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BruceH: IPD of my unit same as yours. Waiting to hear from ZR about line on inner focusing lens (and rough finish). I do think my personal facial quirks aren't the only things to blame for my ED3 issues. I think there's something off with my unit. There's also slight vignetting undetectable on the Monarch and Terra. BTW, did you keep your Prime? Your blackout complaints in 2012 are the same as mine on here.
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Sorry to say I ended up returning the 10X42 Prime HD at the end of the trial period. Although I did adjust somewhat to the issues I was having with blackouts, I never got to the point that I thought I could live with it. I also found (somewhat to my surprise) that I did not adjust to the rolling ball that I saw.
Keep in mind that I had a 10x. The 8x reviews where not reporting black out issues (or rolling ball issues) to the same extent. Also, mine was from the very first production run. I am not reading about blackout issues in current comments so maybe some changes have been made. The only way you will know for sure is to give one a try. Other reviewers had no issues with the early 10x units so it appears to be something that varies between individual Prime owners.
There is one other point to keep in mind about the Prime that I think Steve C pointed out in a prior thread. I believe the eye cups are a little larger diameter than standard binoculars without lens flatteners in the eye piece. If you have a narrow IPD setting and your nose is wide at the bridge, then you may not be able to set the IPD at minimum because the edges of the eye cups will come in contact with the side of your nose before achieving the minimum setting. Again, this is something you will only know by trying.
Getting back to your original issue of blackouts, one comment you made in an above post keeps coming to mind:
"With eyeglasses and with eyecups completely turned down, I was squeezing to the minimum IPC and wanted IPD to get even closer."
I think you need to come to a definitive conclusion as to whether you are able to achieve a correct IPD setting with the ED3. It appears there is a possibility that you can not.
Here is a suggestion for consideration. If you have another binocular on hand that does provide a comfortable full view, then adjust the IPD setting and measure the actual IPD distance. Compare that to the minimum measurement of the ED3. If the result of the test unit is smaller than the minimum of the ED3 IPD measurement, then it looks like you are out of adjustment and there is not much you can do on your end. At that point it would be time to see if Zen-Ray can make any kind of accommodation. You may want to repeat the measurements multiple times to make sure it is correct.
The good news is that Zen-Ray is an excellent company to work with and I have found that Charles will do whatever he possibly can to make sure you are happy with your purchase. I have never had a problem exchanging a unit that I thought had an issue for me (although I am not sure if Charles always agreed!|:d| ) and I had no problem returning the Prime near the end of the trial period. I understand your concerns with the current unit and there is the possibility that an exchange may solve the problem.
Please continue to keep us updated on how things progress.