w2-d operations manual

8/12/2019 w2-d Operations Manual

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Operation Manual

WECO 2-D

Version: 08.97

Order-No.: 1090-9910-01


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Valued customer,

congratulations on the purchase of your W 2-D.

You are now the owner of a device that meets the expectations for the degree ofautomatization, precision and operator convenience expected in the modernoptical laboratory.

The W 2-D is complements and completes the WECO CMS system.

The manual helps the operator to use the device to its`fullest potential and tobenefit from the effectiveness and accuracy of the system. The manual containsinformation for the installation, tips and instruction to effectively operatethe W 2-D.

Our recommendation:

Please read this manual carefully.

WECO wishes you good luck and success with your new W 2-D.

W E C OOPTICAL MACHINERY


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Contents

1 Safety Guidelines ....................................................................................................................4

2 Warranty Conditions...............................................................................................................6

3 Description ..............................................................................................................................73.1 General Information .....................................................................................................................................................73.2 Technical data............................................................................................................................................................113.3 Equipment and Accessories ......................................................................................................................................15

4 Start up...................................................................................................................................174.1 Unpacking and Installation.........................................................................................................................................174.2 First test run...............................................................................................................................................................224.3 Connecting CMS-units...............................................................................................................................................234.4 Block-up System........................................................................................................................................................254.5 Moving the edger .......................................................................................................................................................29

5 Operation Procedures...........................................................................................................305.1 Systematic operating sequence with CAD 2000 (or CAD-e) .....................................................................................305.2 Lens lay-out with edger and MiniCAD (Order-no.: 1119-0800-00).............................................................................315.3 Centering with FormTracer and MiniCAD (Order-no.: 1119-0800-91).......................................................................485.3.1 Active lens lay-out (de-center the pattern) with the FormTracer 2D .......................................................................495.3.2 Passive decentration (De-centering the lens) with MiniCAD ..................................................................................515.4 Roughing procedure (all bevel types) with patterns...................................................................................................535.5 Roughing procedure (all bevel types) patternless operation......................................................................................555.6 Free-float bevel..........................................................................................................................................................575.7 Guided bevel edging............................. .....................................................................................................................585.8 Flat bevel ...................................................................................................................................................................605.9 Operating Procedure to re-edge a bevelled lens .......................................................................................................625.10 Edging with cycle pause ..........................................................................................................................................63

5.11 Lens-fitting foil..........................................................................................................................................................645.12 Plastic lens polishing ...............................................................................................................................................655.13 Polycarbonate lenses...............................................................................................................................................665.14 Keyboard programming............................................................................................................................................665.15 Calling-up a job with a bar-code reader (option)......................................................................................................695.16 Special Cases..........................................................................................................................................................70

6 Maintenance ..........................................................................................................................726.1 Care of the edger.......................................................................................................................................................726.2 Grinding wheel care...................................................................................................................................................746.3 Replacing WECO grinding wheels.............................................................................................................................776.4 Cleaning the coolant re-circulation system ................................................................................................................806.5 Maintenance Intervals................................................................................................................................................81

7 Checking Procedures ...........................................................................................................827.1 Reading the lens counters .........................................................................................................................................827.2 Adjustment of rough and finish size...........................................................................................................................847.3 Fine mechanical axis adjustment (Pattern adapter)...................................................................................................88

8 Trouble Shooting...................................................................................................................908.1 Minor Problems..........................................................................................................................................................908.2 Electric Fuses ............................................................................................................................................................918.3 Error messages..........................................................................................................................................................92


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1 Safety GuidelinesPlease read the machine operating manual carefully before putting the machineinto operation.

Tips and Caution messages are printed in shaded areas for easy recognition

CAUTION Points to a wrong operating procedure which may lead todamage of the edger or to injury to the operator.

TIP Points to a special feature or to a convenient operatingprocedure.

Please note that the machine is connection to an electrical power outlet withthe same voltage as indicated on the machine identification plate. The edgermust properly grounded according to local electrical safety standards. Nevercut or bend the ground pin of the power cord plug denying the machineproper grounding. Never use a plug adapter which bypasses the groundinglead of the power cable

Please never tamper with the electrical wiring and its connections of theedger or its accessories (coolant tank). Any change will impair the electricalprotection features.

Defective fuses may not be repaired or bridged but MUST be replaced with

fuses of the same value and type. Before cleaning and maintenance to the edger switch the power OFF. After replacing the grinding wheels always check that the screws are properly

tightened. Never switch the edger on during a cleaning or servicing operation. Be aware that ingesting of some medicines impair vision and reaction

capability which may cause machine operator error. Always observe the safety and health regulations of the workshop. For increased protection against electrical shock it is recommended to use an

electrical outlet with a ground protection breaker for the edger and ancillarydevices.

Specific Purpose

This machine is built for the exclusive use as an ophthalmic lens edger.

Other objects such as hand tools etc. may under NO circumstances beground or sharpened with the grinding wheels.

Never operate the edger in areas where there is danger that water or other

liquids may enter the electrical compartment of the machine. The edger must always be placed on a solid surface with a base strong

enough to support its weight. This to prevent damage to the edger and toprevent the machine from tipping over possibly causing injury.

The air flow slots in the edger are for ventilation so the machine will run at the

correct operating temperature.

The connection cables must be laid in a protected area to prevent operators fromtripping over the cables.


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Do not attempt to open the edger or to repair it yourself. There is always thedanger of short circuits and electrical shock with danger to personal safety.

Do not operate the edger with the lid of grinding chamber open. Small flying

particles may cause injury to the eyes or skin.During the following instances the edger must be unplugged and shall not

be used until the necessary repairs have been completed;

Plug o power cable defective Liquid has entered the electrical compartment of the edger Despite correct following of instructions the machine does not perform as

designed Damage to the housing in case the edger was dropped. During obvious deviations from normal operation.

In addition to the instructions in this operating manual is it advisable to

observe the generally observed accident prevention recommendations.


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2 Warranty ConditionsAutomatic edgersWECO extends to the original machine owner a warranty for its products andservices in accordance with our specifications against defects in materials andworkmanship which are not the result of an incorrect operating procedure. The,

to WECO returned products, which do not prove to be defective are consideredto be test items for which a charge will be made in addition to the costassociated with the testing plus the transportation costs.

The purchaser is not entitled entitled to make any other claims as a result ofdefects in the products, specifically regarding the cancellation of contracts orcontractual or non-contractual claims for damage. See below for warranty period.

WECO shall not be liable for defects in material that were not visible during themanufacturing process. Unauthorised changes or changes made byunauthorised personnel will void the warranty. The use of accessories,replacement parts as well as grinding wheels (diamond wheels) andconsumables which have not been approved by WECO will void the warranty.

WECO shall under no circumstances be liable to the purchaser in respect todamage or loss of any kind as a result of the use of WECO machinery, devices,grinding wheels and software.

The warranty period is not extended if during the warranty period a repair isdone.

WECO guarantees the automatic edger for a period of 12 months from the timeof installation, if the machine is used in accordance with the guidelines asdescribed in the operating manual for an average use 8 hours on working days.

Electrical ConnectionThe operator is responsible that the edger is connected to an electrical outlet

with the correct voltage for the machine and all utility requirements are met for asafe operation.For the safety of the operator the edger must be connected to a with a circuitbreaker protected outlet.

Transportation Damage

Transportation damage is not covered by the WECO warranty.Thus: The machine delivery is made at the consignees risk. Transportation damage must be reported immediately to the transportation

company. Damage compensation claims must be made to the transportation company

by the consignee. In all cases the products must be left in the packing and in the condition in

which the shipment was received until an authorised representative of thetransportation company has examined the shipment


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3 Description3.1 General Information

1. ApplicationThe purpose of an automatic lens edging machine lies in its task to edgelenses precisely, according to specific lens lay-out instructions, in such a waythat these lenses can be mounted into an ophthalmic eyeglass frame..

2. Lens typesWith the C-91 automatic lens edger are we dealing with a machine capable ofprocessing glass as well as plastic (CR-39) lenses The grinding of lenses isdone wet The removed lens material is flushed from the grinding chamberwith the coolant flow and settles at the bottom of the coolant tank.

3. Diamond grinding wheelsThe automatic lens edger is fitted with highly precise WECO grinding wheelsand selectively with a WECO Speed-Wheel roughing wheel which noticeablyshortens the rough grinding time of plastic lenses

4. Control unit

The operating process is fully automatic and can be interrupted at any time bypressing the red STOP key. After pressing the STOP key the WECOgrinding wheel assembly immediately separates from the lens.The WECO-CNC control unit together with the stored lens shape data createa true lens shape.. Depending on the type of edger, lens edging with a patternis also possible.5. Safety regulationsThe automatic edger meets all general safety regulations and is CE and FCCcertified.

6. This operating manual is applicable for:W 2-D 1090-XXXX

The presence of a FormTracer with a W 2-D edger is a minimum requirementto make a complete lens edging cycle with tracing, lens lay-out, blocking andedging possible. The use of a computerised lens centering / blocking devicee.g. a CAD2000 is recommended.The W 2-D can be operated without additional peripheral devices, however aconventional lens lay-out / blocking device can be used. The W 2-D automaticedger can be upgraded to patternless operation, at any time, with existingWECO-CNC-computerised devices.For further information contact your WECO product adviser.


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(1) Operating panel(1) Grinding chamber lid

(1) Mechanical bevel controller(1) Lens fitting-foil cutter (Option)


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(5) Lens clamp plunger(5) CL port(5) ESS (dedicated connected) port(5) Spare(5) Power cable socket(5) ON / OFF switch

(5) Fuses(5) Pump power cable socket(5) Transportation safety bolt(5) Machine I. D. shield(5) Bar-code reader connection port


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(16) Job number display(16) " Polycarbonate " key (Option)(16) Left lens key(16) Glass / Plastic selector key(16) Right" lens key(16) Size indicator(16) " NEW JOB " key(16) # function key(16) " WECO " key(16) Grinding wheel front!back positioning keys(16) Grinding wheel right!left positioning keys(16) Lens rotation key(16) " START " key

(16) " STOP " key(16) " BREAK " key(16) " Step edging / Continuous edging "(16) " FINISH " key (Re-edging)(16) " Flat-bevel selector key(16) " Polish key (Option)(16) " guided V-bevel" key(16) " Free- floating V-bevel key(16) Pattern key(16) " C " (clear entry) key(16) " ENTER " (confirm entry) key(16) Number pad


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3.2 Technical data

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Voltage

Information on machine ID plate (14)

The voltage: 230 V / 50 Hz; 115 V / 60 Hz other voltages upon request.

W 2-D (Type 1090)

Voltage Cycle Nominal rating

230 V 50/60 Hz 6,9 A115 V 60 Hz 13,6 A100 V 60 Hz 13,7 A100 V 50 Hz 14,5 A

Nominal power consumption WECO coolant recirculation system 140 W.

Main motor rating: 550 W

11

Fuses (11)

T4AT4A PumpT15 A Main fuse (USA)T15 A Main fuse (Europe)

TIP

T = slow blow fuse mT = medium slow blow fuse A dedicated electrical circuit for the edger is recommended.

See guarantee conditions: Power hook-up.

Measurements and Weights

Edger:

Width: 450 mmDepth: 420 mmHeight: 470 mmWeight: 50 kg

Coolant recirculation system:

Width: 320 mmDepth: 430 mmHeight: 280 mmWeight: 6 kg (without coolant)


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Sound level

Device: W 2-D

Measuring device: Brel & Kjaer Type 2233

Standard: dB/A

Measuring horizontal distance = 1mConditions: vertical distance = 1,15 m

Rough edging: Glass = 74/78 dB/APhotochromic glass = 75/80 dB/ACR 39 = 68/70 dB/AHi Index = 69/72 dB/APolycarbonate = 75/78 dB/A

Finish edging: Glass = 62/65 dB/APhotochromic glass = 62/67 dB/ACR 39 = 59/60 dB/AHi Index = 59/60 dB/A

Polycarbonate = 67/71 dB/A

Equipment

Control unit: WECO CNC

Lens clamping: electric motor, pneumatic (option)

Wheel release: automatic

Edging program: fully automatic with memory function

Bevel controller: free floating V-bevel or mechanical bevel curvecontrol.

Lens size setting: digital size sett ing and quick size change keys

Edging pressure: - constant on the W 2-D- automatically adjusted on the W 2-D, independent of the lens size, reduced pressure when processing CR-39


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abe

WECO Grinding wheel combinations

TIP Grinding wheel diameter 110 mm

Three wheel combination with Special-V / flat bevel wheel (Standard)

a - Roughing wheel (glass)b - Speed-wheel roughing wheel for plastic lens materials and / or

polycarbonate (option).e - Special-V - / Flat bevel wheel

abcd

Four wheel combination (Standard)

a - Roughing wheel (glass)

b - Speed-Wheel"-roughing wheel for plastic lenses and / or polycarbonate (option)

c - Special-V-bevel wheeld - Flat- / micro bevel wheel combination

Lens sizes (valid for flat bevels)

largest lens: = 90 mmsmallest lens:- Lens depth: = 21 mm

Lens sizes (valid for V-bevels)

largest lens: = 90 mmsmallest lens: = 23 mm

Lens materials

- Glass- CR 39 and Hi-Index plastic lens materials- Polycarbonate(Optional)


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EC-Conformity Declaration

according to the EC guide line for machinery 89/392/EWG, App. II A last revision by RL 93/68/EWG

Name of the manufacturer Wernicke & Co. GmbHAddress of the manufacturers: Jgerstrasse 58 - D-40231 Dsseldorf

We hereby declare, that the product

Product description: Lens edge grinding machine

Type: W 2-D

Product identification: 1090

meets the following guide lines:

EC-Machinery guide line 89/392/EWG - App. 1 last revised by:RL 93/68/EWG

Test site: TV - RheinlandSicherheits und Umweltschutz GmbHCertificate No. 941115701

EC-low voltage guide line 73/23/EWGEC-electro magnetic radiation acceptability 89/336/EWG

Applied harmonising standardsin particular EN 6020-1/11.85

EN 50081-1:1992pr EN 50082-2:1992

Applied national technical specif icationsin particular DIN VDE 0160/05.88

DIN VDE 0113 part 1/02.86DIN VDE 1000/03.79

For the correct operation of the machine follow the tips and instructions in the operating manual.With changes made to the machine, other than those approved by WECO, this declaration loses its validity.

Dsseldorf, 25.10.1995

.........................................Quality Assurance


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3.3 Equipment and Accessories

1. Standard Accessories

No. Description Quant. Order-No.

1 O-Ring 70x7 1 3102-04582 Allen key, 6,0 mm 1 3801-03073 Allen key, 1,5 mm 1 3801-0301

4 Allen key, 2,0 mm 1 3801-03025 Allen key, 2,5 mm 1 3801-03036 Allen key, 3,0 mm 1 3801-03047 Allen key, 4,0 mm 1 3801-03058 Allen key, 5,0 mm 3801-03069 Spanner, 17/13 mm 1 3801-010310 Spanner, 13/10 mm 1 3801-010211 Spanner, 8/10 mm 1 3801-010612 Screw driver 1 5910-300913 Fuses, 220-240 V, T 4A 2 3566-024414 Fuses 220 V, T 5A 1 3566-024515 Universal adapter, large 1 2001-105616 Universal adapter, small 1 2001-1066

17 Slip-on sleeve, large 1 2001-321418 Slip-on sleeve, small 1 2001-322419 Back-up ring, large 1 2001-320420 Backup ring, small 1 2001-320521 Gear clamp 20 SP 12-20 1 3583-020122 Starblock large white (12 pieces) 1 2001-322323 Starblock small, white (6 pieces) 1 2001-322424 Block-up pads (20 pieces) 1 5020-300125 Dressing stick, white 2 5997-300726 Dressing stick, green 1 5997-300327 Dressing stick (disk) red 1 5997-300928 Coolant supply hose 1 3651-011029 Coolant drain hose 1 3651-012530 Coolant flow control valve 1 1090-1182

2. Optional accessories

Coolant system with disposal filter for CR 39 andglass

1075-0030

Coolant system recirculation pump 1075-0001 NESolenoid valve for direct water hook-up 1018-1021Half-eye-Set 2001-1011WECO Coolant additive with de-foamer 5998-3027WECO plastic bag for coolant system 5999-1008Bar-code labels 2012-3001

WECO Block-paddy 1088-0050Uncut lens fitting foils 2005-1003Accessories to process polycarbonate lenses 1090-1390


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4 Start up4.1 Unpacking and Installation

a

b

c

1. Unpacking the edger

Cut the strapping (a), remove the adhesive tape and the staples.

After opening the box remove the carton liner (b).

Lift the edger with two people from the box, using the carrying straps onthe plywood shipping board (c).

CAUTION

Do NOT lift the edger by its housing.

Tip the edger including the shipping board and lay it carefully on its back

on a soft surface. Remove the four bolts from the shipping board while supporting the

edger.

The four leveling feet stay in the edger base.

2. Preparing machine table

CAUTION

Install the edger always on a stable and vibration free stand or bench.

If no WECO-machine table is available, a solid work bench with a plasticlaminate top will do.

Provide for adequate space under the bench for the coolant re-circulation

tank. No benches with drawers and pay attention to cross supports under

the bench top which could prevent easy passage of the coolant hoses. Transfer the sizes and the locations of the holes for the hoses to the

bench top.

Drill the holes for the drain hose (b) and the coolant supply hose (a)


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3. Removing the transportation safety bolt

Place the edger in its prepared place.CAUTION

Do NOT yet the plug in the edger. If the edger is switched ON, with thesafety bolt still in place, damage to the edger WILL occur.

Remove the cover (13) from the tapped hole of the transportation safetybolt.

Remove the transportation safety bolt (13) with an Allen wrench.

Replace the cover.

TIP

When moving the edger the grinding wheel assembly must always besecured in place with the transportation safety bolt. This precaution alsoapplies when moving the edger inside the lab.

The transportation safety bolt (13) is stored by turning the bolt in thetapped hole in the front side of the automatic edger.

Loosen the thumbscrew (A) and remove the transportation bracket (B)(only on W 2-D edgers).

Install the 40 mm ( C ) idler pattern and secure firmly with thethumbscrew ( A ).


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ba

cdef

g

hi

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4. Installing the coolant re-circulation system

Components of the coolant re-circulation system

(a) electric pump(b) plastic bag(c) coolant tank(d) tank lid with pump

(e) quick connect(f) supply tube(g) barbed hose nipple(h) water valve(i) drain tube(k) drain reducer(l) electrical plug-in

TIP

The electric pump (a is automatically switched on by the control unit oftheedger at the start of the edging cycle.

Place the plastic bag (b) in the coolant tank (c). Wrap the bag over therim of the tank. Fill the coolant tank (c) to about 3 cm (1 1/4) from the edge with water. Add about 150 ccm (1 cup) WECO coolant additive Place the lid with the pump on the tank. Push the male end (e) of the quick connect in the coolant supply hose (f) Connect the quick connect (e) Slide back the slip ring, Insert the male end with the hose, Release the

slip ring, Connector locks in place. Slide the coolant supply hose (3) over the barbed hose nipple (g). Insert the water valve (h) in the middle of the coolant supply hose (f).

CAUTION The coolant must freely flow back to the tank. If necessary shorten the

drain hose.

Fasten the drain hose (i) to the drain hose reducer (k) and push the drainreducer onto the edger.

Secure the coolant supply hose (g) with the gear clamp. Guide the pump power cord from the top through the hole in the bench. insert the pump cable in the socket in the lid of the coolant tank.Lock the safety clip of the plug socket.

TIP

In exceptional cases the edger can also be connected directly to a watersupply line.

With this application a solenoid valve (optional accessory) with apressure reducer is recommended (Installed by a plumber).

The solenoid is connected as a coolant re-circulation system. Consult with local authorities regarding the disposal of lens grinding

waste materials.

To prevent contamination of the water drain pipes a separate drain with aplaster waste trap is highly recommended.

Because of the very high water usage this type of connection is, with

concern for the environment, NOT recommended.


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For the sake of environment!

WECO has a device in its product line which meets the requirements of themodern optical shop operation in connection with an environmentallyresponsible disposal of lens grinding waste as well as protecting the lenssurface quality against scratches during lens edging.

The WECO pressure filter coolant re-circulation system supplements the

WECO CMS and as a result makes the system more complete. The WECOpressure filter coolant re-circulation system is especially developed for use inthe optical lab. and distinguishes itself in particular for the following reasons:

effective filtering with a waste separation rate of 99.9% preventing lenssurface damage by friction of lens material particles.

Compact, fits in any commercially available machine. System independent, may be connected to any other brand of automatic

edger.

Easy to maintain. The filtering cartridge can be replaced without spillinglens grinding waste.

The WECO pressure filter coolant re-circulation system can be orderedunder product number1121-1001.00. For further information contact yourWECO representative.


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A B

5. Leveling the edger

CAUTION

Careful leveling the edger in both directions is a primary condition toachieve perfect lens edging results.

Adjust the four leveling feet in such a way that the edger stands level inthe B and A direction.

B With the edger switched OFF the grinding wheel assembly may NOTslide to one side or the other by itself. The machine needs to be leveledin the B direction so that the wheel assembly stays in any position.


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4.2 First test run

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CAUTION

Before lens edging is switched ON make sure that the transportation safetybolt for the grinding wheel assembly has been removed.

If necessary, remove the bolt. For instructions see par. Unpacking andInstallation.

Starting the automatic edger

Switch the edger ON (10).After the edger has completed its self-check, the size display reads " 040.0".

Clamping a lens, also see par. Block-up System

28

Press the "START" (28) key.The edging program completes automatically.Check coolant supply and drain hoses for leaks.

CAUTION

Switch the edger OFF immediately if it is not working as expected.

Risk of injury:Never put your hands into the grinding chamber while thegrinding wheels are still turning.

a If necessary, adjust the position of the coolant nozzles (a) after thediamond wheels stop turning.


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4.3 Connecting CMS-unitsPlace the CMS-units in-line with the work flow of the optical workshop.

Place all CMS-units in such a way that they can be operated conveniently.

The number of CMS units which can be connected together depends on thesystem manager / memory card:

memory card SM 20: 3 unitsmemory card SM 100: 3 unitsmemory card SM 200: 5 units

When operating more than 3 CMS-units changes in the factory addresssetting will be necessary. In this case ask WECO After-Sales Service forassistance.

In case a personal computer with the OPTOLAB IV program (or othersoftware) is used, the number of units that can be connected hardly has alimit.

The mini-CAD centering / b locking device is not counted as a CMS-unit as it

does not require a separate address.

When a SM memory card is used all CMS-units can be operated by more thanone person simultaneously (multitasking function).

The CMS-units can be set-up in any order you like depending on the availablespace and the work flow of the workshop; the following presentation is just anexample.

Connect WECO CMS-units according to the diagram to the "CL" ports.

CAUTION

Do NOTlink the first CMS-unit with the last one.

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Secure the connectors with screws (a) to the ports.


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Communication Check

Switch ON all the units. Trace a lens shape with the FormTracer. Call-up the shape at the CAD-e or CAD2000 and at the W 2-D edger.

After a successful installation the shape will be visible on the LCD screen of

the CAD and the W 2-D edger will grind a true shape and exact size lens.

TIP

Information messages will appear in case data communication is interferedwith. see paragraph Error Messages.

b

6

Installation of a mini-CAD (Order-No. 1119-0800.91)

Connect the mini-CAD with plug (b) to the for mini-CAD port (6) on theW 2-D and secure the connector with the screws.


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4.4 Block-up System

a b c ed f

WECO Block-up system

(a) Starblock adapter(a) Starblock(a) Blocking pad(a) Lens(a) Clamping pad(a) Swivel adapter

Clamping elements

Large lens clamping adapters for most common frames.

Smallest possible lens diameters with large clamping elements:Lens size with V-bevels: 28 mmLens size with flat bevels: 27mm

Large clamping elements for half eyes and childrens frames.

Smallest possible lens diameters with small clamping elements:

Lens size with V-bevels: 23 mmLens size with flat bevels: 21 mm

CAUTION

Neveruse a large STARblock adapter together with a small swivel joint (orvice versa) as this may result in lens breakage or lens surface damage.

f1 f2

WECO Swivel joints

Swivel joint, large (f2)

Swivel joint, small (f1)

Swivel joints automatically follow the angle of the back curve of the lens givingbetter support to the back-up ring.


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e1 e2

WECO Clamping pad

Clamping pad, large (e2)

Clamping pad, small (e1)

Before clamping, the clamping pads must be placed in the matching swiveljoint. The notches in the adapter must lock into the clamping pad.

WECO clamping pads are covered with a specially impregnated leather layerto provide maximum protection against surface damage and lens slippage.

TIP

Always keep the clamping pads wet. Clamping pads are wear partsand need to be replaced from time to time.

a1 a2

WECO STARblock adapters

STARblock adapter, large (a2)

STARblock adapter, small (a1)

The teeth of the STARblock adapter of the WECO Block-up system offermaximum protection against off axis and lens slippage problems. The pinaligns the block and assures the operator that the lens is clamped correctly.

c b1

WECO Blocking pads

WECO blocking pads (c) give certainty that the lenses are held firmly withoutslippage. The blocking pads are cleanly removed from the lens and Starblock.

WECO Optical Machinery ONLY recommends to use of WECO blocking pads.If blocking components other than WECO recommended products are used,the performance of the CMS-system cannot be guaranteed.

TIP

Starblocks and lenses must be dry and free from dust and grease. Blocking pads are designed to be used only once. When working with small Starblocks the blocking pads may have to be cut

to the correct size. Blocking pads must be stored away from heat.


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b2 b1

WECO STARblocks

STARblocks, large (b1)

STARblocks, small (b2)

WECO STARblocks are made with a soft material that will conform to the frontcurve of the lens. The teeth protect against lens slippage and breakage. The

alignment hole together with the alignment pin in the STARblock adapterassure the operator that the lens is clamped correctly.

TIP

WECO Starblocks are wearparts and have to be replaced from time totime.

Before lens blocking, the STARblocks must be clean and dry.

WECO Block-Paddy (optional) Order Number 1088-0050

With the WECO Block-Paddy lenses can be de-blocked safely and easily.

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Lens clamping

Lift the grinding chamber cover (2).

Pull the lens clamp slide (5) to the right and hold it.

A B

Slide the swivel joint with the appropriate clamping pad onto the right lensdrive shaft.

Place the corresponding STARblock adapter on the left lens drive shaft.

NOTE

The ridge (arrow) on the STARblock adapter must face to the front. The driver pins in the lens drive shaft must seat securely in the notches of

the swivel joint and of the STARblock adapter. Dailyclean the STARblock adapters and the swivel joints. Lightly grease

the lens drive shafts. This will make adapter changes easier.


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Place the blocked-up lens in the STARblock adapter.

CAUTION

The teeth must lock exactly. The alignment pin of the STARblock adapter must fit exactly into the hole

in the STARblock.

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Release lens clamp slide (5).

Close the grinding chamber cover (2).

NOTE

The actual clamping pressure is provided electrically at the beginning ofthe edging program.


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4.5 Moving the edger

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NOTE

Always make sure that the transportation safety bolt is in place wheneverthe edger is moved, even if it is only moved within the workshop.

Remove transportation safety bolt (13) from the threaded hole on the frontof the edger.

13

Remove cover on the right side of the edger.

Switch the edger on.

Move the grinding wheel assembly as much to the front as possible by

pressing the down arrow key (25) ".

Switch the edger OFF.

Pull the power cord

Push the grinding wheels as far back, by hand, as possible and hold it untilthe transportation safety bolt can be pushed in.

CAUTION

Do not reach into the grinding chamber as long as the grinding wheels arestill turning.

Screw in the transportation safety bolt (13) by moving the diamond wheelunit.

Remove all cable and hose connections.

Tip the edger backwards and remove drain reducer from the bottom.

Put cover for the transportation safety bolt back in place.


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5 Operation Procedures5.1 Systematic operating sequence with CAD 2000 (or CAD-e)

Enter a job number at the FormTracer.

Trace an eyeglass frame.

Enter the job number in the lens lay-out blocker e.g. CAD 2000. Enter the lens lay-out data.

Block the lenses with WECO STARblocks and blocking pads.

TIP

The WECO Block-up System guarantees the optimum performance of

each of the individual CMS system components.

Enter the job number at the W 2-D edger.

Edge the lenses.

De-block the lenses with the WECO Block-Paddy.

Safety bevel the lenses with the WECO 590 hand edger.

TIP

The operating sequence may vary according to the different machinetypes.


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5.2 Lens lay-out with edger and MiniCAD (Order-no.: 1119-0800-00)

1. In general

MiniCad and Centering Modul are optional parts and not included in thestandard equipement.

With edgers two different lens lay-out methods can be selected. These twomethods are basically different.

Please read the following paragraph of the instructions carefully and thenedge a pair of test lenses.

ATTENTION

Always use only ONE of the two lens lay-out methods. Decenter either thelens OR the pattern but never both, otherwise the eyeglasses will not becorrect.

2. Lens lay-out procedure lens decentration (passive)

This procedure is suitable for all Rx work.

The lens is decentered.

The Starblock is placed in the geometrical centre of the lens shape

The edged lens when the procedure lens decentration is used.


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3. Lens lay-out procedure pattern decentration (active)

This procedure is suitable for all regular Rx work, in particular for heavy pluslenses and Superlenti lenses.

This procedure is notsuitable for half-eyes and for Rx work whereby theStarblock comes too close to the edge of the lens. The block position ischecked by the lay-out program and a corresponding warning message is

issued.

The pattern is decentered

With single vision lenses the Starblock is placed in the optical centre of thelens, with multifocal lenses the location of the Starblock is determined bythe values of e and t (nominal optical centre)

The edged lens when the procedure pattern decentration is used

4. Operating procedure overview

Enter the lens lay-out data at the keypad of the ZET-90 Select the lens lay-out method at the end of the data entry The shape and centration point is displayed on the screen of the miniCAD Align the uncut lens on the miniCAD Verify lens cut-out of the uncut lens size on the screen of the miniCAD Block-up the lens with the miniCAD

TIP

The data entry can be cancelled or reverted to the previous data entry fieldwith the < C > (38) key

5. Factory set lens lay-out menus

Select the lens lay-out menu for single vision and progressive lenses(Factory setting) by pressing the "+/-" key (40) on the keypad

pr/ pl Monocular PD (Distance)y'r/ y'l Height to the lens edge at the PD (Z)b DBL


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Select the lens lay-out menu for multifocal lenses (Factory setting) bypressing the "+/-" key (40) TWICE on the keypad

pr/ pl Monocular PD (Distance)h'r/ h'l Segment height to the lens edge at the PD (ZFb DBLb' Segment widthe Segment inset

t Distance top of segment to optical centre


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6. For additional lens lay-out menus (Ask WECO After Sales Service)

Single vision and progressive add lenses

ur/ ul Horizontal decentration from the geometrical centrevr/ vl Vertical decentration from the geometrical centre

Decentration IN and UP have plus values.Decentration OUT and DOWN have minus values

pr/ pl Monocular PD (Distance)yr/ yl OC (Z) height (box measurement)b DBL

Multifocal lenses

pr/ pl Monocular PD (distance)hr/ hl Segment height (box measurement)b DBLb' Segment widthe Segment inset (difference between distance-,and near-PD)t Segment drop from optical centre (ZFto the top of segment)

qr/ ql Monocular PD (near)hr/ hl Segment height (box measurement)b DBLb' Segment widthe Segment inset (difference between distance-, and near PD)t Segment drop from optical centre (ZFto the top of segment)


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qr/ ql Monocular PD (near)h'r/ h'l Segment height to the lens edge at the PD ZFb DBLb' Segment widthe Segment inset (difference between the distance- and near PD)t Segment drop from optical centre (ZFto the top of segment)


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7. Single vision lens lay-out procedure decenter the lens (example)

Lens lay-out menus for single vision lenses are identified with one bar (seearrow) in the LED display

Press the key

Read-out

Enter the monocular PD

Read-out

Press the < ENTER > key

Read-out

Enter the height of the optical centre as measured from the lensedge atthe

(Without data entry optical centre on the 180 line) Read-out


Read-out

Enter DBL (without data entry the bridge size as measurement by theFormTracer will be used, if the feature is activated

Read-out

Press the key


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Read-out

Select the lens lay-out method:

"Decenter the lens": Enter "1" Default setting

"Decenter the pattern": Enter "0"


Read-out on the miniCAD LCD monitor

Place the uncut lens on the lens supports (a)

Insert the Starblock with a blocking pad into the adapter (b)

Look through the eyepiece (e) and align the optical centre of the uncut lenswith the dotted cross

Align the lens and verify if the lens will cut-out (Arrow)


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Press down the blocking arm (d)

Press down on the block adapter knob (c), while holding the lens in placewith the other hand

Press the < L > key on the edger and repeat the procedure for the left lens.

TIP

The lens lay-out data are transferred for the left lens. New lens lay-outdata only need to be entered when the PD, the height of the optical centre,fitting cross or the seg. height differs from the right lens


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8. Multifocal lens lay-out procedure decenter the lens (example)

Multifocal lens lay-out menus are identified with the two vertical bars(arrow) in the LED screen

TIP

With the < +/- > key this entry field can be toggled back and forth betweenthe single vision and multifocal lay-out menus

Press the key 2x

Read-out


Read-out


Read-out

Enter the seg. height, as measured from the lens edge below the opticalcentre (thus not the middle of the segment.

Read-out


Read-out

Enter the DBL value (without data entry the bridge size as measurement bythe FormTracer will be used, if the feature is activated)

Read-out



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Read-out

Enter the segment width

Read-out


Read-out

Press the < ENTER > key(Accepts the default reading seg. inset)

Read-out

Press the < ENTER > key(Accepts the default value)

Read-out



"Decenter the pattern Enter "0"


miniCAD LCD monitor read-out


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Insert the Starblock with the blocking pad in the adapter (b)

Look through the eyepiece (e) and align the reading segment with thesegment locating / alignment lines

Align the reading segment of the uncut lens with the segment locating /alignment lines (arrow) and verify if the lens will cut-out (arrow)


Press down on the block adapter knob (c), while holding the lens in place

with the other hand

Press the < L > key on the edger and repeat the procedure for the left lens

TIP

The lens lay-out data are transferred for the left lens. New lens lay-outdata only need to be entered when the PD, the height of the optical centre,fitting cross or the seg. height differs from the right lens


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9. Single vision lens lay-out procedure decenter the pattern (example)

Single lens lay-out menus are identified with the one vertical bar (arrow) inthe LED screen

Press the key

Read-out


Read-out


Read-out

Enter the seg. height as measured from the lens edge at the PD

Read-out


Read-out

Enter the DBL value (Without this data entry the by the FormTracermeasured DBL value will be used, if the feature is activated).

Read-out



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Read-out.



"Decenter the pattern": Enter "0"


miniCAD LCD monitor read-out


Insert the Starblock with the blocking pad in the adapter (b)

Look through the eyepiece (e) and align the optical centre of the uncut lenswith the dotted cross

Align the lens and verify if the lens will cut-out (arrow)


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Press down on the block adapter knob (c), while holding the lens in placewith the other hand

Edge the right lens, if necessary, re-edge immediately

Press the < L > key on the edger and repeat the edging process for the leftlens

TIP

The lens lay-out data are transferred for the left lens. New lens lay-out dataonly need to be entered when the PD, the height of the optical centre, fittingcross or the seg. height differs from the right


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10. Multifocal lens lay-out procedure decenter the pattern (example)

Multifocal lens lay-out menus are identified with the two vertical bars(arrow) in the LED screen

TIP

With the < +/- > key this entry field can be toggled back and forth betweenthe single vision and multifocal lay-out menus

Press the key 2x

Read-out


Read-out


Read-out

Enter the seg. height, as measured from the lens edge below the opticalcentre (thus not the middle of the segment

Read-out


Read-out

Enter the DBL value (Without this data entry the by the FormTracermeasured DBL value will be used, if the feature is activated)

Read-out



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5.3 Lens lay-out with FormTracer and MiniCAD (Order-no.: 1119-0800-91)

FormTracer and MiniCAD are optional and not included in standardequipement.

Enter a job number at the FormTracer.

Enter the lens decentration data (Also consult the FormTracer OperatingManual).

Trace the eyeglass frame.

Align the uncut lens.

Block the lens with WECO STARblocks and Blocking pads.

TIP

The WECO Block-up System guarantees the optimum performance of

each of the individual CMS system components.

Enter the job number at the W 2-D edger.

Edge the lenses.

De-block the lenses with the WECO Block-Paddy.

Safety bevel the lenses with the WECO 590 hand edger.

TIP

The operating sequence may vary according to the different machinetypes.


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5.3.1 Active lens lay-out (de-center the pattern) with the FormTracer 2D

1. Procedure overview

Clamp-in a frame and enter the lens lay-out data via the FormTracer 2Dkeypad. Start the tracing cycle (also see the FormTracer 2D OperatingManual).

Enter a job number e.g. 12 at the FormTracer and confirm by pressing 2 x the "ENTER" key. Press "+/-" key at the FormTracer. Enter the "u" value e.g. 2 and confirm with the "ENTER" key. Enter the "v" value e.g. 1,5 and confirm with the "ENTER" key. Align the uncut lens on the mini-CAD screen. Check if the uncut lens is large enough for the job. Block-up lens with the mini-CAD.

TIP

The lens is blocked on the mechanical centre (boxed centre of the lensshape)

Lens lay-out procedure

"u" - horizontal decentration from the mechanical centre of the lens shape.(in positive, out negative)

"v" - vertical decentration from the mechanical centre of the lens shape.(up positive, down negative)

a

bf

c

de

Select the right- resp. left-lens shape by pressing the ( f ) button.

Place the lens on the lens supports ( a ).

Insert the STARblock with blocking pad in the adapter (b).

View the lens through the alignment loupe (e) and align the optical centreof the lens with the dotted cross on the LCD.


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Align the lens accordingly and verify that the edge of the uncut lens isoutside the outline of the lens shape (arrow).

a

bf

c

de Pull down the blocking arm (d).

Press down the blocking plunger (c), while holding the lens in place.

a

b

f

c

de Press the ( f ) button and repeat the procedure for the left lens.

TIP

The lens lay-out values are transferred for the left lens. A new data entryis only then required when the lens decentration for the left lens is differentfrom the right. In this case the frame needs to be re-traced with theFormTracer 2D.


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a

bf

c

de Lower the blocking arm (d)

Press blocking plunger down, while blocking hold the lens in place byhand.

a

bf

c

de Press the < f> button and repeat the procedure for the left lens.


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5.4 Roughing procedure (all bevel types) with patterns

9

10

11

12

Switch the edger ON (10).

After the self check the size indicator (16) shows " 0 40.0".

37

By pressing the Pattern key (37) the pattern copying wheel moves to theback and allows for the pattern to be placed on the adapter. .

For edging with a pattern replace the 40,0 mm round idler pattern with theappropriate shape (C) and secure with the thumbscrew (D) or with the

quick clamp. When using patterns consider the lens side (right/left) Illustration depicts

an example for the right lens.

TIP

When operating as a CNC machine and during test runs NEVERoperatethe machine WITHOUT the idler pattern.

37

By pressing the Pattern key (37) again the pattern copying wheel movesforward.


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If necessary the lens size may be changed by pressing the keys

< 8 > (larger) or < 2 > (smaller)

in 0.1 mm steps.

2

5

Open the grinding chamber lid (2).

Clamp the blocked-up lens with the lens clamp slider (5) between the lensdrive shafts.

TIP

The actual lens clamping force is applied at the start of the edgingprogram.

The operator must check that the teeth of the STARblock and the teeth ofthe STARblock adapter properly mesh.

The ridge on the STARblock adapter must face to the front.

The roughing position of the plastic roughing or the glass roughing wheelcan be changed before and during the roughing process with the "right/left(26)" arrow keys.

Close the grinding chamber lid (2).

19

30

26

The edging program can be interrupted after the roughing cycle bypressing the "BREAK" (30) key.

Press the GP (19) key for processing plastic lenses (e.g. CR-39) lenses.

The plastic roughing wheel moves to the required position.(Depends on the grinding wheel configuration)

TIP

Plastic lens roughing wheels are NOT suited for processing polycarbonatelenses.

Polycarbonate lenses require a special grinding wheel configuration(Option)

Glass lenses CANNOT be processed on a roughing wheel for plastic.

Further procedure see bevel edging (Free- float/guided).


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5.5 Roughing procedure (all bevel types) patternless operation

9

10

11

12

Switch the edger ON (10).

After the self check the size indicator (16) shows " 0 40.0".

2216

3940

Press the "NEW JOB" (22) key.

Enter the job number on the keypad (40).

The valid job number range depends on the type memory card.

SM20: 1-20 job numbersSM100: 1-100 job numbersSM200: 1-234 job numbers

Press the "ENTER" (39) key.

The job number is displayed in the job number read-out (16) e.g. 234.

18 20 Select the right lens respectively the left lens by pressing the keys (20)

resp. (18).

TIP for W 2-D users

The 40 mm idler pattern must be mounted on the pattern adapter andsecured with the thumb screw for patternless operation.

18 20 If necessary the lens size may be changed by pressing the keys

< 8 > (larger) or < 2 > (smaller)

in 0.1 mm steps.

The safe edging mode can be switched ON with the 9 key (Also seechapter 5.15 Special Cases.


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5.6 Free-float bevel

TIP

The flat-bevel edging procedure requires that the lens has been roughground to shape.

28

Press the Free-float bevel ( 33 ) key.

Press the START" ( 28 ) key.

The edging program completes itself then automatically.

The lens transfers automatically to the free-float bevel wheel.

2

5

The grinding wheel assembly moves to its home position at the end of thefinishing cycle.

CAUTION

Only open the lid of the grinding chamber (2) after the grinding wheelshave come to a complete stop.

Open the grinding chamber lid (2).

Hold the lens and pull the lens clamping slider (5) as far to the right aspossible.

Remove the lens.

TIP

The lens lift off position on the bevel wheel is still in memory.

If re-edging is required, this procedure must be done immediately. Seeparagraph Operating procedure re-edging.


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5.7 Guided bevel edging

35

TIP

This bevel type (35) is particularly well suited for high powered lenses andfor lenses whose bevel placement is dictated by aesthetics or by the typeof frame.

Select the bevel type before the roughing cycle is started. Do NOT YET engage the bevel position controller. The guided bevel edging program operates with an automatic cycle

interruption feature. If a program interruption is not desired then press theBREAK (30) key before the start or before the end of the roughing cycle.

After the roughing cycle, the wheel assembly moves away from the lensand the assembly moves to the right.

The edging program interruption follows, the coolant flow stops.

TIP

The finishing wheel does not touch the lens, as long as the LED in theBREAK " key is on.

b

a

3

c

Set the bevel location with the outside ( c ) ring and the bevel curve with

the knob turning the inside ( a ) ring of the bevel controller ( 3

CAUTION

At the end of the edging program turn the dials so that the arrows ( b ) ofthe outside- and inside ring are again placed in the position as illustrated(home position).

a = 0 a = 0 ...8

a c

TIPS

With the outside ( c ) ring of the bevel position controller the location of thebevel is set.

The red area of the scale:The bevel groove of the grinding wheel shifts to the left.

The white area of the scale:The bevel groove of the grinding wheel shifts to the right

With the inside ( a ) ring the bevel curve is set according to theapproximate curve of the lens.

With the curve setting " 0 " (a=0) a straight running bevel is edged.


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5.8 Flat bevel

TIP

The flat-bevel edging procedure requires that the lens has been roughground to shape.

26

If necessary the rough grinding position, on the glass or the plasticroughing wheel, can be changed before or during the roughing cycle withthe grinding positioning (26) (arrow) keys. (

28

33

Press the Flat-bevel ( 33 ) key.

Press the START" ( 28 ) key.

The edging program completes itself then automatically.

The lens transfers automatically to the flat bevel wheel.


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5.10 Edging with cycle pause

TIP

The flat bevel and V-bevel edging programs complete themselves withoutinterruption.

An interruption in a program run must therefor be expressly entered.

The bevel edging starting point, after a program interruption, is always atthe bottom of the lens (270 degree position), regardless of how the lenshad been rotated.

Program interruption applications:

Bevel position observation when using the guided bevel mode. Scrape bevel edging to verify bevel position. Verifying the starting point for flat bevel edging..

Press the "BREAK" key before the start of the edging program or at thelatest during the roughing cycle but before the edger reaches the finishingposition..

Press the "BREAK" key to continue in the edging program.

TIP

The program run can be ended at any moment by pressing the STOPkey.


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5.13 Polycarbonate lensesTIP

A special grinding wheel configuration is required to process polycarbonatelenses. The standard grinding wheels cannot process polycarbonate.

Conditions

Special grinding wheel configuration

17 Press the " PC " (17) key before pressing Start.

The edging program completes automatically. The function stays switched onuntil the next job is called-up.

During the roughing cycle the coolant supply is switched off..

Only during the last revolution of the finishing cycle is the coolant flowswitched on.

5.14 Keyboard programming

.

16"Hot key" function

Frequently repeated keystrokes may be stored in the keyboard software, notun-like frequently called telephone numbers.

A maximum of 9 keys between and can be programmed.

A maximum of 30 key strokes may be stored under one number.

Simply press one of the keys to and the sequential key strokeswill be executed.

In case a string of commands is carried out, a dot appears in the left digitlocation of the job number display (16).

NOTE

The key strokes stored under the 0 number key are excecutedautomatically when the edger is switched ON.


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5.15 Calling-up a job with a bar-code reader (option)TIP

Bar-code operation requires for each device a special configuration.

Conditions

Bar-code wand and accompanying electronic parts.

Switch the edger ON

Trace a frame Move the bar-code wand of the edger across the bar-code label.

A successful reading in indication by a signal. The job number appearsautomatically on the screen of the edger.

TIP The bar-code wand can be moved across the label from right or left and

vice versa. The bar-code labels can be ordered under product number 2012-3001.


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5.16 Special Cases

24

31

24

27

1. Spiral lowering (Soft touch grinding wheel approach) for large

diameter thin plastic lenses

The approach speed of the grinding wheels toward the lens can be reduced.This feature reduces the changes of lens breakage and lens slippage.

By pressing the "WECO" (24) and "Spiral edging" (31) keys at the sametime the Spiral Lowering feature is switched on

TIP Spiral Lowering can also be switched on by pressing the "9" key (Factory

program setting) (Also see: Keyboard programming).

2. V- and Flat bevel edging on one lens

Eyeglass frames for which the lenses must be edged with a V- and a Flat-

bevel (for grooving) are delivered with two shape patterns.

The pattern is centred, the second one de-centred.The centred shape is edged first with a V-bevel, then the same lens isedged the de-centred pattern for a Flatbevel.

The FormTracer centres all patterns according the box system.

It is possible to switch this automatic centring OFF and ON by pressing thekey combination CTL" and "OFFSET" at the same time. The job numberdisplay shows a dot in each position.

NOTE For the second shape a new job number needs to be entered. ONLY switch this automatic centring OFF in these special cases, otherwise

the optical centring will be wrong.

3. Clamping of strong prismatic lenses

Although the WECO universal adapter is well suited for prismatic lenses, itmay be necessary to be built-up one side of the inside of the lens. For thispurpose WECO block pads are well suited.


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4. Lens shapes with the STARblock off the shape centre.

There are shapes whereby the STARblock cannot be placed in thegeometric centre of the lens. Blocking this way would place the edge of theSTARblock outside the lens edge.

Measure how far the STARblock needs to be moved over before the lens

can be edged.

Enter the de-centration value (5 mm in and 3 mm up) as the de-centrationbefore frame tracing. (Also see Decentration with the FormTracer 2-D)The shape is then de-centred by the entered amount. Calculate thisamount with the required decentration for the prescription. Then block-upthe lens accordingly.


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6 Maintenance

6.1 Care of the edgerTIP

For the care and maintenance of the automatic edger use only originalWECO grinding wheels, WECO replacement parts and consumables.

WECO automatic edgers have NO grease points.

Please observe the by WECO recommended periodic cleaning intervals, then,even over time contaminated coolant will not harm the edger.

At the end of the workday all rubber parts in the grinding chamber should berinsed clean with water. The lens particles and grinding residues are removedand cannot cause blistering and damage the painted surfaces.

Extended use of contaminated coolant causes calcium like built-up in the

grinding chamber, which, by delayed maintenance contributes to prematurewear and operating problems.

Once these residues are present they can only be removed mechanically.This leads in all cases to damage to the seals and to the protective surfaces ofthe edger.

CAUTION

By observing the cleaning interval damage to the edger will be prevented.Please follow our recommendations:

Clean the edger daily. Clean the edger thoroughly weekly.

A

B Remove grinding residues from the grinding chamber.

Carefully remove the grinding residues from the lower reaches of the gaiter(see arrow).

Clean all parts that come into contact with coolant.

Remove the clamping parts from the lens drive shafts, clean and grease

lightly.

Clean around the spray guard.


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6.2 Grinding wheel care

TIP

Only sharp grinding surfaces guarantee short edging times, exact lensshapes and "first time fit" lenses.

Dull grinding wheels may result in axis problems and broken lenses!

An adequate coolant flow with WECO coolant additive improves thegrinding performance and prolongs the life of the grinding wheels.

Clean the grinding wheels ONLY when the edging times increase beyondan acceptable limit.

Grinding wheels must be cleaned with coolant, the dressing sticks have tobe soaked in water before hand.

After cleaning the grinding wheels the grinding chamber and the coolingsystem should be cleaned and the coolant supply replaced.

a c b

WECO dressing sticks

WECO dressing sticks remove lens residue completely so that sharp diamondgrains are brought to the surface, again giving top lens grinding performance.

WECO dressing sticks.

(a) white dressing stick, for finishing wheels

(a) green dressing stick, for finishing wheels in case the white stick is notsufficient.

(a) red dressing stick (disk), for glass roughing wheels only.

abc

Rough grinding wheel for glass

The WECO W 2-D has a 15 mm wide roughing wheel (a). This allows foreasy and safe edging even of heavy minus lenses.


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c

a b Take the pressure pad ( b ) out of the swivel joint ( a ) on the right lens

drive shaft.

Allow the dressing tool ( c ) to absorb water

Clamp the red dressing disk ( c ) for glass roughing wheels into the lensclamp like a lens.

Clamp in the round 40.0 mm idler pattern.

Set the lens size to 80 mm.(Assuming that a new round dressing disk is used)

Select flat bevel.

Press the program interruption key BREAK, press START key.

Move the grinding wheel assembly right / left so that the grinding disk staysin contact with the glass roughing wheel.

Stop the procedure at the end of the roughing cycle.

TIP

Assure that the coolant flow is adequate.

The dressing disk can be used more than once. Reduce the size of theedger roughly 10 - 20 mm every time this procedure is done.

abcd

Rough grinding wheel for plastic (CR-39) - "Speed Wheel"

The rough grinding wheel for plastic ( b ) must only be used for edgingplastic lenses (CR-39 or high-index plastic lenses).

TIP

Glass or polycarbonate lenses cannot be edged on this rough grindingwheel.

Polycarbonate lenses may be processed with an optional polycarbonategrinding wheel and coolant system.

No cleaning necessary. The plastic roughing wheel must neverbe cleanedwith dressing disks or sticks.


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abcd

Finishing wheel free floating bevel

The special V-bevel wheel ( c ) is used for free-float bevel edging.

The sharp corners of the groove and bevel sides control the free floatingbevel position. Timely cleaning of the wheel is recommended. It is usuallysufficient to clean only the right side of the bevel groove.

Clamp in the round 40.0 mm idler pattern.

Set the lens size to 80 mm.(Assuming that a new round dressing disk is used)

Select flat bevel.

Press the program interruption key BREAK, press START key.Wait for cycle interruption.

Start the coolant flow by pressing the GP key.

a

Moisten the white dressing stick and by short bursts of pressure clean theRIGHT side of the bevel groove of the bevel wheel ( a ).

TIP

If the dressing stick is still too wide reduce it by running it over the roughingwheel for glass.

Under NO circumstances use the red dressing stick on a finishing (bevel)wheel.

If no satisfactory results can be achieved, first check the free right / leftmovement of the grinding wheel assembly as well as the levelling of theedger with the power switched OFF. Only if these two conditions check outsatisfactorily dress (clean) the bevel wheel with the green dressing stick.

End the process.

Check the bevel position by edging a test lens in the free-float bevellingmode.

If necessary, repeat the procedure.


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6.3 Replacing WECO grinding wheels

9

10

11

12

TIP

The replacement of a four WECO grinding wheel assembly is illustrated.The procedure for replacing of a three wheel- or a two wheel-WECOgrinding wheel assembly is in principle the same.

Switch (10) the edger OFF Pull the plug (9).

a Remove the swivel nozzles ( a ) of the coolant supply.

TIP

After re-assembly re-position the swivel nozzles.

a

b

c

d

Remove the clamping ( d ) parts.

Remove the spray guard ( a ) of the wheel assembly after loosening thescrews ( b ).

Check the gaiter (2) for rips and leaks.

In case of leakage consult WECO Service.

A

Pull out the hole cover( A ).


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Turn the WECO grinding wheel assembly 90 degrees and take it out of thegrinding chamber.

TIP

Open the lens clamp completely by pulling the lens clamp plunger as far to

the right as possible (also see Overview).

To dismantle the WECO grinding wheel assembly pull the grinding wheelsfrom the shaft.

WARNING

Do not use any tools to remove the grinding wheels from the shaftpreventing damaging the wheels.

When because of stubborn grinding residues the removal of the grindingwheels is not possible apply, before anything else, a penetrating oil (MOS 2in the spaces between the grinding wheels and allow it to work until thewheels can be removed by hand

TIP

During re-assembly observe cleanliness. Grease the sides of the grinding wheel with Vaseline. Re-assembly takes place in reverse order.

CAUTION

Dress new grinding wheels before they are used for the first time, seeparagraph Grinding wheel care

Re-adjust the finish lens size and the roughing size, see paragraph


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6.4 Cleaning the coolant re-circulation system

The main cause of scratched lenses and contamination of the edger is dirtycoolant water.

Regular replacement of the coolant water and the cleaning of the coolant re-circulation system is strongly recommended.

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TIP

Replace the coolant water every 200 to 250 lenses but at least once aweek.

Contact local waste management authorities on the safe and theresponsible disposal of lens grinding waste.

Use the WECO coolant additive (Order no. 5998-3027). The number of edged lenses can be read off on the lens counter ( see

paragraph 7)

Switch ( 10 ) the edger OFF. Pull the plug (9).

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i

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l

Disconnect the coolant supply hose (f) with the quick disconnect (e) (Slideback the slip ring).

Pull the drain hose (i) out of the coolant tank.

Disconnect the pump power cable at the connector.

Lift the lid (d) with the pump off the coolant tank.

Remove the pump screen (Arrow) and clean it. Make sure that all lensgrinding residue is removed from the pump screen..

Replace the WECO-plastic bag (Order no.: 5999-1008)Replace coolant water and add WECO-coolant additive (Order no.: 5998-3027).

Re-assemble the coolant re-circulation unit and prepare for operation, seepar.: Installing the coolant system


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6.5 Maintenance Intervals

WECO maschines and systems have been developed out of long practicalexperience for high productivity and a long life. All this leads to an economicway of lens processing.

Besides the machines and the surrounding equipment we offer the WECOmaintenance concept. We want you to have machines of lasting value whichare always ready to work no matter when or how long and intensively want towork with them.

We therefore recommend to follow the complete maintenance concept forWECO systems.

WECO maintenance concept:

Step I: Daily

Clean the edger inside with water and a very soft brush in places like theleathering and a hard brush for grinding residues in the grinding chamber. The

outside should only be cleaned with a moist dustfree cloth wihout aggressivedetergents. The surface may be cleaned with neutral detergents for plastic. Ifyou use detergents in the grinding chamber make sure they are safe withhigh-grade finished surfaces as well as blockpads.If necessary change filter of high-pressure filter systems.In case of pneumatic elements emty water collector and check pneumatic oil-level.

Step II: Weekly

As in step 1 but additionally Control water tightness. Treat all rubber preservatives Check diamond wheel condition with sample lenses (size, bevel); if

necessary correct size values according to manual or change diamondwheels (new or levelled WECO wheels)

Change water for cooling systems with water tank. Check FormTracer with frame gauge (size, axis) Check centering device (blocking point, axis)

Step III: Monthly

As in step 2, but additionally change elements of the block -up system.


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7 Checking Procedures

7.1 Reading the lens counters

12354

The edger counts the activity of each individual bevel position (roughing aswell as bevelling) with an electronic counter, which can be read at any time.

Edging position numbers:

(1) Glass roughing wheel

(1) Plastic roughing wheel

(1) Free floating V-bevel wheel(1) Guided V-bevel wheel

(1) Flat bevel wheel

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Switch (10) the edger ON.

LED read-out.

Press the # (23) function key.

LED read-out.


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Key-in "1", press the "ENTER" key.

LED read-out.

Key-in the desired edging position (e.g. 1 for the number of lenses groundon the glass roughing wheel) and press the ENTER key.

Lens counter read-out (e.g. 212 lenses) for glass roughing.

Pressing the # (function) key ends the program.

TIP

Before the function is ended by pressing the # key, other edging positionscan be read by keying in the desired position number after the C key is

pressed.


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7.2 Adjustment of rough and finish size

NOTE

Size changes with the "#" (function) and "2" keys affect the size of alllenses which are edged with the respective grinding wheels and / or beveltypes.

For a single job or a single lens the size can be changed by pressing the"C" key and the desired size change is entered on the number pad or withthe number keys 2 or 8 keys, on edgers that have been programmedwith quick-set keys.

All bevelling wheels can be adjusted individually for glass and plastic.

It is advisable to check the lens size after the grinding wheels have beendressed. Make adjustments, if necessary.

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Procedure for free-float- and guided V-bevel size adjustments

The lens sizes for the V-bevels (3,4) should be adjusted in such a way thatmost lenses for metal frames fit the first time.

Trace an average metal frame. Edge two mid-power (+3.00 - -3.00) lenses, one glass and one plastic. Check the lenses for fit into the frame. If necessary, re-edge. Adjust size setting (see following page).

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Procedure for flat-bevel size adjustment

The lens size for flat bevel (5) should be adjusted in such a way that thefinished lens size is the same as the size of the traced lens, demo-lens orpattern.

Trace a round pattern with the FormTracer. Edge two mid-power (+3.00 - - 3.00) lenses, one glass and one plastic. Check lens diameter with a calliper gauge. Adjust size setting (see following page).


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Press the "#" key.

Display read-out.

Press the "2" key.

Display read-out.

Enter the number of the to be changed bevel position (1-7).

Display read-out (example position 3 for free-float V-bevel).

Press the "ENTER" key.

Display (example 57,8).

For plastic lens size setting press the "GP" key, the LED in the GP keylights up and the size adjustment value for plastic lenses is displayed.For position # 2, roughing wheel plastic, the "GP" key mustto bepressed.

NOTE

The displayed value does notreflect the lens size but relates to the travelof the grinding wheel assembly from the back stop to the edge of the lens.

Record the displayed value as it will be deleted once the "C" key ispressed and cannot be re-called.If necessary, enter the factory setting for this position and determine thedifference by edging trial lenses.

Press the "C" key, the value will be deleted.

Display read-out.

Enter a new value (e.g. 57.9).

Press "ENTER" key to confirm.

Display read-out. The position number for another grinding wheel may beentered.

Pressing the "#" key ends the procedure.

RULE FOR SIZE ADJUSTMENT:

If an edged lens istoo large, increase the value. If an edged lens is too small, decreasethe value.

Check lens size by edging a test lens.


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Example for glass lenses with free-float V-bevel

The operator notes that most glass lenses edged in the free-float V-bevelmode have to be reduced by an additional 1/10 of 1.0 mm. in order to fit intothe metal frame.

This means the lenses are 1/10 of 1.0 mm too large.

The size value (in function "#" "2", position 3) has to be increased by 1/10 mm.

Steps to take::

Press "#" key. Press "2" key. Enter position number "3" (for free-float V-bevel). Press "ENTER" key. Display shows e.g. "57.8". Press "C" key. Enter new size value: "57,9" Press "ENTER" key. Press "#" key.

Edge a test lens.


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8 Trouble Shooting

8.1 Minor Problems

Problem Possible cause Solution

After switching the edge ON no lightin grinding chamber

No power at the electrical outlet

Fuse defective.

Check voltage at the outlet

Check the fuses / replace

No function after pressing START Fuse defective Check fuse / replace

Main motor does not run Overload protection switch tripped

The grinding chamber lid is open,when override switch is activated

Allow switch to cool down, thenpress START again

Close grinding chamber lid.

Lens size is not correct Finish size is incorrectly set.

When using patterns:- check the size of the pattern

Correct the finish size setting

The coolant flow does not reach thegrinding chamber

Coolant supply twisted or pluggedwith dirt.

Plug on coolant tank loose

The pump cable is not plugged intothe edger

Pump propeller does not turn freelybecause of lens residue.

The "PC" has been pressed

Clean the coolant system

Secure the plug

Plug the cable in

Clean the pump

Press the PC key again


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8.2 Electric Fuses

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CAUTION

In event the edger is not functioning, check the power outlet first and callan electrician, if necessary..

Pull the plug (9) before changing the fuses!.

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Fuses (11)

T4AT4A Pump

T15 A main fuse (USA)T16 A main fuse (Europe)

TIPS

T = slow fuse mT = medium slow fuse A separate circuit breaker for the edger is recommended.

See Warranty Conditions: Power connection


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Immediately after pressing the NEW JOBkey. The operating type "quick mode isswitched on. Job number 0 is notavailable.

Trace shape under job number 0. Theswitch OFF the quick mode operatingmode hold down the "WECO" key and inaddition press the "#" key.

E 840 No connection with the memory card.Memory card OR the connection isdefective.

Contact WECO Service.

E 841 Interface card (part of the memory card)defective.

Contact WECO Service.


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w2-d operations manual

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