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BOSCH MOTOR ADDENDUM 

 

 

 
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 - 

53

 -

 

NATIONAL

INCORPORATED

 
Replacing the cutter inserts: 

 

1.

 

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. 

 

2.

 

Slip the insert out of the body. 

 

3.

 

Thoroughly clean the cutter body and the clamps in a solvent 

(acetone or alcohol) and blow them dry with the air gun supplied in the accessory kit. 

 

4.

 

Replace the inserts by pushing them as far as possible to the back 

of the cutter body.  This will ensure the alignment of the inserts. 

 

5.

 

Alternate the tightening of each screw 2-3 times, until the clamps 

are evenly seated and tightened securely. 
 

SAFETY NOTE: FAILURE TO SECURELY TIGHTEN THE INSERT CLAMPS 

PRESENTS A SAFTEY HAZARD.

 

 

 

 

Figure A1- Bosch Cutter Body 

 

 

Содержание Horizon II

Страница 1: ...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 Horizon II Edger INSTRUCTION OPERATION MAINTENANCE AND TROUBLE SHOOTING MANUAL ...

Страница 2: ...Horizon II edger should be lifted very carefully by two people Before attempting to move or lift the edger ensure that all electrical connections and the vacuum hose are disconnected from the edger To lift the edger each person should carefully lift the edger from the bottom of each edge using both hands Always assume power is on until you check and verify that the main power and or motor power sw...

Страница 3: ...te Control 16 Periphery Finishes 17 Grooving Procedures Rimless Procedures Roll and Bevel Procedures To Recut for Size Shelving Procedures Faceting Procedures Cutters 20 Removing Installing the Cutter Body Replacing the Cutter Inserts Special Capabilities 23 Pattern From A Pattern Duplication Pattern From A Lens Duplication Safety Features 24 PERIODIC MAINTENANCE On a Daily Basis 25 Every 300 to 5...

Страница 4: ...unctions 36 Cutter Motor 36 Cutter Motor Doesn t Run 36 Motor is Noisy 37 Cycle Irregularities 38 Edger Won t Cycle 38 Neither Motors Run 38 Carriage Flow 40 Lens Drive Assembly 42 Lens Drive Motor Continues to Run 42 Lens Drive Motor Doesn t Run 42 Solenoid Valves 44 Flow Restrictors 46 PARTS REPLACEMENT Replacing the Cutter Motor 49 Replacing the Control Panel 49 Replacing the Lens Drive Assembl...

Страница 5: ...iagram 56 Pneumatic Diagram 57 Wiring Diagram 58 Interconnecting Wiring Diagram 59 Control Panel Assembly 60 Accessory Kit Parts List 61 TABLE OF FIGURES Figure 1 Bench Layout Diagram 7 Figure 2 Control Panel 9 Figure 3 Sight Line and Guide for Bevel Placement 12 Figure 4 Front Curve Tracking System in Place 13 Figure 5 Multi Cam Tracking Bevel Placement System 14 Figure 6 Bodine Beveling Cutter B...

Страница 6: ...refuse Two tracking systems are supplied With the first a white Teflon bevel guide wheel accurately tracks the actual front of the lens With the second a bevel is placed on the lens by following a pre determined base curve of 2 4 5 6 7 or 8 through the use of cams Changes between tracking methods can easily be accomplished in 30 seconds Size and bevel placement adjustments on the Horizon II are ma...

Страница 7: ...side of the edger with the bench opening 3 There are two shipping bolts that need to be removed to operate the edger They are two socket head shipping bolts on the underside of the edger The bolts are tagged Remove these bolts to free the cutter motor carriage and the lens drive carriage 4 Pull the bevel guide wheel adjustment rod its control knob is on the right side of the edger fully to the rig...

Страница 8: ...e fitting of the filter regulator assembly 3 Verify the pressure is at 80 psi on the filter regulator gauge If not locate the adjustment knob on top of the filter regulator assembly Move the yellow locking ring to the up position adjust the pressure then push the yellow locking ring down into the locked position It is required that 80 psi be maintained for the edger to operate properly Clockwise w...

Страница 9: ...ker for overload protection Tracking Pressure Gauge Regulator Control Knob The pressure gauge indicates the pressure of the pattern against the pattern roller and the pressure of the bevel guide wheel on the lens It is factory set at 35 psi and if required can be adjusted by turning the knob directly under the gauge Chuck Blue This button simultaneously activates the lens and pattern clamps Since ...

Страница 10: ...eased The lens spindle and cutter motor will continue to rotate 2 When engaged during the second half of the cutting cycle finishing the lens spindle and cutter motor will continue to rotate but the cycle will not advance until the Pause button is released The Pause button is also a visual indicator as to whether the edger is in the roughing or finishing cycle as the switch light flashes during th...

Страница 11: ...ounter on the left side of the control will register the total number of cycles full and finish only of the edger It should initially read 20 100 cycles as the edger is tested prior to shipment Resettable Cycle Counter The upper cycle counter on the left side of the control panel is resettable similar to a trip odometer in an automobile The counter is provided for scheduling maintenance or measuri...

Страница 12: ... Set the desired size The sizing dial on the left side of the edger reads in millimeters and the indicator plate above the dial in centimeters The edger uses the U S convention of 36 5mm as the size on size setting for beveled lenses 5 Set the bevel placement by turning the knob on the right side of the edger either clockwise or counter clockwise This controls the position of the Teflon tracking w...

Страница 13: ...bevel guide wheel tracking system uses a Teflon wheel which tracks the front curve of the lens Fig 4 The position of the wheel is controlled by the knob on the right side of the edger Figure 4 Front Curve Tracking System in Place It is important that the edge of the Teflon guide wheel be concentric within a few thousandths of an inch as the bevel groove and facet placements on the lens are extreme...

Страница 14: ... 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 Figure 5 Multi Cam Tracking Bevel Placement System The Multi Cam System is most effective with 1 Half eyes 2 Irregular fronts such as executives or lenticulars 3 Lower base lenses when ...

Страница 15: ... left by pushing the bevel placement control rod This will allow clearance for the assembly 2 Slip the bevel guide wheel assembly from the mounting block and replace it with the cam follower assembly provided in the accessory kit 3 Secure the cam follower assembly by retightening the knob post lock The cam follower shaft position can be changed from one base curve to another by pulling or pushing ...

Страница 16: ...l Knob can then be set to a feedrate The higher the number on the dial the faster the feed The feedrate per lens revolution will range from approximately 1mm Setting 1 to 8mm Setting 5 Once the lens has roughed down the operator must release the Rimless and Pause buttons in order to finish the lens Use of this feature will prevent axis slippage when edging dense material lenses while allowing thes...

Страница 17: ...ng the front tracking bevel placement system Teflon wheel system It is suggested that the operator cut the lens using the multi cam system The lens should be cut oversize to check groove placement before bringing it down to final size Rimless Procedures Most insert sets with the exception of the modified hide a bevel cutters which have a 5o 7o or 12o rise can cut a rimless lens by engaging the Rim...

Страница 18: ... sports frames To achieve a shelf on a lens first a specially crafted shelving cutter body is needed as well as shelving blades These are not included with the basic equipment If interested please contact the factory for more details 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 ...

Страница 19: ...bly to the proper position and tighten the post lock knob 4 Mount the rimless pattern specified by the frame manufacturer and engage the Rimless button Set the size with the required 2mm overset Edge both the right and the left lenses as rimless to ensure uniformity of the facet between both sides 5 Bring them both down to the appropriate finished size 6 Remove the rimless pattern and release the ...

Страница 20: ...are also available There is a page towards the back of this manual that shows a complete listing of cutters for the Horizon II Removing Installing the Cutter Body To remove the cutter body from the motor 1 Turn the control panel power switch OFF Release the clasps on the side of the edger and raise the top case 2 The motor controller is located on the right side of edger Turn the toggle switch on ...

Страница 21: ...placing the Cutter Insert 1 Using the TORX wrench provided in the accessory kit loosen the screw that secures the retaining clamp Note A common mistake is to use an Allen wrench to remove the TORX screws This will strip the screw making the insert nearly impossible to remove 2 Slip the insert out of the body 3 Thoroughly clean the cutter body and the clamp in a solvent acetone or alcohol and blow ...

Страница 22: ...98 Page 22 NATIONAL INCORPORATED 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 Figure 6 Bodine Beveling Cutter ...

Страница 23: ... Duplication To duplicate a pattern from a lens 1 Determine the mechanical center of the lens using a protractor or a box a graph Using the special pattern from a lens PFL brass adaptor in the accessory kit block the lens on the concave side with a LEAP pad 2 Place the lens on the edger s pattern retainer as you would a pattern 3 Utilizing the special pattern duplicator adaptor PDA found in the ac...

Страница 24: ...exiglas lid from being opened during the cutting cycle until the cutter motor has fully retracted behind its shields at the end of the cycle Plexiglas Lid Mercury Switch The mercury switch located on the Plexiglas lid prevents the cycle from starting before the lid is closed Cutter Motor Mercury Switch The cutter motor mercury switch located inside the case top to the right of the edger prevents t...

Страница 25: ...e back right corner of the Horizon II to the down position This will turn on the vacuum independently of the edger s operation 5 Vacuum debris from the inside of the edger with the crevice tool being careful not to disturb the control wiring Then depress the trigger on the air gun to blow hard to reach debris into the path of the crevice tool ensuring that the edger is clean 6 Reverse steps 4 thro...

Страница 26: ...to the flat back plate Check the Right Side Clamp Plug If the rubber plug that goes into the right side clamp is worn the clamp does not hold as well as it should The result could be twisting of the lenses on the blocks or the brass portion of the clamp could damage the back surface of the lenses Replace the clamp plug every thirty days To change the plug style clamp pad 1 Remove the old plug and ...

Страница 27: ... canister 4 Expand the bag around the inside of the canister 5 Squeeze the ends of the spring clamp securing the filter bag to the inlet cage on the underside of the vacuum head and slide it off the inlet cage 6 Slip the filter bag off of the inlet cage and dispose of properly 7 Inspect the foam filter sleeve for tears or holes Clean or replace as necessary 8 Slip a fresh filter bag completely ove...

Страница 28: ...6 Fax 888 239 0778 Revision Date 11 98 Page 28 NATIONAL INCORPORATED 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 ...

Страница 29: ...r reference purposes the spindle shaft should make 1 revolution in approximately 9 4 seconds CARRIAGE FLOW RATES The carriage flow rates are set by the use of Flow Restrictors and are not adjustable However the flow rates should be verified occasionally LENS DRIVE CARRIAGE FLOW RATE The lens drive carriage flow cylinder shaft should take 26 to 29 seconds to fully retract into its cylinder from the...

Страница 30: ...etween the diameter of the roughing cut and the finished beveled lens Consequently our method of differential measurement will result in a number greater than that of a traditional edger which excludes the bevel depth If adjustment is ever required it can be accomplished by tightening or loosening the set screw located in the end of the sizing screw Tightening the set screw will decrease the diffe...

Страница 31: ...uld be observed to prevent SERIOUS INJURY Some items that prove useful for troubleshooting purposes hex key set that came with the machine or a good set of Allen wrenches adjustable wrenches of various sizes silicone spray a digital multimeter checks voltage and continuity LENS QUALITY Bumps on periphery LARGE BUMPS ON BOTH TOP AND BOTTOM A The pattern tracking pressure is insufficient Ensure that...

Страница 32: ...e bevel at the end of the cycle Follow the procedures on Page 48 for removing and cleaning the differential flow restrictor Rough Finishes LINES ARE RUNNING ACROSS THE PERIPHERY OF THE LENS A The cutter insert is dull Install a new insert B The cutter is unbalanced Insure that the insert is fully seated in the cutter body PIT MARKS LIKE TINY BUBBLES APPEAR AROUND THE ENTIRE PERIPHERY OF THE LENS A...

Страница 33: ... in accordance with the maintenance procedures B Differential is closing too quickly Follow the procedures on Page 31 for verifying differential flow rate MARKS WHICH APPEAR TO BE SCRATCHES OR INDENTATIONS APPEAR ON THE FRONT OF THE LENS Although these marks appear to come from the Teflon Bevel Guide Wheel the Teflon ring itself is soft and self lubricating and cannot damage a lens at room tempera...

Страница 34: ...enses Off Axis Once set at the factory adjustments to the mechanical axis setting rarely need to be made Before attempting any adjustment the following steps should be performed to verify that the axis setting is indeed off Most perceived axis slippage is NOT the result of the edger being out of adjustment but rather the result of LEAP pad flex from a binding lens clamp dull cutters or reduced air...

Страница 35: ...er will need to be turned clockwise To adjust the mechanical axis 1 Loosen the center locking screw found on the pattern retainer 2 Loosening the rear adjusting screw and tighten the front will rotate the assembly counter clockwise Alternatively loosening the front adjusting screw and tightening the rear one will rotate the assembly clockwise When tightening the screws be sure to apply enough pres...

Страница 36: ... lens block not a full lens into the lens chuck press the Chuck button then press Start This procedure is referred to as cycling the Edger throughout this Troubleshooting Guide If the breaker holds the cutter motor controller will need to be replaced B Vacuum Motor is Bad Switch the Vacuum to OFF position and cycle the edger If the breaker holds the vacuum motor will need to be replaced C Lens Dri...

Страница 37: ...US INJURY could result from operating the Edger in this manner B Motor Controller failure Using a voltmeter verify the motor controller s supply voltage 1 Attach one lead of the meter to the white wire of the motor controller s amp style connector 2 Attach the other lead to the black wire at the motor s amp style connector 3 Ensure the meter is set to the AC voltage scale Close the case top and cy...

Страница 38: ...ercury switch is performed solely for diagnostic purposes and is NOT intended for operation SERIOUS INJURY could result from operating the Edger in this manner Neither Motors Run Carriages move into cutting position but neither motors run Mercury Relay Not Functioning Use a Voltmeter to verify operating voltages AC output voltage 1 Connect one meter lead to the top of the Mercury Relay 2 Connect t...

Страница 39: ... same plug 3 Ensure the meter is set to the DC voltage scale Close the casetop and cycle the edger 24 volts DC should read on the meter If voltage is present replacement of the relay is indicated If no trigger voltage is present the wires should be checked from the plug to the control for breaks If no breaks are found replacement of the control panel is indicated CUTTER MOTOR MOVES INTO THE ROUGHI...

Страница 40: ...onnections on the flow cylinder and the solenoid for leaks B Open Check Valve Locate the IFC 14 restrictor check valve located in airline 6 of the Lens Drive Carriage Flow Cylinder and follow the procedures on Page 49 for removal and cleaning LENS DRIVE WILL NOT FLOW FORWARD A Blocked Restrictor Locate the IFC 14 restrictor check valve in airline 6 of the Lens Drive Carriage Flow Cylinder and foll...

Страница 41: ...n the flow cylinder and the solenoid for leaks B Open Check Valve Locate the IFC 32 restrictor check valve located in airline 7 of the Lens Drive Carriage Flow Cylinder and follow the procedures on Page 49 for removal and cleaning DIFFERENTIAL WILL NOT OPEN A Blocked Flow Restrictor Locate the IFC 11 IFC 15 restrictor check valve assembly located in airline 9 and follow the procedures on Page 49 f...

Страница 42: ...the switch s amp type connector to the control panel if a break is indicated it must be located and repaired B Proximity Switch Malfunction Place a jumper wire from the Black wire to the Blue wire at the switch s amp type connector if the motor ceases to run the switch will need to be replaced C Control Panel Malfunction Disconnect the control panel from the wiring harness at its 15 conductor conn...

Страница 43: ... no voltage is measured at the motor s connector the wires should be checked for breaks Using a multimeter check the White Violet wire from the motor s connector to the Mercury Relay and the White wire from the motor s connector to the power receptacle for breaks D Faulty Lens Drive Capacitor If voltage is present at both connectors check the capacitor by measuring the AC output voltage 1 Connect ...

Страница 44: ...ption The solenoid valves are electro mechanical switches designed to control the flow of air in pneumatic systems Keep in mind that it is possible to have either an electrical or mechanical malfunction of the solenoid Electrical Each solenoid valve has a built in indicator light which can be used to determine if electrical power is reaching the solenoid If a malfunction is indicated due to the fa...

Страница 45: ...If the solenoid does not function after being cleaned replacement is indicated FLOW RATE SOLENOID The Flow Rate Solenoid is located next to the Lens Drive Flow Cylinder It is only active when the Rimless Lock Switch and the Pause Switch are both depressed The Flow Rate Solenoid allows for a gradual feed of the lens into the cutter when edging heavy polycarbonate lenses When activated the lens will...

Страница 46: ...nt After approximately ten seconds the meter should indicate approximately 24 volts DC Every revolution of the lens as the Actuator Magnet passes the Proximity Switch the meter should momentarily read zero volts If none or very low voltage is indicated use a multimeter to check the wires from the Amp style connector back to the control panel for breaks If a broken wire is indicated the break will ...

Страница 47: ...tions in series as one assembly Located in airline 9 the assembly regulates both the opening and the closing of the differential The Restrictors Check Valves utilize quick disconnect fittings to allow easy removal from and installation in the airlines Before removing from the airline take note of its orientation in the line as it must be reinstalled in the same manner The Restrictor Check Valve wi...

Страница 48: ...d 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 NOTE Because the Differential Restrictor assembly is two Restrictor Check Valves in series it will have to be disassembled cleaned and the reassembled Note the orientation of the parts so it can be reassembled so that the air flow ...

Страница 49: ...Disconnect the POWER from the wall outlet 3 Disconnect the air supply from the right side of the Edger 4 Note the airline connections on the regulator assembly and disconnect the airlines from the regulator 5 Disconnect the power switch at its three conductor amp type connector 6 Disconnect the Control Panel from the main wiring harness at it s 15 conductor amp type connector 7 Remove the eight bu...

Страница 50: ...ng holes in the base of the motor position the new assembly on the slide plate and secure it with the three socket head screws 6 Connect the motor to the wiring harness at it s 3 conductor amp type connector and secure the wires 7 Connect the power cord to the wall 8 Switch the power to the ON position 9 Follow the procedures on Page 36 for verifying and adjusting AXIS REPLACING THE LENS DRIVE BRA...

Страница 51: ... screws securing the solenoid to the valve block and lift the solenoid valve and gasket off of the block 5 Clean the top of the block being careful not to let debris fall into the block 6 Position the new solenoid valve and gasket on the block and secure with the two screws 7 Carefully insert the wiring connector into the receptacle at the end of the solenoid 8 Reconnect the air supply to the righ...

Страница 52: ...e 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 250 Volt 5A Slow Blow Motor Line Fuse 250 Volt 15A Slow Blow Transformer 300 Volt 0 5A Fast Acting Bussman GLR type ...

Страница 53: ...ll strip the screws making the inserts nearly impossible to remove 2 Slip the insert out of the body 3 Thoroughly clean the cutter body and the clamps in a solvent acetone or alcohol and blow them dry with the air gun supplied in the accessory kit 4 Replace the inserts by pushing them as far as possible to the back of the cutter body This will ensure the alignment of the inserts 5 Alternate the ti...

Страница 54: ... new insert set is sent as a replacement and is billed to your account This is done to ensure that your lab is not short an insert set When an insert is resharpened a notch is ground in the end to indicate that it has been resharpened Two notches indicate it has been resharpened twice and if returned to the factory it will automatically be replaced with a new set When returning the insert sets to ...

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Страница 58: ... White Lid All WHITE s are Neutral 14 Solenoids 120VAC 5 Lens plugged in Brake Mercury Switch 3 WHITE WHITE ORANGE Panel Solenoid Coil Resistance 580 ohms Lens 4 durring cycle 120VAC Diode Pack WHITE WHITE VIOLET Control Motor 2 Mercury 1 Drive Home power ON Cutter Drive 24VAC WHITE RED Voltages can also be taken with respect to GREEN instead of WHITE Light Sol 120VAC 15 2 5amp Coil s are activate...

Страница 59: ...E ORANGE Plug Solenoid Trans 77460 Spade Conn Motor socket pin socket socket 4 White Red 12 White Black 4 Brown Block Drive 77485 250F Quick Conn 1 Wht 10 Orange socket 2 Red 3 BLU skt Cutter Relay pin socket 6 White Brown 2 WHT skt 7 White Blue Control Panel 1 Red 2 9 Violet 1 Wht Blk 1 EA Pin L D Motor 13 Yellow 11 Yellow Valve pin socket socket 4 White Power 2 Black 2 pin socket socket pin pin ...

Страница 60: ......

Страница 61: ...g 1 74290 Street Elbow 1 73131 O Ring 1 24295 Bracket 1 90330 Multi Cam Follower Assembly 1 65210 Ball Plunger 1 88140 Camtracking Shaft 1 88152 Camtracking Post 1 88160 Camtracking Knob 1 88170 Camtracking Block 1 88210 Camtracking Ind Label 1 70210 Camtracking Follower Bearing 1 87462 5 32 T Handle 1 87472 3 32 T Handle 1 90055 Half Eye Clamp Body Assembly 1 65135 Half Eye Clamp Body 1 65180 Len...

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