User Manual - OptiPro eSX

User Manual – eSX
OptiPro Systems, LLC
User Manual – eSX
OptiPro Systems, LLC. Page 1 of 111 Last Modified: 8/27/2014

User Manual – eSX
1 Contents
2 Contacting OptiPro................................................................................................................................ 6
3 Document Revisions.............................................................................................................................. 7
4 Safety .................................................................................................................................................... 8
4.1 Employer’s Responsibilities........................................................................................................... 8
4.2 General Safety Concerns ............................................................................................................... 8
4.2.1 Personal Safety...................................................................................................................... 8
4.2.2 Electrical Safety ..................................................................................................................... 9
4.2.3 Pneumatic Safety .................................................................................................................. 9
4.2.4 Chemical Safety ..................................................................................................................... 9
4.3 Safe Operation of the Machine ..................................................................................................... 9
4.4 In An Emergency ......................................................................................................................... 10
5 Machine Overview and User Controls ................................................................................................ 11
5.1 Work Area and Machine Axes ..................................................................................................... 13
5.2 Operator Panel Interface ............................................................................................................ 14
5.2.1 Jog Panel ............................................................................................................................. 14
5.2.2 Jog Pendant ......................................................................................................................... 16
5.2.3 Door Interlock ..................................................................................................................... 17
5.2.4 Emergency Stop .................................................................................................................. 17
5.2.5 Coolant Recirculation Control ............................................................................................. 18
5.2.6 USB ports............................................................................................................................. 18
5.3 Utility Control Panel .................................................................................................................... 19
5.4 Vacuum Work Holding ................................................................................................................ 20
5.5 Coolant System ........................................................................................................................... 21
5.5.1 Coolant Tank ....................................................................................................................... 21
5.5.2 Centrifuge............................................................................................................................ 22
5.5.3 Spindle Chiller ..................................................................................................................... 23
5.6 Electrical Cabinet A/C unit .......................................................................................................... 23
5.7 Pneumatic Automatic Greaser .................................................................................................... 24
5.8 Tool Spindle & Tool Holder Precautions ..................................................................................... 25
User Manual – eSX
5.9 Work Holding Chucks .................................................................................................................. 27

5.10 Work and Tool Probing ............................................................................................................... 28
5.11 Integrated Spherometer ............................................................................................................. 29
6 Start Up, Shut Down, and Emergency Recovery Procedure ............................................................... 30
6.1 Startup ........................................................................................................................................ 30
6.1.1 Initial Power Up................................................................................................................... 30
6.1.2 Resuming From E-Stop or Auto Off ..................................................................................... 30
6.2 Shutdown .................................................................................................................................... 31
6.2.1 Retaining Main Power ......................................................................................................... 31
6.2.2 Full Power Down ................................................................................................................. 31
6.3 Emergency Stop .......................................................................................................................... 31
6.3.1 When to press E-STOP ........................................................................................................ 31
6.3.2 Returning machine to normal operation ............................................................................ 31
7 Software Interface .............................................................................................................................. 32
7.1 Screen Layout .............................................................................................................................. 32
7.2 G-Series Submenu ....................................................................................................................... 33
7.3 Manual Jog Mode........................................................................................................................ 34
7.4 Automatic Mode, for Jobs and External Programs ..................................................................... 35
7.4.1 Motion Stop (for non-emergencies) ................................................................................... 35
7.4.2 G-Code Viewer .................................................................................................................... 36
7.4.3 Loading External Programs ................................................................................................. 36
7.5 Tools and the Tool Library........................................................................................................... 37
7.5.1 Tool Library ......................................................................................................................... 37
7.5.2 Add, Delete, and Update Library Tools ............................................................................... 38
7.5.3 Ring Tools ............................................................................................................................ 38
7.5.4 Ball Tools ............................................................................................................................. 39
7.5.5 Edge Tools ........................................................................................................................... 40
7.5.6 End Mill Tools ...................................................................................................................... 41
7.5.7 Toroid Tools ........................................................................................................................ 42
7.5.8 RFID Tools............................................................................................................................ 43

User Manual – eSX
7.5.9 Scoop Tools ......................................................................................................................... 44

7.6 Creating and Running Jobs .......................................................................................................... 45
7.6.1 Loading an Existing Job ....................................................................................................... 45
7.6.2 Deleting an Existing Job ...................................................................................................... 46
7.6.3 Creating a New Job ............................................................................................................. 46
7.6.4 Executing a Process in a Job ................................................................................................ 82
7.7 Settings........................................................................................................................................ 83
7.7.1 Settings – Page 1 ................................................................................................................. 83
7.7.2 Settings – Page 2 ................................................................................................................. 84
8 Error Recovery and Troubleshooting .................................................................................................. 85
8.1 Coolant Flow Fault ...................................................................................................................... 85
8.1.1 Reading the Flow Monitor .................................................................................................. 85
8.1.2 Changing the Required Flow Rate ....................................................................................... 85
8.1.3 Cleaning if Necessary .......................................................................................................... 86
8.2 Recovering from Error Messages ................................................................................................ 86
9 Machine Maintenance ........................................................................................................................ 89
9.1 Daily Maintenance ...................................................................................................................... 89
9.1.1 Start of Shift ........................................................................................................................ 89
9.1.2 End of Shift .......................................................................................................................... 89
9.2 Weekly Maintenance .................................................................................................................. 89
9.3 Monthly Maintenance ................................................................................................................ 90
9.4 Semi-Annual Maintenance.......................................................................................................... 90
9.5 Yearly Maintenance .................................................................................................................... 90
9.6 3-Year Maintenance .................................................................................................................... 90
9.7 Cleaning the Centrifuge .............................................................................................................. 91
9.8 Replacing Existing Safety Windows............................................................................................. 92
9.9 Cleaning the Tool-holder and Spindle ......................................................................................... 97
9.10 Lubrication of Tool Spindle Locking Mechanism ........................................................................ 98
10 Appendices .......................................................................................................................................... 99
10.1 Tram Procedure .......................................................................................................................... 99

User Manual – eSX
10.1.1 Check Hydraulic Chuck Run Out ........................................................................................ 100

10.1.2 Accessing the Tram Screens .............................................................................................. 101
10.1.3 Tram – B Zero Screen ........................................................................................................ 101
10.1.4 Tram – Spindles Aligned .................................................................................................... 101
10.1.5 Tram – Center of B ............................................................................................................ 103
10.1.6 Tram – Pinch Test .............................................................................................................. 104
10.1.7 Tram – Tool Probe ............................................................................................................. 105
10.1.8 Tram – Lens Probe ............................................................................................................ 106
10.1.9 Validation .......................................................................................................................... 106
10.1.10 Tramming Tips............................................................................................................... 107
10.2 Manual Commands ................................................................................................................... 108
10.2.1 M Code List........................................................................................................................ 108
10.2.2 Manual Axis positioning .................................................................................................... 110
10.2.3 Spindle Command ............................................................................................................. 110
10.3 Spare Parts and Consumables................................................................................................... 111

User Manual – eSX
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
For Process and Technical Support

Contact: Advanced Processes Development (APD) Lab
Email: APD_Web@optipro.com

User Manual – eSX
3 Document Revisions
The following is a summary of changes to this document.
Table 3-1: Document Revision Summary
Release Dated Changes

2014, August  Initial Release

User Manual – eSX
4 Safety
Safe usage of the machine requires careful adherence to all safety protocols as 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. Operator safety is the number one priority at all times. Standard
shop safety protocols should always be observed to minimize mechanical, electrical, and chemical
hazards.
4.1 Employer’s Responsibilities

It is the employer’s responsibility to provide a safe working environment for all employees working with
and around the machine. This includes:
 Keeping the working area well illuminated.

 Training operators in all aspects of the operation of the machine.
 Keeping this manual clean, near the machine, and accessible to the operator.
 Following all relevant codes and regulations required by local or national regulatory bodies.
4.2 General Safety Concerns

4.2.1 Personal Safety
The following precautions should be taken when working in or around the machine to avoid severe
injury or death:
 When working inside the machine make sure that all motion is disabled by powering down
the machine and turning off the main air valve (See Section 6), and follow proper lock-
out/tag-out procedures.
 Never leave a loose part or tool in the work area.
 Avoid using any tools in pinch points when possible.
 Safety glasses must be worn at all times.
 Loose fitting clothing, long sleeves, neckties, jewelry and other objects or clothing that could
become caught by moving parts must not be worn.
 Rings, watches, and other jewelry can scratch or otherwise damage delicate machine
components and should not be worn.
 Long hair must be tied back.
 Always wear closed-toe footwear with a good quality tread.
 Avoid walking through or standing in water, coolant, or other spills. Clean up any spills
immediately following precautions outlined in the relevant MSDS.

User Manual – eSX
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.
4.2.3 Pneumatic Safety

Only a qualified technician should attempt to fix or adjust any component of the pneumatic system.
During the repair; the air system should be turned off and locked out.
4.2.4 Chemical Safety

All chemicals must be handled as specified by their Material Safety Data Sheets (MSDS). The MSDS can
be found in the Appendix of this manual if applicable.
4.3 Safe Operation of the Machine

This machine includes many safety features, however, the following guidelines must also be observed:
 Never operate the machine with any doors open or safety guards removed, disabled or
bypassed.
 Remove or properly secure all loose tools and work pieces before operating the machine.
 Keep hands and all other body parts outside of the machine when moving any axis or
spindle.
 Use reduced feed rates and extreme caution if a manual axis jog is necessary.
 Never aim or adjust coolant nozzles while spindles are moving.
 Clean all coolant leaks or spills immediately following precautions outlined in the relevant
MSDS.
 Do not tamper with, override, remove, or otherwise hinder the functionality of safety
equipment installed on the machine.
 Personal injury or equipment damage can be avoided when operating the machine as
designed.
 Always turn the chiller off before service or maintenance.

User Manual – eSX
4.4 In An Emergency
The emergency stop button is located on the operator control panel. When the emergency stop button
is pressed all machine motion and spindle motion is shut down. The controller, however, remains active
and the software functions may be used. Once the reason for the Emergency Stop has been determined
and corrected, normal operations may resume by turning the EMERGENCY STOP button clockwise until
it releases from its locked position. The RESET button must then be pressed to clear the error bar (found
in the top right corner of the display).
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. It is preferred to follow the instructions in Section 6 to
properly shut down the machine.
 Follow your company’s procedures and policies for emergency reporting, response,
resolution, and documentation.
 Once the cause of the emergency has been resolved the procedure for restarting the
machine can be found in Section 6 of this manual.

User Manual – eSX
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.
Work
Operator
Area
Panel
Coolant
Tank
Main
Door

User Manual – eSX
Figure 5-1: Machine Front View
Main Air
Entry
Pneumatics
Panel
Main Power
Disconnect Side Access
Door
Chiller
Left Side
Vacuum
Pump
Figure 5-2: Left-Rear Machine View
Right Side Electrical

Cabinet A/C
Side Access
Door
Pinch Valve
Assembly
Centrifuge
Grease
Coolant Through
Pump
Spindle Filters
Figure 5-3: Right-Rear Machine View

User Manual – eSX
5.1 Work Area and Machine Axes

The eSX has 5 different axes of movement. Figure 5-4 shows the direction for each axis and labels to
spindles.
Tool Spindle
Work Spindle
Figure 5-4: Machine Spindles and Axes
NOTE: If the machine is a twin spindle grinding machine, then the left spindle is referred to as S1 and the
right spindle is referred to as S3. A single spindle grinding machine refers to the spindle as the left spindle
or S1.

User Manual – eSX
5.2 Operator Panel Interface

The machine is equipped with a touch screen interface.
Touch Screen
Jog Panel
Figure 5-5: Operator Panel
5.2.1 Jog Panel

1 2 3 4 5 6 7 8 9 10 11 12 13 14
16 17
Not used on
OptiPro
equipment
15
18 19 20 21 22
Figure 5-6: Jog Panel

User Manual – eSX
Table 5-1: Jog Panel Button Descriptions
Button Label Description

1 Tool Changer Bypass (On/Off) Disables all tool changer functions and ignores tool changer errors.
2 Air Blast (On/Off) Activates foot switch to trigger air blast through the lower work
spindle to assist in part removal. Part fixture must have a thru hole;
else damage to machine could occur.
3 Vacuum (On/Off) Activates vacuum for work spindle part holding. Vacuum level can
be monitored and adjusted from the control panel, see Section 5.3.
4 Left Tool (Instantaneous) Release Left Spindle Tool (Release Enable must be active). WHEN
ALL MOTION HAS STOPPED, HOLD THE TOOL FIRMLY BEFORE
PRESSING BUTTON SO TOOL DOES NOT DROP AND CAUSE DAMAGE.
5 Release Enable (On/Off) Enables ability to release Left and Right tools from spindles.
6 Right Tool (Instantaneous) Release Right Spindle Tool (Release Enable must be active). WHEN
ALL MOTION HAS STOPPED, HOLD THE TOOL FIRMLY BEFORE
PRESSING BUTTON SO TOOL DOES NOT DROP AND CAUSE DAMAGE.
7 Coolant Auto (On/Off) Automatic coolant feed during cycle.
8 Coolant Manual (On/Off) Manually operates the coolant solenoid, turning coolant on and off.
9 Auto Mode Activates CNC Auto Mode for running programs (Section 7.4).
10 Manual Mode Activates CNC Manual Mode (Section 7.3).
11 MDI Command This button is not needed in the G-Series software.
12 Auto Off Used to power off servos and coolant at cycle end +5 minutes. To
activate, select “Auto Off” during a program in AUTO Mode. Air and
Vacuum will remain active. Press again to deactivate if needed.
13 Lights (On/Off) Workspace lighting.
14 Servos Turns Servos on if they are off.
15 Axis Jog Buttons Manually move machine axes.
16 Jog Mode Select Select between continuous and incremental jog modes.
17 Feed Rate Select Feed rate can be overridden during any manual or automatic
motion in any software mode, except during the referencing
routine. Feed Rate Override does not affect spindle speed.
18 Zero Axis Reference (see Section 6).
19 Single Single Block Processing (Used for machine diagnostics).
20 Reset Resets a part program or error condition.
21 Cycle Start Starts the currently loaded program.
22 Motion Stop Stops motion on all axes. DOES NOT STOP SPINDLE ROTATION.
CYCLE START can be pressed to continue program.

User Manual – eSX
5.2.2 Jog Pendant
Emergency
Stop
Feed Rate
Control
Axis Selection
+/- Movement
Jog Wheel
Figure 5-7: 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.
Jog Wheel The JOG WHEEL can be used to move all axes (X, Y, Z, 4, or 5). When Axis
Selection is on 4, the B-axis can be rotated. When Axis Selection is on 5,
the work spindle (S2) can be rotated.
Emergency Stop The EMERGENCY STOP (E-STOP) button should be used to stop the
machine if there is any danger to the operator, machine, or process. See
Section 6.3 for more information.
+ / - Movement Press to move the selected axis in the + or – direction.
See Fagor manual for additional information

User Manual – eSX
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.
Figure 5-8: Door Interlock Selector Switch
5.2.4 Emergency Stop

The EMERGENCY STOP (E-STOP) button should be used to stop the machine if there is any danger to the
operator, machine, or process. Once the button is pressed all motion will stop and servos will be turned
off. Function of the operator panel cannot be restored until the E-STOP button is released.
Figure 5-9: Emergency Stop Button
Twist in the direction of the arrows to release the E-STOP button. Pressing RESET then SERVOS on the
jog panel is also required to return the machine to a fully operational state. See Section 6.3 for more
information.

User Manual – eSX
5.2.5 Coolant Recirculation Control

The coolant recirculation system can be turned on and off by the buttons on the side of the operator
panel.
Coolant Recirc
On
Coolant Recirc
Off
USB Ports
Figure 5-10: Coolant Recirc On/Off, USB ports
5.2.6 USB ports

On the side of the Control Panel are standard USB ports (Figure 5-10) that connect to the CPU. These
ports can be used, just like on a personal computer, to connect peripheral hardware or memory sticks
for data transfer.
Caution: Never run processing programs directly from a USB drive; always copy programs to the internal
storage before running.

User Manual – eSX
5.3 Utility Control Panel

The components and controls shown here are described in various sections throughout this manual.
Main Air
Regulator
Vacuum
Drain Tube Main Air
Valve
Air Prep Mist

Separator Filter
Air Prep
Regulator Filter
Figure 5-11: Utility Control Panel
The pneumatic panel houses all of the air regulators and switches machine. They are set when your
machine is first installed by OptiPro in your facility, and should not require further adjustment.

User Manual – eSX
5.4 Vacuum Work Holding

The Vacuum Drain Tube (in Figure 5-11) collects the small amount of coolant that commonly leaks into
the vacuum system. The purpose of the vacuum drain tube is to collect this coolant before it can get to
and harm the vacuum pump. When the vacuum drain tube gets close to being filled with coolant, it must
be emptied using the drain valve at the base, in order to protect the vacuum pump.
Caution: When draining the vacuum drain tube, vacuum suction will be lost at the work piece. Be sure
the machine is not running and that the work piece is adequately supported or removed from the
machine before draining the vacuum drain tube. Remember to close the drain tube when finished.
The work holding vacuum level can be controlled by a lever valve on the front of the machine. The lever
valve will turn the vacuum on or off. The Vacuum Gage display below will show the instantaneous
vacuum level in inHg. The vacuum circuit contains the Vacuum Safety Cup which will fill up in a situation
where the vacuum drain tube overfills, and will shut off any vacuum going to the pump so the pump will
not be damaged.
Vacuum Gage
Vacuum
Lever Valve
Vacuum Safety
Cup
Figure 5-12: Vacuum Work Holding Controls

User Manual – eSX
5.5 Coolant System

5.5.1 Coolant Tank
OptiPro requires that Deionized (DI) Water be used in the coolant. Tank capacity is approximately 35
gallons.
Caution: Verify that all motion on pump motors have stopped before attempting to service.
Coolant-
Through-Spindle
Pump
Work Area
Coolant Pump
Coolant
Recirculation
Pump
Figure 5-13: Coolant Tank

User Manual – eSX
5.5.2 Centrifuge
The controls to turn the centrifuge on and off are located on the side of the Operator Panel (Figure
5-10). The centrifuge is part of a coolant recirculation circuit, and will be turned on and off with the
entire circuit. The centrifuge is equipped with a safety switch to cut power to the centrifuge
automatically if the cover is removed without first turning the centrifuge off. However, the centrifuge
and motor will still be spinning until they coast to a stop.
Caution: Wait to remove lid on centrifuge until the motor and drum have completely stopped. This can be
observed by the fans on the motor (See Figure 5-14: Centrifuge).
The centrifuge is used to collect grinding particulate from the coolant system. According to the
machine’s grinding load, particulate will accumulate at different rates. It is recommended that the
centrifuge be checked and cleaned regularly. Failing to do so could result in the centrifuge spinning out
of balance and ineffectively filtering particulate from the coolant. The valve on the top of the centrifuge
controls the flow of coolant coming in from the recirculation pump and coolant agitator. The valve can
be adjusted to optimize coolant flow between the agitator and the recirculation pump. For instruction
on cleaning the centrifuge, see Section 9.7.
Input from
Coolant Tank
Centrifuge
Liner Lid Centrifuge
Motor
Output to
Coolant Tank
5µ Coolant
Through Spindle
Filter
10µ Coolant
Figure 5-14: Centrifuge Through Spindle
Filter
If the eSX machine has a coolant through spindle, there will be a coolant through spindle filter on the
back of the centrifuge. This filter will run coolant through a 10 micron then 5 micron filter to collect any
grinding particulate left in the coolant. This ensures no particulate will be pushed through the spindle.

User Manual – eSX
5.5.3 Spindle Chiller

The CHILLER ON/OFF switch (shown below) should always be in the ON position; the CNC will control
the power state of the chiller automatically when Servos are on. Temperature is factory set and is not to
be adjusted. See Section 9 for maintenance. TURN OFF POWER TO THE CHILLER BEFORE ANY CHILLER
SERVICE OR CLEANING AND BEFORE DISCONNECTING ANY CHILLER LINES THROUGHOUT THE MACHINE.
Fill Port
Chiller
On/Off
Fluid Level
Gage
Temperature
Readout
Air Filter
Figure 5-15: Spindle Chiller Unit
5.6 Electrical Cabinet A/C unit

The A/C 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. The A/C has a removable air filter that must be cleaned periodically,
per Section 9.3.
Electrical
Cabinet
A/C Unit
Air Filter
Figure 5-16: Electrical Cabinet Temperature Control

User Manual – eSX
5.7 Pneumatic Automatic Greaser

The eSX is equipped with an automatic pneumatic greaser that will provide the proper amount of
lubrication to the machine’s X-, Y-, and Z-axes. Replace the grease cartridge whenever necessary (see
Section 10.3 for part number). The greaser is located on the base of the Z-axis column, near the pinch
valve assembly. The outer plastic cover is attached by a partial-turn twist lock. The grease cartridge must
be unscrewed and the new one screwed in. See Section 9 for maintenance schedule.
Figure 5-17: Pneumatic Automatic Greaser and Replacement Grease Cartridge

User Manual – eSX
5.8 Tool Spindle & Tool Holder Precautions

Observe the following to avoid injury or equipment damage:
 This machine uses the HSK 63F style tool interface. Only use tool holders conforming to the
HSK 63F standard.
Figure 5-18: HSK 63F Tool Holder profile.
 For machines NOT EQUIPPED with Coolant-Through-Spindle (CTS), only use tool holders
WITHOUT through-holes or those with plugs. Thread-in plugs can typically be purchased
from the tool holder manufacturer.
Figure 5-19: HSK 63F Tool Holder back end with threaded plug installed.

User Manual – eSX
 For machines EQUIPPED with CTS, coolant nozzles must be installed in the tool holder to use
the CTS. When not using CTS the holder must be plugged. Plugs and nozzles can be
purchased from the tool holder manufacturer.
Figure 5-20: Coolant Nozzle installed in HSK holder for CTS applications.
 The maximum tool weight for this machine platform is 6kg (13.2lbs.), including the tool
holder, and must never be exceeded.
 Tools should be as short, compact, and light as possible.
 Never exceed the tool manufacturer’s recommendations for operating speed.
 Hardware, such as bolts and collet nuts, must be properly tightened.
 Tools and holders that are damaged should never be used
 Always make sure tools and holders are properly balanced, and never use a tool that has
excessive vibration.
 Tool kinetic energy must not exceed 1000 Joules (J) in the machine: ,
where I is the tool inertia in kg/m2, is the programmed angular velocity of the tool in
rad/s (never to exceed 30m/s linear edge velocity).
 See Section 9.9 for cleaning instructions.

User Manual – eSX
5.9 Work Holding Chucks

This machine is equipped with manually actuated hydraulic expansion chucks for work holding. To avoid
damaging the chuck, observe the following precautions:
 Never actuate the chuck without a properly manufactured shank in the chuck.
 Only use steel, aluminum, or similar metals and alloys.
 Reducing collets are available. Contact OptiPro Systems for details.
 All shanks inserted into the chuck must be within the following tolerance:
 Shank Diameter (either 25mm or 1.25”, depending on customer option) of h7 tolerance
(+0μm to -21μm) or better. OptiPro recommends -8μm to -18μm for best performance.
 Length between 52mm [2in] and 63.50mm [2.5in] must extend into the chuck (see print
below).
Figure 5-21: Recommended Shank design. “Nominal” refers to either 25mm or 1.25”
 Use care when inserting or removing tools to avoid gouging or scratching the chuck.
 Always check that the chuck and tools are clean and free from burrs before inserting.
 For best performance, turn the chuck actuation screw until it bottoms out. The screw should
always be hand tight. Do not over tighten, and do not use an extension bar or power tool.

User Manual – eSX
5.10 Work and Tool Probing

The machine may be equipped with work and tool probing. In the eSX, the tool probe is located near the
C-axis and the work probe is typically located on the right side of the spindle.
Tool Probe
Figure 5-22: Tool Probe mounting location
Work Probe
Figure 5-23: Work Probe mounting location
Use of the probes is described further in the Software Interface section 7.

User Manual – eSX
5.11 Integrated Spherometer
Trigger
Spherometer Bell
Figure 5-24: Integrated Spherometer
The integrated handheld spherometer is located on the utility tray on the front of the machine. The
spherometer can be used in correcting a radius. Spherometer bells are interchangeable. See Section
7.6.3.2.3 for additional information on using the spherometer.
Contact OptiPro Systems to purchase additional spherometer bells.

User Manual – eSX
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. The operator must always be aware of conditions inside of the
machine to avoid collisions during startup and referencing.
6.1.1 Initial Power Up

 Walk around the machine; perform the start of shift maintenance (Section 9.1.1) and check
to make sure both pneumatic and electrical inputs are correctly attached.
 Move the main breaker switch (located on the rear of the machine) from the OFF to ON
position. If the breaker is found in the TRIPPED position, turn the machine off and report this
problem.
 Once the control has booted-up, the G-Series software will load automatically. If for some
reason the software fails to load automatically it can be opened by double-tapping the icon
below (located on the desktop).
G-Series
 Make sure all fixtures, parts and tools have been removed from the machine.
 Release the E-STOP button.
 Next, start the referencing routine, and all axes will move to their home positions. There is
no control over feed rate during the reference routine; however when the machine finishes
referencing the feed rate override becomes fully functional again. Press the RESET button
found on the control panel. Then press the ZERO button followed by the CYCLE START
button.
 Once motion has stopped your machine is now ready for normal use.
6.1.2 Resuming From E-Stop or Auto Off

 Walk around the machine and complete the start of shift maintenance (Section 9.1.1).
 Release the E-STOP button and press the RESET button, found on the control panel. Press
the SERVOS button.
 Your machine is now ready for normal use.

User Manual – eSX
6.2 Shutdown
The following options can be chosen based on your company policy.
6.2.1 Retaining Main Power

 Complete the end of shift maintenance (Section 9.1.2).
 Turn off lights.
 Press E-STOP button, or activate AUTO OFF option.
6.2.2 Full Power Down

 Complete the end of shift maintenance (Section 9.1.2).
 Remove tools, parts, and fixtures from the machine.
 Double-tap the [G] in the upper left corner of the screen then tap [Exit Software].
 Shutdown Windows by tapping on the [START] button in Windows, select [Shut Down],
select [Shut Down] from the drop down menu and click [Okay]
 Once windows has shutdown, go to the rear of the machine and turn the main breaker
switch from the ON position to the OFF position.
 Turn off the main air supply valve located in the Utility Control Panel.
6.3 Emergency Stop

The EMERGENCY STOP button shuts all energy to drives, coolant pumps and spindles. There should be
no hesitation to use the E-STOP button in an emergency situation.
Note that E-Stop does not disrupt air pressure or vacuum in the machine.
6.3.1 When to press E-STOP

 If anything becomes pinched by the motion of the machine.
 If a part starts to become unstable during a process.
 If there are unexpected noises during the process.
 When leaving the machine unattended for an extended period of time (i.e. end of shift).
 In any situation in which the operator feels it is warranted.
6.3.2 Returning machine to normal operation

 Once the problem has been corrected, twist the red EMERGENCY STOP button clockwise
until it releases.
 Press the RESET button on the front control panel.
 Press the button labeled SERVOS.
 If the machine needs to be referenced, all fixtures and tools should be removed from inside
the machine. Press the button labeled ZERO and then the green CYCLE START button to
begin the referencing routine.

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7 Software Interface
7.1 Screen Layout
Figure 7-1 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. See Table 8-1
and Table 8-2 for all Fault and Status messages for reference. 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. The top left corner of the screen shows the G which indicates this machine is a grinder.
Double tapping on the [G] will bring up a sub menu as seen in Figure 7-2.
Current Mode Message Box
Operation
Buttons
Figure 7-1: Screen Layout Navigation / Function Buttons
7-1: Operation and Navigation Buttons
Button Description
G Double-tap to access the G-Series Submenu (Section 7.2).
New Job Tap to navigate to New Job screen (Section 7.6.3).
Load Job Tap to Load and existing job (Section 7.6.1).
Save Job From the HOME screen, Saves the current job and its parameters.
Setup Blank Navigates to the SETUP BLANK screen (Section 7.6.3.1).
Home Navigates to the HOME screen of the currently loaded Job. Not available when
a Job is running or while the machine is in motion.
Navigation / Function These buttons provide additional screen navigation and function options and
Buttons change based on the current screen.

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7.2 G-Series Submenu
Figure 7-2: G-Series Submenu
Table 7-2: G-Series Submenu Descriptions
Option Description
Manual Mode This mode allows manual jogging and the ability to use the MDI function
(Section 7.3).
Auto Mode The main screen for running jobs or automatic programs (Section 7.4).
Offset Tables These tables are used by qualified technicians in the Tram Procedure
(Section 10.1).
CNC Action List Buttons for commonly used Manual commands. Includes turning ON/OFF
Coolant, Vacuum, Vacuum Monitoring, and Enable/Disable C-axis mode.
Tool Library Navigates the user to the Tool Library where all tools will be input and pulled
from for each process (Section 7.5).
RDS Calculator Opens an RDS Calculator (Radius-Diameter-Sag).
SDR Calculator Opens an SDR Calculator (Sag-Diameter-Radius).
Settings Navigates to the password protected Settings pages (Section 7.7).
PLC Displays the machines PLC program for service and troubleshooting. ONLY
OPTIPRO PERSONNEL SHOULD BE IN THIS SCREEN.
Minimize Will minimize the G-Series software to the operating system.
Close Exits the G-Series software to the operating system.
About Displays the current software version number.
Close Menu Closes the menu and returns to the previous screen.

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7.3 Manual Jog Mode

Manual Jog mode, accessed from the G-Series submenu is also the opening screen after startup.
The machine can be jogged manually in this mode by using the axis buttons combined with the Feed
Rate Selector and the Feed Rate Override controls found on the control panel (Section 5.2.1).
Additionally, MDI commands are executed here by typing a command in the MDI Command field and
pressing CYCLE START. Always reduce Feed Rate Override (FRO) to 0% before pressing CYCLE START and
increase slowly in MDI mode to reduce the risk of collisions. See Section 10.2 for additional information
regarding MDI commands.
The Manual Jog Mode screen (Figure 7-3) displays real time axis position, spindle load, and axis and
spindle speed information.
Axis Status
Window Spindle Load
Meters
Feed Rate and

Spindle Speeds
Active M
and G Codes
MDI Command Vacuum

Figure 7-3: Manual Jog Mode
Field ON/OFF Toggle
Note: Some machines are equipped with Constant Torque Technology (CTT) to improve surface finish.
With CTT, the Spindle Load Meters will start in the 60%-70% range and will have only slight variation
during operation.

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7.4 Automatic Mode, for Jobs and External Programs

The Automatic Mode screen displays during the program cycle, and will appear after tapping [RUN] from
the Job screen or can be accessed from the G-Series Submenu (Section 7.2).
The Automatic Mode screen (Figure 7-4) will display axis position, spindle speed and load information,
cycle time, and (optionally) program lines. The Progress bar indicates the percent of the program that is
complete. Active M and G codes are shown in the lower right corner for reference.
Overriding the feed rate will impact the total processing time, however, the Estimated Time is based on
100% Feed Rate and will not update to reflect the override.
Axis Status Window Spindle Load

Meters
Feed Rate and

Spindle Speeds
Active M
and G Codes
Cycle Time
Figure 7-4: Automatic Mode
7.4.1 Motion Stop (for non-emergencies)

In Emergencies: Press the E-STOP button on the Jog Panel (Figure 5-9) in any situation in which the
operator feels it is warranted to immediately halt axis motion. See Section 6.3 for more information
regarding E-Stop.
To pause the cycle in a non-emergency situation, press the MOTION STOP button (Figure 5-6). Note that
only axis motion will stop; spindle motion will continue as will coolant, vacuum, and any other utilities.
To continue select one of the follow options:
a. Press E-STOP on the Jog Panel (Figure 5-9) to stop all axes, spindles, and coolant flow; work
holding vacuum will remain active. See Section 6.3 for more information regarding E-Stop.
b. Continue the cycle by pressing the CYCLE START button on the Jog Panel (Figure 5-6).

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c. After MOTION STOP is pressed tap [ENABLE JOG] in the Function Bar to enable axis jogging
functionality within Automatic Mode; jog the machine as needed. Use extreme caution when
manually jogging the axes to prevent a collision. See Sections 5.1, 5.2, and 7.3 for additional
information regarding manual jogging. From here do one of the following:
i. Press E-STOP to stop all axes, spindles, and coolant flow; work holding vacuum will
remain active.
ii. Continue the cycle by pressing the CYCLE START button.
iii. Stop the spindles and immediately terminate the program by pressing RESET.
d. Press RESET on the Jog Panel (Figure 5-6) to stop the spindles and immediately terminate the
program.
7.4.2 G-Code Viewer

Tap [VIEW GCODE] to open a window that will display the G-Code for the active program (used for
program verification and/or trouble shooting). This window can be accessed and exited while the
program is running without effecting operation.
7.4.3 Loading External Programs

The machine can execute programs that are generated offline (not with the G-Series software). These
files are usually manually typed out or generated with a CAD/CAM application.
CAUTION: G-Series software has built in safety features may not be available when using external
programs. Only operators who are trained and qualified to write and execute machine tool code, well
versed in CNC machine setup, programming, and operating, and well trained and experienced on this
machine should attempt to run programs not generated within the G-Series software.
1. Access the Offset Tables from the G-Series Submenu (Section 7.2).
NEVER MODIFY OR UNLOCK G54 OR G55 VALUES EXCEPT FOR TRAMMING IN THE G-SERIES SOFTWARE.
2. G56, G57, and G58 Offset can be used for external programs, adjust these values as required for
the application.
3. Enter AUTO MODE from the G-Series Submenu (Section 7.2).
4. Tap [LOAD PROG] in the Navigation/Function Bar, browse for and open the desired file.
NEVER RUN A PROGRAM FROM A USB DRIVE OR OTHER REMOVABLE STORAGE
5. Press CYCLE START to begin the program
regarding E-Stop.

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7.5 Tools and the Tool Library

7.5.1 Tool Library
Access the tool library from the G-Series Submenu (Section 7.2). All tools must have their information
loaded into the tool library before they can be used in a program.
Begin by selecting a tool type from the main Tool Library screen (Figure 7-5).
Figure 7-5: Tool Library – Main Screen

Available Tool Types
Table 7-3: Tool Library – Available Tool Types
Tool Type Description

Ring (Section 7.5.3) Ring tools, are used when creating spherical shapes. They can also be used for
performing asphere grinding, edging and beveling operations.
Ball (Section 7.5.4) Ball tools, or hemispherical tools, are used for creating aspheres.
Edge (Section 7.5.5) Edge tools have a cylindrically shaped bond area and grind using the tools
sidewall during edging operations.
End Mill (Section 7.5.6) End Mills are used for milling out vacuum chucks in the machine.
Toroid (Section 7.5.7) Toric shaped grinding wheels are used to grind aspheric shapes.
RFID (Section 7.5.8) RFID tags are used to encode tool number information to ensure that the
correct grinding wheel is being used for the correct grinding process.
Scoop (Section 7.5.9) Scooping tools are thin walled hemispherical shaped ring tools used to scoop
out lens blanks from a boule.

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7.5.2 Add, Delete, and Update Library Tools

Selecting a tool type will bring up a screen showing all of the existing tools of that type in the library, and
allow the operator to Add, Delete, or Update tools. To add a new tool of the selected type highlight [Add
New Tool] in the Library Tools list, fill out the fields listed for that tool type, and tap [ADD] to save the
information to the library. An existing library tool can be updated in the specified Tool Type screen by
highlighting a tool from the Library Tools list, modifying the desired parameters, and tapping [UPDATE]
to save the modifications. Finally, tapping [DELETE] will permanently delete the selected tool from the
library. Tapping [CANCEL] returns to the main Tool Library screen, any unsaved changes to the Tool
parameters will be discarded.
7.5.3 Ring Tools
Figure 7-6: Tool Library – Ring Tools
Table 7-4: Ring Tool Parameters and Descriptions
Ring Tool Parameters Description

Name A descriptive name that differentiates one tool from another.
Description Additional information that can be used to describe the tool.
Outside Diameter Measured outside diameter of the tool.
Inside Diameter Measured inside diameter of the tool.
Lip Radius Automatically propagated based on OD and ID if the [Round Edge] Function Button is
active, can be manually overridden. This field is inactive if the option [SHARP] is active.
Grit Grit rating of the abrasive material of the tool.

Shank Diameter Measured diameter of the shank of the tool.
Ring Height Overall height of the ring tool, not including the shank, typically measured from the
bottom of the cutting band to the top of the “bell”.
Diamond Height Height of the abrasive material as measured from the bottom of the cutting band to the

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top of the cutting band.
7.5.4 Ball Tools
Figure 7-7: Tool Library – Ball Tools
Table 7-5: Ball Tool Parameters and Descriptions
Ball Tool Parameters Description

Ball Diameter Measured outside diameter of the tool.

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7.5.5 Edge Tools
Figure 7-8: Tool Library – Edge Tools
Table 7-6: Edge Tool Parameters and Descriptions
Edge Tool Parameters Description

Probe Diameter Defines the diameter at which the tool should be probed for measuring tool
length.
Diamond Height Height of the abrasive material as measured from the bottom of the cutting
band to the top of the cutting band.

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7.5.6 End Mill Tools
Figure 7-9: Tool Library – End Mill Tools
Table 7-7: End Mill Tool Parameters and Descriptions
End Mill Tool Parameters Description

Tool Diameter Measured outside diameter of the tool.

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7.5.7 Toroid Tools
Figure 7-10: Tool Library – Toroid Tools
Table 7-8: Toroid Tool Parameters and Descriptions
Toroid Tool Parameters Description

Probe Diameter Defines the diameter at which the tool should be probed for measuring tool
length.
Wheel Width Width of the wheel bond in the axial direction.

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7.5.8 RFID Tools
Figure 7-11: Tool Library – RFID Tools
Table 7-9: RFID Tool Parameters and Descriptions
RFID Tool Parameters Description

ID Number A serial number that is used to identify a particular tool.
Read ID Reads the current ID number that is associated with a particular tool.
Write ID Writes the ID number to the RFID chip in the tool.

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7.5.9 Scoop Tools
Figure 7-12: Tool Library – Scoop Tools
Table 7-10: Scoop Tool Parameters and Descriptions
Scoop Tool Parameters Description

Inside Diameter Measured inside diameter of the tool.

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7.6 Creating and Running Jobs

The G-Series Lens Generating Software allows the operator to generate convex and concave spherical
and aspheric surfaces, perform beveling and edging routines, and machine vacuum fixtures, by utilizing a
Job file structure. A Job file will store parameters for all the processes required to manufacture a lens
surface. Each process is defined by a series of inputs and parameters including lens geometry, tool
parameters, processing parameters, and corrections.
7.6.1 Loading an Existing Job

After the machine is referenced and the correct tools are loaded into the machine, a previously saved
job can be loaded.
1. Tap the [Load Job] button from any screen.

2. Select a job from the dropdown menu. For the job highlighted, the Lens Blank Parameter fields
will be populated with the data that was last saved in that job file. The previously input Job
Description will also appear, along with a graphic illustrating the lens blank defined when the job
was last saved.
Figure 7-13: LOAD JOB screen
3. Tap [OK] to load the selected job. The job can now be modified if needed to update the last
saved parameters (i.e. tool, blank, or process parameters). Modifying an existing job follows a
similar procedure and uses the same software screens as creating a new job; see Section 7.6.3
for details related to modifying an existing job and Section 7.6.4 to run a job.
After loading an existing job it is advised to re-probe tool lengths and part reception height before
processing. Once they have been setup and checked by a qualified operator, the job is ready to run.

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7.6.2 Deleting an Existing Job

To delete a saved job permanently from the machine’s hard drive, follow these steps (refer to Figure
7-13):
1. From any screen tap the [Load Job] button.

2. Select a job from the dropdown menu. For the job highlighted, the Lens Blank Parameter fields
will be populated with the data that was last saved in that job file. The previously input Job
Description will also appear, along with a graphic illustrating the lens blank defined when the job
was last saved.
3. Tapping [DELETE] will permanently deleted the job selected in the dropdown list.
7.6.3 Creating a New Job

The steps involved in creating a new job include defining the shape of the starting lens blank and
defining one or more processes to be performed.
1. To setup a new job, tap the [NEW JOB] Operation Button from any screen.
2. Enter a Job Name in the labeled field (i.e. Part Number, Job Number, or other unique name)
Figure 7-14: NEW JOB screen
3. The next screen is the Lens Blank Setup Screen. Proceed with Section 7.6.3.1 below.
Note: Remember to save your job regularly during set-up. The [SAVE JOB] button only works when you
are at the HOME screen. This is done to safeguard against saving an incomplete process. When the
[SAVE JOB] button is inactive, the text color will be red.

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7.6.3.1 Lens Blank Setup

Providing accurate information to the machine in the Lens Blank Setup screen is critical to helping
prevent machine crashes.
4. Fill in the required parameter fields to accurately define the lens blank.
Figure 7-15: Lens Blank Setup screen
Table 7-11: Lens Blank Parameters and Descriptions
Lens Blank Parameters Description

Diameter Diameter of the blank.
Upper Shape The shape of the upper side of the blank; options include Convex,
Concave, and Plano.
Upper Radius Radius of the upper side of the blank if Convex or Concave.
Upper Sag Diameter Diameter of the sag face of the upper side of the blank, leave empty if
there is no sag face.
Lower Shape The shape of the lower side of the blank; options include Convex,
Concave, and Plano.
Lower Radius Radius of the lower side of the blank if Convex or Concave.
Lower Sag Diameter Diameter of the sag face of the lower side of the blank, leave empty if
there is no sag face.
Initial CT The initial center thickness (CT) of the blank, measured offline.
Reception Height Height of the blank in relation to the machines coordinate system. This
value is automatically filled in when the probing sequence is executed.
Job Description Additional information or notes that can be used to describe the job.
Air Blast (Optional) Sets the air pressure that can be used to lift an optic off its
vacuum fixture after processing, typically set below 1 bar, activated by
the Footswitch (Section 5.2.1).

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5. Verify the parameters were entered correctly by observing the graphic representation of the
lens on the screen.
6. After entering the Lens Blank Parameters, use the probing sequence to set the reception height
automatically.
a. Secure the blank in the work spindle.
b. Tap [PROBE] at the bottom of the Lens Blank screen.
Always use caution when using the automated probing sequences.
7. Tap [OK] to accept the values entered in the Lens Blank Parameter fields and enter the job
HOME screen to begin adding processes to the job, detailed in the sections below.

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7.6.3.2 Spherical Process Setup

The following steps describe adding a Spherical Process to a Job.
1. From the HOME screen, select [ADD] followed by [SPHERE], both in the Navigation Bar.
2. Provide a name for the process (ex. 100mm CC Grind Rough Tool).
3. Define the shape to be cut using the Lens Parameter fields and verify with the graphical
representation provided.
Figure 7-16: Spherical Process – Lens Definition Screen
Table 7-12: Sphere Parameters and Definitions
Sphere Parameters Definition

Diameter Imported from Lens Blank parameters or the previous process if one exists.
Shape Choose from Convex or Concave.
Finished Radius Final spherical radius for this process.
4. Tap [>>] to continue to the Tool screen.

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5. Provide the required information in the Tool Information fields.
Figure 7-17: Spherical Process – Tool Information Screen
Table 7-13: Spherical Process – Tool Information and Descriptions
Tool Information Description

Name Name of selected tool.
Location Location of the tool (Left Spindle or Right Spindle).
Head Angle Calculated based on tool and part geometry.
Outer Diameter (Imported from Library) Outside diameter of the tool.
Inner Diameter (Imported from Library) Inside diameter of the tool.
Tool Radius (Imported from Library) Lip radius of the tool.
Grit (Imported from Library) Grit rating of the abrasive material of the tool.
Tool Length Probed tool length, automatically filled after probing.
Description (Imported from Library) Additional information used to describe the tool.
RFID Active Activates the use of RFID checking if so equipped.
Tool Dressing See Section 7.6.3.8

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6. Probe the tool.

a. Secure the tool in the correct spindle.
b. Tap [PROBE TOOL] to begin the automated probing routine.
7. Tap [>>] to proceed to the Sphere Cut screen.

8. Fill in the Cut and Feed Parameters
Figure 7-18: Spherical Process – Cut Screen
Table 7-14: Spherical Process – Cut and Feed Parameters and Descriptions
Cut and Feed Parameters Description

Initial CT (Imported from Lens Blank Parameters) Center Thickness (CT) of lens blank,
or from previous process if one exists.
Clean Up CT (Calculated) Maximum Center Thickness (CT) to ensure entire surface is cut.
Finished CT User inputted final Center Thickness (CT) for this process.
Safety Height Rapid Feed threshold, offset from lens surface. Since position of tool-lens
contact is calculated and does not account for imperfections in lens or
blocking, or any input errors, the machine will switch from “Rapid Feed” to
the commanded “Feed Rate” at this distance. Use a larger safety height for
initial job setup to help prevent collisions.
Cut Type Select from two feed methods:
a. Z: Feed direction is in the Z-axis only.
b. XZ: Feed direction is in the X and Z axes simultaneously to follow the
path dictated by the head angle.
Lens RPM Rotational speed of the work spindle.
Tool RPM Rotational speed of the tool spindle.

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Tool Velocity (Calculated) Determined by programmed RPM and tool diameter.
Feed Rate Rate of tool-to-lens feed after Safety Height is reached (Feed will be
“Rapid” prior to reaching the Safety Height).
Dwell Time to dwell during cut at Finished CT before retracting.
Retract Height (Optional) Distance to travel away at commanded Feed Rate before
“Rapid” retract.
Retract Feed Rate The rate at which the tool will retract off of the part before rapid retract.
Coolant Through (Optional) If active, will activate coolant center-feed through the spindle.
Vacuum Monitoring (Optional) If active, will monitor for vacuum loss during a processing cycle.
SPC Monitoring (Optional) Will broadcast time/date stamped part count information across
a network.
9. Advance to the Spherical Corrections screen by tapping [>>].

10. The main Spherical Process Corrections screen will display any active correction values.
a. To proceed without adding correction parameters tap [OK] to return to the main job
screen, then tap [SAVE JOB] to save the new or modified process to the job file.
b. To add correction parameters tap the appropriate image or button in the function bar.
Note that the images will reflect if the current process is convex or concave.
c. To clear any active corrections tap [CLEAR], then select the correction type to clear and
tap [OKAY] to return to the main corrections screen.
Figure 7-19: Spherical Process – Main Corrections Screen

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7.6.3.2.1 Spherical Correction – Nib Correction

11. From the Spherical Correction screen Tap [NIB CORR] to add a nib correction.
Figure 7-20: Spherical Process – Nib Correction Screen
12. Determine whether the part has a Left or Right side nib by observing the cutter marks; then tap
[LEFT NIB] or [RIGHT NIB] in the Function Bar. Note that the images will reflect if the current
process is convex or concave.
13. Enter the diameter of the nib in the field.
14. Tap [APPLY] to accept the changes and return to the main Spherical Process Corrections screen.
15. Tap [OK] to accept the new or modified process and return to the HOME screen. Save the
changes to the job by tapping [SAVE JOB].
When correcting a nib, the part should ALWAYS be cut again before doing any other corrections as the
nib correction can affect CT and radius correction.

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7.6.3.2.2 Spherical Correction – CT Correction

16. From the Spherical Correction screen tap [CT CORR] to perform a CT correction.
Figure 7-21: Spherical Process – CT Correction Screen
17. Provide a Measured CT value in one of the following ways:

d. Measure the CT offline and type the value in the “Measured CT” field.
e. Measure the CT with the onboard part probe by tapping [PROBE CT] to initiate the
automated probing sequence.
Always use caution when using the automated probing sequences to avoid collisions.

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7.6.3.2.3 Spherical Correction – Radius Correction

20. From the Spherical Correction screen tap [RAD CORR] to perform a radius correction.
21. There are three options for performing a radius correction; “Direct” offline measurement,
integrated “Spherometer” measurement (if equipped), or “Manual” measurement:
a. Direct method:
Figure 7-22: Spherical Process – Radius Correction Screen: Direct
i. Tap [DIRECT] from the Radius Correction screen.

ii. Measure the lens radius offline with a profilometer or spherometer (or other
device).
iii. Enter the value into the “Measured Radius” field.
iv. Tap [APPLY] to accept the correction value.

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b. Machines equipped with an integrated handheld spherometer (Section 5.11):
Figure 7-23: Spherical Process – Radius Correction Screen: Spherometer
i. Tap [SPHERO] from the Radius Correction screen.

ii. Tap [CALIBRATE] and fill out the “Spherometer Calibration” fields.
1. Calibration Radius: Radius of the calibration plate to be used.
2. Ring Diameter: Diameter of the spherometer ring or “bell” to be used.
For convex parts use the inner diameter of the ring, for concave parts
use the outer diameter of the ring.
Always use care when handling the spherometer on your machine.
iii. Place the integrated spherometer on the test plate and press the trigger button
ONCE to calibrate, or tap [CALIBRATE].
iv. Place the integrated spherometer on the work piece and press the trigger button
ONCE again to capture the Measured Radius, or tap [STORE].
v. Tap [APPLY] to accept the correction value.

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c. Manual method:
Figure 7-24: Spherical Process – Radius Correction Screen: Manual
i. If using a manual spherometer, enter the information required in the screen

above.
ii. Tap [APPLY] to accept the correction.

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7.6.3.2.4 Spherical Correction – Y-Axis Correction
Figure 7-25: Spherical Process - Y-axis Correction Screen
This adjustment is used to make small alignment changes to the Y-axis as required. The graphic will let
the operator know if the machine requires positive of negative adjustment. After making an adjustment,
tap [ACCEPT] to store the value.
The amount of adjustment should not exceed 20μm under normal conditions. If excessive adjustment is
required, then the machines tram should be checked (see Section 11).

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7.6.3.3 Aspheric Process Setup

The following steps describe adding an Aspheric Process to a Job.
1. From the HOME screen, select [ADD] followed by [ASPHERE], both in the Navigation Bar.
2. Provide a name for the process (ex. ASPHERE FINE CUT).
3. Provide the prescription of the lens using the Asphere Parameter fields and verify with the
graphical representation provided.
Figure 7-26: Aspheric Process – Lens Definition Screen
Table 7-15: Asphere Parameters and Definitions
Asphere Parameters Definition

Diameter Diameter of the asphere.
Shape Convex or Concave asphere.
RoC Radius of Curvature of the asphere.
K Conic constant.
A1 through A20 Asphere deformation constants.
Initial Surface
Max Departure (Calculated) Maximum departure of the asphere from the initial
surface (from lens blank or previous process).
Center Departure (Calculated) Departure in the center of the asphere from the initial
surface (from lens blank or previous process).
Best Fist Sphere
Radius (Calculated) Best fit spherical radius of the asphere, material safe.
Max Departure (Calculated) Maximum departure of the asphere from the Best Fit
Sphere.
Center Departure (Calculated) Departure in the center of the asphere from the Best
Fit Sphere.

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Asphere Parameters Definition

Tangent Extension Allows for shape control of the asphere beyond a specified
diameter to its processing diameter.
Surface Extension Type The type of extension to be used. Choices are linear, convex or
concave.
Clear Aperture The specified diameter to start the extension.
Extension Radius Used to define the convex or concave radius of the extension.
4. The [+/-] button is a global sign converter that is used to ensure the correct asphere is defined. It
should be used if the sag table does not match the optical prints sag table.
5. Display the Sag table calculated by G-Series by tapping [SAG TABLE] and compare to a known
table as an additional verification that the parameters have been entered correctly.
Figure 7-27: Aspheric Process – Sag Table

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Figure 7-28: Aspheric Process – Tool Information Screen
Table 7-16: Aspheric Process – Tool Information and Descriptions

Tool Type Asphere processing only supports Ring tools.
Max Tool Radius (Computed) Maximum usable tool radius based on tool geometry. Will also
filter out any tools that do not meet this requirement.
Head Angle User defined head angle for grinding.
RFID Active (Optional) Activates the use of checking for a specific RFID tool.
Tool Dressing See Section 7.6.3.8
7. Probe the tool.

8. Tap [>>] to proceed to the Asphere Cut screen.

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9. Fill in the Cut and Feed Parameters.
Figure 7-29: Aspheric Process – Cut Screen
Table 7-17: Aspheric Process – Cut and Feed Parameters and Descriptions

Initial CT (Imported from Lens Blank Parameters).
Clean Up CT (Calculated) Maximum Center Thickness (CT) to ensure entire surface is cut.
Finished CT User inputted final Center Thickness (CT) for this process.
Step Cut Amount of material to remove with each pass.
Cut Threshold Works with the Step Cut parameter to minimize cycle time “cutting air” by
moving at rapid traverse when the tool is not in contact with the part. The
Cut Threshold must be a value greater than the step cut.
Cut Direction (This option is no longer available).
Feed Rate Rate of tool-to-lens feed after Safety Height is reached (Feed will be “Rapid”
prior to reaching the Safety Height).

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10. Tap [>>] to proceed to the Asphere Corrections screen.
7.6.3.3.1 Aspheric Corrections

11. To proceed without adding correction parameters tap [OK] to return to the main job screen,
then tap [SAVE JOB] to save the new or modified process to the job file.
12. Provide asphere correction parameters as necessary.
Figure 7-30: Aspheric Process – Corrections Screen
Table 7-18: Aspheric Process – Correction Parameters and Descriptions
Correction Parameters Description

Active Corrections Lists all active asphere departure files for form correction.
Total Corrections Displays all active corrections.
Nib Diameter Displays the active nib correction diameter.
CT Adjust Displays the active center thickness (CT) adjustment.
Asphere Correction Displays all asphere corrections.
Nib Diameter Enter measured nib diameter to correct, can be positive or negative.
Predicted CT (Programmed) CT that the software believes the current process to be.
Measured CT Actual CT as measured offline or by onboard part probe.
13. Correct nib and center thickness (CT) (See Figure 7-30 and Table 7-18).
a. Nib Corrections: Enter the measured nib, can be positive or negative
b. Center Thickness: Enter the measured CT, or tap [PROBE CT] to initiate the automated
probing sequence.

User Manual – eSX
14. The G-Series software allows for form correction on aspheres by loading asphere departure files.
a. [ADD FILE]: After measuring the asphere departure offline, load the metrology file,
typically a .csv file from a contact profilometer, to automatically correct the form.
b. [REMOVE FILE]: Remove the selected file in the “Active Corrections” window, thus
disregarding that correction in the future.
15. [CLEAR ALL]: Remove all corrections from the current asphere process. This includes nib, CT, and
form correction.
16. Tap [OK] to accept the new or modified process and return to the HOME screen.
17. Save the changes to the job by tapping [SAVE JOB].
7.6.3.4 Edge Process Setup

The following steps describe adding an Edge Process to a Job.
1. From the HOME screen, tap [ADD] followed by [EDGE], both in the Navigation Bar.
2. Provide a name for the process (ex. FINISHED DIAMETER).
3. Input required Lens Parameters and verify with the graphical representation provided.
Figure 7-31: Edge Process – Lens Definition Screen
Table 7-19: Edge Parameters and Definitions
Edge Parameters Definition

Initial Diameter Imported from Lens Blank parameters or the previous process if one exists.
Diameter Final diameter for this process.

User Manual – eSX
Figure 7-32: Edge Process – Tool Information Screen
Table 7-20: Edge Process – Tool Information and Descriptions

Tool Type Edge processing supports Edge and Ring tools.
Probe Diameter (Imported from Library) Diameter at which the tool should be probed for
measuring tool length.
Opposite Tool Edge (Optional) Allows process to use opposite tool edge.
6. Probe the tool.

7. Tap [>>] to proceed to the Edge Cut screen.

8. Define the Cut Parameters. The available Cut and Feed options depend on the tool selected
(edge or ring tool) on the previous screen. See Table 7-21 for additional details.

User Manual – eSX
Figure 7-33: Edge Process – Cut Screen
Table 7-21: Edge Process – Cut and Feed Parameters and Descriptions

Blow Out Safety Height (Available with Z DOWN Feed Type) The distance from the bottom of the
work piece that the tool will travel to before it moves away in X, down in Z,
back in X to the final diameter. It then feeds in the Z+ direction to finish the
cycle. This safety distance prevents the work piece’s bottom edge from
being damaged during the edging process.
Feed Type Select from three feed methods:
a. Z DOWN (available with ring tools): Z-axis feed from top to bottom of
the lens, then a clean-up pass from bottom to top.
b. X OUT (available with edge tools): X-axis feed into the lens to the
programmed final dimension, then retract out in the x-axis direction.
c. Z UP (available with edge tools): Z-axis feed up the lens at specified
Head Angle.
Retract Distance (Available with X OUT Feed Type) Distance to travel away at commanded
Feed Rate before “Rapid” retract.
Head Angle (Available with Z DOWN and Z UP Feed Types) User defined tool spindle
angle. It is recommended to use a Head Angle between 1° and 5° for better
results.

User Manual – eSX

Feed Rate Rate at which the tool will feed into the part during grinding.
Final Feed Rate Rate at which the tool will use for the finishing portion of the process. i.e.
— Feed Rate for final pass (Z DOWN), Z-axis feed (Z UP), and retract (X
OUT).
9. Tap [>>] to proceed to the Edge Corrections screen.

User Manual – eSX
7.6.3.4.1 Edge Corrections

11. Enter edge correction parameters as necessary.
Figure 7-34: Edge Process – Corrections Screen
Table 7-22: Edge Process – Correction Parameters and Descriptions

Predicted Diameter (Imported) The diameter defined from the Edge Process Lens screen.
Measured Diameter The diameter measured after processing.
Total Corrections Tracks and displays active corrections.
12. To clear all active corrections for this process tap [CLEAR ALL].

User Manual – eSX
7.6.3.5 Bevel Process Setup

The following steps describe adding a Bevel Process to a Job.
1. From the HOME screen, tap [ADD] followed by [BEVEL], both in the Navigation Bar.
2. Provide a name for the process (ex. FIRST SIDE BEVEL).
3. Input Lens Parameters to define the bevel.
Figure 7-35: Bevel Process – Lens Definition Screen
Table 7-23: Bevel Parameters and Definitions
Bevel Parameters Definition

Initial Diameter Imported from Lens Blank parameters or the previous process if one exists.
Bevel Width Face width of the bevel to be created.
Bevel Angle Angle of the bevel.

User Manual – eSX
Figure 7-36: Bevel Process – Tool Information Screen
Table 7-24: Bevel Process – Tool Information and Descriptions

6. Probe the tool.

7. Tap [>>] to proceed to the Bevel Cut screen.

User Manual – eSX
Figure 7-37: Bevel Process – Cut Screen
Table 7-25: Bevel Process – Cut and Feed Parameters and Descriptions

Feed Rate Rate of tool-to-lens feed after Safety Height is reached (Feed will be
“Rapid” prior to reaching the Safety Height).
9. Advance to the Bevel Corrections screen by tapping [>>].

User Manual – eSX
7.6.3.5.1 Bevel Corrections

15. Enter bevel correction parameters as necessary.
Figure 7-38: Bevel Process – Corrections Screen
Table 7-26: Bevel Process – Correction Parameters and Descriptions

Predicted Width (Imported) The bevel width defined from the Bevel Process Lens screen.
Measured Width The diameter measured after processing.
Bevel Correction Tracks and displays active corrections.

User Manual – eSX
7.6.3.6 Fixture
The Fixture process allows the operator to cut vacuum chucks in the machine using an end mill. The
following steps describe adding a Fixture Process to a Job.
1. From the HOME screen, tap [ADD] followed by [MORE], then [FIXTURE], all in the Navigation
Bar.
2. Provide a name for the process (ex. Fixture Cut).
3. Input Lens Parameters to define the shape of the lens to be vacuumed.
Figure 7-39: Fixture Process – Lens Definition Screen
Table 7-27: Fixture Parameters and Definitions
Fixture Parameters Definition

Diameter Outside diameter of lens to be held in fixture.
Upper Shape Upper shape of lens to be held in fixture.
Upper Radius Upper radius of lens to be held in fixture.
Upper Sag Dia Upper sag diameter of lens to be held in fixture.
Lower Shape Lower shape of lens to be held in fixture.
Lower Radius Lower radius of lens to be held in fixture.
Lower Sag Dia Lower sag diameter of lens to be held in fixture.
CT CT of lens to be held in fixture.

User Manual – eSX
Figure 7-40: Fixture Process – Tool Information Screen
Table 7-28: Fixture Process – Tool Information and Descriptions

6. Probe the tool.

7. Tap [>>] to proceed to the Fixture Cut screen.

User Manual – eSX
Figure 7-41: Fixture Process – Cut Screen
Table 7-29: Fixture Process – Cut and Feed Parameters and Descriptions

Max Diameter (Calculated) Determined by lens diameter.
Seat Diameter Diameter in which the bottom side of lens will sit on.
Side Wall Ht. Height of wall of the fixture that holds the side wall of lens.
Seat Gap Gap underneath the seat diameter.
Step Cut Depth of cut on every pass.
Feed Rate Rate at which the tool will feed into the part during cutting.
Dwell Time to dwell during cut at final depth before retracting.
9. Advance to the Fixture Corrections screen by tapping [>>].

User Manual – eSX
7.6.3.6.1 Fixture Corrections

11. Enter fixture correction parameters as necessary.
Figure 7-42: Fixture Process – Corrections Screen
Table 7-30: Fixture Process – Correction Parameters and Descriptions

Predicted Lens Dia (Imported) The diameter defined from the Fixture Process Lens screen.
Measured Lens Dia The diameter measured after processing.
Lens Dia Correction Tracks and displays active corrections.

User Manual – eSX
7.6.3.7 Scooping
The following steps describe adding a Scooping Process to a Job.
14. From the HOME screen, select [ADD] followed by [MORE], then [SCOOP], all in the Navigation
Bar.
15. Provide a name for the process (ex. Scoop)
16. Input Lens Parameters to define radius to be scooped.
Figure 7-43: Scoop Process – Lens Definition Screen
Table 7-31: Scoop Parameters and Definitions
Fixture Parameters Definition

Diameter Imported from Lens Blank parameters or the previous process if one exists.
Finished Radius Final spherical radius for this process.

User Manual – eSX
Figure 7-44: Scoop Process – Tool Information Screen
Table 7-32: Scoop Process – Tool Information and Descriptions

RFID Active Activates the use of RFID checking if so equipped.
19. Probe the tool.

c. Secure the tool in the correct spindle.
d. Tap [PROBE TOOL] to begin the automated probing routine.
20. Tap [>>] to proceed to the Scoop Cut screen.


User Manual – eSX
Displays the active nib correction diameter.
Figure 7-45: Scoop Process – Cut Screen
Table 7-33: Scoop Process – Cut and Feed Parameters and Descriptions

Initial CT (Calculated) Determined by previous process CT.
Finished CT Final desired CT of lens.
Minimum Nib (Calculated) Determined by tool shank diameter.
Nib Diameter Desired diameter left in lens post process.
CCW Work Spindle (Optional) If active, will allow work spindle to rotate counter-clockwise.
22. Advance to the Scoop Corrections screen by tapping [>>].

User Manual – eSX
7.6.3.7.1 Scoop Corrections

24. Enter Scoop correction parameters as necessary.
Figure 7-46: Scoop Process – Corrections Screen
Table 7-34: Scoop Process – Correction Parameters and Descriptions

User Manual – eSX
7.6.3.8 Tool Dressing

The Tool Dressing routine can be accessed from any spherical or aspheric processes Tool Information
Screen. It allows an operator to place a dressing stick in the work spindle and perform an automated
dressing process.
Figure 7-47: Tool Dressing Screen
Table 7-35: Tool Dressing Parameters and Descriptions
Tool Dressing Parameters Description

Tool Speed Rotational speed of the work spindle.
Work Speed Rotational speed of the tool spindle.
X Axis Offset Offset of dressing stick in holder.
Dressing Depth Desired depth of cut into dressing stick.
Dressing Stick Rec Height (Imported if Probed) Reception height of dressing stick.
Head Angle User defined head angle for grinding.
Tap [Probe] to begin automated probing routine to determine dressing stick reception height. NOTE:
Always use caution when probing dressing stick, collision issues my occur.
Tap [Dress] to begin the dressing program.

User Manual – eSX
7.6.4 Executing a Process in a Job

After loading an existing job it is advised to re-probe tool lengths and part reception height before
processing. Once they have been setup and checked by a qualified operator, the job is ready to run.
Figure 7-48: Job HOME Screen
1. See Section 7.6.1 for loading an existing job and Section 7.6.3 for modifying an existing job or
creating a new one.
2. After loading an existing job it is advised to re-probe tool lengths and part reception height
before processing. Once they have been setup and checked by a qualified operator, the job is
ready to run.
3. Once a job has been created or loaded and the tools and parts have been probed, tap the
checkbox of the processes to be executed.
4. Tap [RUN] in the Function Bar.
5. The screen will switch to Automatic Mode and the process will start by pressing the CYCLE
START button on the Jog Panel (Figure 5-6). See Section 7.4 for more information regarding
Automatic Mode.
regarding E-Stop.

User Manual – eSX
7.7 Settings
The settings pages store machine specific configuration information. Access to the settings is password
protected; the password is provided to a supervisor during training.
The machine tramming procedure is executed from Page 1 of the Settings by tapping [TRAM]. See
Section 10.1 for more information regarding tramming.
7.7.1 Settings – Page 1
Figure 7-49: G-Series Settings – Page 1
Table 7-36: Settings Section Descriptions – Page 1
Settings Section Description

Machine Configuration Factory set hardware configuration for the specific machine.
Software Configuration Displays enabled software options. Additional purchased options can be
activated here.
Tool and Lens Probe Parameters used for machine alignment and tram. These parameters should
only be modified by trained personnel or OptiPro Technicians.
Machine Parameters Displays the alignment information of the tool spindle centerline in relation to
the B-axis centerline.

User Manual – eSX
7.7.2 Settings – Page 2
Figure 7-50: G-Series Settings – Page 2
Table 7-37: Settings Section Descriptions – Page 2
Settings Section Description

Additional Parameters Factory set hardware configuration for the specific machine.
Unload Position Allows for a specific location to be moved to at the end of a part
program for part loading/unloading.
Linked Process Is used (with extreme caution) to link multiple spherical part
programs together to reduce overall cycle time. Should only be used
by an experienced operator.
SPC Sets the broadcast rate to be used if active.
RFID Factory set hardware configuration for the specific machine (if
equipped).
Dressing Station Location (G53) Factory set hardware configuration for the specific machine.
Tool Load Meter Threshold Factory set hardware configuration for the specific machine.
Tram Probing Factory set hardware configuration for the specific machine.

User Manual – eSX
8 Error Recovery and Troubleshooting

8.1 Coolant Flow Fault
8.1.1 Reading the Flow Monitor
The flow monitor is located in the pinch valve assembly as seen in Figure 8-1. The display on the switch
shows the current level of the flow and whether the flow is at or above the predetermined level. The
display is made up of a series of LEDs. When the flow level is lower than required there will be a red LED
called the switch point. When this switch point LED changes to orange then the flow requirement has
been met.
Figure 8-1: Coolant Flow Meter Display and Controls
The relative flow is indicated by the number of green LEDs lit. When the coolant flow is below the
displayable range the 1st LED will flash green. The last LED flashes green for a flow above the readable
range.
8.1.2 Changing the Required Flow Rate

To change the switch point on the monitor press and hold either SETPOINT button until the LED starts to
flash, the buttons are found just below the display. Use the pushbuttons to move the switch point to
the desired location. After about 2 seconds of no activity then the switch should resume normal
operation.

User Manual – eSX
8.1.3 Cleaning if Necessary

The switch can develop a buildup on the sensor tip. Remove the sensor from the piping and clean the
sensor tip using a soft cloth. If stubborn build-up exists, it should be removed using vinegar based
cleaner. Figure 8-2 shows the Coolant Flow Meter Sensor tip removed from the pipe system.
Figure 8-2: Coolant Flow Meter Sensor Tip
8.2 Recovering from Error Messages

A coolant flow fault, low air pressure, unreferenced axes or Z Axis over travel may cause error messages
to appear on the user interface. Press the RESET button to clear messages, after action to correct the
error has been taken.
For example: If you see a low air pressure error message, it may be because your air compressor was
shut off at some point causing the machine to fault out. If your compressor has already been turned
back on, the only step needed to clear the error is to hit the RESET button. If the software has been
closed, the axes are no longer referenced. This will cause an error message to appear. Press the RESET
button, turn the SERVOS on, then ZERO and then CYCLE START. This will reference the axes and your
machine will be ready for production.
Contact OptiPro Service if additional support is needed.

User Manual – eSX
Table 8-1: Fault Messages
FAULT MESSAGES (*MESSAGES VARY DEPENDING ON MACHINE MODEL)

M10 GREASE LUBE LONG CYCLE FAULT
M11 GREASE LUBE PRESSURE SW. STUCK-ON FAULT
M12 GREASE LUBE LOW LEVEL FAULT
M13 GREASE LUBE CONSECUTIVE LONG CYCLE FAULT
M15 SERVO POWER SUPPLY FAULT
M17 S3 RIGHT TOOL SPINDLE DRIVE FAULT
M18 B-AXIS DRIVE FAULT
M19 S1 LEFT TOOL SPINDLE DRIVE FAULT
M20 LOW SYSTEM AIR PRESSURE FAULT
M21 VACUUM LOW FAULT
M24 VACUUM PUMP RUN FAULT
M26 MIST COLLECTOR RUN FAULT
M30 S2/C-AXIS WORK SPINDLE AIR PURGE FAULT
M31 S1 LEFT TOOL SPINDLE AIR PURGE FAULT
M32 S3 RIGHT TOOL SPINDLE AIR PURGE FAULT
M38 B-AXIS OVERTRAVEL FAULT
M42 SPINDLE CHILLER TEMP OR FLOW FAULT
M43 SPINDLE CHILLER MOTORS RUN FAULT
M44 COOLANT CHILLER TEMP OR FLOW FAULT
M45 COOLANT CHILLER MOTORS RUN FAULT
M50 TOOL NOT IN LEFT SPINDLE FAULT
M51 TOOL NOT IN RIGHT SPINDLE FAULT
M60 COOLANT PUMP RUN FAULT
M61 COOLANT SYSTEM FAULT
M62 CENTRIFUGE & RECIRC PUMPS RUN FAULT
M63 COOLANT FLUID FLOW FAULT
M65 B-AXIS REFERENCE SLOW FAULT
M66 B-AXIS TIMEOUT CLAMPING/UNCLAMPING FAULT
M67 CTS PUMP RUN FAULT
M68 CTS FLUID FLOW FAULT
M70 S1 RFID LONG CYCLE FAULT
M71 S1 RFID INVALID READ CYCLE DATA FAULT
M90 LEFT DRAWBAR RETRACT (CLAMP TOOL) SLOW FAULT
M91 LEFT DRAWBAR EXTEND (UNCLAMP TOOL) SLOW FAULT
M92 LEFT DRAWBAR SWITCH FAULT
M94 RIGHT DRAWBAR RETRACT (CLAMP TOOL) SLOW FAULT
M95 RIGHT DRAWBAR EXTEND (UNCLAMP TOOL) SLOW FAULT
M96 RIGHT DRAWBAR SWITCH FAULT
M102 RF PROBE FAULT
M107 S1 LEFT TOOL SPINDLE NOT OK TO RUN FAULT
M108 S1 LEFT TOOL SPINDLE SPEED TIMEOUT FAULT

User Manual – eSX
Table 8-2: Status Messages
STATUS MESSAGES (*MESSAGES VARY DEPENDING ON MACHINE MODEL)

M1 INITIALIZING SERVOS
M2 CLOSE FRONT DOOR TO CYCLE START MACHINE
M3 CLOSE FRONT DOOR TO REFERENCE MACHINE
M4 REFERENCE MACHINE
M5 CYCLE START TO ZERO AXES
M7 B-AXIS NOT REFERENCED
M8 AUTO POWER-OFF ACTIVE
M9 SERVOS TURNED OFF
M25 WORK SPINDLE AIR BLAST ON
M40 TOOL RELEASE TIMEOUT
M48 SPINDLE NOT RUNNING - FEEDHOLD
M49 TOOL LOAD HI - REDUCE FEEDRATE
M56 S2/C-AXIS WORK SPINDLE NOT REFERENCED
M59 COOLANT SYSTEM: CENTRIFUGE OR STIRRER OFF
M64 B-AXIS CLAMPED
M93 LEFT TOOL IS OK BUT WON'T RELEASE
M97 RIGHT TOOL IS OK BUT WON'T RELEASE
M99 PROBE CONTACT DETECTED - FEEDHOLD
M100 WORKPIECE PROBE CONTACT
M101 TOOL PROBE CONTACT
M103 RF PROBE BATTERY LOW
M104 TOOL RELEASE ENABLE JOG DISABLE
M105 FEEDRATE OVERRIDE SET AT 0%
M106 CLOSE DOOR AND RESET TO START SPINDLE
M109 CYCLE START TO CHANGE TOOL
M110 CYCLE START TO GO TO HOME
M205 WAITING FOR GRINDER LEFT TOOL SPINDLE AT SPEED
M206 WAITING FOR GRINDER RIGHT TOOL SPINDLE AT SPEED
M210 MOTION STOP ACTIVE
M220 C-AXIS BRAKE DISABLED WHILE HAND WHEEL C-AXIS SELECTED
M223 CTS FLOW NOT MONITORED
M225 SINGLE BLOCK MODE ENABLED

User Manual – eSX
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. For a list of spare parts and
part numbers see Section 10.3.
9.1 Daily Maintenance

9.1.1 Start of Shift
 Check that the main air supply is on and that the regulator (located on pneumatics panel see
Figure 5-11) is set to 85psi.
 Verify all service doors and guarding are closed, locked, or otherwise secured, and that
safety interlocks are functioning properly.
 Verify there are no loose parts, tools, or other objects in the work area.
 Inspect the I.D. of the work and tool holding chucks for debris, burrs or other anomalies.
Verify the chucks actuate and release properly. NEVER ACTUATE A HYDRAULIC CHUCK
WITHOUT A PRECISION STEM FULLY INSERTED (see Section 5.9 for additional information).
 Ensure the tool-holder and spindle tapers are clean and free of burs. See Section 9.9.
9.1.2 End of Shift

 Remove any loose parts, tools, or other objects from the work area.
 Wipe down the machine’s exterior as needed.
 Clean the Touch Screen with a clean soft COTTON CLOTH using any standard glass cleaner as
long as there is no abrasive or oily content; DO NOT USE PAPER TOWELS OR DIRTY CLOTHS.
Vinegar or ammonia will not hurt the screen. To minimize over-run of cleaning solution,
spray the cloth first and then clean the screen.
 Remove and clean the Centrifuge Liner. This may be done more often depending on
material removal rates. See Section 9.7.
 Clean the work area thoroughly.
 Remove the Tool-Holder from the Tool Spindle. Leaving the tool in the spindle for long
periods can cause it to seize and make removal difficult.
9.2 Weekly Maintenance

 Perform a thorough cleaning and inspection of the machine.
 Check the fluid level in the chiller and top-off if it is low with 30% Ethylene Glycol and 70%
Distilled Water; OptiPro recommends DOWTHERM SR-1.
 Wipe down the machine’s exterior.

User Manual – eSX
9.3 Monthly Maintenance

 Check and replace Pneumatic Automatic Greaser cartridge when needed, according to
Section 5.7. See Section 10.3 for grease cartridge part number.
 Check and clean the Chiller unit air filter and condenser fins as needed by vacuuming. This
may be done more or less often depending on the conditions in the shop.
 Check and clean the Electrical Cabinet A/C filter as needed by vacuuming. This may be done
more or less often depending on the conditions in the shop.
 Check the Coolant Through Spindle Filters (in Figure 5-14) and replace if dirty or clogged.
Contact OptiPro for more filters (see Section 10.3).
9.4 Semi-Annual Maintenance

 Check the machine tram and re-tram if necessary. See Section 10.1.
9.5 Yearly Maintenance

 Drain and replace the chiller fluid with approximately 4 gallons of 30% Ethylene Glycol and
70% Distilled Water; OptiPro recommends DOWTHERM SR-1. Allow the chiller to run for 2
minutes and top-off as additional fluid is taken up by the chiller loop; repeat as needed until
the tank level is full and stable. See Section 5.5.3 for more information.
 Replace Air Prep Regulator filter element (see Figure 5-11), and check the filter bowl for
cracks.
 Replace Air Prep Mist Separator filter element (see Figure 5-11), and check the filter bowl
for cracks.
9.6 3-Year Maintenance

 Safety windows provided are polycarbonate which can deteriorate over time, and must be
replaced every 3-years to provide a reasonable level of safety. See Section 9.8 for more
information.

User Manual – eSX
9.7 Cleaning the Centrifuge

1. Turn off the centrifuge by pressing the COOLANT RECIRC STOP Button located on the side of
the Operator Panel and be sure the centrifuge has stopped spinning.
2. Remove the 4 wing nuts on the lid of the centrifuge and remove the lid.
3. Remove the 6 bolts in the catch basin that are circled in yellow and remove the top, as seen
in the Figure 9-1. Make sure to take note of the dowel circled in red.
Figure 9-1: Centrifuge Catch Basin
4. Remove the rubber liner by gripping its sides and pulling straight up. Replace with the spare
liner that was supplied with the machine. Be sure to follow your company’s policies for
disposing of centrifuge wastes.
5. Bolt the top back on the catch basin, making sure to line up the dowel pin.
6. Put the lid back on the centrifuge, making sure that the safety switch is in the correct
orientation, and tighten the 4 wing nuts.

User Manual – eSX
9.8 Replacing Existing Safety Windows
OptiPro Systems recommends that machine enclosure windows made of polycarbonate be replaced
every three (3) years with Makrolon AR2 brand polycarbonate 6mm thick. A longer term upgrade option
is to replace existing polycarbonate panels with laminated glass complying with ISO 23125-B1 standard.
Replacing the side windows:
1. Unbolt the left, right, and top brackets from the inside face of the window panel. Unbolt the
outer two screws first (the screws in the slots). When removing the third (middle) screw, be
sure to hold the bracket so it doesn’t drop when the screw is clear.
Outer Bracket Screws

Window Brackets
Side Window 4mm Allen Wrench Left and Top Brackets

User Manual – eSX
2. While removing the bottom bracket, make sure the window does not fall out of its frame. Most
windows will be held in with silicone. Firmly apply pressure to the window from the outside to
push it out of its frame from the outside to unstick it from the silicone bead. Hold the inside as
shown to stop the window from falling out when it comes unstuck.
Silicone Bead
Window frame (permanent)
Polycarbonate Window
3. Place the new piece of glass or polycarbonate into the window frame. Holding the window in
place, reinstall the bottom bracket. Install the screws in the middle (unslotted) holes first and
then add screws to the slotted holes. Make sure all screws are tightened down. Warning: Over
tightening of bracket screws may cause windows to crack. Use care when tightening screws.
Install the other three window brackets in the same method.
Laminated Safety Glass
Bottom Window Bracket
4. Repeat steps 1 through 3 for the opposite window.

User Manual – eSX
Replacing the front window (requires two people):
Before starting the procedure to remove the window in the front of the machine, make sure
there is space enough to place the door once it is removed.
1. Remove the two clips on the bottom of the door holding the door to the rail (shown) with an
Allen wrench.
Inside of front
door of machine
Inside front face
of machine
Roller
Bracket
Screws
Rail Clips
Table cover
2. Remove the plate on the left inside face of the machine with the rubber window wiper attached.
Wiper
Bracket
Screws
Window Wiper Plate

User Manual – eSX
3. (Two-person lift) Slide the door all the way open (completely to the left facing the machine).
Using two people, lift the handle of the machine and the lower left simultaneously up and
outwards.
Support Here
Support Here
Lift Here Lift Here
4. Follow the directions for removing the windows from the side doors to remove the window
from the front doors. If the silicone bead in the machine comes out with the window, remove
the remaining silicone with a plastic putty knife from the metal window frame. Place another
bead of silicone along the inside of the window frame before installing the new window.
Window Brackets

User Manual – eSX
5. (Two-person lift) Lift the window back into the lower channel in reverse of step 3, ensuring that
the bearings on the top inside face of the door are seated correctly in the rail, and replace the
two brackets removed in step 3.
Top door rail
(View from top

of machine)
Bottom door rail
(View from front

machine door)

User Manual – eSX
9.9 Cleaning the Tool-holder and Spindle

Before inserting a tool in the spindle, ensure that the taper (1) and stop (2) of the spindle and tool-
holders are thoroughly clean, with no traces of dust, grease, cooling liquid, oil or metallic particles, nor
traces of oxide or scale. See the figures below.
Figure 9-2: Tool Holder taper (1) and stop (2) must be clean. Figure 9-3: Spindle taper (1) and stop (2) must be clean.
Use clean soft cloths when cleaning the Tool Spindle and Tool Holder. Never use abrasive instruments
such as wire tool, metal scrapers, emery cloth, acids, or other aggressive media to clean. Do not direct
jets of compressed air into the spindle shaft when the tool-holder is absent.

User Manual – eSX
9.10 Lubrication of Tool Spindle Locking Mechanism

After a long period of time, the tool spindle mechanism could stick causing it not to release the tool;
therefore, it must be periodically lubricated. See Section 10.3 for MetaFlux part number.
1. Lightly spray MetaFlux in the grooves between the fingers of the drawbar on the tool spindle (Figure
9-4).
2. After applying the MetaFlux, perform a number of tool changes with an HSK tool holder. This will
help distribute it evenly.
3. Remove the HSK tool holder, and wipe away any visible lumps of grease with a clean dry cloth.
Figure 9-4: Lubricating the Spindle Drawbar Fingers.

User Manual – eSX
10 Appendices
10.1 Tram Procedure
When running any automated tram programs, be sure to:
 Turn off Coolant Auto from the jog panel.

 Position the indicator and indicator mounting hardware in such a way to avoid collisions.
Alignment should be checked bi-annually, or if there was a crash. Your machine was supplied with a
tram kit that includes all the necessary items to perform a tram operation.
The tram screens will actively set the fixture offsets (G54 for single grinding spindle, G54 & G55 for twin
grinding spindles), and update probe locations in the settings page.
A single spindle grinding machine can be configured as a LEFT or RIGHT spindle. Because of this, it is
recommended that you press the SET LEFT and SET RIGHT buttons whenever possible during the tram
procedure. This will ensure that the proper values are being used for your machine configuration.
Before starting the tram procedure, make sure that your work holding chuck does not have excessive run
out. If it does, loosen the bolts, tap it in, and retighten the bolts.

User Manual – eSX
10.1.1 Check Hydraulic Chuck Run Out

1. Place the precision tram pin in the chuck and tighten down the chuck actuation screw to secure
the pin.
2. Place an indicator on the pin, closer to the top of the chuck (see Figure 10-1).
Figure 10-1: Indicator Placement for Chuck Run Out
3. Spin the C-axis and check the indicator. The run out of the chuck should be between 0-2µm. If
the run out is greater than 2 µm then the chuck needs to be adjusted.
If the chuck needs to be adjusted:
1. Slightly loosen the four M8 bolts holding the chuck to the table.
2. Spin the C-axis and stop on the greatest value on the indicator.
3. Gently tap the hydraulic chuck, using a small rubber mallet or brass bar, to decrease the
reading on the indicator by about half.
4. Slightly tighten the four mounting bolts without moving the chuck.
5. Repeat steps 2, 3 and 4 until the indicator reads between 0-2 µm.
6. Make sure all bolts are tightened completely and the chuck is still within the 2 µm.

User Manual – eSX
10.1.2 Accessing the Tram Screens

To access the new tram screens, you need to go to the SET UP screen. You can get to the SET UP screen
in the following way;
10.1.2.1 G-Series v1.0 or higher

You can access the SET UP screen in one of two ways. First, you can press <CTRL-A>. Second, you can tap
on the “G “icon in the top left corner of your screen. This will bring up a menu, and you can select
SETTINGS from there.
The SET UP screens are password protected. The password is provided to a supervisor during training.
After the password has been accepted, the screen should be active. At the bottom of the screen you
should see TRAM. Tap [TRAM] or the F4 key to start the tram procedure.
10.1.3 Tram – B Zero Screen

The purpose of this screen is to align the angle of the tool spindle and work spindle center lines so that
they are parallel. This is performed by adjusting the b-axis angle for each tool spindle, as equipped.
Figure 1 shows a picture of this screen. Follow the instructions to execute. You can tap [MOVE LEFT] or
[MOVE RIGHT] to bring up the previously set B-axis zero position for each spindle in the “MDI
Command” box. To move to that position, press the green CYCLE START button, and be aware of any
potential crash situation during movement.
Figure 10-2: Tram B Zero screen for aligning spindle parallelism
10.1.4 Tram – Spindles Aligned

Now that the spindle centerlines are parallel to each other, the next step is to make them coaxial. This is
performed by using an indicator mounted in the tool spindle to sweep around a pin placed in the work

User Manual – eSX
spindle. The X and Y axes are jogged around until the indicator reads the same number as it is swept
around the pin. This operation is performed for each tool spindle as equipped.
To execute this operation, follow the instructions on the screen (see Figure 2). You should move to the
previously found B zero and spindles aligned position by tapping [MOVE LEFT] or [MOVE RIGHT] for each
tool spindle accordingly. This is an important step that will ensure you are using the correct B-axis zero
position for each tool spindle that was found in the previous tram page.
Figure 10-3: Tram - Spindles Aligned screen to make the tool and work spindle centerlines coaxial

User Manual – eSX
10.1.5 Tram – Center of B

The purpose of this screen is to locate the center of the B-axis in, with respect to the work piece spindle
axis. This is important because it is used as a reference for defining the tool length, and establishing a
height relationship with the face of the Schunk on the work piece spindle.
The Y-axis should be moved as far forward as possible so that the tool spindle does not collide with the
tram ball in the work piece spindle.
You will have to move the Z-axis down to locate the center of B. Depending on your machine
configuration, this may cause a collision issue with the Tool Probe located behind the work piece spindle.
Proceed with caution, and remove the probe tip or probe assembly as necessary. To remove the probe tip
or probe assembly, use the spanner wrenches provided in your tram kit.
The instructions on the screen will guide you through performing this task (see Figure 3). Utilize the
[MOVE] command to go to the last known center of B position. This should get you close to the proper
location. Make sure that you mount the magnetic base indicator to a stable place on the B-axis that will
allow it to move freely with the B-axis. Once set up, rotate the B-axis in both directions and record the
values on the indicator. If the values are different from left to right then an adjustment in the X-axis is
required. If the values on the sides are equal but different from the value on top of the ball, then an
adjustment in the Z-axis is required. Mastering this technique takes practice, and can be time consuming
if you are unfamiliar with it.
Figure 10-4: Tram - Center of B. This page walks the user through locating the center of the B-axis to the center of a tool ball

User Manual – eSX
10.1.6 Tram – Pinch Test

The Pinch Test screen will establish the relationship between the center of B (found in the previous
step), the tool length, and the face of the Schunk work piece holder. This will allow the OptiPro grinding
platform to calculate the necessary tool positions during the grinding process to correctly grind the
desired shape to the proper thickness. Follow the steps in Figure 4 to perform this operation. You will
have to jog the axis manually to execute.
The tram kit is supplied with a 0.127mm (0.005”) thick metal feeler gage and 25.4mm (2”) precision gage
block that should be used for touching off the HSK tool Pin (also in the tram kit) on the tram ball and the
Schunk face. If the gages are missing, you can use any known thickness shim you want. When using the
gages it is recommended that you use 10 micron or less incremental jog steps when close to touching off.
DON’T FORGET TO INPUT THE SHIM THICKNESS IN BOTTOM RIGHT CORNER OF THE SCREEN.
For a single spindle machine it is recommended to set both the set left and set right conditions in this
screen.
Do not forget to tap [SET OFFSET] before continuing to the next screen.
Figure 10-5: Tram - Pinch Test screen. This screen establishes the heights between the tool and the work piece in relation to
the center of B

User Manual – eSX
10.1.7 Tram – Tool Probe

The purpose of this screen is to establish the location of the tool probe on the machine, and its Z-axis
position in relation to the B-axis center. This will allow the automated tool probing routines to execute
properly. The operator needs only to set the proper B-axis zero for the tool spindle being used (i.e. –
G54 or G55 B zero), and rough align the tool pin that is placed in the tool spindle over the top of the tool
probe tip. This can be done by manually jogging the machine over this location, or by tapping [MOVE L]
or [MOVE R] and pressing CYCLE START to go to the last known positions. Figure 5 will guide you
through this process.
This will have to be performed for each grinding spindle that the machine is equipped with. For a single
grinding spindle application it is advised to run both [ALIGN L] and [ALIGN R] to make sure the values are
input in the proper location for your machines configuration.
Figure 10-6: Tool Probe Screen. This screen will automatically find the alignment of the tool probe

User Manual – eSX
10.1.8 Tram – Lens Probe

The purpose of this screen is to establish the location of the lens probe on the machine, and its Z-axis
position in relation to the Schunk face. This will allow the automated lens probing routines to execute
properly. The operator needs only to set the proper B-axis zero position, and rough align the lens probe
over the top of the tram ball that is placed in the Schunk. Tapping [MOVE] at the bottom of the screen
and pressing the CYCLE START button will move the machine to the last known alignment positions.
Once in place, tapping [ALIGN] will execute an automated probing routine. Figure 10-7 guides you
through this process.
If the old B-axis number is not correct, you can place the magnetic base indicator on the C-axis (in
Position Mode), and run it up and down in the Z-axis direction on the side of the body of the probe to
adjust the B-axis angle until the indicator dial does not move.
Figure 10-7: Tram - Lens Probe screen. This screen will find the alignment of the lens probe
10.1.9 Validation
After the Lens Probe operation is complete, tap [OK]. This will bring you back to the main SETTING page.
Tap [VALIDATE] to accept the new tram values. From here you can tap [HOME] to return to the
previously loaded job, and use your OptiPro grinding machine normally.

User Manual – eSX
10.1.10 Tramming Tips

 Move in small amounts to avoid overshooting. If the total movement is 80 micron, move the
axis 10-15 micron.
 Work on one axis at a time. Very often there is a combination error, adjust the axis with the
greatest error first. With practice, this method will speed up the entire process.
 Remember, the right side of zero on the indicator is plus and the left side is minus.
 If there are issues with tramming don’t hesitate to call OptiPro Systems.

User Manual – eSX
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 Override knob on the control panel to 0% before pressing the CYCLE
START button for a manual command!
Warning: Feed Rate Override knob does not control spindle speeds!
10.2.1 M Code List

LIST MAY VARY DEPENDING ON MACHINE MODEL
M Code Description
0 Feedhold Program STOP
1 Feedhold Conditional Program STOP
3 Work Spindle(S2) clockwise rotation; Left Tool Spindle(S1) clockwise rotation
4 Work Spindle(S2) counterclockwise rotation; Right Tool Spindle(S1) clockwise rotation
5 Stop spindle rotation (M5.S1, M5.S2)
6 Perform Tool Change (T5M6, T1-8)
7 Turn on Thru the Tool Spindle Coolant
8 Turn on coolant
9 Turn off coolant
10 C-Axis Break On
11 C-Axis Break Off
12 Initiate lube cycle
15 C-Axis Position Mode Disable, Work Spindle Mode Enabled
16 C-Axis Position Mode Enable
18 Perform reset for C-Axis Position Control
20 C-Axis Vacuum Enable
21 C-Axis Vacuum Disable
26 C-Axis Vacuum Monitoring Enable
27 C-Axis Vacuum Monitoring Disable
29 End of Spindle/Axis Switch Command
30 End program, Stop Spindles
31 Reference Program Complete
35 Enable Tool RFID Cycle
36 Trip Tool RFID Cycle
38 Orient Tool Spindle Disable
39 Orient Tool Spindle Enable
50 Laser Probe Enable
51 Laser Probe Disable
54 CTS Flow Monitoring Enable

User Manual – eSX
55 CTS Flow Monitoring Disable

56 Dressing Station Spindle Start
57 Dressing Station Spindle Stop
58 Clamp the B-Axis
59 Unclamp the B-Axis
60 Pull Tool Into Spindle
61 Release Tool From Spindle
65 B-Axis Reference Monitor
90 Ultrasonic Gripper Close
91 Ultrasonic Gripper Open
92 Ultrasonic Start
93 Ultrasonic Stop
97 Referencing Subroutine Z, X,Y, B, C
99 Home Position Subroutine
100 TC Door Close Synchronous 1-Arm ATC and Synchronous No Arm ATC
100 TC Pot Up Synchronous 2-Arm ATC
101 TC Door Open Synchronous 1-Arm ATC and Synchronous No Arm ATC
101 TC Pot Down Synchronous 2-Arm ATC
102 TC Gripper Close Synchronous 1-Arm ATC
102 TC Magazine Rotate CW One Pocket Synchronous 2-Arm ATC and Synchronous No Arm ATC
103 TC Gripper Open Synchronous 1-Arm ATC
103 TC Magazine Rotate CCW One Pocket Synchronous 2-Arm ATC and Synchronous No Arm ATC
104 TC Arm Advance to Magazine Synchronous 1-Arm ATC
104 TC Magazine Retract Synchronous No Arm ATC
105 TC Arm Advance to Spindle Synchronous 1-Arm ATC
105 TC Magazine Advance Synchronous No Arm ATC
106 TC Arm Retract Synchronous 1-Arm ATC
106 TC Magazine Reference Synchronous 2-Arm ATC and Synchronous No Arm ATC
107 TC Recovery Program
108 TC Magazine to Take Position Synchronous 2-Arm ATC and Synchronous No Arm ATC
109 TC Magazine to Leave Position Synchronous 2-Arm ATC and Synchronous No Arm ATC
110 TC Arm Home Position Synchronous 2-Arm ATC
111 TC Arm Pick Position Synchronous 2-Arm ATC
112 TC Arm Place Position Synchronous 2-Arm ATC
113 Ultrasonic Tool Check
115 Open File to Write to
116 Write Line to File
117 Close File

User Manual – eSX
10.2.2 Manual Axis positioning

G55G1[axis][position]F[feed rate]
G55G1 = work offset position and linear movement command
[axis] = axis to move (replace with X, Y, Z, or B)
[position] = coordinate position to move the axis to (replace with desired position)
[feed rate] = rate at which to move. Can be overridden by Feed Rate knob on control panel (replace with
desired rate in mm/min for linear axes, deg/sec for rotary axes)
EXAMPLE: G55G1X0F100 (move x-axis to 0 position at 100mm/min)
10.2.3 Spindle Command

S[spindle number]=[rpm]M[spindle parameter]
[spindle number] = command tool or work spindle (1= Left Tool Spindle, 2=Work Spindle, 3=Right Tool
Spindle)
[rpm] = spindle speed (replace with desired spindle speed in rpm)
[spindle parameter] = For the work spindle this is the rotational direction from a downward looking view
(3=Clockwise, 4=Counter Clockwise). For the tool spindle this is used to specify Left or Right spindle
(3=Left, 4=Right).
EXAMPLE: S1=2000M3 (spin Left tool spindle at 2000rpm)

S2=200M4 (spin work spindle at 200rpm)
See Fagor CNC 8070 Quick Reference for additional information.

User Manual – eSX
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 Element OptiPro: 15148A | SMC: AF30P-060S 1
Air Prep Mist Separator Filter OptiPro: 15149A | SMC: AFM30P-060AS 1
Element
Air Prep Regulator Filter Bowl OptiPro: 63164A | SMC: C3SF 1
Air Prep Mist Separator Bowl OptiPro: 63164A | SMC: C3SF 1
Work Spindle Rotary Union OptiPro: 69284A | SMC: KXH08-03S 1
Centrifuge Liner OptiPro: 16137A | ARIKO: Rubber Cover, KJ-CS1 3
Probe Tip OptiPro: 10510A | Marposs: 3191910870 1
10 Micron CTS Filter OptiPro: 60635A | BIESSE: 2422A0135 1
5 Micron CTS Filter OptiPro: 60634A | BIESSE: 2422A0136 1
Pneumatic Automatic Greaser OptiPro: 60593A | LUBE USA: 249126 2
Grease Cartridge
MetaFlux Spray OptiPro: 63977A | MetaFlux: 70-82 1

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OptiPro Systems, LLC

User Manual – eSX

OptiPro Systems, LLC. Page 1 of 111 Last Modified: 8/27/2014

5.9 Work Holding Chucks .................................................................................................................. 27

OptiPro Systems, LLC. Page 3 of 111 Last Modified: 8/27/2014

7.5.9 Scoop Tools ......................................................................................................................... 44

OptiPro Systems, LLC. Page 4 of 111 Last Modified: 8/27/2014

10.1.1 Check Hydraulic Chuck Run Out ........................................................................................ 100

OptiPro Systems, LLC. Page 5 of 111 Last Modified: 8/27/2014

Phone: (585) 265-0160

For Service and Parts

For Process and Technical Support

OptiPro Systems, LLC. Page 6 of 111 Last Modified: 8/27/2014

Table 3-1: Document Revision Summary

Release Dated Changes

OptiPro Systems, LLC. Page 7 of 111 Last Modified: 8/27/2014

4.1 Employer’s Responsibilities

 Keeping the working area well illuminated.

4.2 General Safety Concerns

OptiPro Systems, LLC. Page 8 of 111 Last Modified: 8/27/2014

4.2.2 Electrical Safety

4.2.3 Pneumatic Safety

4.2.4 Chemical Safety

4.3 Safe Operation of the Machine

OptiPro Systems, LLC. Page 9 of 111 Last Modified: 8/27/2014

 Press the EMERGENCY STOP button.

OptiPro Systems, LLC. Page 10 of 111 Last Modified: 8/27/2014

5 Machine Overview and User Controls

OptiPro Systems, LLC. Page 11 of 111 Last Modified: 8/27/2014

Figure 5-1: Machine Front View

Figure 5-2: Left-Rear Machine View

Right Side Electrical

Figure 5-3: Right-Rear Machine View

OptiPro Systems, LLC. Page 12 of 111 Last Modified: 8/27/2014

5.1 Work Area and Machine Axes

Figure 5-4: Machine Spindles and Axes

OptiPro Systems, LLC. Page 13 of 111 Last Modified: 8/27/2014

5.2 Operator Panel Interface

Figure 5-5: Operator Panel

5.2.1 Jog Panel

Figure 5-6: Jog Panel

OptiPro Systems, LLC. Page 14 of 111 Last Modified: 8/27/2014

Table 5-1: Jog Panel Button Descriptions

Button Label Description

OptiPro Systems, LLC. Page 15 of 111 Last Modified: 8/27/2014

5.2.2 Jog Pendant

Figure 5-7: Hand Wheel

OptiPro Systems, LLC. Page 16 of 111 Last Modified: 8/27/2014

5.2.3 Door Interlock

Figure 5-8: Door Interlock Selector Switch

5.2.4 Emergency Stop

Figure 5-9: Emergency Stop Button

OptiPro Systems, LLC. Page 17 of 111 Last Modified: 8/27/2014

5.2.5 Coolant Recirculation Control

Figure 5-10: Coolant Recirc On/Off, USB ports

5.2.6 USB ports

OptiPro Systems, LLC. Page 18 of 111 Last Modified: 8/27/2014

5.3 Utility Control Panel

Air Prep Mist