mycoat operating manual - visionease...1. argon 99.995% purity – regulated to 40 psi or 2.7 bar...

Vision-Ease Lens, 7000 Sunwood Drive NW, Ramsey, Minnesota, 55303

Customer Service Tel: 888-888-3044 or 763-398-6997 [email protected]

Version: 2, Revision: A, Date: 11 March, 2015

MyCoat®

Operating Manual Version: 2, Revision: A

Date: 11 March, 2015

mailto:[email protected]

MyCoat Operator’s Manual Vision-Ease Lens WorldWide

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Customer Service Tel: 888-888-3044 or 763-398-6997 E-mail [email protected]


Manufacturer Information

Vision-Ease Lens

Corporate Headquarters

7000 Sunwood Drive NW

Ramsey, MN 55303 USA

Website:

http://www.MyCoatvel.com

Contact Information

Telephone: 888-888-3044 or

(1) 763-398-6997

Email [email protected]

Distributor

Information

Copyright® 2015 Vision-Ease Lens All Rights Reserved

This manual is intended for use solely with the MyCoat lens coating system and is not intended

to be used, reproduced or distributed for any other purpose. Photocopying, printing or electronic

duplication of any part of this manual is not permitted without prior written consent from Vision-

Ease Lens WorldWide.

Technical information, including content relating to software, assembly schematics, photographs

and instructions are intended solely for use with the MyCoat Lens system. Information contained

within this manual is subject to change at any time, without prior notice.


http://www.mycoatvel.com/



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Table of Contents

Contents

Introduction ................................................................................................................................. - 4 -

What does the MyCoat system do? ..................................................................................... - 4 -

How does the MyCoat system deposit coatings? ................................................................ - 4 -

MyCoat Vacuum System ...................................................................................................... - 6 -

MyCoat Power and Cooling ................................................................................................. - 7 -

Mechanical Installation Checklist ....................................................................................... - 7 -

Daily/Weekly System Set-up & Lens Coating Checklist ................................................... - 9 -

MyCoat System: Key Specifications and Requirements .......................................................... - 10 -

MyCoat System Overview .................................................................................................. - 13 -

Key Safety Features ............................................................................................................ - 13 -

Power Buttons ..................................................................................................................... - 15 -

MyCoat User Interface ....................................................................................................... - 16 -

Operation................................................................................................................................... - 18 -

Running Start Up ................................................................................................................ - 18 -

The Target Clean Process .................................................................................................. - 19 -

Loading Lenses for Coating ............................................................................................... - 20 -

Lens Holder Rings............................................................................................................... - 21 -

Spring Ring Holders ........................................................................................................... - 22 -

Running the Coating Process ............................................................................................. - 23 -

The Hydrophobic Application Process ............................................................................. - 27 -

Conducting the AutoTune Process .................................................................................... - 28 -

Preventative Maintenance ......................................................................................................... - 31 -

MyCoat Warranty and Parts Information ....................................................................... - 32 -

Important Weekly Maintenance Checks and Task List .................................................. - 32 -



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Vented Shutdown Process .................................................................................................. - 33 -

Shutdown Under Vacuum .................................................................................................. - 33 -

Checking Rotary Pump Fluid Levels and Color .............................................................. - 34 -

Items Required for Cleaning Targets, Plasma Source and Chambers (upper and

Loadlock) ............................................................................................................................. - 35 -

Cleaning of the Targets, Plasma Source and Chambers (Upper and Loadlock) .......... - 35 -

Replace Tape on Lens Rings and Rotor ............................................................................ - 43 -

Examine Deposition Cycle Times ...................................................................................... - 46 -

When to Change Targets .................................................................................................... - 46 -

Images of the MyCoat System .................................................................................................. - 48 -



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Introduction

Welcome to the MyCoat family! The MyCoat thin-film optical coating system is used for the

application of AR or Anti-Reflection coatings, as well as dielectric mirrored finishes in a range

of colors. The system is capable of applying AR and mirror coatings to up to six lenses at a time,

with the deposition process lasting around 15 minutes.

What does the MyCoat system do?

The MyCoat system is capable of depositing Anti-Reflective and Dielectric Mirror coatings on

up to six lenses at once.

To deposit these coatings, the MyCoat system applies a nano scale multilayer coating of ceramic

materials to up to three pairs of ophthalmic lenses simultaneously. When applied in the proper

way, this coating virtually eliminates visible reflections from the surface of the lenses. Proper

application of this coating requires an ultra-clean vacuum chamber process in an environment

free of atmospheric gases.

AR Coatings

The difference in the refractive index of each material allows for higher control of light

reflection. The system applies multi-layer AR coatings in total thicknesses less than 1μM (1uM=

10,000 angstroms).

The thickness and type of material applied in each layer allows for control of the overall color

and reflective properties of the lens. The standard color of the AR coating is green, but could be

altered to other choices. During the deposition process, the materials are converted into clear

ceramic material on the surface of the lenses.

Dielectric Mirror Coatings

A dielectric mirror coating is a type of mirror composed of multiple thin layers of material.

Through carefully designed deposition of varying types and thicknesses of layers, the MyCoat

system creates dielectric mirrors coatings that reflect a broad spectrum of light and can be altered

to a wide range of colors and reflective properties.

How does the MyCoat system deposit coatings?

The MyCoat system creates AR and Mirror coatings through the application of two different

ceramic materials, Silicon (Si) and Zirconium (Zr). The system deposits these materials onto

lenses through a process known as magnetron sputtering.



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Magnetron sputtering involves firing high energy Argon plasma at the surface of the materials.

Bombarding the materials with Argon plasma knocks individual atoms off the material discs,

called targets, in turn creating a gas which condenses on the surface of the lens.

Each layer is then exposed to oxygen plasma, turning the material into a dense and durable

ceramic. The process continually repeats until the required coating has been achieved.

Front view of MyCoat and primary components



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Primary “System Display” User Screen

MyCoat Vacuum System

For quality coating results, the deposition process must occur in a very clean environment, free

of pressure and atmospheric gases. To achieve such an environment, the MyCoat system relies

on two vacuum pumps; the rotary pump and the turbomolecular pump.

The rotary pump functions much like a vacuum cleaner to remove most of the atmosphere from

the vacuum chamber. The rotary pump’s power is limited however; once the rotary pump

completes its process, the turbomolecular pump continues to remove the last remnants of oxygen

and atmospheric gases to create a vacuum equivalent to that found in space. The turbomolecular

pump is similar in performance to a jet engine, with numerous small vanes rotating at more than

50,000 rpm to buffer individual gas molecules out of the chamber.

High vacuum systems require extremely critical connections. During maintenance and

manufacture all seals and mating surfaces are carefully examined and great care is taken to

properly achieve high vacuum integrity.

Important - For the MyCoat design: to obtain consistent AR and mirror coatings, it’s best

to maintain high chamber vacuum at all times.

Due to the required level of cleanliness of the main system, and the time it can take to create

such a high vacuum, the MyCoat system consists of two separate vacuum chambers. The main

chamber, in which the deposition process takes place, stays under vacuum except during



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maintenance. The second chamber, also known as the loadlock, is smaller and pumped much

more easily than the main chamber. This allows for quick loading and unloading of lenses. The

system then transfers the lenses between chambers to complete the coating process.

MyCoat Power and Cooling

The MyCoat coating system is comprised of two power supply units. The Pinnacle Plus powers

the Silicon and Zirconium magnetrons while the Plasma Source is powered by a smaller power

supply located in the lower enclosure of the machine.

Due to the nature of the system’s vacuum pumps and the heat associated with the magnetron

sputtering process, the system must be water cooled to 17 degrees Celsius during operation. The

system’s water cooling system is fitted around the chamber and throughout the pumps, with

several quick release, non-drip connections. Water cooling is provided by an external 3.2kW

recirculating deionized water chiller. NOTE: The water chilling system is self-contained and

does not require any permanent water supply or drain services

Mechanical Installation Checklist

Reference: Installation Checklist and Floor Plan Guidance #714

Electrical Checks –

1. 230V AC – 50-60 Hz, Three Phase power (18 Amps) to MyCoat Machine (check with

multi meter)

2. 208/220V AC - 60 Hz or 230V AC – 50 Hz Single Phase power to Chiller (check with

multi meter)

3. 110-120V/60 Hz single Phase power for DI Air Gun (check with multi meter)

4. Internet connection (Ethernet) RJ45 cable

5. Ensure all electrical connections are tight on both electrical cabinets high and low power

cabinets. (no vibration loosening of screws)

6. Once machine is plugged in check rotation on three phase

Gases Check –

1. Argon 99.995% purity – Regulated to 40 psi or 2.7 bar via two stage regulator.

2. Oxygen 99.95% purity – Regulated to 40 psi or 2.7 bar via two stage regulator.

3. Compressed Air 60psi or 4 bar for MyCoat Machine and 40 psi for DI Air Gun.

4. When the main tanks reach 500 psi, it’s time to re-order. Do not operate the system if the

main tank pressure goes below 250 psi.



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Elevator and Loading Arm Assembly –

1. Go through the arm and elevator assembly to ensure all bolts and nuts are tight and none

loosened from shipment

Internet connection –

Internet connection (Ethernet, not wireless) RJ45 cable

Chiller Check –

1. Check supply and return fittings on back of chiller are correct

2. Check H2O level in chiller reservoir (de-ionized water)

3. For the Lytron chiller - Make sure psi setting is between 28-35 psi (lower left button)

For the ATC–K3 chiller – Make sure the psi setting is between 50-60 psi (front gauge)

4. Temperature should be set at 17 degrees Celsius

5. For the Lytron chiller - Set OVERTEMP and LOWTEMP alarm – OT set at 25 degrees

Celsius and LT set at 12 degrees Celsius. HOLD UP AND DOWN ARROWS FOR 3

SECONDS AND USE SET TO NAVAGATE THROUGH SCREENS AND ARROWS

TO SET SETPOINTS

For the ATC-K3 chiller - Only the set-point “temperature” is programmable, ensure it

is set to 17 degrees Celsius. To change the temperature, press the “P” button (SP-1 is

now displayed and blinking) and now you can increase or decrease the temperature with

the up/down arrows. The blinking display will stop in 15 seconds and the new

temperature will take effect.

6. Check to make sure the waterlines connections inside MyCoat are not leaking

Machine Checks –

1. Check oil level in vacuum rotary pump

2. Check that pinnacle turns off when safety switch/doors are opened

3. Check E-stop is working properly

4. Check water flow switch is working properly on MyCoat machine

Vacuum Checks –

1. Check overnight Pirani gauge vacuum

2. Check overnight AIM gauge vacuum



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Daily/Weekly System Set-up & Lens Coating Checklist

Daily (am)

1. Check rotary pump oil level (on left side of system) – the level should be between

minimum and maximum.

2. Assess DI water level on the chiller – In front for the Lytron chillers and on-top for the

ATC-K3 chillers.

3. Check Argon, Oxygen and compressed air tank and regulated output (psi) levels.

4. Tape a rotor (using Lo-Tak tape) and perform one cycle; Calibration (cx) – “Target

Clean”

5. Optional: Color assessment – Coat one CR-39 lens with “VEL AR cc/cx” and dip in

Hydrophobic solution. Lens reflex should be green color in appearance.

6. MyCoat system is now ready for coating production lenses.

Weekly

1. Shut-down & vent system

2. Remove and clean targets; vacuum plasma source, and chambers (upper and Loadlock)

3. Check rotary pump oil level and color (on left back side of system) – the level should be

between minimum and maximum marking on the view port.

4. Assess DI water level on the chiller – In front for the Lytron chillers and on-top for the

ATC-K3 chillers. Ensure the air intake of the chillers are free of dust and debris build-

up.

5. Assess Argon, Oxygen and compressed air levels.

6. Perform “Start-up,” followed by two (2) Maintenance (cx) – “Target Clean” cycles

7. Perform a system “color” test – Maintenance (cx) – “Standard Green” (slide – color test)

– Coat the shiny side of a frosted glass slide with Calibration (cx) - “Standard Green.”

Send the coated glass slide to MyCoat Engineering in Ramsey, MN for spectrometer

testing. Mail-in using the hard plastic case to prevent breakage.

Lens preparation

1. Edge lens substrate, to be coated, to 66mm, 71mm or 76mm to fit the supplied rotor

rings.

2. Perform general cleaning of the lenses with Dawn or equivalent soap and water. .

3. Final clean lenses with Dawn or equivalent soap & water, rinse with de-ionized or

distilled water, using alcohol cleaning for touch-up.

4. Blow lenses dry cc/cx with warm air lens blower.



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5. Perform a final blow-off of lenses with deionized (antistatic) air, just prior to inserting in

the rotor ring(s).

6. Ensure all the lenses are fully inserted into the rings, lying against the ring ledge.

7. Mount rings/lenses into the rotor and verify they are firmly seated.

8. Carefully perform a final blow-off of all lenses in the rotor using deionized (antistatic)

air, just prior to inserting into MyCoat Loadlock chamber for coating. Repeat final de-

ionized air blow off for both the front (cx) and backside (cc) coating.

MyCoat System: Key Specifications and Requirements Mechanical

Width = 31.5” - 34” including the main power switch

Depth = 33.5” - 42.5” including the external tank(s) holding tray

Height = 65” - 67.5” including the optional wireless communication hubs

System Weight

955 lbs / 433 kg

1005 lbs / 455 kg (with the Oxygen and Argon tanks)

Tank Information

Oxygen – tank size: 40 Cu Ft, 22” tall, 7” diameter

Gauge: CGA -540 (The threads on the gas tank need to be male)

Argon – Tank size: 40 Cu Ft, 22” tall, 7” diameter

Gauge: CGA -580 (Threads on the gas tank need to be female)

Environmental Requirements: for optimal system and lens coating quality, the following

temperature, humidity and storage air pressure limits should be maintained.

Operating Temperature: 5 to 40 degrees Celsius (41 to 104 degrees Fahrenheit)

Operating Relative Humidity: 20 to 85% RH (non-condensing)

Operating Air Pressure: 788 to 1060 mbar (2000 to -500 meters equivalent)

Storage Temperature: -30 to 70 degrees Celsius (-22 to 158 degrees Fahrenheit)

Storage Relative Humidity: 20 to 85% RH (non-condensing)

Storage Air Pressure: 656 to 1060 mbar (3500 to -500 meters equivalent)

Installation and Operating Conditions:

Ventilation: One foot minimum clearance is required on all sides to assure proper ventilation.

Noise Level: 60 dB – hearing protection may be required

Location/Mounting Requirements: Install on a level surface capable of supporting 955 lbs

(433 kg)



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The MyCoat system requires a supply of:

Argon: The system requires Argon of 99.995% purity, distributed at a regulated pressure

of 40 psi (2.7 bar) from a two stage regulator. When the main reaches 500 psi, it’s time to

re-order. Do not operate the system if the main tank pressure goes below 250 psi.

Oxygen: A supply of 99.95% pure Oxygen must be distributed at a regulated pressure of

40 psi (2.7 bar) from a two stage regulator. When the main tank reaches 500 psi, it’s time

to re-order. Do not operate the system if the main tank pressure goes below 250 psi.

Compressed Gas: Filtered dry compressed air at 60 psi (4.0 bar) regulated pressure is

required; 40 psi for the deionized air gun. Note: It’s very important that the air

compressor (or tank compressed air) be kept on AT ALL TIMES, or serious system

malfunction may result.

Chilled Water Supply: An external chiller capable of providing filtered deionized water

is required. The Lytron chiller must maintain pressure of 28-35 psi (2 bar) at 2 liters p/m

at 17°C per minute. The ATC-K3 chiller must maintain pressure of 50-60 psi at 17°C

per minute.

ATC-K3 Chiller Lytron Chiller

Front display panels of the ATC-K3 and Lytron chillers

Power Supply: 230V AC – 50-60 Hz, 3 phase (18 Amps), 208/220V - 60Hz or 230V –

50 Hz single phase and 110V - 60Hz Volt power supplies are required for operation.

Active Internet Connection: The MyCoat system can be accessed remotely by MyCoat

service technicians to diagnose faults, upload new coating options and update software.

An active internet connection is required for these functions. The Ethernet connection is

provided by an RJ45 socket near the Oxygen and Argon gas feeds. An optional wireless

configuration is also available.



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Connections of Argon, Oxygen (silver colored lines), Compressed air (red) and Ethernet (blue)

Argon is closest to the cabinet, Oxygen is on the outside

Backside of the system with connections



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MyCoat System Overview

The MyCoat system consists of several components, including the user interface and control

system, the power supply, the pumping system and the vacuum system.

Control System: The control system consists of an industrial Programmable Logic

Controller (PLC), the touch screen interface and the internal relay panel. The control

system also includes various control and safety sensors and valves located throughout the

system.

Power Supply System: The power supply system consists of two different sources, the

magnetron power supply and the plasma source power supply.

Pumping System: The pumping system consists of the rotary and turbomolecular pumps

and includes all valves and tubes necessary to support the function of the system.

Vacuum System: The vacuum system consists of the main chamber and magnetrons, as

well as the lower loadlock chamber and the transfer mechanism.

Key Safety Features

The MyCoat system is outfitted with safety features to protect both the user and the system itself

from harm. These safety features include:

Safety Interlocks: The MyCoat system is fitted with safety interlocks on all of the main

panels. These interlocks will cut off the high voltage power supplies in the event of a

panel being opened. Any lens coating operation currently underway will be immediately

aborted.

Emergency Off Button: Located prominently on the front of the MyCoat system, the red

emergency off button instantly disrupts the flow of power to the system beyond the main

circuit breaker. Pursuant to its name, this button is intended to be used only in the event

of an emergency situation: system recovery after pushing the emergency button will take

considerable time. To deactivate the emergency button, simply twist it to return it to its

original position. See photo below.



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Emergency Off Button

Main Power Switch, located on the left side of the system

“0” green = OFF and “1” red = ON

During operation and maintenance, be sure to adhere to all posted warning signs, including those

related to high voltage and high power magnets. The meanings of each type of warning symbol

are listed below.



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Magnetrons operate at a high voltage. Be sure to isolate the power system before

opening the system.

The MyCoat system contains high powered magnets. Do not expose these magnets to

medical devices – Radio Frequency (RF) and magnetic fields can interact with implantable

pacemakers and defibrillators, typically not with non-metallic catheters, etc. If in doubt, contact

your physician. Avoid exposure to cell phones, watches, credit or security cards, or any object

that may be sensitive to magnetic fields.

Material Safety Data Sheets (MSDS)/Safety Data Sheets (SDS) are available from the MyCoat

Support Team. Refer to these data sheets for additional safety information and proper handling

instructions of chemicals involved in the system’s operation.

Power Buttons

Three power buttons located on the right hand side of the system, controls the various power

supplies.

The GREEN power button controls the Main Power of the system, and starts data

devices and the Programmable Logic Controller (PLC).

The BLUE power button turns on the magnetron and high voltage power supplies.

The BLACK power button turns off the magnetron and high voltage power supplies

while the system is idle.



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MyCoat User Interface

Users control all functions of the MyCoat system through the touch screen located prominently

on the front panel of the system. Through this touch screen, users can select the desired coating

operation, begin the coating operation, access maintenance functions and review system

specifications and statistics.

The user interface is powered by an industrial Programmable Logic Controller (PLC). User

software consists of multiple screens, depending upon the user’s desired operation. Pressing the

main menu button at the top right corner of the screen allows the user to access the various

operations.

Primary User Interface “System Display” Screen

Additions and alterations to coating recipes can be conducted remotely by MyCoat technicians

using the system’s internet connection. Remote access of the MyCoat system can be made in an

effort to diagnose malfunctions, alter processes, update software and upload new coating options.

In addition to coating and maintenance operations, operators may perform many functions and

operations through the user interface screen, including:



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Shut Down: Turning off the system is done by simply selecting the Shut Down option.

You will be asked to select a sealed or vented shut down; vented shut downs are

performed in an effort to conduct maintenance in the chamber, while sealed shut downs

are ideal for extended periods of inactivity.

Note: It’s very important that the air compressor (or tank compressed air) be kept on AT

ALL TIMES, or serious system malfunction may result.

Seal/Vent Loadlock: Sealing or venting the Loadlock may be required when undertaking

servicing or whenever a system error occurs.

AutoTune: The AutoTune routine is used to calibrate the deposition process.

System Display – Shutdown Screen

Features Used by MyCoat Service Technicians

Recipe Files: These files dictate the coating parameters of the system’s processes.

Factors such as gas flows, power settings, layer thicknesses, pulse widths and frequencies

are considered in each different recipe. Recipe files may not be altered, except by an

authorized technician or by Vision-Ease Lens directly. Unauthorized changes to recipe

files may result in poor coating quality or coloration, and may damage the machine.

Log Files: Information such as run times, system states, error messages and coating

recipe usage are stored in Log Files. These files are often used during diagnostic testing

of the system.

Remote Support: Vision-Ease Lens has the ability to remotely operate, review and alter

the MyCoat system over an internet connection. An optional wireless configuration is

available.



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Operation The following section details operation of the MyCoat system.

Running Start Up

Starting the system from shut down requires several steps. When starting the MyCoat system,

you should:

Check required supplies: Be sure that all supplies to the MyCoat system are active,

including the water chiller and the argon and oxygen flows.

Check mechanical pump oil level: Check the pump oil level. The oil level should be in

the middle of the site glass located on the left hand side of the rear of the system. If oil

overflow is present in the Mist filter on top of the rotary pump, there may be a vacuum

issue. Contact a MyCoat technician for assistance.

Examine DI water level in chiller: To check the water level in the ATC-K3 chiller,

open the 8x12 inch panel on top of the chiller system. Remove the plastic filling cap and

visually inspect the water level inside the reservoir. Fluid level should be less than one

inch from lop of the rectangular reservoir body. For the Lytron chiller, examine the fluid

level by the front fill view port. Note: Ensure the air intake (front grill) of the chiller is

free of dust and debris. Vacuum on a weekly basis.

Check system for leaks: Before starting chiller, open the top front and upper back doors.

Turn on chiller and inspect for any visible water leaks around magnetrons and plasma

source. If any leaks are observed, immediately shut down the chiller system. If no leaks

are observed, the chiller can be left running.

Turn on “main” electrical power supply: Activate 3-phase circuit powering system,

using the rotary switch on the left side of the system’s framework.

Check Emergency Button: Be sure that the red Emergency Button is in the out position.

Switch the system on: On the right side, press the green power button. Press the middle

blue button to turn on Pinnacle power supply. Ensure from the front system display

screen the following: Air press, Argon press, Oxygen press, Chiller temp and Chiller flow

are “OK” blue icon and the Mag Power is “OK” icon system lights up blue.

Select start up: Select the startup option on the user interface. This will start the pumps

and ready the chamber for coating. NOTE: The startup process can take approximately

45 minutes from a shutdown vented state, or 10 minutes from a shutdown sealed state.

Vent Loadlock: When the startup process is completed, it will read … “Start-up System,

Open Loadlock.” The system is now ready for the “Target Clean” process

Unique Startup Scenarios

When starting the MyCoat system for the first time, it is essential that the system has been set up

properly and that all connections and supply flows are functioning properly. Before initial

startup, review the connection and pressure requirements. Additionally, check to ensure that the

rotary pump oil level is adequate.



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Starting the system after services have been disconnected and reconnected requires additional

care. In this situation, perform two “Target Clean” conditioning cycles and one “Standard

Green” AR cycle.

The Target Clean Process

Note 1: The terms Carrier, Rotor and Lens Box are interchangeable and each describes the

holding mechanism for the lenses to be coated

Note 2: Deionized Air and Antistatic Air are the same

The system conditioning, or “Target Clean,” process is required whenever the MyCoat system

has been shut down or has rested idle for more than 8 hours. This process applies a dummy

coating of pure metal from the targets to ensure that they are sufficiently clean and free of

oxidation and contaminates before applying a coating to lenses.

To conduct the “Target Clean” process:

1. From the user interface screen - Press “Vent Loadlock” and open the door.

2. Lift carrier tray from underneath, raising it off the carrier arm and removing it from the

system.

3. Wrap a layer of Lo Tak tape around the carrier, making sure that tape does not overlap

onto tray or above the carrier and that tape is secure. Only a single layer of tape needs to

be applied. This will protect the carrier from coating build-up.

4. Blow carrier and Lo Tak tape clean with anti-static gun.

5. Open Loadlock door and place the carrier on the loading arm.

6. Clean both the O-ring and O-ring sealing surfaces with cleanroom wipes.

7. Close the Loadlock door.

8. Select “Maintenance” from the Coating Cycle/Coating Design user interface screen. If

this screen is not present – press “Change Coating.”

9. Select recipe – “Target Clean” and enter “Load.” When it prompts the user “Do you

want to write specified data” – select “OK.”

10. On the Coating Cycle/Coating Design screen, select “Start Coating.”

11. At this point, all recipe/software information has been entered.

12. The Target Clean process will take approximately 5 minutes.

13. When finished with the coating, the system will prompt the user - “Coating Complete –

Venting Loadlock, Open Loadlock Door, Unload Lens box.”

14. The Loadlock is now vented and you can remove the carrier from the Loadlock arm.

15. Remove the Lo Tak tape. Tape should be blue/gold in color, not silver.

16. Shut the Loadlock door after removing tape. The Loadlock will not go under vacuum

until rotor has been replaced in Loadlock.

17. System is now ready to process lenses.



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Upon completion of the process, the Lo Tak covering should have a shiny finish. Remove the

tape and discard. At this point, the system is prepared to coat lenses.

Lo Tak tape prior to target clean process:

Lo Tak tape after successful target clean process.

Loading Lenses for Coating Loading and unloading of lenses is done using the carrier. This can be done while the carrier is

still in the Loadlock or by removing the carrier entirely. Always wear nitrile rubber gloves when

handling lenses to preserve the cleanliness of the lenses. Note: Pre-cleaning of the lenses is



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EXTREMELY IMPORTANT in order to obtain consistent high quality AR and mirror coatings.

If you have questions, please contact the MyCoat engineering team.

Lens Holder Rings

The MyCoat coating system includes 3 sets of lens rings to mount the lenses in the carrier (rotor)

during the coating cycle. These rings are manufactured to accept lenses with 66, 71, and 76mm

diameters. Larger lenses and sizes between should be cribbed on the generator or edged after

hard coating to fit one of these ring sizes.

The rings attach to the rotor magnetically and the lenses are held in place by the white spring-

loaded pusher inside the rotor.



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Spring Ring Holders

Lenses with small diameters or of irregular shape can be held in place with the optional Spring

Ring Holders. A spring loading device is used to facilitate placing the lens into the spring clips.

To avoid deposition of coating material inside the rotor, it is necessary to insert a blocking disc

to the area behind the spring ring.



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The disc attaches to the rotor with two Phillips screws making it easy to go from regular rings to

spring rings.

Once the lens is fastened into the spring holders it can be magnetically attached to the rotor.

1. On the main user interface screen – Select Coating/Coating Design.

2. Once the Loadlock has been vented, open the door and remove the carrier.

3. Remove rings with lens ring tool and load the lenses to be coated into the proper sized

ring. Be sure that all lenses are oriented in the same manner, with concave (CC) or

convex (CX) side.

4. Place the lens rings into the rotor – double check what AR coating is going to be applied

and verify the lens are mounted correctly (CC/CX).

5. Blow off the lenses and rotor with a deionized (antistatic) gun at an angle of about 45

degrees and 12” away (depending on the air pressure), to remove any debris particles

from the lenses.

6. Place the lens carrier into the Loadlock.

7. On the user interface screen, select the coating type – Maintenance, AR-CC, AR-CX or

Mirror-CX. You may need to press “Change Coating.” Once you have selected the

desired coating - press” Load,” - Do you want to write the specified data? - Press “OK.”

You are now ready to “Start Coating.”

8. When the coating is completed, the system will prompt the user – “Coating Complete

Venting Loadlock, Open Loadlock Door, Un-load Lens Box and Load Lens box.” You

are now ready to start the next cycle.

Running the Coating Process

For best results, Vision-Ease Lens suggests:

Hard coating all lenses prior to AR or Mirror coating

Thoroughly cleaning all lenses prior to the coating process with a non-destructive

cleaning process.

The MyCoat system should be kept under vacuum at all times when not applying

coatings



- 24 -




Maintain strict cleaning procedures. It is important to keep the Loadlock and chamber

clean and free of debris and particles to ensure vacuum integrity.

Starting the coating process once lenses have been loaded is relatively simple.

1. From the Select Coating/Coating Design screen – select “CC-AR,” “CX-AR,”

“Maintenance” or “CX-Mirror.” If not on this screen – press “Change Coating.”

2. Select the desired coating recipe. For example, “VEL AR” or “Vivid AR.”

3. Highlight and Press “Load.” It now prompt the user - Do you want to write the selected

data – “OK”

4. At this point, the system has loaded the selected recipe/software and is waiting for the

user to “Start Coating.” The coating cycle screen will track the progress and time of the

coating process.

5. Once coating is complete, the system will prompt the user “Venting Loadlock.”

6. The system will vent the Loadlock and then prompt the user “Coating Cycle Complete,

Open Loadlock Door.” You can now open the door and remove the lens carrier.

7. Remove lenses – load new lenses or flip the existing lenses to begin the coating process

on the other side (cc/cx).

The Select Coating screen allows for selection of the desired type of coating.



- 25 -




At this point, the coating type has been selected and you must “Load” the recipe.

Do you want to load the specified data? Press “OK.”

The above screen highlights the typical coating process – Loadlock Vacuum, Load Cycle,

Chamber Vacuum, Coating Cycle and Unload Cycle. The “Standard Green” recipe has been

selected and loaded. The system is waiting for the user to “Start Coating”



- 26 -




Once the coating process has begun, the touch screen interface displays a progress bar detailing

the type of coating currently being applied, the surface being coated, the elapsed time of the

process and the current stage of deposition. If any of this information is incorrect, the process can

be aborted by pressing the “Stop Coating” button.

Once AR coating is completed, the system will display a message “Venting Loadlock, “Open

Loadlock Door,” and then “Unload Lens box.” The lens rotor can now be removed and the

coated lenses can be removed or rotated for coating on the other side (cc/cx).



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The Hydrophobic Application Process Hydrophobic application is a very important step in the processing of AR coated lenses. The

hydrophobic layer enables the lenses to be cleaned very easily and to maintain resistance to

water spotting, fingerprints and minor abrasions for the life of the prescription.

MyCoat offers two levels of protection, “Standard” and “Super”. MyCoat Hydro is a standard

level which tests out just below the ranking of a “Super Hydrophobic.” The MyCoat Super-

Hydro offers a greater degree of hydrophobic action. Both offer the same easy to apply

procedure.

The Hydrophobic material is placed in a clear plastic sealed container for use at the work station.

The lenses are taken immediately from the coating chamber after both sides have been coated

and placed into the lens holders. Use the two lens holders as supplied and dip them into the

solution for 15 seconds. Lift and drain the excess solution from the lenses and place on an

absorbent lint-free material. At this time the lenses can be removed and buffed with a clean lint-

free cloth.

Repeat this procedure for all of the lenses.

An optional method for applying the hydrophobic solution is using a spray bottle.



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A drop of water can be placed on the treated surface to see the results of the hydrophobic action

by testing the drop’s contact angle.

VERY IMPORTANT: Care should be taken to eliminate any cross-contamination of cloths or

gloves between the hydrophobic application and prep work prior to coating. Hydrophobic

properties inhibit adhesion which can cause AR coating failures. A separate work station away

from the AR prep area is highly recommended for hydrophobic application.

Conducting the AutoTune Process AutoTune is a method of tuning the system as the targets age, and is intended to keep the

system’s coating output in line with desired quality and coloration. A calibration recipe named

“Standard Green” will be used during the AutoTune process. “Standard Green” can be found in

the coating options Maintenance menu.

The AutoTune process must be performed on a glass test piece using the special holder ring.

Place a spare lens behind the glass slide with the frosted surface of the glass facing the lens.

Note: The AutoTune process coats the shiny/glossy side of the glass slide.

Be sure that the glass slide is cleaned with a soft cotton cloth and alcohol before coating.

New slide holder ring set-up



- 29 -




Optional method for coating a test slide

The AutoTune Procedure:

1. Place glass slide into carrier and position the test slide in a vertical position in the rotor.

Be sure to note that the shiny/glossy side of the slide will be coated during this process.

2. Run “Standard Green” deposition recipe, under Maintenance

3. Using a spectrometer, measure the AR coating and record values

4. Input the three AutoTune parameters into the AutoTune Screen

5. Once parameters have been entered, select the Accept Data option

Use of a Spectrophotometer is necessary for the most detailed and accurate AutoTune Process

possible. If you don’t have a Spectrophotometer, consider sending the slide by overnight

shipping to the MyCoat Support Team for measurements, or make arrangements with a local lab

that has a Spectrophotometer.



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Spectrophotometer Chart of AR Green

The Importance of the AutoTune Process

The MyCoat AutoTune process has been designed to calibrate the deposition system. This

ensures a consistently repeatable highest quality AR and Mirror coatings. It is recommended that

the AutoTune process is conducted on a regular basis, especially after any major maintenance

and weekly target cleaning is performed.

To reach the optimal coating, the AutoTune process should be repeated until the trace is 525 nm

+/- 5nm and the Blue Minima and Red Minima valleys are level and within 0.1% of each other.

If the color variation is great, and no change has been made to the system, check gas levels,

vacuum consistency and target material levels.

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

350 400 450 500 550 600 650 700

%R

Wavelength ( nm )

Autotune Peak 525nm

Blue Minima

Red Minima0.03 % R

Blue Minima0.02% R

Green Reflex

Peak Value

525nm

52525nm525nm



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Reference: Visible Light Spectrum

Preventative Maintenance

Your machine has been designed to minimize the daily maintenance associated with optical

coating. However, for best performance, smooth running and maximized up-time, it is essential

that the preventative maintenance checks are performed as documented in this manual

The following section describes routine maintenance processes, including weekly checks and

target changes. Note: It’s very important that the air compressor (or tank compressed air) be kept

on AT ALL TIMES, or serious malfunction may result.

Caution: Electrical Energy

The Plasma Source and Magnetrons operate at a high voltage and power must be isolated before

making contact to these components. Make sure the power has been turned off with the

Emergency shut-off or the Main breaker switch.

The MyCoat system contains high powered magnets. Do not expose these magnets to

medical devices – Radio Frequency (RF) and magnetic fields can interact with implantable

pacemakers and defibrillators, typically not with non-metallic catheters, etc. If in doubt, contact

your physician. Avoid exposure to cell phones, watches, credit or security cards, or any object

that may be sensitive to magnetic fields.



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MyCoat Warranty and Parts Information

Vision-Ease Lens strongly recommends the exclusive use of approved parts and lubricants within

the MyCoat system. Use of non-approved parts may void the system’s warranty. Vision-Ease

Lens cannot guarantee the quality of coatings deposited using non-approved parts, nor accept

responsibility for system errors and malfunctions caused by such parts and lubricants.

For a full list of approved repair part and lubricants, speak with your MyCoat service technician.

Important Weekly Maintenance Checks and Task List

To ensure proper operation of the MyCoat system, it is important to conduct routine weekly

maintenance. After any system maintenance – “Start-up” and “pump-down” the system back to

high vacuum as soon as possible.

Helpful Task List:

Daily Checks:

Inspect Surface Saver tape protecting rotor and rings; replace if flaking or damaged

Check Argon and Oxygen pressure and capacity

Chiller fluid level and temperature

Oil Level in rotary pump

Air Pressure – System and deionized (antistatic) air gun pressure

Run ‘Target Clean” cycle

Weekly Checks:

Shut down and vent coater

Clean targets, vacuum plasma source and chambers (upper and Loadlock)

Chiller fluid level and temperature

Check rotary pump oil level and color

Replace Surface Saver tape protecting rings and rotor

Inspect rotor for loose fasteners and tighten as needed

Inspect and Clean Loadlock seal and vacuum debris

Check supplies and order stock as needed

Quarterly Checks:

Oil change on Rotary Pump



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6 Month PM service by a MyCoat Technician

List of items to be determined by usage

System Display – Shut Down Screen

Vented Shutdown Process

To perform maintenance or replace targets, it is necessary to conduct a vented shutdown process.

This allows for easy access of the internal mechanisms of the MyCoat system. To perform a

vented shutdown:

1. From Select Coating, System Display or Magnetrons menus, select “Shut Down.”

2. Your options are now; Shut down–Seal Loadlock, Shut down-Vent Loadlock or Shut

down–Vent System.

3. Choose “Shut Down and Vent System.”

4. Once the MyCoat system is shut down and vented … the main screen will now say:

“What do you want to do? Start-up or Maintenance.”

5. Turn off the chiller system.

6. The MyCoat system is now vented and ready for maintenance.

Shutdown Under Vacuum Some maintenance procedures, including cleaning the external panels of the system, do not

require the system to be vented. In this case, it is highly recommended to conduct a shutdown

under vacuum sequence. To perform a sealed shut down:

1. From Select Coating, System Display or Magnetrons menus, select “Shut Down.”

2. Your options are now; Shut down–Seal Loadlock, Shut down-Vent Loadlock or Shut

down–Vent System.



- 34 -




3. Choose “Shut Down and Seal Loadlock” to keep the system under vacuum.

4. Once the MyCoat system is shut down and sealed … the main screen will now say:

“What do you want to do? Start-up or Maintenance.”

5. Turn off the chiller system.

6. Shut off air supply.

7. Close main supply valves for Argon and Oxygen tanks. Do not adjust regulator valves.

8. The MyCoat system is now properly sealed shutdown.

Checking Rotary Pump Fluid Levels and Color The rotary pump is located at the rear of the system and requires special oil in order to maintain

its pumping ability. It is important to check the oil level and color every week to avoid damage

to the pump, which can lead to loss of vacuum and other serious problems. Check by examining

the visible gauge located directly on the rotary pump itself. The oil level should be between the

lower and upper level marks as shown below. When the oil is new, it is light tan in appearance.

When the oil is old and should be replaced, it is brown (like the color of coffee) in appearance.

Every 168 hours, there is a prompt to the user to “check” rotary pump oil level and every

3000 hours there is a prompt to “change” the rotary pump oil.

The presence of overflow oil in the upper Mist filter may be an indication of a vacuum

issue. See photo below.

On the right hand back side of Mycoat, the Rotary pump oil gauge – always keep between Min

and Max. Oil in the Mist Filter – not critical to operation



- 35 -




Light Tan – OK - continue to monitor

Brown – Change oil immediately

Dark Brown/Black – Discontinue operation, overhaul

pump and change oil

Items Required for Cleaning Targets, Plasma Source and Chambers (upper and

Loadlock)

5/16” or 8 mm Door Key

5/32” Allen Key – for removing the grounding strap

Medium flat blade screwdriver

Isopropyl Alcohol

Paper towels

Nitrile gloves

Lint free clean room wipes

Apiezon Grease – for optional light coating of the high vacuum O-rings

Green Scotch-Brite Pads (must be non-ferrous due to system magnets)

Hepa filter vacuum cleaner

Cleaning of the Targets, Plasma Source and Chambers (Upper and Loadlock)

On a weekly basis, it’s extremely important that the Silicon and Zirconium targets be removed

for cleaning of debris; debris is a normal phenomenon for magnetron sputter coating. This

includes cleaning of the critical seal areas on the targets, chambers and the elevator/turn table

assembly where it matches up with the upper chamber during coating. Excessive debris can

create pinnacle hard arcs and affect AR and mirror coatings. During a hard arc, the coating can

be momentarily stopped, causing a variation in coating thickness and lens tint. The tint on both

the back-side (cc) and front-side (cx) should be green. Debris in any of the high vacuum sealing

areas can extend pump-down time during Start-up.



- 36 -




1. Shut-down and vent the system.

2. Once vented and the elevator is on the bottom, turn off MyCoat, using the red

(Emergency Off) button.

3. Turn off the chiller.

4. Remove the chiller red/blue snap connectors from each target.

5. Remove the ground hex lug bolts (5/32”).

6. Remove the pinnacle power plug – facing the front, clockwise rotation loosens.

7. Remove the three tightening knobs holding the target to the MyCoat.

Set all hardware off to the side in a tray, so it does not fall inside MyCoat.

Always wear Nitrile powder free gloves when handling the targets or touching

anything inside the chambers.

8. The targets may be slightly stuck to the MyCoat because of the extreme system high

vacuum, carefully jostle to release. Once loose, set to the side in a safe location, handle

side down.

9. Be positive not to mix-up the targets – the Silicon is on the left and the Zirconium is on

the right.

10. Vacuum the Silicon and Zirconium debris with a HEPA vacuum in the port liner and

mask area. Near the system port liners, ensure the high vacuum sealing O-ring is in place.

Carefully wipe with a lint free cloth and a little alcohol.

11. Carefully chip and scrape any semi-loose debris in the port liner and mask region. This is

best performed using a small screw driver, not a hammer. Be EXTREMELY careful of

the system high vacuum areas. Vacuum any additional debris.

12. Vacuum the loose debris particles on both targets, also being especially careful of the

system high vacuum areas. Watch for any significant scratches on the sealing ledge; if

present, use 3M Scotch Bright (green) to remove. If very deep, you may need to use 400

grit sandpaper to remove. Wipe all areas with clean lint-free cloth lightly and a little

alcohol

13. Vacuum the back Plasma Source for debris – inside the barrel and ledges.

14. While the targets are off the system, vacuum out the Loadlock chamber and rotor turn-

table and loading arm components. Pay special attention vacuuming the gear assembly on

top of the turn table.

15. Inspect the sealing area on the Loadlock door (O-ring) and where it matches on Mycoat.

Wipe clean with a lightly moistened alcohol lint-free cloth and a small amount of

Apiezon Grease, as needed.

16. The last item to clean is the upper seal area, where the elevator/turn-table assembly meet-

up with the upper chamber. Also use a clean lint-free cloth and a little alcohol. This seal

can only be reached via the Loadlock chamber. If any debris or contamination is on any

of the system high vacuum sealing areas, long pump-down times (during start-up) may be

encountered.

17. Once the port liner and target areas and targets are cleaned, carefully re-attach the cooler

components (red/blue snap-connectors & hose), pinnacle power cable, ground and the

attaching knobs. Do not over-tighten any of these components; especially after the

vacuum has been pulled, this makes removal very difficult.



- 37 -




18. Release the red (Emergency Off) button and start MyCoat - green button.

19. Turn on the chiller

20. “Start-up” the system and attentively watch for water leaks. NO water leaks are

acceptable. Wait for pump-down and start-up to complete.

21. After start-up, perform two (2) “Target Clean” cycles and a “Standard Green” warm-up

cycle. When completed, coat glass slide with “Standard Green” to be sent in to Vision-

Ease Lens, attention: MyCoat team for assessment (spectrometer measurement).

22. While you have the vacuum out, don’t forget to vacuum the air intake to the ATC-K3 or

Lytron Chillers and the air intake for the MyCoat pinnacle power supply (lower front

panel).

High vacuum chamber, showing all critical connections; chiller water flow (red/blue) snap

connectors, black mounting knobs, ground and pinnacle electrical connection.



- 38 -




All hardware removed from the Silicon target; the target is now ready to be removed.

Chiller water out (red)

Mounting Knobs (3)

Pinnacle Power Chiller water in (blue) Ground



- 39 -




Silicon target carefully removed from the MyCoat system, note flaking debris and the system

high vacuum sealing areas (including the O-ring).

All hardware removed from the Zirconium target; the target is now ready to be removed.



- 40 -




Zirconium target carefully removed from the MyCoat system, note flaking debris and the system

high vacuum sealing areas (including the O-ring).

Always wear power free Nitrile powder free gloves when cleaning the targets and touching

anything inside the chambers. Using a Scotch-Brite pad, carefully clean the outer circumference

of the pole piece of the target to minimize electrical arcing.

Target Wear Reference: Starting with the Silicon target Look carefully at the target surface. You

will notice two distinct areas; a race track midway between the center and the edge of the target

and a scarred area in the very center. The race track is the area that is eroded and shows a

geometric design influenced by the permanent magnets. No erosion occurs at the center but

rather some oxidized material will build up a bit in this area. The Silicon target also shows some

cracking. This is normal and is of no concern or consequence. Notice can be taken of the areas

where deposition has accumulated on the pole piece.



- 41 -




Critical sealing region on the target and Silicon debris on the target pole piece. Vacuum first

using the HEPA vacuum, clean with Scotch-Brite pad and then wipe with a clean lint-free cloth

lightly moistened with alcohol.



- 42 -




Vacuum the back Plasma Source – inside the barrel and ledges

Inspect the Loadlock sealing O-ring for damage and contamination-lightly grease as needed



- 43 -




Ensure the Loadlock sealing area on Mycoat is free from damage and contamination

Replace Tape on Lens Rings and Rotor On a regular basis, be sure to replace the surface saver tape on carrier lens rings. To do so,

simply remove the old tape and add new tape. Cut away any excess tape, using a straight edge

razor blade, making sure that tape does not hang over carrier when applied. Avoid air pockets or

bubbles in tape, and pierce vent holes located on the rotor.

Very dirty/heavy AR coated rotor and lens rings – new Surface Saver tape is blue



- 44 -




Peeling off the heavy coated Surface Saver tape – note the large amounts of Silicon and

Zirconium fragments/debris – this rotor and lens rings should have been re-taped long ago

After the Surface Saver tape is removed, blow off and then wipe clean with an alcohol

Moistened lint free cloth



- 45 -




Re-apply the Surface Saver tape and then carefully cut off the excess with a straight edge razor

blade

Re-apply the Surface Saver tape on the rotor sections and cut off the excess with a straight edge

razor blade. Note how a newly taped rotor and rings look



- 46 -




Caution: there are a number of permanent magnets in the rotor sections. A metal razor blade

from re-taping could accidently get stuck under a rotor and cause load/unloading issues in the

coater

Examine Deposition Cycle Times The time the system takes to run a deposition process can be a good indication of the quality of

the vacuum and the overall state of the coating system. Take note of abnormal run times, as these

can be a sign of internal issues or errors.

Reviewing run time statistics is as simple as taking note of how long it takes to run a cycle.

When to Change Targets Depending upon usage the first change of target materials may occur approximately at the 6

month preventative service visit. Some allowance can be made to shorten or extend the timing of

the service visit so that in addition to the normal 6 month preventative maintenance this

procedure can also be performed. This is an excellent opportunity to work with a trained MyCoat

technician and it is recommended that at this time hands on training can be given to technical

staff, primary supervisor, operator or all three.

Turning on Chiller

VERY IMPORTANT

With the help of a co-worker the chiller can be started and the system can be checked for any

cooling leaks. Have your helper look through the back door to watch for leaks at the

plasma source. They should look for any leakage at the connections, the center oxygen

opening, and the bottom of the Plasma Assembly.



- 47 -




On the front side the magnetrons should be examined for any leaks at the same time the

Plasma Source is checked by your helper. It is imperative to look for leaks under the

magnetron and around the seams. If anything is seen it is necessary to turn off the chiller

right away and investigate.

The chiller will need to be topped up with Deionized water as it is usually low after draining the

magnetrons. Verify appropriate pressure and temperature (17 degrees Celsius).

Start Up from Cold

VERY IMPORTANT

Follow the startup procedure for start-up from cold. As the chamber pulls a vacuum, it can cause

a bit of flexing of the newly placed assemblies. Again, inspect for any leakage in the same areas

as before.

Fuse Locations and Designations

Fuses are only to be changed by qualified service personnel

The Fuses are located in the High Voltage cabinet on the left side of the machine

Fuse designations are as follows:

o F1 20 amp, 600 VAC, Class CC, time-delay





o F6 .5 amp, 600 VAC, Class CC, time-delay





- 48 -




Images of the MyCoat System

Main high vacuum chamber and top frame

Right side of the main chamber



- 49 -




Left side of the main chamber

Inside the left side of the electrical panel (high voltage)



- 50 -




Inside of the right side of the electrical panel (low voltage)

Connections of Argon, Oxygen, Compressed air and Ethernet



- 51 -




Backside of the system with connections

Optional wireless communication hubs (antenna)


mycoat operating manual - visionease...1. argon 99.995% purity – regulated to 40 psi or 2.7 bar...

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