The Q-2100 Lens system utilizes digital free form crown glass molds during the lens production process.  There is an infrequent possibility that a mold may break during production. Use the following tips to diagnose the reason.

Mold Breakage During the Demolding Process

Possible Cause #1: Mold was directly placed into the soaking solution before one mold was separated from the mold assembly and while still hot. This can cause thermal shock to the mold.

Solution: Demold one of the molds from the mold assembly prior to placing in the Q-Soak solution

Possible Cause #2: Improper technique when using the demolding tool

Solution: The operator needs to pry (not twist) the molds apart with the proper Optical Dynamics demolding tool. If the operator twists the demolding tool the corners of the tool may have stressed the mold to break or chip.

Mold Breakage Inside the Post Cure Chamber

Possible Cause: The mold assembly may not have been processed in a timely manner.

Solution: Ensure that the mold assembly is immediately placed into the Post Cure chamber after the initial does of light in the Main Chamber.

For additional technical support, please call the Bob’s at 800-797-2743 ext. 276 or ext. 283

Don’t forget to regularly clean your Q-2100 Digital Lens System. The production process involves varying materials that produce small amounts of debris with each job processed. Buildup and leftover residue can cause your unit to perform below its optimal levels. Keep your system looking  and running like new with the following daily & weekly tasks.

Daily Maintenance

• Keep production area and machines clean wiping up any spills
• Remove and clean out excess fluid from the spin bowls and blot dry
• Clean excess coating build up from the spin stages
• Wipe down the drawers in the main chamber and post cure chamber
• Visually inspect the filter plates for any residue and wipe clean with Kaydrys and Q-Spray if necessary
• Ensure that all molds are cleaned and returned to the mold storage cabinet and never leave molds to soak overnight
• Top off all cleaning solutions and monomer as needed

Weekly Maintenance

• Remove the Q-2100’s front panels and visually inspect the air filters. Clean the filters with tap water and a mild soap if necessary. Blot dry and allow to dry overnight before returning to the panel
• With the oven at room temperature, clean the glass plate in the top of the oven box (DO NOT attempt to clean the glass while the oven is hot). Use Q-Spray and a clean, nonabrasive cloth to clean. Reinstall the front panels
• Change Q-Soak solutions at least once per week unless required more frequently due to volume or contamination
• Remove spin bowls to soak overnight in a separate tub or bucket and then scrub with a scrub pad and rinse with hot water. Due to volume or debris build up this process may be required more frequently than once per week.
• Change scrub pads as needed

After processing a job, your molds will normally have some monomer residue and flashing stuck to the surface. All excess debris must be removed before the mold can be used again successfully.  Cleaned molds must be stored properly to guarantee mold safety while the mold is not in use. Also, proper mold storage simplifies the picking process when the mold is needed again.

Scrub-A-Dub

Molds must be cleaned after each use. Molds should be left in the soaking bins for at least 5 minutes before cleaning.  Scrub molds thoroughly with the disposable mold scrubber pads.  Pay special attention to edges.  Rinse molds with running water if it is available.  If running water is not available, use a container of tap water. (Remember to change the rinse container water frequently.)  Spray rinsed molds immediately with Q-Spray and wipe them dry.  Never store a wet mold.

TIP: Thoroughly clean and dry all molds. Anything left on a mold can cause an issue the next time it is used. This includes water spots.

The Q-2100 Lens System comes with several hundred digital free form molds.  It is very important that they are stored properly in order to keep them organized.  Each space in the mold storage unit is labeled for one specific mold.  Make sure the mold you place there is the right one.

Pick a clean and dry mold.  Read the mold designation near the edge of the mold and find the proper storage location in the storage unit.  Put the mold back into its wrapper and put it into the allotted space.  Do not put a mold into a space that is already occupied by another mold.  Be careful not to bump molds against anything while storing them.

TIP: Always store molds properly. The protective wrapper prevents scratches and can help identify molds. Return molds to their proper storage locations so you can find them quickly.

Instant Replay:

1. Take mold from soaking bin and scrub
2. Rinse mold
3. Spray mold with Q-Spray and dry
4. Place mold in protective wrapper
5. Return mold to proper storage location

Prior to lens production,  always make sure the molds are loaded properly, the syringes are positioned correctly and the filters and tips are affixed accurately. Below are images to help walk you through the process.

Don’t worry, if a lens falls into the post cure oven, follow these simple steps to remove it.

Immediately turn off the machine.

Disconnect all power and data cables from the post cure unit

Remove the fill stand set it aside

Tilt the post cure unit onto its back

Turn the machine around so that the fill stand plate is facing you

Tilt machine toward you and set the machine upside show on the fill stand plate with the drawer facing you

Tilt the unit toward you so that the drawer faces the floor

Open the drawer and gently shake the unit if necessary

The lens should fall out

When returning your nanoCLEAR AR unit for service, always remember to follow the packing instructions correctly to prevent damage and unnecessary repairs.

Located in the back of the nanoCLEAR AR unit:

• Remove power cord
• Remove network data cable
• Remove data cable from wash module
• Remove video PC cable
• Remove high pressure supply hose
• Remove drain hose to wash module
• Remove all chemistry inlet tubing and replace with white caps
• Remove vacuum inlet
• Remove monitor from stand
• Remove monitor stand & push monitor plug down the tube that it is housed in

Located in side your nanoCLEAR AR system:

• Remove black mold stages
• Remove wash bowl ring
• Remove chemistry ring
• Remove chemistry bowl liner and discard
• Remove chemistry bowl and clean all chemistry from bowl
• Remove tips and filters and replace with red caps

Lock motion arm into position to prevent movement. If possible, place the motion arm in the chemistry bowl position and lower the arm. When the motion arm reaches the lowest point press STOP COATING BUTTON. Place bubble warp or packing material on either side of motion arm to prevent movement and install the shipping bracket provided.

Placing nanoCLEAR AR system in the special system box:

• Place tape or the shrink wrap it came with on the front door panel to prevent door from opening during shipping

• Gently place nanoCLEAR AR system into box making sure it rests inside the foam cut out inside of box
• Gently place the top foam insert on top of the nanoCLEAR AR system and push into place
• Close box and remove any labeling on the outside
• Tape box closed and place the appropriate shipping labels on the outside

When your system has been boxed up and/or you have any questions, please call Optical Dynamics Technical Support at 8000-587-2743.

Topic: You are getting ready to process a job or you have tried to process a job and the lenses didn’t cure properly when you notice that a message line has appeared on the upper left side of your Post Cure menu screen that reads SERVICE REQUIRED PRESS HELP.

The Reason Why: Your Post Cure Unit controls all of the functions for the Main Chamber.  It runs checks on the lamps, lamp intensity, filament power as well as the temperature of the heating oven from the time the unit it is turned on until you turn the unit off.  The System also monitors the current coming into your system and keeps track of the age of your lamps and air filter.  If there is something that the system checks that is out of calibration the SERVICE REQUIRED PRESS HELP line will appear in the upper left portion of the main menu screen.

The Fix: When you press the HELP button located next to the main menu screen you will get a screen that looks like this:

01         OK       Post Cure Temperature

02         OK       Light Intensity

03         OK       Lamp Power

04         OK       Filament Heat Power

05         OK       Lamp On Time

06         OK       Post Cure Heaters

07         OK       Lamp Temperature

08         OK       Line Voltage

09         OK       Communications

Any error detected will be highlighted and will have SERVICE in place of OK.

Example:  03      SERVICE   Lamp Power

If SERVICE appears, select the item that indicates service required and press the encoder to get specific instructions regarding the error and how to proceed in troubleshooting.

The instructions may guide you as to how to repair this issue or it may guide you to call the Technical Support Team at Optical Dynamics (1800-587-2743 Ext. 276 or 283)

Utilize the below diagrams when reconnecting your nanoCLEAR AR unit, wash pump and computer.