M583) (see the lower right photo). Turn the left shaft so that its pin (44001-M551) aligns with the notch of the Y axis adjustment jig (40396-M002). 3. Move the carriage ASSY to the right of the X axis by hand and insert the left shaft into the notch of the Y axis adjustment jig. Adjust the axis so that the pin (M551)is inserted into the notch of the Y axis adjustment jig. Left shaft 551 Notch 4. Tighten HH6 6 (n = 2) of the large pulley (44001-M583) with the θ axis origin sensor aligned. 5. Press. Initialization occurs and the setting for θ axis of the Y axis is changed. 6. Remove the Y axis adjustment jig

91 Adjusting position of carriage ASSY left/right shaft Purpose: Adjust and calibrate the position of the left/right shaft using the left/right shaft adjustment jig after adjusting the height and θ axis of the carriage ASSY Y axis. Jig: Left/right shaft adjustment jig (40396-M001) 1. Display the Calibration screen and enter the Carriage Free mode (see 7.5.1). 2. After adjusting the height and θ axis of the carriage ASSY Y axis (see and ), remove the Y axis adjustment jig ( M002). 3.Attach the left/right shaft adjustment jig (40396-M001) to the left shaft. Left shaft (40396-M001) 4. Turn the timing belt by hand to move the right shaft near the left/right shaft adjustment jig. 5. Loosen HH4 6 (n = 2) fixing the gear retainer (44001-M541). 6. Turn the right shaft by hand so that the pin aligns with the notch of the left/right shaft adjustment jig. 7. Tighten HH4 6 (n = 2) with the right shaft inserted in the left/right shaft adjustment jig. 8. Press to perform initialization and confirm again that the right shaft can be inserted into the left/right shaft adjustment jig smoothly. 9. Remove the left/right shaft adjustment jig HH

92 7.3.2 Lens measurement unit ASSY Height of feeler ASSY Purpose: Adjusting the height of the feeler ASSY ( ) Jig: Calibration jig LEDJ-16 (40396-M011) Turn on the power switch. 2. Open the top cover ASSY ( ) (see 5.3). 3. Loosen the set screws [40340-M293 (n = 2)] of the feeler ASSY ( ) and attach it to the lens measurement unit ASSY ( ). 4. Loosely attach 3PW4 and the hexagon socket head screw (40340-M293) by hand PW Attach the calibration jig (40396-M011) to the left shaft. 6. Turn off the power switch with the height of the Y axis maintained. (40396-M011) Lower the feeler ASSY by turning the area of the lens measurement unit ASSY ( ) indicated by the arrow as shown to the right. 8. While the left feeler (40340-M983) of the feeler ASSY contacts the calibration jig, tighten the hexagon socket head screw (40340-M293) by hand, then tighten the set screws [ M293 (n = 2)]. 9. Raise the feeler ASSY by turning the area of the lens measurement unit ASSY ( ) indicated by the arrow as shown to the right, then slide the feeler ASSY to left. Tighten the hexagon socket head screw (40340-M293) with a hexagonal wrench. 10. Remove the calibration jig (40396-M011) 7-26

93 Initial position of feeler ASSY Purpose: Adjusting the initial position of the feeler ASSY ( ) 1. Open the top cover ASSY ( ) (see 5.3). 2. Turn the crank (40340-M272) until the feeler ASSY ( ) flips up and the crank cannot be turned. 3. Loosen HH4 6 on the dog (40340-M970). 4. Adjust the position of the dog (40340-M970) so that the micro switch roller of cable CA (40340-CA31) is centered in the notch of the dog, then tighten HH Reassemble the parts in the reverse order. 1) Calibrate the lens measurement unit ASSY (see 7.5.7). 2) Adjust the feeler axis (see 7.6.1). Notch Roller 272 CA31 HH Volatage of lens measurement unit ASSY Purpose: Adjusting the voltage of the lens measurement unit ASSY ( ) 1. Open the top cover ASSY ( ) (see 5.3). 2. Turn on the main body. 3. After initialization, disconnect cable connector J2 (P602) of the pulse motor for flipping up the feeler (40340-E033). 4. Turn the crank in the direction of the arrow as shown to the right, release the lock of the feeler ASSY ( ), and lower the ASSY to the measurement position. 5. Touch the positive probe of the multimeter to the connector J5 2nd pin of the BA06 board and the negative probe to the GND of the main board (44101-BA01) SB4 10 E33 BA

94 6. Adjust the attachment position of the shading plate (40340-M249) so that the multimeter reads 0.7 to 0.9 V. 7. Loosen SB4 10 (n = 2) fixing the cover support (40340-M290). With the cover ASSY closed, press the cover support against the cover ASSY and retighten SB4 10 (n = 2) to fix the cover support. 8. Reassemble the parts in the reverse order. 1) Calibrate the lens measurement ASSY (see 7.5.7). 2) Adjust the feeler axis (see 7.6.1). 249 CA33 2 SB

95 7.3.3 Safety beveling and grooving ASSY Position of safety beveling and grooving ASSY arm Purpose: Adjusting the position of the safety beveling and grooving ASSY ( ) arm (spindle ASSY) Jig: SFB adjustment jig LEDJ-16 (40396-M003) 1. Open the top cover ASSY ( ) (see 5.3). 2. Remove the wheels (see 6.10). 3. Turn on the power switch. 4. Remove the set screws (SB4 10 [n = 2]) of the wheel cover (44001-M986) and leave the cover inside the processing chamber SB SB Move the spindle ASSY ( ) of the safety beveling and grooving ASSY ( ) to the front by hand as shown to the right. Loosen the set screws (SB4 6 [n = 2]) of the spindle ASSY 6. Loosely attach the SFB adjustment jig ( M003) to the shaft of the motor ASSY ( ) by turning the hexagon bolt ( M722) and nut (40347-M721) by hand. 7. Turn the spindle ASSY by hand to move it until it is loosely attached to the SFB adjustment jig LEDJ-16 (40396-M003) 2 SB4 6 LEDJ-16 (40396-M003) 8. Turn manually the large gear (44001-M623) of the safety beveling and grooving ASSY ( ) in the direction of the arrow as shown to the right until it stops. Tighten the set screws (SB4 6 [n = 2]) of the spindle ASSY where the large gear stopped. 9. Reassemble the parts in the reverse order. 1) Calibrate the safety beveling and grooving ASSY ( ) (see 7.5.3)

96 7.3.4 Chuck pressure Tentative chuck pressure Purpose: Adjusting tentative chuck pressure using the chuck pressure measurement jig Jig: Chuck pressure measurement jig LEDJ-11 ( ) 1. Open the top cover ASSY ( ) to remove the left side cover (44001-M204) (see 5.3 and 5.4). 2. Loosen the set screws (SB2 3 [n = 2]) of the shading plate (44001-M554). 3. Move the shading plate (44001-M554) of the chuck pressure sensor (44001-CA27) to left (to increase the pressure) or right (to decrease the pressure). 4. Display an appropriate job (or internal data) to enter the desired layout. SB CA27 5. Set the chuck pressure measurement jig ( ) and press. Repeat Steps 3 to 5 until the jig reads 14.5 to 15.4 kg. * For the operation of the chuck pressure measurement jig ( ), refer to the operator s manual. 6. When the measurement result is within the range (14.5 to 15.4 kg), tighten the set screws (SB2 3 [n = 2]). 7-30

97 Chuck pressure Purpose: Setting chuck pressure on the Parameter Setting screen and adjusting it using the chuck pressure measurement jig Jig: Chuck pressure measurement jig LEDJ-11 ( ) 1. Display Parameter Setting (see ). 2. Press Prev page or Next page to display Parameter Setting 9/16. 3.Press to select Chuck pressure according to the wheel type (see 3.3). 4. Display an appropriate job (or internal data) to enter the desired layout. 5. Set the chuck pressure measurement jig ( ). Press, then press. 6. Pressing tightens the chuck securely, so press to suspend the processing and confirm the chuck pressure. * For the operation of the chuck pressure measurement jig ( ), refer to the operator s manual. 7. Press or to change the parameter value so that the chuck pressure is always 45 ±5 kg regardless of the lens materials. If the chuck pressure is not within the range, adjust the parameter value. Chuck pressure (CR39/Hi-index): 45 ±5 kg Chuck pressure (Polyca./Acrylic/Trivex/Urethane): 45 ±5 kg Chuck pressure (Glass): 45 ±5 kg 7-31

98 7.3.5 Tracing unit Adjusting tilt of tracing unit stylus Purpose: Adjusting the tilt of the tracing unit stylus (40340-M474) Jig: Standard frame (40340-M391) 1. Set the standard frame (40340-M391) to the tracing unit. 2. Press and hold (both-eye tracing) for approx. 3 seconds. 3. Confirm that the stylus (40340-M474) moves toward the frame and that it contacts the frame at an angle of 90º. 4. If the angle is not 90º, perform Steps 2 and 3 of 6.12 Stylus. (However, replacement of the stylus is unnecessary.) Adjusting position of cable CA63 Purpose: Adjusting the position of cable CA63 (40340-CA63) Jig: Pattern setting unit ( ) 1. Set the pattern setting unit ( ) Loosen CS3 6 (n = 2) to adjust the position of cable CA63 (40340-CA63) sensor so that the shading plate (40340-M324) can be set into the cable. CA63 CS

99 Cleaning pattern tracing pin Purpose: Cleaning the pattern tracing pin (40340-M824) Jig: Lint-free wiper, mixed-alcohol solution 1. Turn on the power. 2. Open fully the sliders of the tracing unit, hold them by hand, and press. 3. When the pattern tracing pin comes out and tracing starts, turn off the power. Slider 4. Soak the lint-free wiper in the mixed-alcohol solution and wipe around the tracing pin (40340-M824) with the wiper. 5. Turn on the power and store the pin

100 7.4 Electrical Components Parameters of BL motor inverter Purpose: Setting the parameters of the BL motor inverter (40347-E066 for 100 V or E067 for 200 V) with the control panel 1. Remove the top cover ASSY ( ), rear cover (44001-M203), left side cover ( M204), and right side cover (44001-M205) (see 5.4). 2. Turn on the main body. (The inverter is also turned on at this time.) 3. Pressing the DATA SET button on the inverter control panel once blinks the parameter No. display (2-digit LED). * When calling up parameter No.100 or later, before performing the step right above, press STOP, DATA SET,, and simultaneously. * See the parameter list of the BL motor inverter (see 7.4.2). 4. Press or to select the desired parameter No. (For parameter No. 100 or later, blinks to the lower right of the 2-digit LED display.) * The trip history is saved in parameters No.81 to 85. (The latest trip history is saved in parameter No. 81. The history gets older in the order of No. 82, 83, 84, and 85.) * See the trip table of the BL motor inverter (see 7.4.3). 5. After changing the parameter settings, press the MODE button to return to the normal state. 6. Reassemble the top cover ASSY ( ), rear cover, left side cover, and right side cover. * Parameter No. is displayed in two-digits. Parameter No. 100 or later can be recognized by the position of decimal point. (e. g. Parameter No. 117: 17., parameter No. 201: 0.1 ) * When the setting of parameter No. 100 or later is changed, the wheel motor may not rotate to prevent misoperation. In such case, turn off the instrument. Confirm that the display of the inverter goes off, then turn on the device again. 7-34

101 7.4.2 Parameter table of BL motor inverter 7-35

102 7.4.3 Trip table of BL motor inverter LEDdisplay Monitor (blink) L Protective function Electron thermal operation Power restoration restart protection This page is intentionally vacant..p. 0.C. 0.C.-U 0.C.-d 0.C.-C 0.U. H 0.H. E..-0.S. Under voltage warning instantaneous interruption protection Overcurrent protection Regeneration overvoltage protection Overload protection function (electron thermal) Radiating fin overheating protection Overspeed protection Contents of protection When the output current reaches the electron thermal level and the timer starts, the indication on the monitor will blink. When the direct voltage becomes approx. DC 200 V or less for AC 200 V, or the direct voltage becomes approx. DC 100 V or less for AC 100 V, the inverter output will be interrupted since it is taken as "instantaneous interruption". For AC 200 V, the control circuit will be reset when the DC becomes 75 V or less. If the voltage is restored before the control circuit is reset, the system can resume the operation automatically. If the operation order was given when the system was restored from instantaneous interruption during operation, automatic resumption is prevented and it will be tripped. If the control circuit is reset, this function does not work. When the output current of the converter exceeds the current which is set to each inverter, it will be tripped. When the output current of the converter exceeds the current which is set to each inverter during acceleration, it will be tripped. When the output current of the converter exceeds the current which is set to each inverter during slowdown, it will be tripped. If the detected value exceeds the current set to each inverter, it will be tripped. When the direct voltage of the converter becomes DC 400 V or more for AC 200 V or DC 200 V or more for AC 100 V, it will be tripped. If the motor current continues to flow with 100% or more, it will be taken as overload and it will be tripped. While the current continues to flow, the 5-digit LED will blink. When the radiating fin heats up, the temperature sensor will be turned on and it will be tripped. When the rotation number exceeds 1.5 times of the upper limit speed, it will be tripped. E..-C.S. Sensor failure protection When CS signal failure is detected, it will be tripped. E CPU error When the control microcomputer failure is detected, it will be tripped. CAU. Self-check warning When the parameter such as "16 operation order selection" is changed, it will be tripped. 0.L. E.0. External forced protection Rotation failure detection When the point between "applicable terminal" and "SG" is opened with "47I5 function selection" or "48I6 function selection" set to external forced trip, it will be tripped. When "d2 rotation failure detection" is set to "yes" and rotation failure of the set speed is detected, it will be tripped. 7-36

103 7.5 Calibration Displaying calibration screen 1. Turn on the power. 2. Press, then press. 3. Press to select Calibration, and press. 4. Press with Carriage Free selected. * The carriage X axis is set free in this state Attaching calibration jig Purpose: Attaching the calibration jig (40396-M011) Jig: Calibration jig LEDJ-16 (40396-M011) 1. Remove the cup holder with a hexagonal screwdriver. 2. While aligning the grooves on the calibration jig (40396-M011) with the pins, insert the jig with the set screw facing up. Tighten the set screw to secure the jig. Set screw (40396-M011) 7-37

104 7.5.3 Calibration of safety beveling and grooving ASSY Purpose: Performing calibration of the safety beveling and grooving ASSY ( ) (approx. 5 minutes) Jig: Calibration jig LEDJ-16 (40396-M011), SFB adjustment jig LEDJ-16 (40396-M003) 1. Adjust the position of the safety beveling and grooving ASSY arm (see ). 2. Display the Calibration screen (see 7.5.1). 3. Attach the calibration jig (40396-M011) (see 7.5.2). 4. Press to select SFB Calibration. 5. Press. 6. Push the SFB arm by hand so that it contacts the SFB adjustment jig LEDJ-16 ( M003). While holding the SFB arm by hand, press to fix the arm. 7. Press again to start calibration. 8. After calibration is completed, remove the calibration jig. SFB arm LEDJ-16 (40396-M003) Full calibration Purpose: Performing bevel, wheel, and LMU calibration and θ axis autognosis (approx. 10 minutes) Jig: Calibration jig LEDJ-16 (40396-M011) 1. Display the Calibration screen (see 7.5.1). 2. Attach the calibration jig (40396-M011) (see 7.5.2). 3. Press to select Full Calibration. 4. Press. 5. After calibration is completed, remove the calibration jig. 7-38

105 7.5.5 Bevel calibration Purpose: Perform bevel calibration (approx. 5 minutes) Jig: Calibration jig LEDJ-16 (40396-M011) 1. Display the Calibration screen (see 7.5.1). 2. Attach the calibration jig (40396-M011) (see 7.5.2). 3. Press to select Bevel Calibration. 4. Press. 5. After calibration is completed, remove the calibration jig Wheel calibration Purpose: Perform wheel calibration (approx. 2 minutes) Jig: Calibration jig LEDJ-16 (40396-M011) 1. Display the Calibration screen (see 7.5.1). 2. Attach the calibration jig (40396-M011) (see 7.5.2). 3. Press to select Wheel Calibration. 4. Press. 5. After calibration is completed, remove the calibration jig. 7-39

106 7.5.7 Calibration of lens measurement unit ASSY Purpose: Performing calibration of lens measurement unit ASSY ( ) (approx. 1 minute) Jig: Calibration jig LEDJ-16 (40396-M011) 1. Display the Calibration screen (see 7.5.1). 2. Attach the calibration jig (40396-M011) (see 7.5.2). 3. Press to select LMU Calibration. 4. Press. 5. The feeler ASSY comes out and calibration starts. 6. After calibration is completed, remove the calibration jig θ axis autognosis Purpose: Performing θ axis autognosis to diagnose its operation properties necessary for the advanced soft mode (approx. 1 minute) If the operation properties are diagnosed as proper, a short beep sounds once. If they are not, it is necessary to adjust the engagement of the θ axis gear. Jig: Calibration jig LEDJ-16 (40396-M011) 1. Display the Calibration screen (see 7.5.1). 2. Attach the calibration jig (40396-M011) (see 7.5.2). 3. Press to select θ Axis Autognosis. 4. Press. 5. After calibration is completed, remove the calibration jig. 7-40

107 7.5.9 Calibration of lid ASSY Purpose: Calibrating the lid ASSY ( ) (approx. 3 seconds) 1. Display the Calibration screen (see 7.5.1). 2. Press to select the Door Calibration. 3. Press. 4. Follow the messages to be displayed on the information bar to open fully the lid ASSY ( ). 5. Press. Perform calibration. 7-41

108 Torque calibration of tracing unit Purpose: Performing torque calibration of the tracing unit 1. While pressing and simultaneously, turn on the power. 2. After confirming the LED of blinks, open fully the sliders of the tracing unit by hand. 3. Press. * After the torque calibration is completed, perfrom the frame auto calibration (see ) Frame auto calibration of tracing unit Purpose: Performing frame calibration using the 45 standard frame jig Jig: 45 standard frame jig LEDJ-10 (40390-M301) (40390-M301) 1. Set the 45 standard frame jig (40390-M301). 2. While pressing, press. 3. After confirming the LED of blinks, press Pattern auto calibration of tracing unit Purpose: Performing pattern auto calibration using the 45 standard pattern jig Jig: 45 standard pattern jig LEDJ-6 (41476-M002) (41476-M002) 1. Set the 45 standard pattern jig ( M002) to the pattern setting unit as shown to the right. * Be sure to use the provided pattern setting unit. 2. While pressing, press

109 3. After confirming the LED of blinks, press. * After the auto calibration is properly completed, a short beep sounds. If continuing beeps sound, the calibration is not completed properly. The measurement data may be out of tolerance. It is necessary to inspect the inside of the tracing unit Full calibration of tracing unit Purpose: Performing full calibration of the tracing unit using the 45 standard pattern jig, 45 standard frame jig, φ30 standard frame jig, and φ60 standard frame jig Jig: 45 standard pattern jig LEDJ-6 (41476-M002), 45 standard frame jig LEDJ-10 (40390-M301), φ30 standard frame jig LEDJ-10 ( ), φ60 standard frame LEDJ-10 jig ( ) 1. Set the 45 standard frame jig (40390-M301) to the left end of the sliders as shown to the right. 2. Turn on the power while pressing,, and simultaneously. 3. After confirming the LED of blinks, press. (40390-M301) 4. After measurement is completed, confirm the LED of blinks. Then set the 45 standard frame jig (40390-M301) in the center of the sliders as shown to the right. 5. Press. (40390-M301) 6. After measurement is completed, confirm the LED of blinks. Then set the φ30 standard frame jig ( ) as shown to the right. * Set the jig in the maximum possible center since the frame gain adjustment can be affected. 7. Press. ( ) 7-43

110 8. After measurement is completed, confirm the LED of blinks. Then set the φ60 standard frame jig ( ) as shown to the right. * Set the jig in the maximum possible center since the frame gain adjustment can be affected. 9. Press. ( ) 10.After measurement is completed, confirm the LED of blinks. Then set the 45 standard frame jig (40390-M301) in the center of the sliders as shown to the right. 11. Press. (40390-M301) 12.After measurement is completed, confirm the LEDs of,, and blink alternately. Then set the 45 standard pattern jig ( M002) to the pattern setting unit ( ). 13.Press. 14.After calibration is completed properly, a short beep sounds. * If continuing beeps sound, calibration is not completed properly. The measurement data or operation may have failure. It is necessary to inspect the inside of the tracing unit (41476-M002) 7-44

111 7.6 Processing Adjustment Feeler axis Purpose: Adjusting the front and rear feeler axes Jig: Axis alignment jig 1. Display Parameter Setting (see ). 2. Press Prev page or Next page to display Axis Adjustment 6/16. <When using the axis alignment jig> 3. Adjust the rear feeler axis as follows: 1) Prepare a flat lens and apply powder or grease only to its rear surface. 2) Call up the 45 internal data. 3) Set the lens and press in the flat edging mode. 4) After the measurement of the rear surface is completed, press. 5) Set the lens to the axis alignment jig to confirm the axis angle of the measurement trace. 6) When the measurement trace is diagonally right up, increase the value; when the trace is diagonally right down, decrease the value to adjust the axis. 4. Adjust the front feeler axis as follows: 1) Prepare a flat lens and apply powder or grease only to its front surface. 2) Call up the 45 internal data. 3) Set the lens and press in the flat edging mode. 4) After the measurement of the front surface is completed, press. 5) Set the lens to the axis alignment jig to confirm the axis angle of the measurement trace. 6) When the measurement trace is diagonally right up, decrease the value; when the trace is diagonally right down, increase the value to adjust the axis. 7-45

112 <When using 45 internal data> 1. Call up the 45 internal data. 2. Set the size to and flat edge the lens. 3. Apply powder or grease to the rear surface of the processed lens. Set the size to 0.00 and press. 4. After the measurement of the rear surface is completed, press. 5. Confirm that the measurement trace on the rear surface is parallel to the lens edges. If it is not, change the parameter setting to perform adjustment. Rear surface Measurement trace 6. Apply powder or grease to the front surface of the same lens. 7. Set the lens and press. 8. After the measurement of the front surface is completed, press. 9. Confirm that the measurement trace on the front surface is parallel to the lens edges. If it is not, change the parameter setting to perform adjustment. Front surface Measurement trace 7-46

113 7.6.2 Finish size Purpose: Adjusting finish size of the lens processed with the φ45 internal data Jig: To adjust CR39 finish size, a -3 to -5 D lens is recommended. 1. Display Parameter Setting (see ). 2. Press Prev page or Next page to display Finish Size 1, 2/ Call up the φ45 internal data. 4. Bevel a lens, and flat edge a lens. 5. Measure the diameters of the processed lenses. 6. Press or to adjust the diameters to be φ45.00 ±0.05 mm for beveling and φ45.00 ±0.10 mm for flat edging. 7.For example: When the diameter of the processed lens is mm, input -1.00; when it is mm, input Adjust the finish size of each lens material for beveling and flat edging. * Note: Before adjusting finish size for high base curve processing, adjust the wheel positions of HCrvFr and HCrvRe Bevel position Purpose: Adjusting bevel position of the lens processed with the φ45 internal data Jig: For adjusting CR39 bevel position, a -3 to -5 D lens is recommended. 1. Display Parameter Setting (see ). 2. Press Prev page or Next page to display Parameter Setting 9/ Call up the φ45 internal data. 4. Bevel a lens in guide processing mode (5:5) and check the bevel position. 7-47

114 5. If the bevel position is not in the center of the lens edge when visually checked, change the parameter value by pressing or to perform adjustment. Decreasing the value moves the bevel position toward the front surface; increasing the value moves it toward the rear surface. 6. Adjust the bevel position for glass lenses in the same manner Lens axis Purpose: Adjusting the axis of the lens processed with the 45 internal data Jig: Axis alignment jig, a -3 to -5 D lens for adjusting CR39 axis 1. Display Parameter Setting (see ). 2. Press Prev page or Next page to display Axis Adjustment 6/16. <When using the axis alignment jig> 1. Call up the 45 internal data. 2. Set the processed lens to the axis alignment jig, then measure the axis angle using the lens top edge and jig horizontal lines as the reference. 3. If the axis is misaligned, adjust it by changing the parameter value. 4. With the lens set in the axis alignment jig, if the lens top edge is diagonally right up, increase the value; if the edge is diagonally right down, decrease the value. 7-48

115 <When drawing a horizontal line on the lens> 1. Call up the 45 internal data. 2. Process a lens blocked with a cup while the lens was aligned to the horizontal line. 3. Measure the axis angle of the processed lens using graph paper. 4. If the angle is misaligned, adjust it by changing the parameter value. If the horizontal line is diagonally right up as viewed from the lens front, increase the value. Horizontal line Polish (differential and polish wheel height, bevel, axis) Purpose: Adjusting polish (differential and polish wheel height, bevel, axis) of a lens processed with the φ45 internal data Jig: For adjusting CR39 polish, a -3 to -5 D lens is recommended Polish (differential and polish wheel height) <When checking a lens flat edged in type PL-8> 1. Display Parameter Setting (see ). 2. Press Prev page or Next page to display Polish Differential 5/ Press or to select CR39, Flt. Press or to set the value to Call up the φ45 internal data and set as follows: Size: Polish: Polishing 5. Polish a lens. After the lens contacted the polishing wheel and rotated one quarter of a rotation, press lens). to stop processing (to save the adjustment From here, the lens contacts the polish wheel 7-49

116 6. Remove the lens and check it for unpolished or burnt area. 7.Unchange the differential and adjust the polishing wheel height so that the lens is half polished. 1) Display Parameter Setting. 2) Press Prev page or Next page to display Polish Size 4/16. 3) Press or to select Polish wheel size, then press or to adjust the numeric value. Decreasing the numeric value moves the lens close to the wheel. Increasing the numeric value moves the lens away from the wheel. 8. After adjustment is completed, display Polish Differential (5/16). Press or to select CR39, Flt, then press or to return the set value to <When checking a lens beveled in type PLB-8, PLB-G> 1. Display Parameter Setting (see ). 2. Press Prev page or Next page to display Polish Differential 5/ Press or to select CR39, Bvl. Press or to set the value to Call up the φ45 internal data and set as follows: Size: Polish: Polishing 5. Polish a lens. After the lens contacted the polishing wheel and rotated one quarter of a rotation, press to stop processing (to save the adjustment lens). 6. Remove the lens and check it for unpolished or burnt area. From here, the lens contacts the polish wheel. 7-50

117 7.Unchange the differential and adjust the polishing wheel height so that the lens is half polished. 1) Display Parameter Setting. 2) Press Prev page or Next page to display Polish Size (4/16). 3) Press or to select Polish wheel size, then press or to adjust the numeric value. Decreasing the numeric value moves the lens close to the wheel. Increasing the numeric value moves the lens away from the wheel Bevel position to be polished 1. After adjusting the polishing wheel height, continuously adjust Bevel position (Pol). 1) Display Parameter Setting. 2) Press Prev page or Next page to display Parameter Setting (9/16). 3) Change the numeric value of Polish Differential to 0. 4) Press or to select Bevel position (Pol), then press or to adjust the numeric value. Increasing the numeric value moves the position to be polished toward the lens front. Decreasing the numeric value moves the position to be polished toward the lens rear. 2. Adjust Bevel position (Pol) so that the front and rear of the bevel (indicated by black arrows in the right figure) are evenly polished. 3. After adjustment is completed, display Polish Differential (5/16). Press or to select CR39, Bvl. Press or to return the set value to Return the numeric value of Polish Differential to the original one. 7-51

118 Polish axis 1. Display Parameter Setting (see ). 2. Press Prev page or Next page to display Axis Adjustment 6/16. 3.Change the numeric value of Polish Differential to Press or to select Pol, then press or to set the value to Call up the 45 internal data. 6. Polish a lens. 7. Check the polish axis. If it is misaligned, adjust it by pressing or to change the Pol parameter value. Perform adjustment so that each edge of the 45 lens is polished evenly from left to right. 8. When the left part of the edge largely remains unpolished as shown to the right, decrease the value. 9.Return the numeric value of Polish Differential to the original one. Unpolished areas Polish size Purpose: Adjusting polish size of a lens processed with the φ45 internal data Jig: For adjusting CR39 polish size, a -3 to -5 D lens is recommended. 1. Display Parameter Setting (see ). 2. Press Prev page or Next page to display Polish Size 4/ Call up the φ45 internal data. 4. Bevel and polish, and flat edge and polish each lens material. 5. Measure the diameters of the processed lenses. Press or to change the parameter values so that the diameter of beveled and polished lens is φ45.0 ±0.05 mm and that of flat edged and polished lens is φ45.0 ±0.10 mm. 6. When the diameter of the processed lens is mm, input When it is mm, input

119 7.6.7 Groove depth Purpose: Checking the groove depth of a lens processed with the φ45 internal data Jig: For adjusting CR39 groove depth, a -3 to -5 D lens is recommended. 1. Display Parameter Setting (see ). 2. Press Prev page or Next page to display Parameter setting 9/16 and select Groove depth. 3. Call up the φ45 internal data. 4. Select Nylor and Guide, and groove a CR39, -3 to -5 D lens with the depth of 0.0 mm. Press or to change the parameter value so that the groove trace is slightly made on the processed lens. Decrease the value to make the groove shallower; increase the value to make the groove deeper Groove position Purpose: Adjusting groove position of a lens processed with the φ45 internal data Jig: For adjusting CR39 groove position, a -3 to -5 D lens is recommended. 1. Display Parameter Setting (see ). 2. Press Prev page or Next page to display Parameter Setting 9/16 and select Groove Position. 3. Call up the φ45 internal data. 7-53

120 4. Select Nylor and Guide (5:5), and groove a CR39, -3 to -5 D lens. Check the groove position of the processed lens. Press or to change the parameter value so that the groove is positioned in the center of the lens edge. Decreasing the value moves the groove position toward the lens front surface; increasing the value moves the groove position toward the rear surface Groove axis Purpose: Adjusting groove axis of a lens processed with the 45 internal data Jig: For adjusting CR39 groove axis, a -3 to -5 D lens is recommended. 1. Display Parameter Setting (see ). 2. Press Prev page or Next page to display Axis Adjustment 6/ Call up the 45 internal data. 4. Select Nylor and Guide, and groove a CR39, -3 to -5 D lens with the depth of Confirm that the groove depth remains nearly the same along the lens top edge from left to right as viewed from the lens front. If it does not, adjust it by pressing or to change the parameter value. If the groove is deeper on the right part of the lens top edge, decrease the value; if it is deeper on the left part, increase the value. 6. Use a Polyca. lens and adjust the groove axis in the same manner. Front surface Groove 7-54

121 Safety bevel Purpose: Processing a lens with the φ45 internal data and adjusting the safety beveling wheel positions for beveling and flat edging Jig: For adjusting CR39 safety bevel, a -3 to -5 D lens is recommended. 1. Before adjusting safety bevel, set each safety bevel size in Default Setting to 0.3 as shown inside the dotted line of the right figure. 2. Set SFB mode (Bevel) in Grinding Setting to F & R as shown inside the dotted line of the right figure. <Adjusting SFB wheel position (Bvl)> 1. Display Parameter Setting (see ). 2. Press Prev page or Next page to display SFB 8/ Call up the φ45 internal data. 4. Select Metal and Guide (5:5), and bevel a CR39, -3 to -5 D lens with safety beveling on. 5. Press or to change the SFB wheel position parameter value so that the SFB amount is within each set value ±0.2 mm. Increase the parameter value to increase the SFB amount on both front and rear surfaces; decrease the parameter value to decrease the SFB amount. 7-55

122 <Adjusting SFB wheel position (Flt)> 1. Display Parameter Setting (see ). 2. Press Prev page or Next page to display SFB 8/ Call up the φ45 internal data. 4. Select Nylor and Flat, and process a CR39, -3 to -5 D lens with safety beveling on. 5. Press or to change the SFB wheel position parameter value so that the SFB amount is within each set value ±0.2 mm. Increase the parameter value to increase the SFB amount on both front and rear surfaces; decrease the parameter value to decrease the SFB amount Safety bevel axis (bevel) Purpose: Adjusting safety bevel axis (bevel) of a lens processed with the 45 internal data Jig: For adjusting CR39 safety bevel axis (bevel), a -3 to -5 D lens is recommended. 1. Display Parameter Setting (see ). 2. Press Prev page or Next page to display SFB 8/ Call up the 45 internal data. 4. Select Bevel and Guide (5:5), and process a CR39, -3 to -5 D lens with safety beveling on. 5. Check the safety bevel axis on the front surface. Confirm that the SFB amount remains nearly the same along the top edge from left to right as viewed from the lens front. If it does not, adjust it by pressing or to change the parameter value. If the SFB amount on the right part of the top edge is larger, decrease the parameter value; if it is larger on the left part, increase the value. Front surface 7-56

123 6. Check the safety bevel axis on the rear surface. Confirm that the SFB amount remains nearly the same along the top edge from left to right as viewed from the lens rear. If it does not, adjust it by pressing or to change the parameter value. If the SFB amount on the right part of the top edge is larger, increase the parameter value; if it is larger on the left part, decrease the value. Rear surface Safety bevel axis (flat) Purpose: Adjusting safety bevel axis (flat) of a lens processed with the 45 internal data Jig: For adjusting CR39 safety bevel axis (flat), a -3 to -5 D lens is recommended. 1. Display Parameter Setting (see ). 2. Press Prev page or Next page to display SFB 8/ Call up the 45 internal data. 4. Select Nylor and Flat, and process a CR39, -3 to -5 D lens with safety beveling on. 5. Check the safety bevel axis on the front surface. Confirm that the SFB amount remains nearly the same along the top edge from left to right as viewed from the lens front. If it does not, adjust it by pressing or to change the parameter value. If the SFB amount on the right part of the top edge is larger, decrease the parameter value; if it is larger on the left part, increase the value. Front surface 6. Check the safety bevel axis on the rear surface. Confirm that the SFB amount remains nearly the same along the top edge from left to right as viewed from the lens rear. If it does not, adjust it by pressing or to change the parameter value. 7-57

124 If the SFB amount on the right part of the top edge is larger, increase the parameter value; if it is larger on the left part, decrease the value. Rear surface High base curve processing For high base curve processing, process a lens while maintaining the setting on the guide screen (bevel position: 0.0, bevel height: 0.8) and adjust each parameter setting as necessary. Lenses to be used for adjustment are not necessarily high base curve ones (8- base curve etc.) CR 39, -3 D to -5 D lenses are available. However, after all adjustments are completed, process a high base curve lens to check the finishing state and lens fitting into a frame Wheel position (HCrvFr) Purpose: Adjusting wheel position (HCrvFr) of a lens processed with the φ45 internal data Jig: For adjusting CR39 wheel position (HCrvFr), a -3 to -5 D lens is recommended. 1. Display Parameter Setting (see ). 2. Press Prev page or Next page to display Parameter Setting 11/ Call up the φ45 internal data. 4. Select Metal and Hi-curve, and process a CR39 lens. Do not change the setting on the guide screen. 5. After high base curve processing on the front surface is completed, press to stop the processing. 6. Confirm that the processed width on the front surface is 0.3 mm. If it is not, adjust it by pressing or to change the parameter value. Increase the parameter value to expand the width; decrease the value to reduce the width. 0.3 mm 7-58

125 Wheel position (HCrvRe) Purpose: Adjusting wheel position (HCrvRe) of a lens processed with the φ45 internal data Jig: For adjusting CR39 wheel position (HCrvRe), a -3 to -5 D lens is recommended. 1. Display Parameter Setting (see ). 2. Press Prev page or Next page to display Parameter Setting 11/ Call up the φ45 internal data. 4. Select Metal and Hi-curve, and process a CR39 lens. Do not change the setting on the guide screen. 5. Confirm that the beveled top width is 0.3 mm. If it is not, adjust it by pressing or to change the parameter value. Decrease the parameter value to expand the width; increase the value to reduce the width. 0.3 mm Size adjustment for high base curve processing Purpose: Adjusting size for high base curve processing of a lens processed with the φ45 internal data Jig: For adjusting CR39 size, a -3 to -5 D lens is recommended. 1. Display Parameter Setting (see ). 2. Press Prev page or Next page to display Finish Size 1, 2/ Call up the φ45 internal data. Process each lens material in the Hi-curve processing mode and check the finish size. 7-59

126 Bevel height (HCrv) Purpose: Adjusting bevel height (HCrv) of a lens processed with the φ45 internal data Jig: For adjusting CR39 bevel height (HCrv), a -3 to -5 D lens is recommended. 1. Display Parameter Setting (see ). 2. Press Prev page or Next page to display Parameter Setting 11/ Call up the φ45 internal data. 4. Select Metal and Hi-curve, and process a CR39 lens. Do not change the setting on the guide screen. 5. Confirm that the bevel height (HCrv) of the processed lens is 0.8 mm. If it is not, adjust it by pressing or to change the parameter value. Increase the parameter value to extend the height; decrease the parameter value to reduce the height Axes (HCrvFr and HCrvRe) Purpose: Adjusting axes (HCrvFr and HCrvRe) of a lens processed with the 45 internal data Jig: Adjusting CR39 axes, a -3 to -5 D lens is recommended. 1. Display Parameter Setting (see ). 2. Press Prev page or Next page to display Parameter Setting 11/ Call up the 45 internal data. 4. Process a CR39 lens in Metal and high curve mode. Do not change the setting on the guide screen. 7-60

127 5. Check the axes (HCrvFr and HCrvRe) of the processed lens. 6. Confirm that the axis (HCrvFr) is not tilted as viewed from the lens front. If the axis is diagonally right up, decrease the parameter value; if it is diagonally right down, increase the value. Front surface 7. Confirm that the axis (HCrvRe) is not tilted as viewed from the lens rear. If the axis is diagonally right up, decrease the parameter value; if it is diagonally right down, increase the value. Rear surface 7-61

128 7.7 Other Setting and Adjustment Dressing wheels Purpose: If wheels are dull, the processing time becomes longer or the accuracy in size and polishing becomes low. Dress wheels periodically. Jig: Dressing stick for roughing wheel (orange) WA80K, dressing stick for finishing wheel (white) WA320K, compound kit ( ) 1. Be sure to wear protective glasses during dressing wheels. Spray containing processing waste may cause eye damage. 2. Be sure to select a dressing stick suited to the wheel type. An improper dressing stick may damage the wheel, which prevents normal lens processing. Roughing wheel for glass lenses (types PLB-G, PL-8 only) Dressing wheel for roughing wheel (orange) WA80K Finishing wheel Dressing wheel for finishing wheel (white) WA320K Finishing wheel for high base curve lenses (types PL-8 and PLB-8 only) Dressing wheel for finishing wheel (white) WA320K Finishing wheel for glass lenses (type PLB-G only) Dressing wheel for finishing wheel (white) WA320K Polishing wheel Maintain the wheel with the compound kit ( ). Safety beveling wheel Dressing wheel for finishing wheel (white) WA320K Never dress the roughing wheel for plastic lenses. Doing so may damage the wheel, which prevents normal lens processing. 3. Apply only the flat surface of the tip of the dressing stick to the wheel, not its corners. Otherwise, the wheel may be damaged. 4. Hold the dressing stick with both hands. The stick cannot be held securely enough with one hand, and as a result, its corner may contact and damage the wheel. 5. Lightly apply the dressing stick to the wheel. Otherwise, the wheel may be damaged. 6. Dress the wheel holding the dressing stick with a minimum of 2 or 3 cm protruding. Failure to do so may hurt your fingers due to the contact with the wheel. 7. When the dressing stick is worn to the length of 4 cm, replace it with a new one. As it is hard to hold the shortened dressing stick securely, your fingers may be hurt or the wheel may be damaged. 1. Soak the dressing stick in water and leave it for 5 minutes. 2. Press to display the Menu screen. 3. Press to select Dressing and press. 7-62

129 4. Dress the wheel. <Roughing wheel for glass lenses, finishing wheel for glass lenses, finishing wheel for high base curve lenses, and finishing wheel> * The roughing wheel for glass lenses is types PLB-G and PL-8 only. The finishing wheel for glass lenses is type PLB-G only. The finishing wheel for high base curve lenses is types PL-8 and PLB-8 only. 1. Press. The wheel rotates and the cooling water runs. 2. Wet the dressing stick well with running water. Finishing wheel for glass lenses, finishing wheel for high base curve lenses, and finishing wheel Use the dressing stick for finishing wheel. Roughing wheel for glass lenses Use the dressing stick for roughing wheel. 3. Press to stop the cooling water. 4. Apply the dressing stick to the rotating wheel with slightly increased pressure. Continue applying the stick to the wheel for approx. 5 seconds. 5. Release the dressing stick from the wheel. 6. Press. Start the cooling water to wash the wheel surface away. 7. Repeat Steps 4 to 6 two or three times. 8. Press. The wheel and water come to a stop. <Polishing wheel and flat polishing wheel> * Maintain the polishing wheel and flat polishing wheel with the compound kit. The polishing wheel is types PLB-G and PLB-8 only. The flat polishing wheel is type PL-8 only. 1. Press. The wheel rotates and the cooling water runs. 2. Press to stop the cooling water. Compound kit 3. Press to stop the water of the water curtain. 4. Attach a pad to the specified stick. Attach the blue surface of the pad to the rough surface of the stick. Specified stick Pad 7-63

130 5. Evenly apply the supplied compound to only one side of the pad. 6. Holding the stick by its handle, lightly touch the compound covered pad surface to the rotating polishing wheel. The pad is gradually worn away. Dress the wheel until the white surface of the pad wears away. Take care not to let the pad wear away all the way to the stick. 7. Apply the compound to the other side of the pad according to Steps 5 and 6, and dress the polishing wheel again. 8. Press to start the cooling water and wash the wheel. With the water running, hold the stick by its handle and lightly touch the pad to the polishing wheel to wash away any compound from the surface of the wheel. 9. Press. The wheel and cooling water come to a stop. 10. After confirming that the wheel has stopped, remove moisture from the surface of the polishing wheel by patting with a soft, dry cloth. Do not scrub the wheel roughly with the cloth. Cloth fibers may remain, interfering with polishing. 11. When the surface of the polishing wheel dries, confirm that the compound is completely washed away. When the dried polishing wheel has a shine on its surface, the compound has been washed away. Check the wheel entirely. When part of the surface has no shine, the compound remains. Press to start the cooling water and wash the compound away. <Safety beveling wheel> * When safety beveling glass lenses frequently, dress the safety beveling wheel as well. 1. Press. The safety beveling wheel comes out and the cooling water runs. 2. Wet the dressing stick for finishing wheel well with running water. 3. Press to stop the cooling water. 4. Lightly touch the dressing stick to the wheel surface for safety beveling. 5. Release the dressing stick from the safety beveling wheel. 6. Press to start the cooling water and wash the wheel surface away. 7.Press. The safety beveling wheel is stored. 7-64

131 7.7.2 Setting and operation of Print screen Purpose: Copying screen (BMP) data to the compact flash card (40273-E030) using the print screen function Jig: Compact flash card (40273-E030) 1. Confirm that the compact flash card ( E030) is inserted into the main board. 2. Display Parameter Setting (see ). 3. Press Prev page or Next page to display Parameter Setting 13/ Press or to select Print screen. 5. Press or to set the mode Enable. 6. Press to return to the original state, and display the screen to be captured. 7. When the screen appears, press and hold the R/L button until a beep sounds. However, on the screen where the language is switched, press and hold until a beep sounds. The screen (BMP data) is copied to the compact flash card. 8. Repeat Steps 6 and 7 to copy the desired screens. 9. When copying is completed, open the top cover ASSY ( ) and remove the compact flash card (40273-E030) from the main board. Using the compact flash card reader/writer, save the BMP data to a PC. 10.Insert the compact flash card into the main board. R/L button 7-65

132 [This page is intentionally left blank.]

133 8 SUPPLEMENT 8.1 Wiring Diagram

134 8.2 Connector Cable 8-2

135 8-3 LLE13ARDA001D/E

136 8-4

137 8.3 Main Board (BA01) BA01 J-2 J-20 J-22 J-3 J-11 J-1 J-13 J-14 J-15 J-16 J-10 J-9 J-21 J-12 J-7 J-8 J-5 J-6 J-4 8-5

138 8.4 Grease E E58 Grease (NBU15) CA Grease (NBU15) Grease (NBU15)

139 b 2 522b c a a C C A A C C A030C A A A A030C Grease (NIPPECO LLP) Grease (SHV-2) SL030 Grease (NIPPECO LLP) Grease (NIPPECO LLP) Grease (NIPPECO LLP) Grease (SHV-2) Grease (SHV-2) 534 E R CA C Grease (NIPPECO LLP) C Grease (NIPPECO LLP)

140 8.5 Grease MSDS NIPPECO LLP 8-8

141 8-9 LLE13ARDA001D/E

142 8.5.2 BE

143 8-11

144 8.5.3 SHV

145 8-13

146 8.5.4 NBU

147 8-15 LLE13ARDA001D/E

148 8-16

149 8-17 LLE13ARDA001D/E

150 8-18

151 Troubles and Measures

152 8-20

153 8-21

154 8-22

155 8-23

156 8.7 Jigs 45 standard pattern (41476-M002) Long offset wrench (40390-M603) φ30 standard frame ( ) Left/right shaft rotation adjustment jig (40396-M001) φ60 standard frame ( ) Y axis adjustment jig (40396-M002) SFB adjustment jig (40396-M003) Wheel remover ( ) Calibration jig (40396-M011) Chuck pressure measurement jig ( ) 45 standard pattern (40390-M301) 8-24

157 8.8 Tools Article name Model Manufacturer Phillips screwdriver D Hozan D Hozan D Hozan Phillips screwdriver with magnet No Vessel Stubby Phillips style screwdriver D65P No Hozan Precision Phillips screwdriver set DK-20 Futaba kogu Flathead screwdriver D55-75 Hozan Precision flathead screwdriver set No Vessel Ball hex screwdriver DB-25 Futaba kogu DB-30 Futaba kogu Hex screwdriver set DK-02 Futaba kogu (1.5, 2, 2.5, 3, 4, 5, 6 mm) Hex wrench set TWB-01 Futaba kogu (1.5, 2, 2.5, 3, 4, 5, 6, 8 mm) Nipper N Hozan Needle nose pliers P Hozan Tweezers P-88 Hozan Wire stripper T-7 Settsu Kinzoku Kogyo Hand lap C-type Iuchi Seieido Soldering iron (20-30 W) N453P Hakko Cleaner for soldering iron tip H-8 Hozan Multimeter MD-180C Sanwa Denki Keiki Vernier calipers N15 Mitsutoyo 8.9 Consumables Article name Model Manufacturer Rubber bond G17-50 Konishi bond Thread-locking adhesive TB Three bond Solder with resin KR19-08 Nihon almit Gasket 1211 Three bond Lubricating oil CRC-5-56 Kure kogyo Mixed-alcohol solvent (50% ether and 50% ethanol) * The articles listed above have been used in NIDEK factories. Equivalent ones can be substituted. Grease ISOFLEX NBU15 NOK fluber Grease NIPPECO LLP Nihon koyu Grease PHOTOLUB BE-4 Nihon koyu Grease PERMALUB SHV-2 Nihon koyu * Use the grease listed above, which have been used in NIDEK factories. When using different grease as substitute, confirm the effectiveness. 8-25

158 8.10 Annex Upgrade to MAIN V1.01 and wheel cover replacement Reference: SM/ANNEX NO. (44001-AN001E) 1. Outline Upgrade to V1.01 Drilling has become possible. See 2 6 for details of upgrade. Wheel cover replacement Occasionally when rough edging a high-curve lens, it came into contact with the right nozzle. The nozzle is now located in the front by changing the wheel cover configuration. See 7 9 for details of replacement of the wheel cover. 2. Precautions 1. After upgrading the software or replacing the wheel cover, perform SFB calibration and LMU calibration and then adjust the SFB and high-curve bevel and check the master size. Refer to Technical Information LLE13ARTZ005A (Adjustment after Upgrade to V1.01). * The master size indicates size parameters in the adjustment menu on the MENU screen. 3. New function 3.1. Support for Lex Drill Connecting the Lex Drill allows lens drilling. To use the Lex Drill, connect with the Drill port and change the communication setting to Blocker/Lex or MiniLab. (Lex Drill should be displayed.) 3.2. Support for Blocker/Lex Information of hole position and groove is available by the conventional communication system Blocker/LE. *A blocker needs to be provided for the Blocker/Lex system Hole position edit function Received hole position data can be precisely adjusted. For precise adjustment, parameters to be changed are limited. Parameters to be changed 1. Hole position (x, y coordinates ±1.00 mm) 2. Hole diameter 3. Hole depth 3.4. Upgrade function of string information file String information files can be upgraded from USB memory. 8-26

159 4. Improvements 4.1. Improvement in accuracy of high-curve bevel Edging accuracy is improved in high-curve lens beveling mode. Thus, high-curve lens beveling mode is limited in passive mode. PD correction is also improved in high-curve lens beveling Default of high-curve bevel The default of high-curve lens bevel height is divided into Metal (MTL) and celluloid (CEL). MTL is 0.8 mm as ever and CEL is 1.0 mm Support for high-curve lenses The X axis control is added at the start of measurement. It may be helpful when a sharply-curved lens cannot be measured because the feeler contacts the lens Improvement in safety beveling accuracy The safety beveling accuracy is improved Improvement in lens measurement A front/rear measurement limit error is added. The error occurs when a sharply-curved lens cannot be correctly measured because the feelers do not reach the lens. Additionally, if the feeler contacts the lens after measurement, the lens can be manually located and the process is initialized Nano cup guided processing mode When processing lenses in nano cup mode, the guided screen is no longer necessary at the time of first roughing so it is not displayed now Processing start when lens is not chucked Even when a lens is not chucked, processing can be started Parameter defaults The default of the PD Correction in Passive parameter is changed to Exec. The default of the Additional SFB parameter is changed to Exec. The default of the Pol idle rot. (PC/ACR/TRX/PUR) parameter is changed to Vacuuming during wheel dressing As long as the water curtain is flowing from at least one side, the vacuum system turns on Maintenance message corrections The maintenance message for the pump tank did not appear every time 70 lenses were processed. It is now improved. 8-27

160 4.11. Edge thickness shortage message The message for shortage of edge thickness was not properly displayed. It is now improved Trivex lens polishing size When the polish size was changed for trivex lens processing, the processed result did not change. It is now improved Safety bevel retouching For polycarbonate, two-point, flat-edging, polish, and safety beveling, processing was performed even though the SFB arm was not ready in retouching of SFB. 5. Procedure Refer to Technical Information LLE13ARTZ004A (Lex 1000 MAIN Program Upgrade Procedure) for details MAIN program version upgrade 1. Copy the MAIN program to USB memory. 2. Insert the USB memory into the USB connector and turn on the power while pressing the STOP button. 3. Select the copied program file and press the SELECT button String information file version upgrade 1. Create a RES folder in USB memory and copy the string information file to the RES folder. 2. While the MENU screen is displayed, insert the USB memory. 3. Select Update string info. and press the NEXT button. 4. Select the copied string information file and press the NEXT button. 6. Application Timing S/N October 2007 and later and later 8-28

161 7. Replacement parts Wheel cover M986-A M986-A1 8. Parts replacement procedure 8.1. Removing parts Disconnect connectors and remove the white vinyl tape to remove M931 (guide). - Reuse of the vinyl tape is possible. Connector M931 Disconnect three connectors and remove two SB6 screws to remove (SFB unit). Connectors SB6 screws 8-29

162 Loosen the wire band on both sides and on the water curtain (rear side of the wheel chamber) to remove the hose. Wire band Wire band Rear side of wheel chamber Loosen the HH screw on both sides and remove the SB4 screw on the water curtain (rear side of the wheel chamber) to remove SB4 screw Rear side of wheel chamber HH screws Loosen the SB3 screw to remove M979 and M987 (pipe). Loosen the two SB4 screws to remove M986. screw screw 8-30

163 8.2. Remounting replacement parts Loosen the FC3 screw to remove M980 and mount M980 on M986-A1 using the FC3 screws. screw 8.3. Assembling replacement parts Assemble parts in the reverse order of 8.1 Removing parts Positioning the nozzle Place M979 so that it fully contacts with M978. Bring M979 into contact with M

164 8.5. Adjusting the nozzle direction When the instrument is ready to be used, turn on the power. Adjust the direction of the nozzle in dressing mode. Press while pressing (STOP). Select Machine Test to display the screen shown below. Select Others and press the SSR1 button to flow water from the nozzle. Adjust the direction of the nozzle properly. After adjustment is completed, press and then press to return to the initial screen. 9. Application S/N - S/N (only for NIDEK Inc.) 8-32

165 Modification procedure of chuck axis motor ASSY. Reference: SM/ANNEX NO.(44001-AN002E) 1. Outline In the current configuration of carriage, when the lens thickness is 6 mm or more, the carriage interferes with the side cover. As a measure, replace the parts of the chuck axis motor ASSY. 2. Replacement parts Feed nut clamp M532-A M532-A1 (1 unit) Whirl-stop plate M536-A M536R-A (1 unit) Shaft M537-A M537-A1 (1 unit) Screw SB410 FC410 (5 units) 3. Parts replacement procedures 1. Remove the parts. Rotate the timing belt in the direction of arrow. The whirl-stop part is pushed out in the direction of arrow. Remove the four screws, and remove M M532-A 8-33

166 2. Recombination of the replacement part Remove the SB screw, and remove the feed screw. Attach the feed screw to the replacement part with the FC screw. 3. Assembly of the replacement part Assemble M532-A1 with the four FC screws. *Tighten the screws while holding the timing belt securely. Assemble the replacement part in the reverse order of removal. *Apply grease (Nippeco LLP) to M537. Rotate the timing belt in the direction of arrow and securely engage the feed screw. Apply grease 4. Operation check Return the ASSY. to its original state. Turn on the power to confirm that chucking is performed properly. 4. Instrument targeted Targeted serial number to

167 Procedure for upgrade to MAIN V1.02 Reference: SM/ANNEX NO. (44001-AN003E) 1. Outline The built-in tracer becomes available for orders via Meganet or NAVIS-EC. (only for Japan) Remedies for the Blocker/Lex system and -axis problems are taken. 2. Precautions After upgrading from V1.00, calibrate the LMU, adjust safety beveling and high base curve beveling, and check the master size. For adjustment, refer to the technical information, LLE13ARTZ005A. Adjustment is not necessary when upgrading from V1.01. * The master size is the Size parameter of Adjustment on the Menu screen. 3. New function 3.1. Supporting Meganet and NAVIS-EC (only for Japan) To use the Lex 1000 as a tracer for orders from Meganet or NAVIS-EC, connect a PC to the COM2 port. However, this function is available only when the communication system is Stand Alone, Blocker/LE, or Blocker/Lex. 4. Improvement, change, correction 4.1. Blocker/Lex system In the Blocker/Lex system, when a lens shape was traced, it was automatically displayed on the screen at the same time that the trace data was sent to a blocker. Now, it is improved. It prevents the trace data from being read automatically even though the lens has not yet been processed Remedy for over current in -axis The problem that the -axis motor driver detects over current is resolved. It may improve the symptom that the Lex 1000 stops suddenly in retouching High base curve processing for polyurethane The high base curve processing sequence for polyurethane is improved. It improves the quality of finishing. 8-35

168 5. Procedure For details on upgrade procedure, refer to the technical information, LLE13ARTZ004A Main program upgrade (1) Copy the main program to a USB flash drive. (2) Insert the USB flash drive into the USB port and turn on the power while pressing the STOP button. (3) Select the copied program file and press the change button. 6. Time necessary for upgrade Timing Targeted serial number November 2007 or later or later 8-36

169 Nozzle replacement procedure Reference: SM/ANNEX NO.(44001-AN004E) 1. Outline Due to the replacement of the wheel cover in AN001E (Upgrade to MAIN V1.01& Wheel Cover Replacement), the location of (nozzle ASSY) has changed. Therefore, cooling water may not be applied to the lens properly. As a result, cooling water may splash into the hole of the measurement arm and get into the instrument. Take measure 1 or 2 below as preferred. 1. Adjust (reduce) the volume of cooling water so that the water does not splash on the hole of the measurement arm. 2. Replace with * The replacement procedure for measure 2 is described below. 2. Replacement part Nozzle ASSY A A 1 unit 3. Part replacement procedure 1. Replacing the nozzle ASSY. Pull in the direction of arrow A to remove from the pipe. Push in the direction of arrow B to attach to the pipe. * Pushing the nozzle while turning makes its attachment easier. A B 2. Checking the orientation of the nozzle Return the instrument to its original state and turn on the power. Flow the cooling water in dressing menu and adjust the orientation of the nozzle properly. 4. Application Instrument targeted: S/N

170 Change of Lex 1000 tracer measurement range Reference: SM/ANNEX NO.(44001-AN005E) 1. Outline The minimum measurement range in the vertical direction of pattern tracing has been changed from 20 mm to 14.5 mm according to the improvement of tracing unit minimum measurement range and pattern setting unit shape change. The measurement range of frame tracing is same as before. New tracer measurement range Pattern tracing Measuremen t range From 24 to 76mm and from 14.5 to 66 mm in the vertical direction. 2. Changes To distinguish whether or not the unit corresponds to this change, the following label is attached to the tracing unit. In addition, the M361 (sensor holder) upper cover is shortened. For units displaying Type D, the minimum measurement range is improved. For the tracer software, use Ver 3.** as with Type C. Tracer type indication example Type B Ver2.09 Tracer type indication example Type D Ver3.03 Type C Ver3.01 Old type (Type A,B,C) New type (Type D) Shape change of pattern setting unit Location where shape is changed Old pattern setting unit New pattern setting unit 8-38

171 3. Notes The Lex 1000 and Ice 1000 cannot be equipped with any tracers other than Type D. The Type A, Type B, and Type C tracers cause failure or interference between Lex 1000 or Ice 1000, so never use those tracers. Tracing can be performed in the new measurement range only when the tracer Type D and new pattern setting unit are used. 4. Timing Time frame for installation of the tracer Type D and new pattern setting unit For the Lex 1000 and Ice 1000, changed from the start of shipping. For all other models, changed from August 2007 production. 8-39

172 Upgrade to MAIN V1.03 Reference: SM/ANNEX NO.(44001-AN006E) 1. Outline Ethernet communication is supported. Malfunctions of the 1/2PD and retouch size are corrected. 2. Precautions (1) After upgrading from V1.00, calibrate the LMU, adjust safety beveling and high base curve beveling, and check the master size. For adjustment, refer to the technical information, LLE13ARTZ005A. Adjustment is not necessary when upgrading from V1.01. * The master size is the Size parameter of Adjustment on the Menu screen. (2) When upgrading the software in Japan, the resource file also must be upgraded. The resource file version corresponding to main program V1.03 is V New function 3.1. Ethernet communication supported The Lex 1000 can communicate with a PC or the Ice 1000 via a LAN port VCA communication VCA communication protocol is supported. (only preset initialization) 4. Improvement, change, correction /2PD When specifying a different 1/2PD between the left and right eyes, the left-eye lens could not be processed with the specified PD. Now it is corrected. It helps to prevent the left-eye lens PD from being shifted when the layout is different between the left and right eyes Retouching in frame change mode Even though the size was reduced on the Retouch menu screen in frame change mode, the lens was not processed with the specified size. Now, it is corrected High base curve beveling When measuring the front surface twice in high base curve beveling, the bevel shape (bevel tip point width on the front surface) was less stable than one-time measurement. Now, it is corrected. It may improve the finishing quality of high base curve beveled surfaces Feeler AXIS The Front feeler and Rear feeler parameters on the Parameter Setting screen (Axis Adjustment) acted in different directions between the left and right eyes. Now, it is corrected. It helps to prevent the bevel or groove position from being shifted. 8-40

173 4.5. Master AXIS The master AXIS during measurement acted in opposite directions between the front and rear. Now, it is corrected. It helps to prevent the bevel or groove position from being shifted when the Axis parameter on the Menu screen is other than Polyurethane The high base curve beveling sequence of polyurethane lenses was reexamined. It may improve the high base curve beveling quality of polyurethane lenses Guided processing After specifying Curve and processing a lens in guided processing mode, the Curve display changed to Auto when processing the other side lens. Now, it is corrected Blocker/Lex The Lex 1000 could not communicate with the ICE mini when setting the communication baud rate to Now, it is corrected. 5. Procedure For details on upgrade procedure, refer to the technical information, LLE13ARTZ004A MAIN program upgrade (1) Copy the main program to a USB flash drive. (2) Insert the USB flash drive into the USB port and turn on the power while pressing the STOP button. (3) Select the copied program file and press the change button Resource file upgrade (1) Create the RES folder in the USB flash drive and copy the resource file to the RES folder. (2) Insert the USB flash drive into the USB port while the Menu screen is displayed. (3) Select String info. update and press the next data button. (4) Select the copied resource file and press the next data button. 6. Instrument targeted This upgrade is applied to the products of December 20, 2007 or later. 8-41

174 Remedies for EEPROM error Reference: SM/ANNEX NO.(44001-AN007E) 1. Details When information saved in EEPROM is improper, beeps sound immediately after power-up and initialization is interrupted.(eeprom error) The cause of EEPROM error and the remedies for error occurrence are described below. 2. Cause There are two EEPROM error conditions. They can be determined by the LED indicators which blink at the occurrence of an error EEPROM version error Beeps sound and the LED indicators for blink. This informs the user that the version of EEPROM data is improper Parameter error Beeps sound and the LED indicators for blink. This informs the user that the parameter settings are improper. This error may occur when earlier software is reinstalled. 3. Remedies When an EEPROM error occurs, follow the applicable procedure below EEPROM version error 1) The error occurs immediately after the main board has been replaced Press and As EEPROM needs initial values to be written, restore the parameters. Refer to the Restoring parameters of the Lex 1000 Service Manual. 2) For other than those above Turn on the power again. If the EEPROM version error still occurs even after the power is turned on again, EEPROM information might have been erased. Press while the LED indicator blinks and restore the parameters after startup Parameter error 1) The error occurs immediately after the main board has been replaced Press As parameters which contain invalid values need initial values to be written, restore the parameters. Refer to the Restoring parameters of the Lex 1000 Service Manual. 8-42

175 2) The earlier software is reinstalled Press As parameters which contain invalid values need initial values to be written, restore the parameters. Refer to Restoring parameters of the Lex 1000 Service Manual. When restoring parameters, restore data for the same version as that of the software being used. Should data of the same version not exist, do not reinstall the earlier software. 3) For other than those above Turn on the power again. If the EEPROM version error still occurs even after the power is turned on again, EEPROM information might have been erased. Press while the LED indicator blinks and restore the parameters after startup. Refer to Restoring parameters of the Lex 1000 Service Manual. If the parameter error still occurs even after the parameters are restored, reset to the factory settings. Refer to Restoring parameters of the Lex 1000 Service Manual. 8-43

176 Remedies for failures of control panel buttons Reference: SM/ANNEX NO. (44001-AN008E) 1. Outline The START button and CHUCK button as well as the DATA button on the control panel did not work because they were obstructed by the cover. As a remedy, insert the spacer (44001-M211) between the button and board. 2. Required part Spacer M211-A 3 units 3. Procedures 1. Removing the board Remove five M047 (P tight screw) which hold BA03, BA04 to remove the board and M275 (spacer) 8-44

177 2. Fitting M211 (spacer) Fit M211 (spacer) on the START button and CHUCK button over M257 (waterproof sheet). Fit M211 (spacer) directly on the DATA button. 3. Mounting the board Mount the board and M275 (spacer) in the reverse order of Step 1. Tighten the screws while holding them with pliers or such so that M275 is not inclined. At the front Circuit board * Supplement If the switch failure is not improved by the above remedy, mount the board while slightly pressing it at the front. If the switch cannot be pressed on the processing unit due to the insufficient stroke length, remove the adjusting PET spacer which is affixed to M257 (waterproof sheet). 4. Applicable S/N S/N:

178 VCA conformance statement Reference: SM/ANNEX NO. (44001-AN010E) 1. Outline The VCA conformance statement is released because the Lex 1000 supports VCA communications. 2. Application The VCA conformance statement corresponds to the Main program V1.04. The information described here may not be supported in the versions earlier than V

179 Built-in barcode scanner Reference: SM/ANNEX NO. (44001-AN011E) 1. Purpose The information about the built-in barcode scanner is released. 2. Available barcode types The Lex 1000 built-in barcode scanner can read the following six types of barcodes. Standards Sample of barcode EAN (JAN) UPC CODE39 (without check digit) ITF (without check digit) NW-7 (without check digit) CODE Setting procedure The barcodes that the built-in barcode scanner reads are a maximum of five types. Setting change is required depending on the barcodes to be used. However, EAN (JAN), UPC, and CODE39 can be read in any settings other than Disable. 1) Press while pressing. 2) Select Parameter Setting and press. 3) Change the setting of Built-in barcode scanner. Setting value Disable ITF / NW-7 ITF / CODE128 CODE128 / NW-7 The built-in barcode scanner becomes disabled. The barcodes of EAN (JAN), UPC, CODE39, ITF, and NW-7 can be read. The barcodes of EAN (JAN), UPC, CODE39, ITF, and CODE128 can be read. The barcodes of EAN (JAN), UPC, CODE39, CODE128, and NW-7 can be read. 4. Application CODE128 is available only for the MAIN program V1.04 or later. In the versions earlier than V1.04, only EAN (JAN), UPC, CODE39, ITF, and NW-7 can be read. 8-47

180 MAIN V1.04 upgrade Reference: SM/ANNEX NO. (44001-AN013E) 1. Outline The shape change function becomes available. The end mill of 1.0 mm diameter can be used in the Lex Drill. 2. Precautions 1) When upgrading the software from V1.01 or later Perform the following after upgrading. (1) LMU calibration (2) Wheel calibration (3) Calibration for LMU limit detection (4) Edging axis adjustment (5) Grooving axis adjustment (6) Safety bevel axis and size adjustments (7) High base curve bevel axis check * For details of each calibration and adjustment, refer to the technical information, LLE13ARTZ008B. 2) When upgrading the software from V New function Perform the following in addition to above calibration and adjustments after upgrading. (1) High base curve beveling adjustment (2) Master size check * For high base curve beveling adjustment, refer to the service manual, LLE13ARDA001A/E or the technical information, LLE13ARTZ005A. * The master size is the Size parameter of Adjustment on the Menu screen Shape change function The shape change function becomes available. A lens shape can be changed when the frame type is Two point or Nylor Supporting the end mill of 1.0 mm diameter in the Lex Drill The end mill of 1.0 mm diameter can be used in the Lex Drill. Select the desired diameter of the end mill on the Menu screen. * Upgrading the Lex Drill software to V1.01 is required. 8-48

181 4. Improvements, changes, and corrections 4.1. Addition of calibration for LMU limit detection The method for detecting the LMU mechanical movable limit is changed to semiauto in order to extend the LMU movable area. It may improve the problem that a measurement limit error occurs with a high frequency Improvement of LAN protocols Bevel information in the LAN communication specifications are supported. The high base curve information can be received in the Blocker/Lex and Mini Lab systems. * High base curve processing must be available in the server such as an intelligent blocker and irx Server Dressing The operating procedure is changed on the Dressing screen. Refer to the Lex 1000 operator s manual (44001-P902D) for details Change for the Lfu-200 The vacuum port timing to control the water for the Lfu-200 is changed Supporting auto initialization (VCA) Auto initialization is supported. It allows the Lex 1000 to communication with a server supporting only auto initialization or not-supporting initialization sessions Change of measurement position when beveling When the feelers may come into contact with the cup, the Lex 1000 measures the outside of the traced shape. It may improve the problem that the feelers come into contact with the cup while measuring the area near the cup Supporting CODE128 The built-in barcode scanner supports the barcode of CODE128. Change the internal barcode setting on the parameter setting screen Improvement of safety beveling The process is changed to make the safety-beveled width stable. It may improve the problem that there is a large amount of variations in the safety-beveled width Frame changing in the Blocker/LE (Lex) system The shapes for frame changing were overlaid in the Blocker/LE (Lex) system. Now, it is corrected SFB wheel height Changing the SFB wheel height parameter value did not influence actual processing. Now, it is corrected High base curve beveling The lens ran off the roughing wheel during roughing high base curve lenses. Now, it is improved. 8-49

182 4.12. Grooving axis The process is changed to make the grooving axis stable. It may improve the problem that the grooving axis becomes shifted suddenly Calibration jig check The Lex 1000 checks whether or not the specified jig for SFB calibration is installed Retouching polycarbonate lenses Retouching the groove on polycarbonate lenses started before preparation. Now, it is corrected. 5. Procedure For details on upgrade procedure, refer to the technical information, LLE13ARTZ004A MAIN program upgrade (1) Copy the main program to a USB flash drive. (2) Insert the USB flash drive into the USB port and turn on the power while pressing the STOP button. (3) Select the copied program file and press the change button Resource file upgrade (1) Create the RES folder in the USB flash drive and copy the resource file to the RES folder. (2) Insert the USB flash drive into the USB port while the Menu screen is displayed. (3) Select String info. update and press the next data button. (4) Select the copied resource file and press the next data button. 6. Instrument targeted This upgrade is applied to the products of March 03, 2008 or later. 8-50

183 MAIN V1.05 upgrade Reference: SM/ANNEX NO. (44001-AN014E) 1. Outline Frame-based curve processing has become available. In high base curve beveling, the bevel curve can be now specified. High base curve lens measurement has become available. A cleaning mode has been added. An axis shift during processing of water repellent lenses has been reduced when double-coated adhesive pad other than specified is used. In rare cases, error 206 (measurement limit error) or error 404 ( axis initialization error) occurred. It is now improved. 2. Precautions 1) When upgrading the software from V1.04 Perform the following adjustment after the upgrade. 1. High base curve bevel position adjustment * For adjustment of high base curve bevel, refer to the Lex 1000 Service Manual (LLE13ARDA001B/E) or 6.1 High base curve bevel position adjustment. 2) When upgrading the software from V V1.03 Perform the following adjustments after the upgrade. 1. LMU calibration 2. Wheel calibration 3. Calibration for LMU limit detection 4. Outer shape axis adjustment 5. Groove axis adjustment 6. Safety bevel axis and safety bevel size adjustments 7. High base curve bevel axis check * For details of each calibration and adjustment, refer to the Technical Information Adjustment associated with V1.04 upgrade (LLE13ARTZ008B). 3) When upgrading the software from V1.00 Perform the following adjustments in addition to the calibrations and adjustments above after the upgrade. 1. High base curve bevel adjustment 2. Master size check * For high base curve bevel adjustment, refer to the Lex 1000 Service Manual (LLE13ARDA001B/E) or the Technical Information Adjustment after upgrade to V1.01 (LLE13ARTZ005A). * Master sizes are the Size parameters in the Adjustment menu on the Menu screen. 8-51

184 3. New functions 3.1. Frame-based curve beveling A beveling function to follow the frame curve is added. In guided processing, setting Bevel curve to Frame allows the beveling to follow the frame curve. * When the pattern trace or frame curve is 0.0, frame-based curve processing is disabled. * When the software is upgraded from V1.04 or earlier, this function is not available. To enable this function, see To enable the frame-based curve processing below Auto frame-based curve beveling In auto processing, a beveling function to follow the frame curve is added. Setting the Bevel curve in Auto mode parameter to Frame allows the beveling to follow the frame curve in auto processing mode. In frame-based curve processing, F is displayed to the upper left of the processing mode. If the bevel drops off the lens edge, a warning message appears and the instrument enters the guided processing mode. * When the pattern trace or frame curve is 0.0, frame-based curve processing is disabled. * When the software is upgraded from V1.04 or earlier, this function is not available. To enable this function, see To enable the frame-based curve processing below. To enable the frame-based curve processing 1. Upgrade the software of the built-in tracer (including that of the connected blocker) to V3.06 or later. 2. Set the Frame curve bevel parameter (Parameter screen to Parameter Setting [12/16]) to Enable. * For proper frame-based curve processing, the software of the tracer (LT-900) to be used needs to be V3.06 or later. When tracing is performed using a tracer with the software of V3.05 or earlier, the frame-based curve processing may not follow the actual frame curve High base curve lens measurement Before high base curve beveling, high base curve lens measurement (lens front surface measurement roughing front and rear surface measurements) can be performed. High base curve lenses with which the rear surface feeler may contact during measurement can be now properly measured. Whether to perform high base curve lens measurement can be set with the Hi-curve lens measurement parameter (Menu screen to Grinding Setting [2/3]). 8-52

185 Setting None Exec Plastic Operation High base curve lens measurement is not performed. For this setting, edge of the lens rear surface may contact the arm of the feelers and proper measurement may not be performed or feelers may be damaged since lens has a high base curve. High base curve lens measurement is performed. If polycarbonate lenses or such are processed, proper measurement may not be performed or the feelers may be broken by the processing waste adhered to the lens after roughing. Only when the lens material is CR39, Hi-index, or Glass, high base curve lens measurement is performed. (default) 3.4. Cleaning mode A cleaning mode is added. To clean the processing chamber after use, enable this mode Lex Drill software upgrade The software of the Lex Drill can be upgraded from the Lex For the upgrade procedure, see 5.3 Lex Drill software upgrade. 4. Improvements, changes, and corrections 4.1. Remedy for roughing end error The expected process of the lens front curve is enhanced. This is a remedy for cases where part of the lens moves down on the polishing wheel during roughing and the roughing does not complete in the processing of lenses such as a aspheric lens which is almost flat on the front surface Remedy for error 206 In high base curve beveling, the origin position of the lens rear surface measurement is moved 3 mm to the right. This may allow the processing of lenses which were not able to be processed due to measurement limit error Remedy for error 404 The maximum speed of the axis during initialization is now decreased. This is a remedy for cases where the axis initialization error occurs immediately after the power is turned on or the axis starts rotating before moving to finishing and the lens and the roughing wheel come in contact resulting in deformation of part of the edge Built-in barcode scanner When tracing was performed with Blocker/LE (Lex) during processing, the barcode scanner became unusable. It is now improved Addition of conventional soft processing The control method of soft processing can be changed to that of the conventional software processing (processing amount control). This may improve cases where an axis shift occurs using tape other than the 3M double-coated adhesive pad. To change the control method, set the Advanced soft mode (Parameter screen to Parameter Setting [13/16]). 8-53

186 Setting value Disable Enable Operation Conventional soft processing is performed. Advanced soft processing (torque control) is performed. (default) When Enable is selected, the cutting amount can be changed. (default: 2.0 mm) To change the cutting amount, set the Amount of soft edging parameter (Parameter screen to Parameter Setting [13/16]. (unit: [mm]) * In the conventional soft processing, the processing speed is remarkably decreased compared to the advanced soft processing Small diameter lens processing with no supporter Without using a supporter, small diameter lens cups (mini cup or nano cup) can be now used. When lenses cannot be processed using a pliable cup, the minimum lens diameter automatically changes to that of mini cups or nano cups. Therefore, the lens adapter and lens clamp need to be replaced before roughing. Processing does not stop temporarily as in the case of small diameter cups with a supporter. To use this function, set the Cup mode parameter (Parameter screen to Parameter Setting [12/16]). Setting Pliable P / Nano+supporter Pliable / Mini Pliable / Nano Operation Small diameter cups cannot be used. Small diameter lens processing using a supporter is performed. As in the conventional manner, processing stops temporarily for removing the supporter and replacing the lens adapter and lens clamp. When the lens cannot be processed using a pliable cup, the minimum lens diameter changes to that of mini cups or nano cups. Because processing does not stop temporarily, the lens adapter and lens clamp need to be replaced beforehand. * Because the small diameter cup is used from the roughing process, an axis shift occurs easily. If an axis shift occurs, use a supporter. * For the use of mini cups, use the lens adapter and lens clamp for nano cups. * The instrument switches to small diameter cup mode, soft processing is automatically applied. When the small diameter processing is performed with Pliable / Mini or Pliable / Nano, the confirmation message is displayed. Whether to display this confirmation message can be set with the Massage for small cup check parameter (Menu screen to Grinding Setting [1/3]). Setting value None Exec Operation The confirmation message is not displayed. The confirmation message is displayed. (default) * Regardless of this setting, the confirmation message is displayed on the information bar. * In a mode other than Pliable / Mini or Pliable / Nano, this parameter is not displayed Measurement position change of small diameter shape If the feeler may contact the cup, the lens is now measured outside the lens shape. This is a remedy for cases where processing was not possible due to the contact between the feeler and cup during measurement Additional safety beveling of polycarbonate lenses In additional safety beveling of polycarbonate lenses, processing was performed with the chuck open. It is now improved. 8-54

187 4.9. Roughing wheel for high base curve lenses Even if the Rough wheel type (HPL) parameter (Parameter screen to Parameter Setting [12/16]) is set to Glass, the roughing wheel for plastic lenses is used for high base curve beveling Drill bit replacement timing indication The replacement timing of a drill bit can be displayed. For systems to which the Lex Drill can be connected, a drilling counter bar graph is displayed to the upper side of the R/L indication. The value specified in the Tool exchange setting parameter (Menu screen to Grinding Setting [2/3]) is the maximum value of the bar graph. By the ratio between Tool exchange setting and actual drilled number, the bar length and color change. Bar color Blue Yellow Red Condition The number of drilled holes is less than 80% to Tool exchange setting. The number of drilled holes is 80% or more and less than 100% to Tool exchange setting. The number of drilled holes reaches Tool exchange setting. * Replacing drill bits without using the drill replacement mode results in improper display High base curve bevel processing for glass lenses The roughing position of glass lenses is corrected to the left from the conventional position. This is a remedy for cases where the lens breaks during roughing in the processing of high base curve glass lenses Bevel simulation disappears. When processing started in guided mode, the bevel simulation display disappeared. It is now improved DBL value is not transmitted In the transmission process of LAN protocol, the DBL value was not stored. It is now improved. When the Blocker/Lex system was connected to the Ice 1000, the DBL field was blank after both-eye tracing. It is now improved LMU excitation off When Carriage Free (Parameter screen to Calibration) is executed, excitation of the LMU is also turned off now. The height adjustment of the feelers becomes easier Reduction of processing time The processing speed (time requiring axis complete rotation) of safety beveling and grooving can be now changed. The balance between the processing quality and processing time can be adjusted. To increase the processing speed, reduce each value of the Grinding speed (SFB) parameter and Grinding speed (Groove) parameter (Parameter screen to Parameter Setting [11/16/]). (unit: [s/rev]) * Increasing the processing speed deteriorates the finish quality. 8-55

188 4.16. STOP button beep Pressing the STOP button produced a short beep in any cases. Only when the processing is interrupted, a short beep is produced now High base curve tilt angle The initial value of the tilt angle in the beveling of high base curve lenses can be now changed. Tilt angle (Hi-curve) (Menu screen to Default Setting ) is the initial setting Addition of COM port check function A function to check whether communication occurs properly at three COM ports is added. Select Port in the Machine Test screen and press the COM1<->COM2 or COM1<->COM3 button. If each port is connected via a cross cable, Connected is displayed. If not connected, Disconnected is displayed. If Disconnected is displayed even though the ports are connected via a cross cable, improper connection may be done inside. * After cable connection is changed, be sure to press the COM1<->COM2 button or COM1<->COM3. Communication check is not performed unless the button is pressed. 5. Procedure For details on the upgrade procedure of the Lex 1000, refer to the Technical Information Lex 1000 MAIN program upgrade procedure (LLE13ARTZ004A) MAIN program upgrade (1) Copy the main program to a USB flash drive. (2) Insert the USB flash drive into the USB port and turn on the power while pressing the STOP button. (3) Select the copied program file and press the ENTER button Resource file upgrade (1) Create the RES folder in the USB flash drive and copy the resource file to the RES folder. (2) Insert the USB flash drive into the USB port while the Menu screen is displayed. (3) Select Update string info and press the DATA button. (4) Select the copied resource file and press the DATA button Lex Drill software upgrade (1) Create the DRILL folder in the USB flash drive and copy the program file for Lex Drill (hm2_*.bin file) to the DRILL folder. (2) Set the Lex Drill to upgrade mode and turn on the power. (3) Insert the USB flash drive into the USB port while the parameter screen is displayed. (4) Select Update Lex Drill software and press the DATA button. (5) Select the copied program file and press the DATA button. * For the upgrade procedure from a PC, refer to the Lex Drill Service Manual Annex Software upgrade to Lex Drill V (44101-AN003E). 8-56

189 6. Adjustment procedure 6.1. Position adjustment of high base curve bevel 1) Press + to read the ø45 internal data and process a lens with CR39, Metal, and Hi-curve. 2) Check that the front edged width is 0.3 mm and the bevel top width is 0.3 mm When the bevel top width is 0.3 mm and the bevel is misaligned Change the Bevel position (HCrv) parameter. 1) Change the Bevel position (HCrv) parameter so that the front edged width becomes 0.3 mm. Increasing the value moves the bevel to the rear surface and decreasing the value to the front surface. 03mm 03mm When the bevel top width is not 0.3 mm Change the Wheel position (HCrvFr) and/or Wheel position (HCrvRe) parameter. 1) Change the Wheel position (HCrvFr) parameter so that the front edged width becomes 0.3 mm. To increase the width, add the value. To decrease the width, reduce the value. 0.3 mm 8-57

190 2) Change the Wheel position (HCrvRe) parameter so that the bevel top width becomes 0.3 mm. To increase the width, reduce the value. To decrease the width, add the value. 0.3 mm + Parameter Setting 7. Application This upgrade is applied to products manufactured in July 29, 2008 or later. 8-58