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OptiPro Systems ePx 200 User Manual

Optical polishing machine
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User Manual – ePX 200
OptiPro Systems, LLC.
User Manual – ePX 200
OptiPro Systems, LLC.
Page 1 of 60
Last Modified: 7/30/2014

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  • Page 1 User Manual – ePX 200 OptiPro Systems, LLC. User Manual – ePX 200 OptiPro Systems, LLC. Page 1 of 60 Last Modified: 7/30/2014...

  • Page 2: Table Of Contents

    User Manual – ePX 200 1 Contents Contacting OptiPro ..........................5 Document Revisions ..........................6 Safety ..............................7 Employer’s Responsibilities......................7 General Safety Concerns ....................... 7 4.2.1 Personal Safety........................7 4.2.2 Electrical Safety ........................8 4.2.3 Pneumatic Safety ........................8 4.2.4...
  • Page 3 User Manual – ePX 200 Electrical Cabinet A/C Unit ......................23 Pneumatic Automatic Axis Greaser .................... 23 Work and Tool Holding Chucks ....................24 Start Up, Shut Down, and Emergency Recovery Procedure ............... 25 Startup ............................25 6.1.1 Initial Power Up ........................25 6.1.2...
  • Page 4 User Manual – ePX 200 Machine Maintenance ........................45 Daily Maintenance ........................45 9.1.1 Start of Shift ........................45 9.1.2 End of Shift .......................... 45 Weekly Maintenance ........................45 Monthly Maintenance ........................ 46 Semi-Annual Maintenance ......................46 Yearly Maintenance ........................46 Replacing the Lower Rotary Union .....................

  • Page 5: Contacting Optipro

    User Manual – ePX 200 2 Contacting OptiPro Main Office OptiPro Systems 6368 Dean Parkway Ontario, NY 14519 Phone: (585) 265-0160 Fax: (585) 265-9416 Website: www.OptiPro.com For Service and Parts Contact: Service Coordinator Email: Service@OptiPro.com For Sales Contact: Sales Coordinator Email: Sales@OptiPro.com...

  • Page 6: Document Revisions

    User Manual – ePX 200 3 Document Revisions The following is a summary of changes to this document. Table 3-1: Document Revision Summary Release Dated Changes  2014, July Initial Release OptiPro Systems, LLC. Page 6 of 60 Last Modified: 7/30/2014...

  • Page 7: Safety

    User Manual – ePX 200 4 Safety Safe usage of the machine requires careful adherence to all safety protocols specified in this manual. In order to ensure that all protocols are followed, the machine operator must be trained in all operational aspects of the equipment.

  • Page 8: Electrical Safety

    User Manual – ePX 200 4.2.2 Electrical Safety All inspection and repair of any electrical components should be done by a qualified electrician. During electrical repair, the power should be turned off and locked out. It must always be assumed that a component is powered up when working with complex electronic systems.
  • Page 9 User Manual – ePX 200 IN AN EMERGENCY SITUATION:  Press the EMERGENCY STOP button.  In the case of serious injury, fire, or other hazardous conditions, IMMEDIATELY CONTACT YOUR LOCAL EMERGENCY RESPONSE PROFESSIONALS.  If necessary, switch off the main power disconnect on the rear of the machine and the main air supply at the utility control panel.

  • Page 10: Machine Overview And User Controls

    User Manual – ePX 200 5 Machine Overview and User Controls This section provides a brief description of the components, controls, and features this machine is available with. Some of the features shown in this manual are options and may not be included in your machine.

  • Page 11: Operator Panel Interface

    User Manual – ePX 200 5.2 Operator Panel Interface The ePX200 is equipped with a touch screen interface and may come with an external keyboard. Figure 5-3: Operator Panel 5.2.1 Jog Panel Not used on OptiPro equipment Figure 5-4: Jog Panel OptiPro Systems, LLC.
  • Page 12 User Manual – ePX 200 Table 5-1: Jog Panel Button Descriptions Button Label Description Left Door (Open/Close) Operates the left-hand containment door Right Door (Open/Close) Operates the right-hand containment door Air Blast (On/Off) Air blast through the polisher spindle at cycle end. Tool must have a thru hole or damage to machine could occur.

  • Page 13: Jog Pendant

    User Manual – ePX 200 5.2.2 Jog Pendant Emergency Stop Feed Rate Control Axis Selection +/- Movement Jog Wheel Figure 5-5: Hand Wheel Button Description Axis Selection Selects which axis on the machine to move. Feed Rate Control Controls the feed rate of the selected axis.

  • Page 14: Door Interlock

    User Manual – ePX 200 5.2.3 Door Interlock The Door Interlock simply locks or unlocks the main door of the machine. While in the Active position the door is locked and all controller functions are available for use. Override unlocks the door and only allows the most basic functions such as jogging, mainly for cleaning or service.

  • Page 15: Utility Control Panel

    User Manual – ePX 200 5.3 Utility Control Panel Main Air Regulator Main Air Valve Air Prep Mist Separator Filter Air Prep Regulator filter Vacuum Trap Tube Vacuum Tube Valve Figure 5-8: Pneumatics Control Panel The pneumatic panel is home to all of the air regulators and switches for the ePX machine. They are set when your machine is first installed by OptiPro in your facility, and should not require further adjustment.

  • Page 16: Vacuum Workholding

    User Manual – ePX 200 5.4 Vacuum Workholding The Vacuum Drain Tube (in Figure 5-8) collects the small amount of slurry that commonly leaks into the vacuum system. The purpose of the vacuum drain tube is to collect this fluid before it can get to and harm the vacuum pump.

  • Page 17: Containment

    User Manual – ePX 200 5.5 Containment 5.5.1 Upper Containment The upper containment of the machine is stationary. Maintenance items for the upper containment can be found in Section 9: Machine Maintenance. 5.5.2 Lower Containment The lower containment tray moves with the x- and y-axes of the machine. The lower tray is fitted with quick-disconnect hose fittings for easy removal and cleaning.

  • Page 18: Containment Safety Reminders

    User Manual – ePX 200  If it is necessary to adjust the tilt of the tray, loosen the jam nuts on each support and unscrew or screw the four threaded rods into the linkages to adjust the tilt until the containment drains properly.

  • Page 19: Slurry System Basics

    User Manual – ePX 200 5.6.2 Slurry System Basics Lift lid to access bag filter and chiller coil Output Hose to Valve Assembly On/Off Valve for Pump Output Chiller Coil Input/Output Containment Fittings drain hose Figure 5-12: Slurry Cart with Chiller Option...

  • Page 20: Changing Between Slurry Types

    User Manual – ePX 200 5.6.3 Changing Between Slurry Types When a different type of slurry is required for a process, the slurry system must be thoroughly flushed to prevent cross-contamination of slurry types. If, for example, you are switching from a larger diamond size to a smaller size, the larger particles could result in an uneven, rougher polish than intended.
  • Page 21 User Manual – ePX 200 Quick- disconnect hose fitting Figure 5-14: Containment Drain Hoses  The Z-axis bellows screens are one-sided. The eight plastic pieces holding the top and bottom bellows on (Figure 5-17) can be carefully pried open to pull the bellows screens out.
  • Page 22 User Manual – ePX 200 Figure 5-16: Side Containment Doors, Installed (Left) and Removed (Right) Bellows Holders Figure 5-17: Bellows Holders Below Upper Spindle OptiPro Systems, LLC. Page 22 of 60 Last Modified: 7/30/2014...

  • Page 23: Electrical Cabinet A/C Unit

    User Manual – ePX 200 5.7 Electrical Cabinet A/C Unit The air conditioner attached to the electrical cabinet is factory set to 25°C and is not to be changed. Doing so could result in damage to the machine. Right Side...

  • Page 24: Work And Tool Holding Chucks

    User Manual – ePX 200 5.9 Work and Tool Holding Chucks This machine is equipped with manually actuated hydraulic expansion chucks for work and tool holding. To avoid damaging the chuck, observe the following precautions:  Never actuate the chuck without a properly manufactured shank in the chuck.

  • Page 25: Start Up, Shut Down, And Emergency Recovery Procedure

    User Manual – ePX 200 6 Start Up, Shut Down, and Emergency Recovery Procedure 6.1 Startup Powering up the machine correctly is very important. An incorrect performance of this procedure could result in damage to machine components or waste valuable production time. The operator must make sure to follow all steps specified by this manual and steps that were taught during training to ensure that no unexpected errors occur.

  • Page 26: Shutdown

    User Manual – ePX 200 6.2 Shutdown The following options can be chosen based on your company policy. 6.2.1 Retaining Main Power  Complete the end of the shift maintenance (Section 10.1.5).  Clean any excess slurry spatter.  Turn off flood lights.

  • Page 27: Creating And Running Programs

    User Manual – ePX 200 7 Creating and Running Programs 7.1 Screen Layout Figure 7-9 shows the main screen at startup; this is the Manual Jog Mode Screen. The current mode of the machine is indicated in the top left box. The top right box displays fault and status messages; the box can be expanded with the down arrow button to display multiple messages if they exist.

  • Page 28: Jump To

    User Manual – ePX 200 7.2 Jump To… The [JUMP TO…] button, from any screen, allows quick navigation to Job Setup, True Tool, and Polish Setup menus. Figure 7-2: “JUMP TO…” buttons activated for quick navigation 7.3 P-Series Submenu Figure 7-3: P-Series Submenu OptiPro Systems, LLC.

  • Page 29: Manual Jog Mode

    User Manual – ePX 200 Table 7-2: P-Series Submenu Descriptions Option Description Manual Mode This mode allows manual jogging and the ability to use the MDI function (Section 7.4). Automatic Mode Automatic mode shows the current program and the axis positions (Section 7.5).

  • Page 30: Automatic Mode

    User Manual – ePX 200 7.5 Automatic Mode The Automatic Mode screen displays during the program cycle. From the Polishing / Truing Program Setup screen, tapping [Run Program] and pressing CYCLE START will force the machine from Manual Mode to Automatic Mode.

  • Page 31: Settings Screen

    User Manual – ePX 200 7.6 Settings Screen Tapping the [SETTINGS] button will open up the following screens. The first tab is the General Settings page. This page contains two sections for cycle end adjustments and one section for Visual Preferences.
  • Page 32 User Manual – ePX 200 Figure 7-7: Recirculation Settings The Advanced Settings page (Figure 7-8) consists of two modes. In User Mode, the screen is blank. Entering Setup Mode requires a password, which is provided to a supervisor during training. This mode is not recommended for untrained personnel and is used for tramming the machine.

  • Page 33: Creating A New Job

    User Manual – ePX 200 7.7 Creating a New Job Figure 7-9: Startup Screen Figure 7-9 shows the main screen at startup. The current mode of the machine is indicated in the top left box. The top right box displays current messages/faults. The left side of the display consists of the operation buttons, each button will bring up sub menus which will be covered in detail throughout the following pages.
  • Page 34 User Manual – ePX 200 Table 7-3: P-Series Sub Menu Descriptions Option Description Manual Mode This mode allows manual jogging and the ability to use the MDI function. Automatic Mode Automatic mode shows the current program and the axis positions.
  • Page 35 User Manual – ePX 200 Figure 7-12: New Job Menu Screen 2 – Truing and Correcting the Polishing Tool Screen 2 of setting up a new job is the Truing and Correct Tool Screen. This screen can also be accessed by tapping the [Jump To] button.
  • Page 36 User Manual – ePX 200 The Polishing Program Setup screen is the third screen in the new job setup sequence. This screen consists of four independent polishing programs. Each program can be run individually or chained together by toggling the checkbox under [Enable Cycle]. The grayed out boxes contain data that is calculated based on the values that are entered in the other fields and cannot be interacted with.

  • Page 37: Loading A Job From File

    User Manual – ePX 200 7.8 Loading a Job from File Figure 7-15: Load job Menu The Load Job menu provides a drop down menu selection to load previously saved jobs. The technician can also load a job, change the name, and tap [Save Job] to save a job under a different name. After loading a job tapping [Jump To] will bring up the tabs for all the processes.
  • Page 38 User Manual – ePX 200 options in the measurement method view. Figure 7-17 through Figure 7-20 below show the different combinations and what the screens look like filled in. Figure 7-17: A correction measuring the Optic with a test plate on an interferometer, showing a 5 ring high bias.
  • Page 39 User Manual – ePX 200 Figure 7-19: A correction measuring the Pad with direct radius measurement. Figure 7-20: A correction measuring the Pad with a sphereometer. OptiPro Systems, LLC. Page 39 of 60 Last Modified: 7/30/2014...

  • Page 40: Creating The Tram Check Program

    User Manual – ePX 200 Figure 7-21: Corrections History Tapping the [History] tab at the top of the Corrections screen (Figure 7-16) will bring up the correction history for the currently loaded job. This allows the technician to keep track of the adjustments that have been made as the job progresses.
  • Page 41 User Manual – ePX 200 Move on to the Polishing Setup page after all the parameters are entered correctly. The tram check simulates polishing the gauge ball, so you will enter most of the parameters into the Cycle Number 1 column.

  • Page 42: Error Recovery And Troubleshooting

    User Manual – ePX 200 8 Error Recovery and Troubleshooting 8.1 Slurry Flow Fault 8.1.1 Reading the Flow Monitor The display on the switch shows the current level of the flow and whether the flow is at or above the predetermined level.

  • Page 43: Z-Axis Over Travel At Cycle End

    User Manual – ePX 200 8.2 Z-Axis Over Travel at Cycle End This error will occur when the Z axis load offset is too large. The machine is effectively trying to move Z beyond the axis limits. The machine will not physically move the axis but will fault before moving the axis based on the calculations it is performing.
  • Page 44 User Manual – ePX 200 M 38 B-AXIS OVERTRAVEL FAULT M 44 SLURRY CHILLER TEMP OR FLOW FAULT M 45 SLURRY CHILLER MOTORS RUN FAULT M 59 SLURRY FLUID FLOW FAULT M 60 COOLANT PUMP RUN FAULT M 61 SLURRY PUMP RUN FAULT M 62 CENTRIFUGE &...

  • Page 45: Machine Maintenance

    User Manual – ePX 200 9 Machine Maintenance Proper maintenance of the machine is very important for maintaining performance, longevity and safety. Observe all safety guidelines in Section 4. Only qualified technicians should perform inspection, maintenance, and repair of pneumatic, electrical, and mechanical systems.

  • Page 46: Monthly Maintenance

    User Manual – ePX 200 9.3 Monthly Maintenance  Check and clean the Chiller unit air filter and condenser fins (seen in Figure 5-11) as needed by vacuuming. This may be done more or less often depending on the conditions in the shop.
  • Page 47 User Manual – ePX 200  The rotary union is attached to the bottom of the spindle shaft with a metal adapter. The adapter has 22mm flats for rotating against to unscrew the rotary union. Unscrew the union with the tube attached.

  • Page 48: Appendices

    User Manual – ePX 200 10 Appendices Contacting OptiPro ..........................5 Document Revisions ..........................6 Safety ..............................7 Employer’s Responsibilities......................7 General Safety Concerns ....................... 7 4.2.1 Personal Safety........................7 4.2.2 Electrical Safety ........................8 4.2.3 Pneumatic Safety ........................8 4.2.4...
  • Page 49 User Manual – ePX 200 Electrical Cabinet A/C Unit ......................23 Pneumatic Automatic Axis Greaser .................... 23 Work and Tool Holding Chucks ....................24 Start Up, Shut Down, and Emergency Recovery Procedure ............... 25 Startup ............................25 6.1.1 Initial Power Up ........................25 6.1.2...
  • Page 50 User Manual – ePX 200 Machine Maintenance ........................45 Daily Maintenance ........................45 9.1.1 Start of Shift ........................45 9.1.2 End of Shift .......................... 45 Weekly Maintenance ........................45 Monthly Maintenance ........................ 46 Semi-Annual Maintenance ......................46 Yearly Maintenance ........................46 Replacing the Lower Rotary Union .....................

  • Page 51: Tramming

    User Manual – ePX 200 10.1 Tramming When running any automated tram programs, be sure to:  Turn off SLURRY AUTO from the jog panel.  Position the indicator and indicator mounting hardware in such a way to avoid collisions, including with the load door.

  • Page 52: Starting The Tram Sequence And Checking B-Zero (Vertical Alignment)

    User Manual – ePX 200 4. Rotate the spindle by hand. The runout should be less than 4µm (0.004mm). Reposition the pin to minimize the runout before attempting to adjust the chuck. Make sure to only rotate the pin in one direction to minimize indicator backlash.
  • Page 53 User Manual – ePX 200 Figure 10-3: Indicator Position for Finding B-Zero 7. Follow the directions on the screen to find the center of B. When the indicator reads a movement of less than 6µm, tap [SET]. Leave the indicator on the tram pin. Move to the next tram screen.

  • Page 54: Spindles Align (X- And Y-Axis Alignments)

    User Manual – ePX 200 10.1.4 Spindles align (X- and Y-Axis Alignments) Figure 10-5: Tram Sequence Screen 2, Spindles Aligned 1. Tighten a second tram pin into the lower chuck. 2. Position the indicator tip on the gauge pin. Zero the indicator.

  • Page 55: Checking Tram Ball Runout

    User Manual – ePX 200 10.1.5 Checking Tram Ball Runout 1. Thread the indicator base into the side of the tool spindle. 2. Install the long tram ball from the tram kit into the lower spindle. Align the indicator tip parallel to the circumference of the ball.
  • Page 56 User Manual – ePX 200 7. Follow the directions on the screen to find the center of the b-axis. 8. Once the indicator reads 2µm through the entire travel, tap [SET] and move to the next screen. Figure 10-8: Tram Sequence Screen 3, Center of B OptiPro Systems, LLC.

  • Page 57: Finding Z-Axis Tool Length

    User Manual – ePX 200 10.1.7 Finding Z-axis Tool Length 1. Remove the indicator mount with indicator from the machine. Type [G53 Z0] in the [MDI] box, tap [OK] and then press CYCLE START. Tap [FILL MDI] and press CYCLE START to go to Spindles Align.

  • Page 58: Finding The Z-Axis Chuck-To-Chuck Distance

    User Manual – ePX 200 10.1.8 Finding the Z-axis Chuck-to-Chuck Distance 1. Jog Z down so that the upper and lower hydraulic chucks are close to each other as shown. Figure 10-10: Finding the Chuck-to-Chuck Distance 2. Using a gauge block from the tram kit, follow the directions on the tram screen and press [SET] when finished.

  • Page 59: Manual Commands

    User Manual – ePX 200 10.2 Manual Commands Warning: Any manual data commands can cause machine collisions. Do not perform them unless properly trained to do so. Warning: Always set the feed rate knob on the control panel to 0% before pressing the CYCLE START...

  • Page 60: Spare Parts And Consumables

    User Manual – ePX 200 10.3 Spare Parts and Consumables Table 10-1: Spare Parts and Consumables List Part Description Part Number Recommended Qty On hand Air Prep Regulator Filter OptiPro: 15148A | SMC: AF30P-060S Air Prep Mist Separator Filter OptiPro: 15149A | SMC: AFM30P-060AS...

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