NATIONAL
INCORPORATED
The 2G Generator
User's Manual
February 14, 2002

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Warnings, Cautions, and Notes
as Used in This Publication
Warning
Warning notices are used in this publication to emphasize that hazardous voltages,
currents, temperatures, or other conditions that could cause personal injury exist in this
equipment or may be associated with its use.
In situations where inattention could cause either personal injury or damage to
equipment, a Warning notice is used.
Caution
Caution notices are used where equipment might be damaged if care is not taken.
Note
Notes merely call attention to information that is especially significant to understanding and
operating the equipment.
This document is based on information available at the time of its publication. While efforts
have been made to be accurate, the information contained herein does not purport to cover all
details or variations in hardware or software, nor to provide for every possible contingency in
connection with installation, operation, or maintenance. National Optronics assumes no
obligation of notice to holders of this document with respect to changes subsequently made.
©Copyright 1998-2002, National Optronics, Inc.
All Rights Reserved.

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Preface
Revisions to This Manual
Software versions 3.xx and 4.xx reflect internal hardware differences that are
transparent to the user; that is, screen appearance and machine operation is
identical.
The Communications Screen changed in software versions 2.55 and 3.15. The
fields are similar to those found on the NOP 6E and 4T. For more details, refer to
the end of Chapter 4.
In Version 3.29, there are also changes on the both Lens Material Screens
(formerly called the Blank Materials Screens), as well as a new screen, the Lap
Material Screen.
This manual was released with Software Version 3.29. Future software upgrades
do not necessarily affect the manual. Call Technical Support (434) 295-9126) if
you feel you need a newer manual.
Related Publications
The Optronics 4T User’s Manual
The Optronics 6E User’s Manual
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Contents
Chapter 1
Before You Begin.................................................................................................1-1
General.............................................................................................................................. 1-1
For Further Assistance................................................................................................ 1-1
To Order Parts:................................................................................................... 1-1
For Technical Assistance: .................................................................................. 1-1
Introduction....................................................................................................................... 1-2
Installation Procedures...................................................................................................... 1-3
2G Boot-Up Sequence ...................................................................................................... 1-7
The First Time After a Black Box Is Installed ................................................... 1-7
Chapter 2
Entering a Job......................................................................................................2-1
Process Overview.............................................................................................................. 2-1
Entering a Job ................................................................................................................... 2-1
Entering a Job Direct (without a Host Computer/Server) .......................................... 2-2
Job Screen................................................................................................................... 2-2
Job Number ........................................................................................................ 2-3
Base Curve ......................................................................................................... 2-3
Cross Curve........................................................................................................ 2-3
Center Thickness................................................................................................ 2-4
Crib Diameter..................................................................................................... 2-4
Pin Bevel:........................................................................................................... 2-4
Layout Axis........................................................................................................ 2-4
Prism .................................................................................................................. 2-4
Prism Axis.......................................................................................................... 2-4
Prism Direction .................................................................................................. 2-5
Front Curve ........................................................................................................ 2-5
Back Curve......................................................................................................... 2-5
Edge Thickness .................................................................................................. 2-5
Diameter............................................................................................................. 2-5
Material .............................................................................................................. 2-5
Block Diameter .................................................................................................. 2-6
Cut Matching Lap .............................................................................................. 2-6
Chapter 3
Generating a Lens ...............................................................................................3-1
Process Overview.............................................................................................................. 3-1
Generating a Lens ............................................................................................................. 3-1
Blocking ..................................................................................................................... 3-1
Setup Screen ............................................................................................................... 3-1
Job Input ..................................................................................................................... 3-1
Mounting the Lens Blank ........................................................................................... 3-2
Running a Lens........................................................................................................... 3-2
Lap Cutting ....................................................................................................................... 3-3
Process Overview............................................................................................... 3-3
Lap Screen.................................................................................................................. 3-3
Base Curve ......................................................................................................... 3-3
Cross Curve........................................................................................................ 3-4
Pad Thickness .................................................................................................... 3-4
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Contents
Lap Manufacturer............................................................................................... 3-4
Lap Type ............................................................................................................ 3-4
Blank Base Curve............................................................................................... 3-4
Blank Cross Curve ............................................................................................. 3-4
Diameter............................................................................................................. 3-4
Center Thickness................................................................................................ 3-5
Center Removal.................................................................................................. 3-5
“center removal” and “edge removal” at bottom ............................................... 3-5
Cutting a Lap .............................................................................................................. 3-5
Chapter 4
Setting Up the 2G.................................................................................................4-1
Setup Screen...................................................................................................................... 4-1
Setup Screen Field Descriptions................................................................................. 4-2
Block Brand ....................................................................................................... 4-2
Block Diameter for Sag...................................................................................... 4-2
Blade Radius ...................................................................................................... 4-2
End Mill Flute Length........................................................................................ 4-2
Prism Arrow Location........................................................................................ 4-2
Screen Flowchart........................................................................................................ 4-3
Calibration Screen ...................................................................................................... 4-5
Axis Bias ............................................................................................................ 4-5
Thickness Bias ................................................................................................... 4-6
Lens Curve Bias ................................................................................................. 4-6
Lap Curve Bias................................................................................................... 4-6
Lap Holder Thickness ........................................................................................ 4-6
-6.00D Correction .............................................................................................. 4-6
+6.00D Correction ............................................................................................. 4-6
Range Calibration............................................................................................... 4-6
Axis Calibration Screen............................................................................................. 4-7
Lens Material Screen.................................................................................................. 4-8
Lens Material Screen (Finish and Rough)................................................................. 4-9
Material .............................................................................................................. 4-9
Sep (Finish & Rough) ........................................................................................ 4-9
Feed (Finish & Rough)....................................................................................... 4-9
TO ...................................................................................................................... 4-9
RPM ................................................................................................................. 4-10
Tool (Tool Index)............................................................................................. 4-10
$ - Final Pass Is Skim Cut ................................................................................ 4-10
# - Gentle Entry into Lens................................................................................ 4-10
& - Variable Spiral Separation ......................................................................... 4-10
Lens Material Screen (Cribbing) ............................................................................. 4-11
For .................................................................................................................... 4-11
Bck ................................................................................................................... 4-11
PBW................................................................................................................. 4-11
Ring Index........................................................................................................ 4-11
Lap Material Screen ................................................................................................. 4-12
Sep (Finish & Rough) ...................................................................................... 4-12
Feed Rate.......................................................................................................... 4-12
Take Off ........................................................................................................... 4-13
Pad Thickness .................................................................................................. 4-13
Skim Cut .......................................................................................................... 4-13
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Contents
Tool (Tool Index)............................................................................................. 4-13
Diagnostic Screen..................................................................................................... 4-14
Axis/Depth/Radius ........................................................................................... 4-14
Start Switch ...................................................................................................... 4-14
Start Lamp........................................................................................................ 4-14
Emergency Loop .............................................................................................. 4-15
Keypad ............................................................................................................. 4-15
Serial Loopback ............................................................................................... 4-15
ARCNet Connected.......................................................................................... 4-15
Communications Screen........................................................................................... 4-16
Statistics Screen........................................................................................................ 4-18
Cycle Stats........................................................................................................ 4-18
Maintenance Stats ............................................................................................ 4-18
Servo Burn-In Screen ............................................................................................... 4-19
Move Carriages for Cleaning ................................................................................... 4-20
Chapter 5
Calibration ...........................................................................................................5-1
Calibration......................................................................................................................... 5-1
To Calibrate the 2G:........................................................................................... 5-1
Lenses: Lens Curve Bias ............................................................................................ 5-2
Calibrate Lens Curve Procedure ........................................................................ 5-2
Verify the Lens Curve (Carbide) Setting ........................................................... 5-3
Verify the Lens Curve Bias Setting.................................................................... 5-4
Lap Curve Bias........................................................................................................... 5-4
Adjusting the Lens Curves ......................................................................................... 5-5
Adjusting Lap Curves................................................................................................. 5-5
Thickness.................................................................................................................... 5-6
To Calibrate the Thickness:................................................................................ 5-6
Calibrating the Axis.................................................................................................... 5-7
Chapter 6
Periodic Maintenance and Troubleshooting.....................................................6-1
Periodic Maintenance........................................................................................................ 6-1
Daily ........................................................................................................................... 6-1
Cleaning the Interior .......................................................................................... 6-1
Drain the Air Filter............................................................................................. 6-1
Check the Air Pressure....................................................................................... 6-2
Every 200 to 300 Cycles............................................................................................. 6-2
Change the Vacuum Bags .................................................................................. 6-2
Every Two Weeks ...................................................................................................... 6-2
Clean the Collet Assembly and Cutter Motor .................................................... 6-2
Clean the Electronics Enclosure Fan Filter ........................................................ 6-3
As Needed .................................................................................................................. 6-3
Change the Cutting Tool .................................................................................... 6-3
Every Cutter Change .................................................................................................. 6-4
Clean the Collet and Collet Nut ......................................................................... 6-4
Troubleshooting ................................................................................................................ 6-5
Quick Reference ......................................................................................................... 6-5
Contents
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Contents
Unit does not boot up ......................................................................................... 6-5
Cycle will not start ............................................................................................. 6-5
Carriages stop mid-cycle.................................................................................... 6-5
Unit resets mid-cycle.......................................................................................... 6-5
Curves incorrect ................................................................................................. 6-5
Thickness incorrect ............................................................................................ 6-5
Axis incorrect..................................................................................................... 6-5
Lens Quality ............................................................................................................... 6-5
Unfined or gray areas toward the outside edge of the lens................................. 6-6
Unfined or gray areas at the center of the lens ................................................... 6-6
Unfined area resembling an hour glass or off axis condition ............................. 6-6
Hump or depression at or near the center of the lens ......................................... 6-6
Excessive chatter................................................................................................ 6-6
Center thickness is inconsistent.......................................................................... 6-6
Prism direction incorrect .................................................................................... 6-7
Prism amount incorrect ...................................................................................... 6-7
Job Entry Screen......................................................................................................... 6-8
Screen entries are barely visible......................................................................... 6-8
“Invalid Value” message appears at the bottom of screen ................................. 6-8
Cross Curve........................................................................................................ 6-8
Center Thickness................................................................................................ 6-8
Edge Thickness .................................................................................................. 6-8
Cycle Irregularities ..................................................................................................... 6-9
Job entry data is accepted, however, cycle won't start ....................................... 6-9
Collet appears to stutter or stall during the cutting cycle ................................... 6-9
Cycle times too long........................................................................................... 6-9
Carriages move into cutting position, however neither cutter motor nor vacuum
operate..................................................................................................................... 6-10
Mercury Relay not functioning. ....................................................................... 6-10
Cutter Motor ............................................................................................................. 6-11
Motor does not run........................................................................................... 6-11
Motor is Noisy ................................................................................................. 6-11
Processor Initialization Failure (Start Up Failure) ................................................... 6-12
Blown 20 Volt Power Supply Fuse .................................................................. 6-12
Home Switch Malfunction ............................................................................... 6-12
Servo Motor Encoder Malfunction................................................................... 6-13
Blown 5 Volt Fuse ........................................................................................... 6-13
Encoder and Home Switch Diagnostics ................................................................... 6-13
Servo Motor Malfunction................................................................................. 6-14
Checking and Adjusting Voltages ............................................................................ 6-14
Preparation ....................................................................................................... 6-15
Checking and Adjusting the 5 Volt DC Processor Voltage.............................. 6-15
Checking and Adjusting the 20 Volt DC Processor Voltage............................ 6-15
Checking the Power Supply Input Voltages..................................................... 6-15
Transformer Supply Voltage............................................................................ 6-16
24 Volt AC 4 AMP, Output ............................................................................. 6-16
8 Volt AC, Output ............................................................................................ 6-16
24 Volt AC, 0.2 AMP Output .......................................................................... 6-16
Parts Replacement........................................................................................................... 6-17
Replacing the Cutter Motor ...................................................................................... 6-17
Replacing the Cutter Motor Controller..................................................................... 6-17
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Contents
Replacing the Electronics Enclosure ........................................................................ 6-18
Replacing a Servo Motor.......................................................................................... 6-19
Replacing the Home Switches.................................................................................. 6-19
Replacement Parts List ............................................................................................. 6-20
Chip Chute ....................................................................................................... 6-20
Case Top .......................................................................................................... 6-20
Pneumatic......................................................................................................... 6-21
Electrical .......................................................................................................... 6-21
Cutter Motor..................................................................................................... 6-21
Vacuum ............................................................................................................ 6-21
Motion Control................................................................................................. 6-21
Accessories....................................................................................................... 6-22
Cutters .............................................................................................................. 6-22
Collet Assembly............................................................................................... 6-22
Appendix A
Control Panel & Monitor Descriptions ............................................................ A-1
Control Panels ........................................................................................................... A-1
Right Side panel ................................................................................................ A-1
Left Side panel .................................................................................................. A-1
Keypad....................................................................................................................... A-2
Monitor...................................................................................................................... A-2
Monitor Contrast Control .......................................................................................... A-3
Appendix B
Summary of Calibration Process ...................................................................... B-1
Calibration Summary................................................................................................. B-1
Appendix C
Error Codes......................................................................................................... C-1
Job Data Errors.......................................................................................................... C-1
Legal Range .......................................................................................................C-1
Invalid Value......................................................................................................C-1
Blade will contact the block!..............................................................................C-1
Blade will be within 0.5mm of block! Proceed with caution .............................C-1
Please verify and correct ....................................................................................C-1
Communication Errors .............................................................................................. C-2
LAN Hardware Failure ......................................................................................C-2
Duplicate LAN ID..............................................................................................C-2
LAN Receive Error ............................................................................................C-2
LAN Transmit Timeout......................................................................................C-2
LAN Receive Timeout .......................................................................................C-2
Appendix D
Specialty Lenses.................................................................................................. D-1
Bi-Concave Lenses.................................................................................................... D-1
Lenticular................................................................................................................... D-1
Myodisc..................................................................................................................... D-3
Off-Center Blocking.................................................................................................. D-3
Progressive ................................................................................................................ D-3
Saddle Back............................................................................................................... D-3
Contents
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Contents
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The 2G Generator User's Manual–February 14, 2002

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Document Outline

• Table of Contents
• Ch. 1 Before You Begin
  • Before You Begin
    • General
      • For Further Assistance
        • To Order Parts:
        • For Technical Assistance:
    • • Introduction
      • Installation Procedures
      • 2G Boot-Up Sequence
        • The First Time After a Black Box Is Installed
• Ch. 2 Entering a Job
  • Entering a Job
    • Process Overview
    • Entering a Job
      • Entering a Job Direct (without a Host Computer/Server)
      • Job Screen
        • • Job Number
          • Base Curve
          • Cross Curve
          • Center Thickness
          • Crib Diameter
          • Pin Bevel:
          • Layout Axis
          • Prism
          • Prism Axis
          • Prism Direction
          • Front Curve
          • Back Curve
          • Edge Thickness
          • Diameter
          • Material
          • Block Diameter
          • Cut Matching Lap
• Ch. 3 Generating a Lens
  • Process Overview
  • Generating a Lens
    • Generating a Lens
      • Blocking
      • Setup Screen
      • Job Input
      • Mounting the Lens Blank
      • Running a Lens
    • Lap Cutting
      • Process Overview
      • Lap Screen
        • Fields-Options
          • Base Curve
          • Cross Curve
          • Pad Thickness
          • Lap Manufacturer
          • Lap Type
          • Blank Base Curve
          • Blank Cross Curve
          • Diameter
          • Center Thickness
          • Center Removal
          • center removalŽ and edge removalŽ at bottom
      • Cutting a Lap
• Ch. 4 Setting Up the 2G
  • Setting Up the 2G
    • Setup Screen
      • Setup Screen Field Descriptions
        • Fields-Options
          • Block Brand
          • Block Diameter for Sag
          • Blade Radius
          • End Mill Flute Length
          • Prism Arrow Location
          • Default Pin Bevel
      • Screen Flowchart
      • Calibration Screen
        • Fields-Options
          • Axis Bias
          • Thickness Bias
          • Lens Curve Bias
          • Lap Curve Bias
          • Lap Holder Thickness
          • -6.00D Correction
          • +6.00D Correction
          • Range Calibration
        • Axis Calibration Screen
      • Lens Material Screen
        • Lens Material Screen (Finish and Rough)
          • Material
          • Sep (Finish & Rough)
          • Feed (Finish & Rough)
          • TO
          • RPM
          • Tool (Tool Index)
          • $ - Final Pass Is Skim Cut
          • # - Gentle Entry into Lens
          • & - Variable Spiral Separation
        • Lens Material Screen (Cribbing)
          • For
          • Bck
          • PBW
          • Ring Index
      • Lap Material Screen
        • Fields-Options
          • Sep (Finish & Rough)
          • Feed Rate
          • Take Off
          • Pad Thickness
          • Skim Cut
          • Tool (Tool Index)
      • Diagnostic Screen
        • Fields-Options
          • Axis/Depth/Radius
          • Start Switch
          • Start Lamp
          • Emergency Loop
          • Keypad
          • Serial Loopback
          • ARCNet Connected
      • Communications Screen
        • Comm Settings:
        • Comm Software:
      • Statistics Screen
        • Cycle Stats
        • Maintenance Stats
      • Servo Burn-In Screen
      • Move Carriages for Cleaning
• Ch. 5 Calibration
  • Calibration
    • Calibration
      • To Calibrate the 2G:
      • Lenses: Lens Curve Bias
        • Calibrate Lens Curve Procedure
        • Verify the Lens Curve (Carbide) Setting
        • Verify the Lens Curve Bias Setting
      • Lap Curve Bias
      • Adjusting the Lens Curves
      • Adjusting Lap Curves
      • Thickness
        • To Calibrate the Thickness:
      • Calibrating the Axis
• Ch. 6 Periodic Maintenance and Troubleshooting
  • Periodic Maintenance and Troubleshooting
    • Periodic Maintenance
      • Daily
        • Cleaning the Interior
        • Drain the Air Filter
        • Check the Air Pressure
      • Every 200 to 300 Cycles
        • Change the Vacuum Bags
      • Every Two Weeks
        • Clean the Collet Assembly and Cutter Motor
        • Clean the Electronics Enclosure Fan Filter
      • As Needed
        • Change the Cutting Tool
      • Every Cutter Change
        • Clean the Collet and Collet Nut
    • Troubleshooting
      • Quick Reference
        • Unit does not boot up
      • Lens Quality
        • Conditions & Solutions
          • Unfined or gray areas toward the outside edge of the lens
          • Unfined or gray areas at the center of the lens
          • Unfined area resembling an hour glass or off axis condition
          • Hump or depression at or near the center of the lens
          • Excessive chatter
          • Center thickness is inconsistent
          • Prism direction incorrect
          • Prism amount incorrect
      • Job Entry Screen
        • Conditions & Solutions
          • Screen entries are barely visible
          • Invalid ValueŽ message appears at the bottom of screen
          • Cross Curve
          • Center Thickness
          • Edge Thickness
      • Cycle Irregularities
        • Conditions & Solutions
          • Job entry data is accepted, however, cycle won't start
          • Collet appears to stutter or stall during the cutting cycle
          • Cycle times too long
        • Carriages move into cutting position, however neither cutter motor nor vacuum operate
          • Mercury Relay not functioning.
      • Cutter Motor
        • Conditions & Solutions
          • Motor does not run
          • Motor is Noisy
      • Processor Initialization Failure (Start Up Failure)
        • Conditions & Solutions
          • Blown 20 Volt Power Supply Fuse
          • Home Switch Malfunction
          • Servo Motor Encoder Malfunction
          • Blown 5 Volt Fuse
      • Encoder and Home Switch Diagnostics
        • Conditions & Solutions
          • Servo Motor Malfunction
      • Checking and Adjusting Voltages
        • How to's
          • Preparation
          • Checking and Adjusting the 5 Volt DC Processor Voltage
          • Checking and Adjusting the 20 Volt DC Processor Voltage
          • Checking the Power Supply Input Voltages
          • Transformer Supply Voltage
          • 24 Volt AC 4 AMP, Output
          • 8 Volt AC, Output
          • 24 Volt AC, 0.2 AMP Output
    • Parts Replacement
      • Replacing the Cutter Motor
      • Replacing the Cutter Motor Controller
      • Replacing the Electronics Enclosure
      • Replacing a Servo Motor
      • Replacing the Home Switches
      • Replacement Parts List
        • Chip Chute
          • Case Top
          • Pneumatic
          • Cutter Motor
          • Electrical
          • Vacuum
          • Motion Control
          • Accessories
          • Cutters
          • Collet Assembly
• Ap. A Control Panel & Monitor
  • Control Panel & Monitor Descriptions
    • Control Panels
      • Right Side panel
      • Left Side panel
    • Keypad
    • Monitor
    • Monitor Contrast Control
• Ap. B Calibration Summary
  • Summary of Calibration Process
    • Calibration Summary
• Ap. C Error Codes
  • Error Codes
    • Job Data Errors
      • • Legal Range
        • Invalid Value
        • WARNING!
        • WARNING!
        • Setup numbers are invalid.
    • Communication Errors
      • Categories
        • LAN Hardware Failure
        • Duplicate LAN ID
        • LAN Receive Error
        • LAN Receive Error
        • LAN Receive Error
        • LAN Transmit Timeout
        • LAN Receive Timeout
• Ap. D Specialty Lenses
  • Specialty Lenses
    • Bi-Concave Lenses
    • Lenticular
    • Myodisc
    • Off-Center Blocking
    • Progressive
    • Saddle Back

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