Table of Contents
Summary of Contents for National Optronics Horizon II
- Page 1 ® Horizon II Edger NSTRUCTION PERATION AINTENANCE AND ROUBLE HOOTING ANUAL 100 Avon Street, P.O. Box 1547 Charlottesville, VA 22902 Tel: 434-295-9126 Tech Support: 800-247-9796 Fax: 888-239-0778 Revision Date: 11/98 Page - 1 -...
- Page 2 ♦ The left cutter shield, the top cutter shield, and the shield keeper have been designed into the Horizon II to protect operating personnel from rotating cutter blades. All machine covers and guards should be in place when operating the machine, and any alteration, removal, or damage of these parts will cause a serious safety hazard, as well as void any warranty.
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Page 3: Table Of Contents
TABLE OF CONTENTS Page INTRODUCTION TO OPERATION • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • INSTALLATION PROCEDURES •... - Page 4 TROUBLESHOOTING: Page Lens Quality • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Bumps on Periphery •...
- Page 5 REFERENCE DRAWINGS: Horizon II Dry Bevel Edger Part No. Reference Diagram • • • • • • • • • • • • • • • • • • • • • • • • • • • • Pneumatic Assembly Diagram •...
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Page 6: Introduction To Operation
5 hide-a-bevel, a rimless edge, and a groove. With the addition of specialty cutters, the Horizon II can also apply other finishes with a degree of precision not found on many conventional edgers, including a roll and bevel, a facet, a safety hide-a-bevel, and a shelf for snap in frames. -
Page 7: Installation Procedures
INSTALLATION PROCEDURES Note: These procedures should be followed in sequence, as the proper completion of a given step may depend on the one previous to it. Assorted hex key wrenches are supplied in the accessory kit to aid in the installation and operation. - Page 8 OFF position. 3. The HORIZON II Edger is designed to be connected to a grounded 115V, 60 Hz power supply. The wall receptacle should be of at least 15 amp capacity. The power consumption of the edger is 12.4 Amps.
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Page 9: Operating Procedures
OPERATING PROCEDURES REVIEW OF THE CONTROL PANEL: The following section describes the various Control Panel switches, controls, and indicators, as displayed in Figure 2. Figure 2: Control Panel Looking from Right to Left: On/Off Circuit Breaker: This switch controls line power to the edger and vacuum. It contains an integral 20 amp resettable circuit breaker for overload protection. - Page 10 OPERATING PROCEDURES Indicator Light (Red - When the Pause and Rimless buttons are engaged, this indicator lights to show that the edger is in the Flow Control mode. (See Flow Control Knob.) Stop/Reset (Red - Pressing this button at anytime will abort the cycle and return the lens drive/cutter motor carriages to their start position.
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Page 11: Sizing And Bevel Placement Adjustment Controls
OPERATING PROCEDURES Finish Only (Orange - Engaging this switch, before pressing the Start button, will permit the edger to run the finish portion of the cycle only. This should be used for recutting and touch-up only. Running uncut lenses in this mode may result in axis and finish problems, as well as possible damaged lenses and blades. -
Page 12: Edging A Lens
The edger is shipped with the beveling cutter body installed in the cutter motor. It is highly recommended that the operator run several test lenses to become familiar with the Horizon II’s operation prior to beginning production. 1. With the clear Plexiglas shield raised, mount the frame pattern on the spring clip on the left side of the lens drive motor shaft. -
Page 13: Bevel Placement Systems: Two Alternatives
OPERATING PROCEDURES It is suggested that the operator now run additional test lenses, changing the bevel placement and size. The operator can also experiment with the three control features (Finish Only, Rimless, and Pause), to gain a familiarity with the edger’s operating sequence and controls. -
Page 14: Multi-Cam Tracking Bevel Placement System
OPERATING PROCEDURES Multi-Cam Tracking Bevel Placement System The second bevel placement method is the multi-cam tracking system. The system utilizes a stair-step cam mounted on the lens drive motor carriage, and a cam follower assembly that replaces the bevel guide wheel assembly. The cam has six “steps” that approximate nominal 2, 4, 5, 6,7, or 8-base fronts. - Page 15 OPERATING PROCEDURES Changing Bevel Placement Systems: To change from the bevel guide wheel system to the multi-cam system: 1. Remove the bevel guide wheel assembly from its slide block by loosening the knob (post lock) on the left side of the slide block. It is helpful to remove the air supply and slide the cutter motor carriage to the left by pushing the bevel placement control rod.
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Page 16: Flow Rate Control
The Flow Control Cycle is a standard feature on all edgers shipped after April 1990. Retrofit kits are available for Horizon II’s shipped prior to that date. NATIONAL 100 Avon Street, P.O. Box 1547... -
Page 17: Periphery Finishes
OPERATING PROCEDURES PERIPHERY FINISHES: The “V” of the hide-a-bevel insert set has a depth of 1mm and included angles of . This results in a 120° angle on the lens bevel. To bevel a lens, follow the procedures in the EDGING A LENS section. The front-to-back location of the bevel can be adjusted using either of the two systems explained in the BEVEL PLACEMENT SYSTEMS section. -
Page 18: To Recut For Size
As with any new procedure, it is recommend that the operator practice with a junk lens when attempting this for the first time. 1. Install the shelving body with cutter inserts into the Horizon II. 2. Push the Rimless button. Set sizing knob to final size, which should be the ‘A’ measurement of the unshelved portion of the lens, allowing for the 2mm rimless overset. -
Page 19: Faceting Procedures
Faceting Procedures: The Horizon II is capable of faceting a lens. This requires a double pattern/two-cycle method, as well as a specially crafted cutter body and cutter inserts. 1. Install the faceting cutter body with cutter inserts into the edger. -
Page 20: Cutters
OPERATING PROCEDURES CUTTERS: The disposable insert type of cutter used on the Horizon II is manufactured by National Optronics, Inc. There are five standard style cutters. They are: BEVELING Part No. 93150 MODIFIED 5 BEVELING Part No. 93242 GROOVING Part No. 93302 FACETING Part No. -
Page 21: Replacing The Cutter Inserts
OPERATING PROCEDURES 2. Carefully push the cutter body onto the motor shaft as far as possible. 3. Tighten the set screws with the hex key wrenches. 4. Lower the cutter shield, reposition the bevel guide wheel, and turn the motor controller toggle switch back to the ON position. - Page 22 In 1995, we began using a DC brushless motor, manufactured by Bodine, on all new Horizon II models. Below, Fig. 6 represents the cutter body needed for this motor. If your Horizon II is not equipped with this type of motor, please refer to the Bosch Motor Addendum at the back of this manual.
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Page 23: Special Capabilities
OPERATING PROCEDURES SPECIAL CAPABILITIES: Pattern-From-A-Pattern Duplication: To duplicate a pattern from a pattern: 1. Place the pattern to be copied on the pattern retainer. 2. Utilizing the special pattern duplicator adaptor (PDA) found in the accessory kit, mount a pattern blank on the adaptor. Chuck the blank into the lens clamp. 3. -
Page 24: Safety Features
National Optronics, Inc. has incorporated several safety features into the Horizon II Bevel Edger. Removing or disabling any of these safety features could result in serious injury to the operator, and will null all liability on the part of National Optronics, Inc. Safety Shield Keeper:... -
Page 25: Periodic Maintenance
3. Remove the 2 ½” hose from the vacuum canister’s inlet and install the 1 ½” hose fitted with the crevice tool. 4. Move the toggle switch on the back right corner of the Horizon II to the down position. This will turn on the vacuum independently of the edger’s operation. - Page 26 PERIODIC MAINTENANCE Check the Teflon Bevel Guide Wheel: The guide wheel should be checked for wear and contamination. If the guide wheel is nicked or gouged, or feels rough to the touch, it will need to be replaced. Any wax pen buildup should be removed with rubbing alcohol and the guide wheel allowed to dry thoroughly before being used.
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Page 27: Every 300 To 500 Cycles
PERIODIC MAINTENANCE EVERY 300 TO 500 CYCLES: Change the Vacuum Bags: Both the blue collection bag and the white filter bag should be changed together. To ensure proper operation, the bags should be changed when the collection bag has reached 2/3 of its capacity or 300-500 cycles. -
Page 28: Every 2500 Edges Or 30 Days
PERIODIC MAINTENANCE EVERY 2500 EDGES OR 30 DAYS - [Whichever comes first]: Inspect Both the Lens and Pattern Clamp Assemblies for Wear: Apply hand pressure to the clamps and rotate. The clamps should turn smoothly. If any rough areas are detected, the clamp(s) should be replaced. NATIONAL 100 Avon Street, P.O. -
Page 29: Operating Specifications
OPERATING SPECIFICATIONS AIR PRESSURE: The recommended operating pressure of the edger is 80 psi. This should be adjusted by the regulator located on top of the air filter on the right side of the unit. Should it be allowed to drop too low, lens slippage could occur. Excessive pressure, on the other hand, could result in premature clamp wear or lens damage. -
Page 30: Differential Settings
OPERATING SPECIFICATIONS switched from Off to On, the differential should open (push away from the front of the machine) quickly. When switched from On to Off, the differential should close smoothly, taking approximately 1.5 to 2 seconds. If the flow rate is found to be out of tolerance, refer to the Troubleshooting Guide for further diagnostics. -
Page 31: Troubleshooting
TROUBLESHOOTING When using this Troubleshooting Guide, the steps within a given category should be followed in the sequence given. Since this guide lists the most probable cause of a problem first, it is best to follow accordingly. In some cases, a chain of tests makes the determination of the source of the problem, and each one is dependent on the test prior to it. -
Page 32: Incomplete Bevels
TROUBLESHOOTING SMALL BUMPS OR LIFT-OFF MARKS The differential is closing too slowly. Follow the procedures in the Maintenance Section for verifying Differential Flow Rate. Incomplete Bevels: THE UNBEVELED PORTION OF THE LENS IS HIGHER, OR LARGER, THAN THE BEVELED PORTION: The differential is closing too slowly. -
Page 33: Marks, Scratches Or Indentations On Surface
TROUBLESHOOTING the gear lash is properly set, and these marks still occur, the lens drive assembly should be replaced. To adjust gear lash: 1. Locate the Adjustment screw and lock nut in the back of the gear box. 2. Loosen the lock nut. 3. -
Page 34: Lenses Off Axis
TROUBLESHOOTING become imbedded in the surface of the lens. Spraying the Bevel Guide Wheel with Anti-Static Spray, which can be purchased locally, will remedy any static build-up. Also, grease on the BGW transferred from lenses can attract dust. Clean any grease marks off the lenses. MARKS ON CR-39 LENSES - A. - Page 35 Note to older Horizon II owners: Prior to serial number 6777, Horizon II machines had a two-piece stainless steel pattern retainer on the Lens Drive Assembly.
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Page 36: Electrical Failure
TROUBLESHOOTING ELECTRICAL FAILURE: No Electrical Power: A. Edger Circuit Breaker. The edger's circuit breaker is incorporated into the On/Off switch. To reset, move the switch to the Off position, and after pausing approximately 30 seconds, move the switch back to the On Position. B. -
Page 37: Motor Is Noisy
TROUBLESHOOTING A. Cutter Motor Mercury Switch malfunction. The Cutter Motor Mercury Switch is located inside the case top secured to the right hand side near the wiring harness. It is tucked up into the sound coat foam. 1. Ensure the switch is tied securely to the inside of the case and is parallel with the case top. -
Page 38: Cycle Irregularities
TROUBLESHOOTING CYCLE IRREGULARITIES: Edger Won’t Cycle: Mercury Switch Malfunction. 1. Check the wires of the main mercury switch, mounted on the Plexiglas shield, for breaks. 2. If the wires appear to be in good condition, verify the switch operation by unplugging the switch's amp-style connector and placing a jumper wire in it's wiring harness receptacle. - Page 39 TROUBLESHOOTING 1. Switch the power to the Edger to the OFF position. 2. Connect one meter lead to the RED wire at the base of the Mercury Relay. 3. Connect the other lead to any large White neutral wire. 4. Switch the power to the ON position. When the power is switched on 115 volts AC (230 VAC where applicable) should be read on the meter.
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Page 40: Carriage Flow
TROUBLESHOOTING A. The Bevel Guide Wheel is set too low. If the BGW is not set the proper distance from the cutting blades, the lens may ride up on the edge of the Teflon ring. Follow the procedures on Page 28 for setting BGW height. B. - Page 41 TROUBLESHOOTING Blocked Flow Restrictor. Locate the RF354 restrictor, located in airline #8 of the Cutter Motor Carriage Flow Cylinder, and follow the procedures on Page 49 for removal and cleaning. Solenoid Valve Malfunction. Refer to Page 45 for Solenoid identification and troubleshooting. CUTTER MOTOR FLOW TO THE RIGHT IS TOO SLOW OR WILL NOT FLOW AT ALL: Blocked Flow Restrictor.
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Page 42: Lens Drive Assembly
TROUBLESHOOTING FLOW CONTROLLED CYCLE WILL NOT OPERATE: The Lens Drive Carriage flows forward at a steady rate even though the Flow Rate has been activated. A. Lens Drive Flow Rate too fast. If the forward flow rate of the Lens is too fast, the flow rate may not have time to activate. - Page 43 TROUBLESHOOTING If the diode pack is functioning, 55 Volts AC (115 VAC where applicable) or half of the line voltage should be measured. If no voltage is present, verify the AC voltage to the diode pack. 1. Connect one meter lead to the RED wire of the lens drive motor's three conductor amp-type connector.
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Page 44: Solenoid Valves
TROUBLESHOOTING If the motor now operates, replacement of the brake is indicated, refer to Page 52 replacing the Lens Drive Brake. If the motor still will not operate, replacement of the Lens Drive Assembly is indicated. SOLENOID VALVES: Identification: For identification purposes, the solenoid valves are referred to as numbers 1-5 from left to right. - Page 45 TROUBLESHOOTING control panel for any possible breaks. (Note: The #5 solenoid only functions when the finish button is activated.) Mechanical: If the indicator lights when the edger is cycled, a mechanical problem or malfunctioning coil is indicated. 1. Locate the mechanical override button on top of the solenoid. 2.
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Page 46: Flow Restrictors
TROUBLESHOOTING 3. Watch the LED indicator on the solenoid. After approximately ten seconds, the LED indicator should light, this will indicate power to the solenoid. Every revolution of the lens as the Actuator Magnet passes the proximity switch the light should go out momentarily. If the LED indicator fails to light, verify DC power using a voltmeter. - Page 47 TROUBLESHOOTING RF354 - This is a Flow Restrictor. Located in airline #5, it regulates the rearward movement of the Lens Drive carriage. CUTTER MOTOR FLOW CYLINDER: RF354 - This is a Flow Restrictor. Located in airline #8, it regulates the Cutter Motor carriage movement to the left.
- Page 48 TROUBLESHOOTING 1. Disconnect the air from the right side of the edger and install the safety air gun supplied in the edger's accessory kit. 2. Remove the Restrictor/Check Valve from the airline. 3. Use the air gun to force air through the Restrictor/Check Valve in both directions.
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Page 49: Parts Replacement
PARTS REPLACEMENT REPLACING THE CUTTER MOTOR: 1. Switch the POWER to the Edger to the "OFF" position. 2. Remove the cutter assembly from the motor. 3. Unplug the motor from the controller by rotating the connector. 4. Remove the four bolts holding the cutter motor to the cutter motor cradle. 5. -
Page 50: Replacing The Lens Drive Assembly
PARTS REPLACEMENT 13. Set the pressure gauge on the front of the panel to 35 psi and check for air leaks. 14. Connect the power cord to a wall outlet. 15. Switch the power to the "ON" position and verify operation. REPLACING THE LENS DRIVE ASSEMBLY: 1. -
Page 51: Replacing The Solenoid Valve
PARTS REPLACEMENT 7. Align the set screws on the locking collar with the flats on the motor shaft and position the collar on the shaft so that only the chamfered end of the shaft (about 1/16") protrudes past the collar. 8. -
Page 52: Replacement Fuses
PARTS REPLACEMENT screws. 7. Reconnect the airlines to the valve block as noted in step four. 8. Connect the assembly to the wiring harness at its 6 conductor amp-type connector. 9. Reconnect the air supply to the right side of the edger and check for air leaks. REPLACEMENT FUSES: The fuse ratings are as follows: Motor Power Fuse:... -
Page 53: Bosch Motor Addendum
BOSCH MOTOR ADDENDUM Replacing the cutter inserts: Using the “TORX” wrench provided in the accessory kit, loosen the screws that secure the retaining clamps. Note: A common mistake is to use an Allen wrench to remove the TORX screws. This will strip the screws, making the inserts nearly impossible to remove. -
Page 54: Resharpening Service
BOSCH MOTOR ADDENDUM Resharpening Service: All National Optronics carbide cutter inserts, barring disposable carbide inserts, are entitled to receive two resharpenings at no charge. After two resharpenings, the inserts are worn out of tolerance and need to be replaced. The normal resharpening turn-around time is 24-48 hours from receipt of the insert set at the factory. - Page 59 socket Vacuum Switch On / Off Vacuum Plug socket socket Socket Power socket socket socket Diode/MOV...
- Page 61 H-II Accessory Kit Parts List 1 22244 HV-B Teflon Ring 1 73151 (Outer) Clamp O-Ring 1 73166 Replaceable RSC Pad 1 73168 Half-Eye Replaceable RSC Pad 2 65232 T-15 #6-32 x 3/8" Lg FHCS 3 (HDW) 6-32 x 3/8" Flathead Screws 1 74262 Quik Disconnect 1 74272 Male Coupler Fitting 1 87260 Blow Gun...
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when troubleshooting the Horizon II Ophthalmic Lens Edging Machine, the steps within a given category should be followed in the sequence given.