Mercury THD User Manual English

MERCURY T-HD

Kodak

OPERATOR MANUAL Rev.H_Eng Mercury Plate Processor Serial Number ___________________________ Year of Manufacture __________________ Date of Installation ___________________ Service Key Number_______________________

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MERCURY T-HD TABLE OF CONTENTS ITEM

PAGE NO.

EC Declaration of Conformity

5

Changes Made to This Manual

6

Safety

7

Installation

11

Specification

13

Operating Setting Range & Defaults

13

Machine Label Key

15

General View – Front

17

General View – Rear

19

General Description

23

Plate Path

24

Developer System

25

Developer Tank

27

Developer Cooling System

29

Rinse System

30

Gum System

33

Drying System

34

Wash Down System

35

General Operating Information

37

The Operator Control Panel

43

Screen Trees

45

Operator Screen Descriptions

51

Operator Control Panel Error Codes

99

Routine Maintenance

105

Trouble Shooting

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MERCURY T-HD EC - Declaration of Conformity We hereby declare that the equipment described below conforms to relevant European Community Safety & Health regulations with respect to its design, fabrication and serial production. Use of this equipment for any other purpose than for which it has been designed and/or unauthorised modification of this equipment renders this declaration invalid. Type of Equipment:

Plate Processor

Authorised application:

Processing of Lithographic Plates

Serial Number(s):

MB1001 & Subsequent ME9001 & Subsequent

Relevant EC Regulations:

Machinery Directive 98/37/EC EMC Directive 89/336/EEC Low Voltage Directive 73/23/EEC Amended by 93/68/EEC

Applied Harmonised Standards, especially:

EN 61326:1998 Electrical equipment for measurement, control and laboratory use. EMC requirements. EN 60950-1:2002 Information technology equipment. Safety. General requirements UL 60950-1, First Edition 2003, Standard for Safety of Information Technology Equipment, CAN/CSA-C22.2 No. 60950-1-03 Information Technology Equipment Safety - Part 1: General Requirements

Notified Body Certificates:

TRLEMC ITS Intertek Testing Services, ETL Semko

Manufacturer:

Heights UK Ltd. Wainstalls, Halifax, West Yorkshire, HX2 7TJ, United Kingdom

Date:

01/07/2004

Original Signatures on File

David F. Garrity Group Operations Director

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MERCURY T-HD Changes Made to this Manual Rev

Changes Made

G

Logo & machine name Main power connection instructions Chiller type and description

H

Introduction of Unites States & Canada options. Change of software operating parameters Add Error code reporting Amend minor errors to formatting

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MERCURY T-HD SAFETY OPERATOR SAFETY Anyone operating the Mercury unit must take safety into consideration. Here are some points to be noted when operating the machine: 1.

The machine must be connected to the mains electrical supply by a suitably qualified technician. All electrical installations must conform to local statutory regulations. (See INSTALLATION).

2.

The machine is designed for processing CTP litho printing plates and must be operated as described in these instructions. It must not be modified or used for any other purpose.

3.

Do not climb on the machine or stand on top of it.

4.

The machine should be installed so that the operator can easily reach all parts. (See INSTALLATION).

5.

If a machine is moved, either use the wheels supplied with the machine or a forklift or pallet truck with a minimum of SWL of 800kg (1760 lbs).

6.

During operation, all covers, guards and doors must be closed and, where possible, kept locked.

7.

The top covers may need to be removed for cleaning. This should only be performed by authorised/trained operators. Safety switches are fitted to stop the machine running when the top covers are removed.

NOTE: The safety switches only stop the machine, they do not isolate it from the electrical supply.

8.

Always isolate from the electrical supply before carrying out maintenance work on the machine.

9.

Access to the main electrical power isolator and emergency stop buttons must not be obstructed.

10. The area around the machine should be kept clean, dry and clear of any waste material. 11. Only authorised and suitably qualified engineers should be permitted to carry out maintenance work on this machine. 12. Guards, other than the top covers, must NOT be removed by anyone other than an authorised, qualified engineer. When replacing these covers, the earth continuity wires must be re-connected correctly. 13. Always use the lifting hooks provided for roller removal.

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MERCURY T-HD

14. Lithographic chemicals can be harmful – always refer to the manufacturer’s safety notes. Follow the manufacturer’s directions when handling chemicals, filling thanks and containers and when disposing of chemicals. 15. Health and safety precautions should always be adhered to when working with lithographic plate processors. The wearing of gloves, goggles and protective clothing is recommended when working in the water section of the processor where bacteria can be present which can, under certain circumstances, cause infection.

Safety Switches 1.

Isolator This is mounted on the electrical cabinet door. The isolator must be turned to OFF before the door can be opened.

2.

Top Cover Switches Two switches are fitted to each cover; they stop the machine if the top cover is lifted when the machine is running.

Caution: These switches do not isolate the machine from the mains supply. 3.

Emergency Stop A red emergency stop button is mounted at each corner of the machine (Only two on the 850). When pressed, power is removed from the pumps and drives only, it is not isolated from the mains supply, the buttons must be turned to unlock and reset.

4.

Service Key Switch This can be used to bypass the safety switches on the top cover. The conveyor drive can be inched and automatic processing features are disabled. It must always be set to automatic and the key removed when in normal operation.

Machine Protection a) Do not attempt run the machine dry – damage could be caused to the pumps. b) Do not cover the ventilation slots on the covers of the machine. c) Do not insert a plate into the machine unless the display indicates “READY”.

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MERCURY T-HD IMPORTANT KODAK CANNOT ACCEPT RESPONSIBILITY FOR ANY DAMAGE TO PERSONS OR PROPERTY, LEGAL INFRINGEMENT, OR CONSEQUENTIAL LOSSES ARISING FROM THE MISUSE OR MODIFICATION OF THIS PRODUCT BY UNAUTHORISED PERSONNEL. This product has been designed and tested in accordance with EMC to:BS EN 61326:1998 Electrical equipment for measurement, control and laboratory use. EMC requirements. SAFETY COMPLIANCE to:BS EN 60950-1:2002 Information technology equipment. Safety. General requirements UL 60950-1, First Edition 2003, Standard for Safety of Information Technology Equipment, CAN/CSA-C22.2 No. 60950-1-03 Information Technology Equipment - Safety – Part 1: General Requirements (Bi-national standard, with UL 60950-1) To ensure that this product continues to comply with relevant requirements it is in the customer interests to ensure that any necessary remedial or maintenance works are carried out by suitable qualified and authorised personnel as recommended by Kodak in the country of installation. Note United States & Canada only: This product is not for use in a computer room as defined in the Standard for the Protection of Electronic Computer / Data Processing Equipment, ANSI/NFPA 75.

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MERCURY T-HD INSTALLATION The installation, connection of services and commissioning of the machine must be carried out by Kodak approved equipment service engineers, or qualified representatives. The installation site must be clean, dry and strong enough to support the unit (See Mercury THD Processor specification). Contact your Kodak representative for any environmental requirements regarding plate chemistry. There must also be sufficient room to operate the machinery efficiently. It is recommended that the machine is at least 600mm from any wall or adjacent equipment to allow easy access for operation and servicing. The machine can be moved by using a forklift or pallet truck under the frame or by using the built in wheels (if fitted).

WATER SUPPLY The user must provide a water supply that complies with local water authority regulations. The water inlet is centrally located at the rear of the machine (3/4” BSP hose supplied). A stopcock or gate valve must be connected in the supply line at a convenient point to allow local disconnection of the machine (See Mercury T-HD Processor specification minimum water pressure).

ELECTRICAL The electrical cabinet access panel is located at the left hand side of the machine when viewed from the operator panel, and is secured by two 5mm screws and is fitted with an interlocked isolator switch. The operator panel consists of a liquid crystal display (LCD) panel which controls all functions of the machine. Emergency stop buttons are fitted at each corner of the machine. These may be reset after use by turning them clockwise. (Note 850 size machine only has 2 emergency stop buttons at opposing corners.) The machine is suitable for connection to the following mains supply: 1. 2.

200 – 230V Single Phase + GND 200 – 230V 2-Wire + GND (United States & Canada)

All versions require an earth line.

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MERCURY T-HD POWER SUPPLY CONNECTIONS

MAINS FILTER

Z2 LOAD

LINE

L PE GROUND

L

N

MAINS IN

X1

PE

N

ELECTRICAL TECHNICAL INFORMATION Specification 200-230V L+N+PE/GND or 2W+PE/GND

Full Load Current

Protected Device Rating

16A

20A *

Minimum Cable Size 12 AWG or 2.5mm2

50/60 Hz This Product is not for use in a computer room as defined in the Standard for Protection of Electronic Computer/Data Processing Equipment, ANSI/NFPA 75.

Installation Cable Recommendation The cable sizes shown are a MINIMUM size only. The actual installation wiring size required should be calculated in accordance with local electrical codes. For Europe and International countries, H05VVF3 VDE Approved Type cable to be used. In North America SJT or better cable is required. Notes *SUPPLY TO EQUIPMENT TO BE PROTECTED BY A 2 POLE 20A CIRCUIT BREAKER TYPE C

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MERCURY T-HD SPECIFICATION 850 850mm

1250 1550 Maximum Plate Width 1250mm 1550mm Minimum Plate Length 320mm 1650mm (excluding feed & delivery Machine Lengh tables) 1080mm (Min) incl feet, excluding Machine Height wheels) Machine Width 1423mm 1823mm 2123mm 870mm/- 940mm (with wheels removed) Plate Feed Height 905mm ~ 940mm (with wheels fitted) Water Connection 3/4" BSP Male (*) Drain Connection 1 1/2" BSP MALE Water Pressure Minimum 1.4bar / Maximum 5 bar Developer Tank 43ltr 65ltr 80ltr Capacity Rinse Tank Capacity 33ltr 48ltr 60ltr Gum Tank Capacity 5ltr 6.5ltr 8ltr Noise Level <70db (A) Plate Gauge 0.15mm minimum / 0.5mm maximum Gross weight in Kgs 635 785 845 Nett weight in Kgs 585 735 795

OPERATING SETTING RANGE & DEFAULTS Parameter

RangeV22(*)

Default

10 - 60 rpm

10 - 60 rpm

40 rpm

5 - 26 °C

5 - 32 °C

22 °C

Plate Speed 1

0 - 1500mm

0 - 2000mm

750mm

Plate Speed 2

0 - 1500mm

0 - 2000mm

750mm

Plate Speed 3

0 - 1500mm

0 - 2000mm

750mm

0 - 600ml

0 - 600ml

100ml

Dosing Rate

Time Setting

Time Setting

30Secs

Dryer Output

0 - 100%

0 - 100%

75%

1 or 2

1 or 2

1

Exit Sensor

1

1

1

Conductivity

0 - 100% Span

0 - 100% Span

N/a

Brush Speed Dev Temp

Developer Replenishment

Entry Sensors

Range

V22(*)

(*) V22 Refers to Software revision 05.01.22 (**) If 2 entry sensors are selected, the exit sensor is disabled (*) For USA only P/N 0231C434 ¾” BSB to ¾” NPT Adaptor

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MERCURY T-HD Customers Individual Settings (please complete on installation) Parameter

Range

Brush Speed

Default * rpm

40 rpm

C

22 C

Plate Speed 1

mm

700mm

Plate Speed 2

mm

800mm

Plate Speed 3

mm

900mm

Developer Replenishment

ml

100ml

Dosing Rate

secs

Dev Temp

Dryer Output

%

30 secs 100%

Entry Sensors

1

Exit Sensors

1

Conductivity

mS

N/a

* NOTE: The Default Settings do not relate to any specific plate system. They are basic reference settings. Please refer to your local Kodak representative for specific settings relating to the plate system used

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MERCURY T-HD MACHINE LABEL KEY

DEVELOPER FILL & REPLENISHMENT GUM FILL

GUM RETURN

SERVICE KEY SWITCH

DEVELOPER FILL & REPLENISHMENT GUM FILL & RETURN TO BOTTLE

WASH BOTTLE

DEVELOPER

GUM

OVERFLOW

REAR DRAIN HOSES

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MERCURY T-HD MACHINE LABEL KEY (cont)

DRAIN POINT 1 1/2" BSP

WASH DOWN ON / OFF

DRAIN POINT 1 ½ BSP

WASH DOWN ON / OFF

MAINS WATER 3/4" BSP

MAINS WATER ¾” BSP

DEV FILTER

WASH FILTER

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MERCURY T-HD GENERAL VIEW – FRONT 2 7 1 8 12

11 10

4

9 6 5

3

1.

Top Front Cover

7.

Re – entry Position (Option)

2.

Top Rear cover

8.

Operator Panel

3.

Removable front cover

9.

Developer Filter 10” (*)

4.

Chiller Access Cover

10.

Wash down Hose

5.

Adjustable feet & wheels (if fitted)

11.

Gum Flush Bottle (Option)

6.

In - feed cover

12.

Removable Side Cover

(*) See overleaf for United States & Canada

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MERCURY T-HD (*) For United States & Canada Only

9.

20” Developer Filter Housing

13.

Drain Tap

9

13

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MERCURY T-HD GENERAL VIEW - (REAR) 12 13 11

10 2 1 3 9 4 6 5

7

8

1.

Gum Flush Bottle (Option)

8.

Water Inlet (*)

2.

Wash Down Hose Tap

9.

Drain Taps/Hoses (*)

3.

Biocide Dose Hose (Option)

10.

Rear Exit Cover

4.

Gum Feed Hose

11.

Emergency Stop Button

5.

Gum Return Hose

12.

Exit Wheels

6.

Wash Filter (Option)

13.

Exit Sensor

7.

Rear Direct to Drain Manifold (*)

(*) See overleaf for United States & Canada

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MERCURY T-HD (*) For United States & Canada Only

7.

1.½” BSP Waste Water Manifold (Direct to Drain & Recirculation Mode)

8.

Water Inlet C/W ¾” NPT Adaptor

9.

Drain Taps

7

8

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9

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MERCURY T-HD GENERAL DESCRIPTION The Mercury Processor is an automatic plate processor for CTP plate development. It is available in three sizes: 850, 1250 and 1550*. These indicate the maximum width in mm of plates which can be processed. There are 3 specifications available in each size: Spec 1 – Base machine with no options, direct to drain. Spec 2 – Base machine with no options, internal water recirculation. Spec 3 – Fully specified machine, direct to drain & internal water recirculation. The Mercury processor automatically develops, rinses, gums and then dries the plate. Provision is made for automatic re-entry (option). The unit is operated by a microprocessor based control system and LCD operator panel providing simple, easy to use operator controls. While reading the following description, please refer to the Plate Path illustration on the following page. The following process is started whenever a plate is detected by the optical sensor at the infeed. The plate is gripped by rollers and fed into the temperature-controlled developer, where sprays and rotating brushes assist in completing development. Developer exit squeegee rollers help to avoid carryover of developer; the plate is then rinsed by the action of water sprays and a rotating brush. Surplus water is removed from the plate by rollers, and the plate passes into the gum section. Gum is delivered from a spray bar and is spread via a spiral applicator roller, and then the gum rollers produce a thin even film of gum on the plate. Finally, the plate is dried on both sides by powerful jets of hot air. The re-entry tray (option) can be used when rinsing and gumming after manual deletions (and/or baking), without re-developing the plate. A re-entry sensor starts the rinse and gum cycle, but the developer section remains inactive helping to preserve the life of the developer. If the machine is not being used for long periods of time the control system will exercise the machine and associated services as though a plate were being processed; this will operate the machine for the period (programmable) normally every 60 minutes for a period of 30 seconds. This automatic programme may be interrupted at any time by the entry of a plate. The operation of an emergency stop button or opening of a guard will cause the mains power to be removed from the pumps and drives. For the removal of jammed plates, maintenance and cleaning operations (by authorised personnel only) a service key switch is provided on the right hand side of the control panel door. This allows an authorised person to remove the guards and by-pass the safety switch circuit.

*There is also a 1560 version for special order.

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MERCURY T-HD PLATE PATH

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MERCURY T-HD DEVELOPING SYSTEM A pump draws developer fluid from the tank, and pumps it continuously through a filter to the spray bars. For United States & Canada only please see overleaf.

Dev Flow Switch

Dev Replenishment Pump (*)

Dev Circulation Pump (Totton Type)

Dev Bulk Fill

(*) From machine serial number ME9121 the Developer Replenishment Pump type has changed to a bellows type shown below. The mounting position of the Dosing pump (option) has also changed.

Wash Water Dosing Pump (Option)

Developer Replen Pump

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MERCURY T-HD For United States & Canada Only

Dev Flow Switch (Option)

Pump Isolation Valves (*)

Wash Water Dosing Pump (Option)

Dev Replenishment Pump

Dev Circulation Pump (March May Type) (*) The 2 pump isolation valves are fitted to allow for easy removal of the developer pump without having to drain the tank.

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MERCURY T-HD DEVELOPER TANK

Removable Front Dev Bed

Centre Dev Roller Gearbox Housing

Removable Rear Dev Bed

Centre Dev Rollers

1st and 2nd Brush/Scrub Roller

Dev Exit Rollers Developer Input Rollers Brush/Scrub Gearbox Housings

To remove the front and rear developer beds, remove the brush/scrub rollers from the developer section. Gently lift both developer beds upwards for removal. Please note that the front and rear developer beds are NOT interchangeable. Care must be taken to ensure that they are replaced in the correct position and that they are correctly seated on their respective mounting points.

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MERCURY T-HD

Float Switches

Float switches detect the level of developer in the tank. The level and concentration of the developer are maintained by a replenish pump, which supplies an automatically calculated amount of fresh developer from an external container. Replenishing is supplied by the per area setting and by the intelligent Anti-ox programme. If the level of developer falls below the low level float, power to the heaters and drive system is interrupted. The temperature of the developer is closely controlled. A temperature sensor and a heater/chiller enable the control system to maintain the optimum temperature.

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MERCURY T-HD DEVELOPER COOLING SYSTEM The Cooler unit comprises a compressor, condenser heat exchanger, circulation pump, and header tank fitted into its own removable box as shown below. The chiller is accessed from the side of the machine by removing the access panel. The chiller assembly is controlled from the CPU. The two cooling trombones in the developer section are connected in series to the chiller and cold water is pumped through the cooling system until the temperature is stabilized. Protection is provided by the flow switch, high-pressure switch and header tank level switch, all of which have to be closed to allow the chiller to start. The chiller unit also has a digital temperature control unit which controls the fluid temperature in the cooling trombones. This is factory set at 10 Deg C and should not be altered as it prevents freezing of the exchanger. It does not control the developer temperature. If the fault indicator lamp is illuminated the problem will be either no water flow, low level in the header tank or the auto reset high-pressure switch

Water Fill Access

Fault Indicator Lamp Water Level

Digital Temperature Readout Re-Set Button

Regularly inspect the water level and keep the water header tank filled too between the upper and lower indicator marks.

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MERCURY T-HD RINSE SYSTEM DIRECT TO DRAIN / RECIRCULATION (OPTION) The rinse system can be set-up to either run in a direct to drain mode or recirculation mode. This change over must only be done by a qualified engineer. The system comprises a circulation pump, inlet / replen solenoid (recirculation use) spray bar solenoid (Direct to drain use), dual float switch, filter and spray bars. Initially the wash is filled via the water inlet solenoid to the high-level float switch; this is controlled automatically via the operator LCD panel. The inlet solenoid is turned off and the circulation pump is turned on. If running direct to drain then a solenoid opens and controls the spray operation allowing all wastewater to run to drain. The lower float remains active to detect if the drain is blocked. If the level rises above the lower float switch, a “drain blocked” warning will be issued The spray bar taps can be adjusted to the required pressure as indicated below. Wash replenish is microprocessor controlled measuring the plate area and operating the second water inlet solenoid accordingly.

Spray bar Taps

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MERCURY T-HD

Water Recirculation Pump Position (850 & 1250 Has 1 Pump, 1550 & VLF Has 2 Pumps)

Water Inlet / Replen Solenoid and Spray Bar Solenoid

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MERCURY T-HD

Drain Taps, Hoses & Water Recirculation Filter Housing (Option)

For The United Stated & Canada Only

Drain Taps & Hoses

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MERCURY T-HD GUM SYSTEM Gum is contained in an external container. It is fed by a pump to a gum nozzle bar, which applies gum onto a spiral applicator roller and gum exit rollers; it then drains back to the container. Gum flushing (option) is provided via a gum flush pump, which takes water from a bottle and feeds directly into the gum spray bar. Ensure the Gum Flush Bottle is full of water at all times.

WARNING: Lithographic solutions can be harmful; follow the manufactures instructions for safe use.

Gum Flush Bottle

Gum Return Hose

Gum Feed Hose Gum Nozzle Bar Spiral Applicator Roller

Gum Pump Gum Flush Pump

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MERCURY T-HD DRYING SYSTEM As the plate leaves the gum section, it passes between powerful jets of hot air, which effectively dry the gum to provide protection to the developed plate. The dryers are switched on and off automatically whenever a plate is processed. The output is adjustable via the control system from 0 to 100%.

Gum Tap Gum Flush Tap

Hot Air Blower Hoses

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MERCURY T-HD WASH DOWN SYSTEM The wash down system comprises a spray gun with tap, fed directly from mains water supply. The hose is supplied to reach all parts of the machine, all that is required is to turn on the tap and depress the trigger on the spray gun. Be Careful when using the spray gun. Water must be contained within the tank area

Spray Gun Tap

Spray Gun

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MERCURY T-HD GENERAL OPERATING INFORMATION NOTE: Before using the processor the operator must read the safety notes.

Operating Controls & Safety Switches Isolator The isolator is mounted on the electrical cabinet door on the side of the machine. The isolator must be turned to OFF before the door can be opened.

Top cover switches Two actuators are mounted on the top cover of both the front end and rear top covers. These stop the machine if either of the top covers are lifted when the machine is running.

WARNING: These switches do not isolate the machine from the mains supply.

Emergency Stop Red emergency stop buttons are mounted at each opposing corners of the machine; when pressed, the power to the machine is interrupted, but the machine is not isolated from the mains supply. The buttons must be turned to unlock to reset and resume normal operation. (Note 850 size machine only has 2 emergency stop buttons at opposing corners.)

WARNING: These switches do not isolate the machine from the mains supply.

Service Key Switch Skilled personnel should only use the service key switch. This can be used to bypass the safety switches on the top covers so maintenance work can be carried out on the processor. The key is located on the RH side of the Electrical Control Cabinet. When the key has been rotated to the Service position, the pumps and heater/chiller can operate normally, however a plate cannot be processed automatically. Furthermore the roller transport can be inched in both directions. The service key must always be reset to automatic when in normal operation and the key removed and kept in a safe place.

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MERCURY T-HD Alarm Displays These are accompanied by an audible warning tone, and the message is superimposed on the current LCD screen display. Ready – Machine is Ready to process or Re-Enter a plate. Not Ready – Machine is in the process of warming up ready for processing a plate. This is an automatic procedure. In Use – There is a plate being processed in the machine so another plate MUST NOT be entered with the entry or re-entry. Once the plate has passed through the processor the display will change to Ready. Fault – The machine is unable to process a plate and requires operator intervention. Go to the Alarms Menu (Top left hand corner of the main operator screen) where the alarms will be displayed. Emergency Stop – Once one of the emergency stop buttons has been pressed or a lid has been removed, reset the switch and return the machine to normal operating mode by exiting the recovery screen. Safety Lockout – If this appears, no further functions can be carried out on the machine. Check that all safety devices are correctly fitted. Turn off the machine at the isolator and wait ten seconds. If the machine returns to the Safety Lockout condition, contact your local Kodak Representative.

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MERCURY T-HD Starting Procedure Before Starting 1.

Check that all brushes, rollers, spray bars and plate guides are in place in the tank and that there are no obstructions.

2.

Check that the electrical cabinet doors are closed and locked. covers have been replaced.

3.

Check that the developer waste bottles are in position and the feed pipes installed.

4.

Check that the developer replenish bottle is in place and the feed pipe installed.

5.

Check that all drain taps have been closed.

6.

Switch the machine ON at the isolator. The LCD screen will display the software version and a “Press any key” instruction.

Check that all removable

Press any key and the display changes to the Auto Run Screen. Once this has been finished (providing there are no reported errors or warnings) the display will show the main operation screen. 7.

Filling the Developer Section Fill the tank with rollers in place. If the rollers are fitted after filling some developer will be displaced to the drain and so wasted. Fitting the rollers after filling can also cause a splashing hazard. Place a full container of developer at the front of the machine and insert the feed pipe into it. To fill the developer section select the fill menu and press the Dev. Fill button – This will start the auto fill pump. The fill menu can also be accessed through the service menu. When the container is empty, stop the pump, remove the empty container and replace with a full container. Re start the developer fill pump. When the tank is full the developer fill pump will turn off automatically and the developer circulation pump will turn on. If the developer replenish solution is the same as the bulk fill, place the replenishment pipe into the developer container. If the replenishment is a concentrate type, place the replenishment feed pipe into the concentrate developer. Note that the manual developer replenishment is supplied by the bulk fill pump, therefore when the manual replenishment button is pressed on the LCD screen; the fill pump draws solution through the developer fill pipe and not the small replenishment pipe.

8.

Filling the Rinse Section To fill the wash section, (when in recirculation mode) select the fill menu from the change menu and press the wash button. The tank will automatically fill and stop when full. This menu can also be accessed through the service key menu. The rinse section will require an initial injection of bactericide if used (option). This is done by selecting “Manual Dose”.

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MERCURY T-HD 9.

Filling the Gum Section The gum section will fill automatically as plates are produced. Place a full bottle of gum at the left hand rear of the machine and insert the feed pipe and return hose from the gum section. Fill the gum flush bottle (option) with water and replace.

Starting 1.

Wait until the developer temperature has reached the required set value.

3.

The LCD display will show the word “READY” when the machine is ready to process plates.

Starting from Close Down Menu 1.

If the machine has been set to “Close Down”, restart from the LCD screen, pressing the Main Menu key will automatically bring you to the “Close Down” menu. Select the “End Close Down” button. The machine will then automatically start.

2.

To reset the plate counter to zero, if required, press RESET under the plate count total on the LCD screen.

Processing a Plate 1.

Place the plate image side up on the in-feed table. Ensure that the plate is within the plate guides moulded into each side of the in-feed table and that part of the plate passes above the in-feed sensor. (Dual Plate Feeding – this is only possible on machines fitted with dual in-feed sensors. Plates should have a gap of at least 30mm between them).

2.

Push the plate gently into the machine. The machine will sense the plate and start the drive automatically. Continue pushing the plate into the machine until the infeed rollers are felt to grip the plate.

3.

The plate will be processed and fed automatically onto the exit table. The machine will stop, unless another plate is in the processor. Once there are no further plates in the machine the conveyor will stop.

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MERCURY T-HD Re-entry Operation (Option) This provides plate washing and gumming after manual deletions. Remove any excess deletion gel with damp cotton wool then: 1.

Place the plate, image side up, in the re-entry slot.

2.

The sensor will detect the plate and start the machine.

3.

Push the plate gently into the machine until the drive rollers are felt to grip the plate.

4.

The plate will be washed and gummed and fed automatically onto the out-feed table. The machine will stop.

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MERCURY T-HD


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MERCURY T-HD THE OPERATOR CONTROL PANEL The operator control panel consists of an LCD display area and eight operational buttons. The buttons execute the commands displayed along side or in some cases a screen instruction will state ‘press any key’. The plate is tracked by the microprocessor via the in feed sensor and rotation sensor on the drive motor to determine the position of the plate within the machine. The plate path is used to turn the services on and off at the appropriate time

1

Operator Settings

2

Exit

3

Developer Menu

5

Wash Menu

7

Dryer Menu

Manual Dev Replen

4

Manual Wash Replen

6

Save Settings

8

The above is an example of a typical screen.

Note: For illustrative purposes only, numbers have been assigned to the buttons on the display illustrations to aid in the following explanations of their functions. In reality there are NO numbers on these buttons

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MERCURY T-HD


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MERCURY T-HD

SCREEN TREES Rev 01.05.22 Display 02.45

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Turn M/c ON

A Go To L

Startup Display

Select Conveyor Speed

Operation Display

Plate Counter Re-Set

Main Menu

Active Alarms

Guard Switch Override

Operator Settings Menu

Change Menu

System Summary Menu

Close Down Menu

Conveyor Menu

Go To B

Go To

Go To D

Go To E

Go To F

Turn M/c ON

A Go To L

Startup Display

Select Conveyor Speed

Operation Display

Plate Counter Re-Set

Main Menu

Active Alarms



Change Menu

System Summary Menu

Close Down Menu

Conveyor Menu

Go To B

Go To

Go To D

Go To E

Go To F

B

From A


Developer Menu

Wash Menu

Dryer Menu

Plate Speed Menu

Wash Replen Type

Dryer Warm Up

Developer Temperature

Biocide Dosing

Dryer O/P

Brush Speed

Manual Dose

Dev Replen Type

Manual Wash Replen

Set Plate Sizes

Screen Saver

NOTE The wash related screens are only

B


From A

Screen Saver

Developer Menu

Wash Menu

Dryer Menu

Plate Speed Menu

Wash Replen Type

Dryer Warm Up

Developer Temperature

Biocide Dosing

Dryer O/P

Brush Speed

Manual Dose

Dev Replen Type

Manual Wash Replen

NOTE

Set Plate Sizes

The wash related screens are only

C Change Developer

Change Menu

From A

Change developer Filter

Change Wash Filter 1

Change wash

Cleaning Cycle

D

From

Summary Processing

System Summary Menu

Summary Consumables

Alarm Menu

Alarms

The W scre disp the w

Change Menu

From A

C Change Developer

Change developer Filter

Change Wash Filter 1

Change wash

Cleaning Cycle From

D

Summary Processing

System Summary Menu

Summary Consumables

Alarm Menu

The W scre disp the w

Alarms

Alarm History

From A

E Flush Gum

Set Closedown

F

From A

Stop

Restart Conveyor

Close Down Menu

Set Warmup Time

End Closedown

Conveyor Menu

Inch Forward

From A

E Flush Gum

Set Closedown

F

From A

Stop

L Exit/ Restart

Set Warmup Time

Inch Forward

End Closedown

Conveyor Menu

Restart Conveyor

From A

Inch Back

Close Down Menu

Inch Forward


Fill Tanks Menu

Hold to Run

Cancel Plates

Developer

Wash

NOTE The wash related screens are only displayed when the wash section type is selected as recirculation

L

From A

Exit/ Restart

Inch Back

Inch Forward


Cancel Plates

Hold to Run

Fill Tanks Menu

Developer

NOTE

Wash

The wash related screens are only displayed when the wash section type is selected as recirculation

MERCURY T-HD OPERATOR SCREEN DESCRIPTIONS Start up Screen

1

3

5

HT PRO, 205 [Software Version] [Date & Time software was compiled] Heater system DC Drive system ADC system Read Clock – Done Read PT Cal - OK

2

4

6

Any Key To Start 8

7 [Machine Type]

This Start up screen will be displayed when the mains power to the processor is switched on. This screen shows information on the software version and self-checks of the system.

MERCURY T-HD OPERATOR SCREEN DESCRIPTIONS Start up Screen

1

3

5

HT PRO, 205 [Software Version] [Date & Time software was compiled] Heater system DC Drive system ADC system Read Clock – Done Read PT Cal - OK

2

4

6

Any Key To Start 8

7 [Machine Type]

This Start up screen will be displayed when the mains power to the processor is switched on. This screen shows information on the software version and self-checks of the system. The Mercury Processor uses a digital control system. The software parameters are factory preset. The operator settings can be changed at any time; however the engineering settings can only be changed by approved personnel using a secure password.

Exercise Machine 1

2

3

4

5

6 Flushing Gum System

7

Any Key To Stop

8

Pressing any key will start the processor and bring up the Exercise Machine Screen The processor will go into an Auto run mode running for 30 seconds. • Pressing any button will stop this function. • Usually when the processor is first switched on the Developer temperature will be out of • specification. In most cases the next screen will show the active Alarms Menu

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MERCURY T-HD Alarms

Alarms 1

3

Exit

Restart Circ Dev Temp Low

2

4

5

6

7

8

This screen shows the active alarms. (Typical Example) In normal operation these alarms are temperature related and will clear as the processor warms up. In other cases i.e. “Developer Level Low”. User intervention will be necessary. The restart circulation option will only appear when the developer pump has stopped Pressing the Exit button will take the operator to the Main Menu

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MERCURY T-HD Main Menu Main menu 1

Exit

3

Operator Settings

5

Change Menu

7

System Summary

1. Returns to Operator Display 3. Moves to the Operator Settings menu 5. Moves to the Change menu 7. Moves to the System Summary menu

2

Close Down

4

Conveyor

6

Engineering

8

2. No selection Available 4. Moves to the Close Down menu 6. Moves to the Conveyor menu 8. Moves to the Engineering menu (Password Protected)

This screen gives access to the functions described above.

From this screen the operator can also address some faults: E.g. Developer low level, by going into change menu and fill tanks the developer section can be filled/ topped up.

Pressing Exit will take the operator to the Operation Display

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MERCURY T-HD Operator Display

1

Main Menu/Alarms

3

Plates:0000 Reset

5

Select Speed 600 mm/m

2

01 Jan 00 00:00:00

4

Entry: READY Re-Entry: READY Act

7

22.0 C Developer Dev Conductivity

6 Set 26.0 C 100.1mS

8

1. Moves to the Main Menu / Active Alarms (if any exist) 3. Shows the current plate count. When pressed it will allow the operator to reset the Plate Counter to Zero 5. No Selection Available

2. Allows Selection of 3 different programmable conveyor speed 4. Date and Time – from this information the processor can be set to automatically start up or shut down. 6. No Selection Available

7. No Selection Available


This is the normal Operation Display. From this screen the operator can monitor the condition of the processor. It shows the state of the Entry and Re-Entry slots. These change from Ready to In-Use when a plate is being processed. If there is a fault, the display will change to Fault. This would then require operator intervention. The developer temperature actual (Act) and set point (Set) are displayed. The developer conductivity is displayed in milli siemens (<5 mS and there will be no display). Depending on the plate type used, the conductivity system may be disabled. The current plate count is displayed with the ability to zero the counter by pressing the Reset it if required. Values shown in Bold Italics are examples only

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MERCURY T-HD Operator Settings

1

Exit

3

Developer Menu

Operator Settings Screen Savers

2

Wash Menu

4

6

5

7

1.

Save Settings

Dryer Menu

Returns to previous menu

2. 4.

3.

Moves to the Developer Menu

5.

No Selection Available

7.

Moves to the Dryer Menu

6. 8.

8

Allows the selection of the screen saver Moves to the Wash Menu (this is only displayed when the machine is configured for recirculation wash) No Selection Available Moves to the Save Settings menu

Selection of the screen saver changes the operation display to a clear screen which only displays Entry Ready or In Use or Fault. The screen saver is activated after 20 seconds automatically. To return temporarily to the operator screen, press any key.

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MERCURY T-HD Developer Menu Developer Menu 1

Exit

2

3

Plate Speed

Dev Replen

5

Developer Tem erature

Manual Dev Replen

6

7

Brush Speed

Set Plate Sizes

8

4

This screen provides access to all the other screens which control the development of the plate.

1. Returns to previous menu


3. Moves to the plate speed setting screen 5. Moves to the developer temperature setting screen 7. Moves to the brush speed setting screen

4. Moves to the developer replenishment type selection screen 6. Moves to the manual developer replenishment screen 8. Moves to the plate size data input screen

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MERCURY T-HD Set Plate Speed

Set Plate Speed 1

Exit

2

3

Speed 1

4

5

Speed 2

6

7

Speed 3

8

Developer Menu



3. Enters speed 1 setting screen






The three conveyor speed settings can all be set to different settings. In normal operating mode the different speeds can be easily accessed from the main operation screen. This screen allows the machine to have three different pre-set conveyor speed options available. These are accessed from the normal operation display button two.

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MERCURY T-HD Set Plate Speed Set Plate Speed 1/2/3 1

Exit

Default

2

3

Increase

Left Digit

4

5

Decrease

Right Digit

6

750 mm / minute 7

8



3. Increases the numeric value

4. Moves the cursor left

5. Decreases the numeric value 7. No Selection Available

6. Moves the cursor right 8. No Selection Available

All three speed settings have their own Set Plate Speed screen. Pressing the Increase button constantly increases the numeric value from 1 to 10 and 10 to 100.Using the Left and Right digit buttons moves the cursor left or right. After 5 seconds the cursor automatically moves back 1 digit to the right.

Values shown in Bold Italics are examples only

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MERCURY T-HD Developer Temperature

Dev Temperature 1

Exit

3

Increase

5

Decrease

Default

2

Left Digit

4

Right Digit

6

22.0 C 8

7


2. Restores the temperature to the default value. 4. Moves the cursor left

5. Decreases the numeric value

6. Moves the cursor right




Pressing the Increase button constantly increases the numeric value increments of 1 to 10. Using the Left and Right digit buttons moves the cursor left or right. After 5 seconds the cursor automatically moves back 1 digit to the right. Values shown in Bold Italics are examples only

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MERCURY T-HD Brush Speed Brush Speed 1

Exit

3

Increase

5

Decrease

Default

2

Left Digit

4

Developer Menu Right Digit

6

40 RPM 8

7


2. Restores the brush speed to the default value. 4. Moves the cursor left






Pressing the Increase button constantly increases the numeric value increments of 1 to 10. Using the Left and Right digit buttons moves the cursor left or right. After 5 seconds the cursor automatically moves back 1 digit to the right.


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MERCURY T-HD Developer Replenishment

Dev Replenish 1

2

Exit

Per Area None

3

4

5

Up

6

7

Down

8

1. Returns to previous menu*




5. Moves Cursor Up


7. Moves Cursor Down


* When None is selected - exits to previous menu. When Per Area is selected the Dev Replenish Rate screen (next page) is displayed. (**) Where up to software Rev 01.05.13 is used there is an extra option for Level Sense. This means that the developer replenishment can be done by using the top level float switch. This method of replenishment is no longer recommended.

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MERCURY T-HD Dev Replenish Rate Dev Replenish Rate 1

Exit

3

Increase

5

Decrease

Default

2

Left Digit

4

Right Digit

6

75 ml / sq m 8

7


2. Resets to the default value








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MERCURY T-HD Manual Dev Replenishment Manual Dev Replenish 1

2

Exit

4

3 1200 ml * 5

6

Start

8

7



3. No Selection Available 5. Initiates Manual Dev Replenishment 7. No Selection Available

4. No Selection Available 6. No Selection Available 8. No Selection Available

When manual developer replenishment is initiated by pressing the Start Button, it may be stopped by pressing any key. The pump that delivers the manual replenishment is the developer bulk fill pump. * The amount of developer delivered is displayed until the menu is exited.


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MERCURY T-HD Set Plate Sizes Plate Size Table 1

3

5

7

Next

Exit

1 2 3 4 5 6 7 8

Length 0 0 0 0 0 0 0 0

Decrease

Width mm 0 0 0 0 0 0 0 0 Increase

2

4

6

8


2. Moves cursor to next position





7. Decreases the value

8. Increases the value

The plate size menu allows the processor to accurately calculate replenishment by plate surface area. The machine measures the plate length and compares it to the Plate Size Table with all the used plate sizes stored in it. When the plate length is matched to a size on the Plate Size Table, the computer can then calculate the area of the plate so that an accurate replenishment volume can be added (developer, wash water etc). To input a plate size, use the Decrease and Increase buttons. Pressing these buttons continuously, the number will increase in value from 1 to 10, then from 10 to 100 and then from 100 to 1000. For example: 1,2,3,4,5,6,7,8,9,10,20,30,40,50,60,70,80,90,100,200,300,400, 500,600,700,800,900,1000,2000 If the button is released, the counting process will reset and pressing the button again, the number will change 1 to 10, 10 to 100 etc. Press Next to move to Width. When correct, Press Next to move to the next plate size to be entered. Please remember when entering the plate size to take into account the way the plate is entered into the processor. If plates are fed manually, it is advisable to enter the plate dimensions in for both portrait and landscape. The values entered into the Plate Size Table as default when the machine is delivered can be overwritten at any time. Press Return to go to Operator Settings Then select – Save Settings

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MERCURY T-HD Wash Menu (This screen is only available when the machine is configured for Recirculation Wash) Wash Menu 1

Exit

2

3

Manual Wash Replen

5

Manual Dose

Wash Replen

Biocidal Dosing

4

6

8

7

1. Returns to previous menu 3. Initiates Manual Wash Replenishment 5. Initiates Manual Biocidal Dosing 7. No Selection Available

2. Moves cursor to next position 4. Moves to the Wash Replen Type screen 6. Moves to the Biocidal Dosing screen 8. No Selection Available

Manual Wash Replen is initiated by pressing the button 3 constantly; it may be stopped by releasing the button. Manual Dose (Biocide) is initiated by pressing the button 5 constantly; it may be stopped by releasing the button.

Please Note: The inclusion of Water Recirculation or Direct to Drain may be an option on your machine.

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MERCURY T-HD Wash Replenishment (This screen is only available when the machine is configured for Recirculation Wash)

Wash Replenish Type 1

2

Exit

Level Sense Per Area None

3

4

5

Up

6

7

Down

8

1. Returns to previous menu*




5. Moves Cursor Up


7. Moves Cursor Down


* When None or Level Sense is selected - exits to previous menu. When Per Area is selected the Wash Replenish Rate screen (next page) is displayed.


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MERCURY T-HD Wash Replenish Rate (This screen is only available when the machine is configured for Recirculation Wash) Wash Replenish Rate 1

Exit

3

Increase

5

Decrease

Default

2

Left Digit

4

Right Digit

6

100 ml / sq m 8

7











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MERCURY T-HD Biocidal Dosing (Option) (This screen is only available when the machine is configured for Recirculation Wash)

Biocidal Dosing 1

3

5

7

Advance

Exit Sunday Monday Tuesday Wednesday Thursday Friday Saturday

00:00 00:00 00:00 00:00 00:00 00:00 00:00

00:00 00:00 00:00 00:00 00:00 00:00 00:00

4

6

Next Day

Next Time

2

8





5. No Selection Available 7. Moves to the next time slot for that day

6. No Selection Available 8. Moves to the Next Day

The Biocidal Dosing can be programmed to work 2 times per day on a 7 day cycle. Use the Next Day button to move days, the Advance button to increase the numeric value displayed and the Next Time button to move to the next available time slot. The function is not activated if the times are set to 00:00. Press Exit to go to the Dose Pump Run Time screen.

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MERCURY T-HD Dose Pump Run Time (Option) (This screen is only available when the machine is configured for Recirculation Wash)

Dose Pump Run Time 1

Exit

3

Increase

5

Decrease

Default

2

Left Digit

4

Right Digit

6

10 sec 8

7










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MERCURY T-HD Screen Saver Screen Saver 1

2

Exit

OFF ON

3

5

7

Up

4

6

Down

8

1. Returns to previous menu and updates screen saver status 3. No Selection Available 5. Moves cursor up 7. Moves Cursor Down

2. No Selection Available 4. No Selection Available 6. No Selection Available 8. No Selection Available

Selecting the Screen Saver (On) means that when the screen is showing the normal operation display, the screen saver will activate after 20 seconds. To return to normal operation display, press any key.

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MERCURY T-HD Dryer Menu Dryer Menu 1

Exit

2

3

Dryer Warm Up

Dryer O/P

4

5

6

7

8

1. Returns to previous menu 3. Moves to Dryer Warm up menu 5. No Selection Available

2. No Selection Available 4. Moves to the Dryer Power menu 6. No Selection Available



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MERCURY T-HD Dryer Warm-Up Time Dryer Warm Up 1

Exit

3

Increase

5

Decrease

7

Default

2

Left Digit

4

Right Digit

6

10 Seconds

8










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MERCURY T-HD Dryer Power Dryer Power Default

2

Increase

Left Digit

4

Decrease

Right Digit

6

1

Exit

3

5

75 % 8

7










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MERCURY T-HD Save Settings Save Settings 1

Exit

2

3

Save Settings

4

5

Restore Settings

6

7

Restore Cons Data

8

1. Returns to previous menu 3. Updates EPROM 5. Restores saved data from E2ROM (Machine Settings) 7. Restores saved data from E2ROM (Consumable data)


When Save Settings is pressed all inputted Data is saved to the memory. Restore Settings, restores previously saved Data. Restore Cons Data, restores information on consumables, developer consumption, filter life etc. that is held in the Consumable Summary menu When any of these keys is pressed the message: EPROM Update Successful – Any Key to Continue is displayed This would be mainly used by a Technician for Saving Data should the control board need changing. Press Return to go to Operator Settings Then Return again to go to Main Menu Then select Change Menu

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MERCURY T-HD Closedown Menu Close Down 1

Exit

2

3

Flush Gum

4

5

Set Closedown

7

Set Warm-up Time

End Closedown

6

Set Clock

8



3. Flush gum section – gum flushing stopped by pressing any key

4. No selection available

5. This will manually put the machine into closedown mode

6. This will manually take the machine out of closedown mode and start the warm up cycle

7. Moves to set warm-up time screen


To Set Warm-up / Closedown times, first check that the processor clock is reading the correct time. To Adjust - Press Set Clock

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MERCURY T-HD Set Clock Set Clock 1

Exit

2

3

Advance

4

5

Next

YY/MM/ DD hh:mm 00 / 00 / 00 00:00

6

^ 7

8

Previous

1. Returns to previous menu 3. This will advance the number above the cursor 5. This will move the cursor to the next field 7. This will move the cursor back to previous field


Advance - This will advance the number above the cursor Next - This will move the cursor to the next field -^ Previous - This will move the cursor back to previous field Exit – Saves setting and returns to previous. It is important that the time and date are set correctly. The auto closedown and startup functions rely on this setting.

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MERCURY T-HD Closedown Mode In most cases it is preferable to leave the machine turned on all the time; however the processor can be put into a Closedown Mode when not required. This allows replenisher to be added to the developer and gum section to maintain the activity in the bath. It also allows ‘Wake-up’ cycles to take place, which run the machine at regular intervals to keep the chemistry mixed and prevent any problems with rollers sticking (this is set by a technician on installation and will only be done if it is appropriate for your plate making process). All heating circuits (Developer and Plate Drier) are disabled during this time. The Closedown and restart (End Closedown) can either be set manually or pre-programmed to start or stop automatically.

To set Closedown Press - Set Closedown – The Main Menu is displayed with the message - Machine Closed Down.

To End Closedown Press – Main Menu (any key) – End Closedown. The processor will go into auto run – Exercise Machine appears on the screen, then the processor will begin to Warm-up.

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MERCURY T-HD Set Warm-up Times

Set Warmup Time 1

3

5

7

Exit

Next Sunday Monday Tuesday Wednesday Thursday Friday Saturday

On -

Off Decrease

Increase

2

4

6

8


2. This will move the cursor to the next field 4. No Selection Available

5. No Selection Available 7. This will increase the number above the cursor

6. No Selection Available 8. This will decrease the number above the cursor


This menu allows the operator to enter the times when the machine will Closedown and start up and automatically. The On and Off times can be entered once per day. To do this, use the Increase and Decrease buttons to set the time. By pressing these buttons continuously, the number will increase in value from 1 to 10, then from 10 to 60. If the button is released, the counting process will re set and pressing the button again, will change the number from 1 to 10, 10 to 60 etc. When “-“ is the time entered into a time slot, this represents 12.00 midnight. The computer sees this as a zero entry and ignores it. Any other time entered is recognised by the computer. When programmed the processor will automatically start up or closedown at the pre-set time. Pressing End Closedown at any time during a closedown period will manually re-start the processor.

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MERCURY T-HD Developer/Wash Change Menu Developer / Wash Change Change Wash

1

Exit

3

Change Developer

5

Change Dev Filt

7

Cleaning Cycle

Change Wash Filt

2

4

6

Fill Tanks


3. Moves to the Change Developer screen. 5. Moves to the Change Developer Filter screen. 7. Moves to Cleaning cycle menu

8

2. Moves to the Change Wash screen (this is only displayed when the machine is configured for recirculation wash) 4. Moves to the Change Wash Filter screen (this is only displayed when the machine is configured for recirculation wash) 6. No selection Available 8. Moves to fill tanks menu

The Change Wash and Change Wash Filter items are only displayed when the machine is configured for recirculation wash.


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MERCURY T-HD Change Developer or Developer Filter or Wash or Wash Filter

Change Developer or Change Dev Filt or Change Wash or Change Wash Filt

1

3

2

4

6

5

7

Continue

Quit

8



7. This will quit the selection and return to previous menu

8. This will record the change and reset consumables screen

Press Change Developer/Change Dev Filt/Change Wash/Change Wash Filt Choices Quit - or - Continue Press Continue to Reset Message – Change Recorded, EPROM Updated Successfully – Return to Change Menu Press Quit to Return to Change Menu Message – No Action taken It is very important that this is done each time one of the change actions listed above takes place. The Change Wash and Change Wash Filter items are only displayed when the machine is configured for recirculation wash.


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MERCURY T-HD Fill Tanks

Fill Tanks 1

Exit

3

Developer

2

Wash

4

5

6

7

8

1. Returns to previous menu 3. Runs Developer Fill pump Press to run 5. No selection available 7. No selection available

2. No Selection Available 4. Runs the Wash Fill (this is only displayed when the machine is configured for recirculation wash). Press to run 6. No Selection Available 8. No Selection Available

Developer Fill. • • • •

• • •

Make sure that the fill and overflow pipes are placed in the corresponding container When the Developer button is pressed, the pump will run and start filling. The display will indicate ‘Stop’ beneath the Developer message. If the button is pressed again the pump will stop, allowing an empty container to be replaced with a full one. Pressing Developer again will restart the pump. The pump will be switched off automatically As soon as the upper level is reached.

Wash Fill (This screen is only available when the machine is configured for Recirculation Wash) •

Press the Wash button. The wash section will fill up until the top (full) float switch is activated. The water will then turn off automatically.


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MERCURY T-HD Cleaning Cycle Cleaning Cycle 1

2 Drop Dev Tank Contents Remove Filters Clean Deposits From Tanks

3

6

5

7

4

Continue

Quit

8





5. No Selection Available 7. Returns to developer/wash menu – No action taken

6. No Selection Available 8. Moves to Second cleaning cycle instruction screen

This instruction screen lists tasks to be performed to fully complete the cleaning of the plate processor.

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MERCURY T-HD Cleaning Cycle Cleaning Cycle 1

2 Add Water And concentrate

3

5

7

4

850 Machine use 35 Litre 1250 Machine use 50 Litre 1550 Machine Use 65 Litre

Continue

Quit

6

8





5. No Selection Available 7. Returns to developer/wash menu

6. No Selection Available 8. Moves to cleaning process menu

This screen gives the instruction to add water and concentrate and lists the quantities for each machine type.

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MERCURY T-HD Cleaning Process (Cleaning Cycle) Cleaning Process 1

Exit

3

Start

2

Circ Time 10 Min Temperature Set 30.0C Actual 15.0C

5

7

Time Remaining* 10:00

4

6

8


1. Returns to previous menu 3. Initiates Cleaning Process 5. No Selection Available 7. No Selection Available

2. No Selection Available 4. Moves to circulation times menu 6. Moves to Temperature set menu 8. No Selection Available

* Time remaining in wash process is displayed here.

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MERCURY T-HD Temperature (Cleaning Cycle) Temperature 1

Exit

3

Increase

5

Decrease

2

Left Digit

4

Right Digit

6

30 C

7



3. Increase the numeric value






8

Values shown in Bold Italics are examples only For a recommended clean temperature, please contact your local Kodak representative.

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MERCURY T-HD Circulation Timer (Cleaning Cycle)

Circ Time 1

Exit

2

3

Increase

Left Digit

4

5

Decrease

Right Digit

6

10 Mins 8

7



3. Increase the numeric value






Values shown in Bold Italics are examples only. For a recommended circulation time, please contact your local Kodak representative.

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MERCURY T-HD Water Rinse (Cleaning Cycle)

Water Rinse 1

2 Drop Dev Tank Contents Add Water

3

850 Machine use 35 Litre 1250 Machine use 50 Litre 1550 Machine Use 65 Litre

5

7

4

Continue

Quit

6

8






6. No Selection Available 8. Moves to next cleaning process menu

This screen prompts you to fill the tanks with water for rinsing out the developer section.

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MERCURY T-HD Water Rinse Cleaning Cycle) Cleaning Process 1

Exit

3

Start

2

Circ Time 20 min

6

5

7

4

Time Remaining* 10:00

8

Values shown in Bold Italics are examples only 1. Returns to previous menu


2. No Selection Available 4. Moves to circulation times menu 6. No Selection Available



3. Initiates Cleaning Process

To set the circulation time is the same as previously described for the Cleaning Cycle * Time remaining in wash process is displayed here. For a recommended circulation time, please contact your local Kodak representative

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MERCURY T-HD Developer Flush (Cleaning Cycle) Developer Flush 1

2 Drop Dev Tank Contents Add Developer

3

850 Machine use 7-10 Litre 1250 Machine use 10-15 Litre 1550 Machine Use 15-20 Litre

5

7

4

Continue

Quit

6

8






6. No Selection Available 8. Moves to next cleaning process menu

Pressing Continue will take you to the Developer Flush Timer. This operates exactly the same way as the previous timers used in the Cleaning Cycle. For a recommended circulation time, please contact your local Kodak representative

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MERCURY T-HD Final Screen (Cleaning Cycle)

1

2 Drop Dev Tank Contents

3

5

4 Fit New Filters Add Developer For Normal Use

6

Any Key To Finish 8

7

Press any key to return to the Developer/Wash Change menu.

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MERCURY T-HD System Summary

System Summary 1

Exit

3

Summary: Processing

2

Summary: Consumables

6

5

7

4

8

Alarm Menu

Change Menu 1. Returns to previous menu 3. Moves to the Summary: Processing Screen 5. No Selection Available 7. Moves to the Alarm Menu

2. No Selection Available 4. Moves to Summary: Consumables Screen 6. No Selection Available 8. No Selection Available

This screen gives the operator information on the pre-set parameters and a record of the consumables used. There is also a menu that gives access to the Alarm Menu. Summary Processing – Information on processor settings. Summary Consumables – Information on chemistry, filter life etc Alarm Menu – shows active alarms, open alarms and an alarm history. There is also a button to cancel any active alarms.

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MERCURY T-HD Summary Processing

Summary: Processing 1

3

5

7

Dev Temp Set Plate Speed Brush Speed Dryer O/P

22.0 C 750 mm/m 40 RPM 75 %

Dev Replenish Per Area Type 75 ml Rate 0 Total Plates 0.0 sq m Total Area KPG V-6 850 CTP V02.05.00

2

4

6

8

This screen is a status only display as it shows the current active settings entered into the processor memory. To exit this menu and return to the System Summary Menu screen, press Button 1 the top left hand button. The type of machine and the version of software found at the bottom left hand corner of the screen. The software version will vary with each different version of machine. The values shown in Bold Italic are examples only. To Exit press the key number 1.

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MERCURY T-HD Summary Consumables (page 1)

1

3

Summary Consumables Developer Since Change 0 Plt 0.0 sq m 1000 sq m Change At Max Period 30 days 30 days Remaining

5

Developer Filter Since Change

7

Change At Max Period Remaining

2

4

6 0 0.0 250 30 30

Plt sq m sq m days days

8

The values shown in Bold Italic are examples only. Explanation of the counters shown above for the Developer section; Since the developer has been changed, no plates have been made and therefore no square meters of plate have been processed (remember that the Change menu has to be reset for each item for the computer to know when developer or filters or water has been changed). The counter has been set to issue a warning to change the developer at 1000 sq metres. Also the timer has been set to issue a warning at 30 days (whichever comes first) to change the developer and there are 30 days left till the next change. To Exit press the key number 1. The screen will automatically change to the second Consumable screen.

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MERCURY T-HD Summary Consumables (page 2)

Summary Consumables 1

Wash Since Change

3

Change At Max Period Remaining

5

7

Wash Filter 1 Warn Level Stop Level Current Level Max Period Remaining

0 0.0 100 10 10

Plt sq m sq m days days

2

4

6 75 85 20 30 30

% % % days days

8

The values shown in Bold Italic are examples only. This screen will only be displayed if the machine has been configured to recirculation wash. Explanation of the counters shown above for the Wash section; Since the wash has been changed, no plates have been made and therefore no square meters of plate have been processed (remember that the Change menu has to be reset for each item for the machine to know when developer or filters or water has been changed). The counter has been set to issue a warning to change the water at 100 sq metres. Also the timer has been set to issue a warning at 10 days (whichever comes first) to change the wash and there are 10 days left till the next change. The wash filter warnings have been set to work with the built in pressure transducer which monitors the state of the filter (when it gets blocked with dirt). The values refer to the settings for the transducer readout – Warning on the LCD screen at 75%, stop the machine at 85% and the current level being read currently at 20 %. There are also timers for the number of days since the last filter change.

To Exit press the key number 1.


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MERCURY T-HD Alarm Menu Alarm Menu 1

Exit

3

Alarms

2

5

7

Alarm History

4

Open Alarms

6

8

Cancel Alarm

1. Returns to previous menu 3. Moves to a list of current alarms 5. No Selection Available 7. Moves to the Alarm Menu

2. No Selection Available 4. Moves to a list of past and present alarms 6. Sorts the Alarm History for Open Alarms 8. No Selection Available

The purpose of this menu is to allow the operator and service engineer to track how the machine has operated if the processor issues faults during operation. If there are Open Alarms present in the Open Alarms list which are stopping the processor from operating, please contact your local Kodak Polychrome office or Agent.

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MERCURY T-HD Conveyor Menu Conveyor 1

Exit

3

Stop

5

Restart Conve or

7

Cancel Plates

2

Inch Forward

4

Inch Back

6

8

1. Returns to previous menu 3. Stops the conveyor 5. This will restart the Conveyor motor 7. If a plate has been removed from the processor while processing, this cancels the rest of the cycle.

2. No Selection Available 4. If a plate is jammed, pressing this key will inch the plate forward. 6. If a plate is jammed, pressing this key will inch the plate back.


To stop the conveyor while it is processing a plate press Stop. The processor can then be re started by pressing Restart Conveyor. If the processor is stopped using the E-Stop buttons, the conveyor can also be re-started by using the Restart Conveyor button once the E-Stop button has been returned to its working position. If a plate is removed from the processor due to a mis-feed, press the Cancel Plates button. This ensures that the exit sensor doesn’t look for the removed plate. To move the conveyor forward or backwards, use the Inch Forward and Inch Back keys. This is a Hold to Run operation. As soon as the button is released, the function stops.

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MERCURY T-HD Guard Switch Over-ride Menu This menu is reached by switching a service key located on the RH side of control panel at the side of the machine. It should only be used by fully trained operatives . Once the service key is switched to the service position you can remove the top cover while the machine is still active. Its purposes are; Machine Cleaning / Chemistry Change. Plate Path Check. Removal of a plate if a jam occurs Plates cannot be made while the machine is in Guard Switch Override Mode. Do not override safety guard switches. They are fitted for your safety. Guard Switch Override Fill Tanks

2

Hold to Run

4

Cancel Plates

6

Engineering

8

1

Exit / Restart

3

Inch Back

5

Inch Forward

7

Cleaning Cycle

1. If the top cover is in place and the key switched back to run position this will restart the machine and return to main menu. 3. Pressing this key will inch the conveyor back (reverse). 5. Pressing this key will inch the conveyor forward. 7. Moves to the Cleaning Cycle menu (described earlier on).

2. Moves to fill tanks menu.

4. Will simulate the processor cycle while kept pressed. 6. If a plate has been removed from the processor while processing, this cancels the rest of the cycle. 8. Moves to engineering menu (Password Protected).

Pressing the Hold to Run button will simulate an automatic processing cycle. Place a plate over the in-feed sensor and push it into the nip of the rollers. Press the Hold to Run button constantly. The machine will now process a plate automatically with all parts of the process sequential starting as they would normally. If you release the Hold to Run button, the process will stop. To restart, press the Hold to Run button again. When the plate has completed its cycle and the dryer has stopped, the button can be released. This feature is useful for testing the processor after a full maintenance procedure has taken place to ensure that all components have been replaced correctly.

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MERCURY T-HD


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MERCURY T-HD OPERATOR CONTROL PANEL ERROR CODES The Operator Control Panel on the Mercury processor displays a number of Error Codes depending on the machine condition. These Error Codes are based on whether the machine is Ready, Not Ready, In-Use or in Fault mode. Therefore they have a different severity associated with them. The following table describes these Error Codes and any action that needs to be taken to rectify the reason for the code being displayed.

Message Number

Text

Description

Action Required

Emergency Stop

The safety circuit has been activated due to the operation of an emergency stop switch or due to a cover being opened.

Release the emergency stop switch, ensuring first that the safety hazard has been cleared, or replace the machine covers.

3

Safety Lockout!

The safety circuit self checking system has detected an integrity error in the safety circuit and disabled the machine.

This fault is only cleared by removing power from the machine (10 secs) then powering up again. If the fault re-occurs, DO NOT try to operate the machine. Call a Kodak Service Technician.

7

Plate in Machine

The operator has attempted to enter the engineering menu when the machine is processing a plate.

Wait for the processing of the current plate to complete, or use the 'Cancel Plates' option in the conveyor menu.

2

14

17

.

Conveyor not Running

An attempt was made to halt the conveyor (from the conveyor menu) when the conveyor was already halted.

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MERCURY T-HD

18

20

21

23

24

25

Last Plate too Close

A new plate had been entered before the previous plate had passed far enough into the processor to ensure correct processing of both plates.

Ensure a sufficient gap is allowed between plates.

Change Developer

The developer has exceeded the usage limit and requires changing.

Change the developer and inform the control system that it has been changed by using the 'Change Developer' option in the change menu.

Change Dev Filt

The developer filter has exceeded the usage limit and requires changing.

Change the developer filter and inform the control system that it has been changed by using the 'Change Developer Filter' option in the change menu.

Short Plate

The length of the last plate detected by the control system was below the minimum length that the machine can process.

If a plate was actually entered, ensure that it has not become lodged between roller sets in the developer section or elsewhere in the processor.

The load on the conveyor motor has caused the motor to take excessive current for a period of more than 10 seconds. The conveyor motor has been shut down.

Clear the problem which caused the excessive load on the conveyor motor, then use the 'Restart Conveyor' option in the conveyor menu to restart the conveyor. Do not restart the conveyor repeatedly if this error appears shortly after the last restart. Repeated restarts when a fault exists can damage the control board and/or the motor. Call a Kodak Service Technician.

The load on the brush motor has caused the motor to take excessive current for a period of more than 10 seconds. The brush motor has been shut down.

Clear the problem which caused the excessive load on the brush motor, then use the 'Restart Conveyor' option in the conveyor menu to restart the motor. Do not restart the conveyor repeatedly if this error appears shortly after the last restart. Repeated restarts when a fault exists can damage the control board and/or the motor. Call a Kodak Service Technician.

Conv Current Limit

Brush Current Limit

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MERCURY T-HD

28

57

Automatic Run Due

The machine has not processed a plate for some time. To prevent problems with rollers, gum and other items, the processor will be run automatically.

If an automatic run is not required, hit any key to prevent it. Entry of a plate during an automatic run, or during the lead up to it, will cause the processor to return to normal operation so that the plate is processed correctly.

Conveyor Not Halted

An attempt was made to restart the conveyor (from the conveyor menu) when the conveyor was already running.

No action required.

.

.

100

119 & 292

Dev Temp Error

The developer temperature is outside the allowed limits.

Wait for the temperature to return within the limits before processing a plate. If the developer temperature does not settle within limits in a reasonable time, Call a Kodak Service Technician.

121

Dev Level Low

The developer level has been detected as low.

Top up the developer level by the normal means..

Change Wash

The wash water requires changing.

Change the wash water and inform the control system that it has been changed by using the 'Change Wash' option in the change menu.

The developer circulation has failed.

Check that the taps in the developer recirculation circuit are all open, and that nothing is blocking the spray bars or any other part of the circuit such as a blocked filter.

126

182

Dev Circ Failed

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MERCURY T-HD

196

Wash Level Low

The wash level has been detected as low.

Top up the wash level by the normal means.

220

Machine NOT Closed Down

An attempt was made to 'wake up' the machine when it was not already closed down.

No action required.

Dev Temp Probe Failed

The developer temperature probe has been detected as being open circuit or short circuit.

Call a Kodak Service Technician..

Conveyor Fault

A fault has been detected in the conveyor drive system.

A fault is reported when the control system commands the conveyor system to run, but no conveyor rotation sensor detection pulses are detected. The motor is shut down and the error reported. Check the motor drive circuit fuses on the control board only if you are qualified to do so, otherwise Call a Kodak Service Technician..

Drain Blocked

In a 'Direct to Drain' machine, the wash section float switch has been activated, indicating that the waste water is not flowing to drain fast enough.

Ensure that the drain pipe is clear and not kinked, and that there is sufficient fall to remove the waste water quickly enough. Ensure that the spray bar taps are not allowing excessive water to enter the tank.

Wash Filter Blocked

On a system fitted with a filter pressure sensor, the wash filter has been detected as being blocked.

Change the wash filter and inform the control system that it has been changed by using the 'Change Wash Filter' option in the change menu.

Plate Over Sensor

The operator has attempted to exit from the plate jam menu while a plate is over the in-feed or re-entry sensors. This error prevents an instant restart of the machine when a jam has been cleared.

Remove the plate which is causing the error from the machine, and then exit the plate jam menu before offering up the plate again.

252

313

329

330

376

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MERCURY T-HD

389

390

468

469

Brush Fault

The control system has attempted to run the brush drive, but has detected a problem in the brush system.

Check the motor drive fuses on the control board only if you are qualified to do so, otherwise Call a Kodak Service Technician..

Length Error

A table of plate sizes is maintained within the control system. This error indicates that a plate has been over the sensor for a period that indicates that the plate length is greater than 50% longer than the largest plate in the table. This error prevents the machine running continuously if a plate is left over the in-feed table by accident or by a failure of an upstream machine.

Remove the plate from over the infeed sensor. Check that reasonable plate lengths have been entered into the plate size table. This error occurs every time a plate is offered up to the processor when no entries exist in the plate size table.

Jam: Exit Sensor Error

A plate jam has been detected by the exit sensor. The sensor did not become uncovered before the expected plate was detected.

Remove the item causing the exit sensor to be covered, or adjust the sensitivity of the exit sensor.

Jam: Exit - No Plate

A plate jam has been detected by the exit sensor. The sensor did not become covered when the expected plate was due.

Recover the plate from the machine and clear the problem which caused it to jam.

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MERCURY T-HD


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MERCURY T-HD ROUTINE MAINTENANCE Consumables / Filters Variations in machine size, water quality, plate, chemistry and regular machine maintenance may affect filter life. It is in the interests i nterests of the customer to optimise processor operating conditions to maximise maximise further performance by changing the developer filter at the same time as developer. As standard the Mercury T-HD is fitted with a 10” filter for both the Developer section and also the Water Recirculation section (Option). For the United States & Canada Only; the Developer section is fitted with a 20” filter filt er and the Water Recirculation section is fitted with a 10” filter fil ter (Option).

Changing Filters 1. Close the inlet and outlet taps on top of the filter unit. unit. 2. Drain contents contents via drain tap. 3. Unscrew the filter bowl from the top part of the unit by turning turning clockwise (a special special spanner is supplied). 4. Fit a new filter element – make sure it locates correctly correctly in the bowl. bowl. 5. Check ‘O’ ring seal in the filter bowl for damage damage and ensure that it is seated correctly in the groove. If in doubt fit a new seal. Apply a small amount of petroleum jelly to the “O” Ring if required to avoid the seal kinking when the filter bowl is tightened. T IGHTEN WTH FILTER BOWL SPANNER) and open the 6. Replace the filter bowl (DO NOT TIGHTEN inlet valve then slowly open the outlet valve so that any trapped air is pushed out. 7. Reset software software at the control panel using using the the Change Menu (See Operator Control Panel).

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MERCURY T-HD Shutting Down – End of Shift 1.

Remove the top clear covers.

2.

Remove the re-entry tray.

3.

Apply a cleanser to the nip rollers and wipe all the the rollers with clean water. To inch the rollers with the top covers removed use the service key selected into the maintenance position.

4.

Replace the re-entry tray and the top clear covers ensuring the safety guard switches locate correctly.

5.

Menu. Press any key to display the Main Menu.

2.

Menu. Select the Close Down display from the Close Down Menu.

3.

Press the Set Closedown button.

4.

System. The screen will display Flushing Gum System.

5.

Display. The machine is now closed down. The display returns to the Main Display.

Shutting Down for Longer Periods Follow the same procedure as shutting down at end of shift, and switch the machine off at the isolator. If the machine is to be left for a period of more than about 10 days it is recommended recommended that all the t he tanks should be drained and the whole machine should be cleaned.

Points to Remember 1.

Regularly check the contents contents of the external developer replenish developer waste, gum flush (option) and gum bottles. Empty or replace as necessary. necessary.

2.

The service service key must be kept in a safe place away from the machine and must must only be used by qualified personnel for service needs.

3.

Always change the developer filter when renewing the developer.

4.

Always change the rinse filter when renewing the rinse water. Keep the machine clean. It will improve the efficiency of the machine in the long term.

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MERCURY T-HD Periodic Cleaning and Maintenance Regular cleaning is far more effective than prolonged sessions after weeks of use.

Machine Cleaning Isolate machine before any cleaning takes place 1. All rollers and brushes should be removed when a thorough tank cleaning is carried out. 2. Ensure that all other side covers and guards are in position before washing out the tanks, and then follow the procedure below: Follow the manufacturer’s instructions carefully when using and disposing of any waste material. Wear personal protective equipment recommended in the appropriate product data sheets. Waste of any kind must be disposed of in accordance with local and national waste disposal regulations. 3. Drain all tanks. 4. Close drains. 5. Clean out the tank area using the supplied hose. 6. Clean all the rollers. Consult your local Kodak office or local agent for recommendations on the appropriate chemicals to use for cleaning the rollers. Wash all brushes thoroughly with water. 7. Wipe the infeed roller on the inside of infeed cover to remove any collected dirt. 8. Clean around float switch area ensure that switches are free moving after cleaning. 9. Replace all tank fittings. 10. Drain water from tank and dry off.

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MERCURY T-HD


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MERCURY T-HD TROUBLESHOOTING Any problems that arise are likely to be of a minor nature and easily rectified. The following is a brief guide:

FAULT

CAUSE / REMEDY

Machine does not start

Covers not correctly positioned No mains power Fuse blown or MCB tripped Emergency stop button depressed Sensor faulty Developer Float not covered

Plates not feeding correctly

Excessive brush pressure In-feed roller wet Not enough roller pressure

Plate jammed in machine

Free by using drive reverse function On operator display

Insufficient/no developer flow

Filter blocked Filter tap partially closed Air lock in hose Spray bar blocked with deposit Faulty pump

Developer temperature low

Developer set point setting wrong Heater faulty MCB tripped

Developer temperature too high

Ambient temperature too high Chiller not functioning- Cooling circulation flow switch (no flow), high pressure or low pressure switches on the chiller not closed Developer set point incorrect

No water flow. Type (direct to drain)

Supply turned OFF Rinse taps closed Faulty solenoid valve MCB tripped

Rinse water runs continuously

Dirt under solenoid valve diaphragm

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MERCURY T-HD FAULT

CAUSE / REMEDY

No gum flow

Gum bottle empty Gum spray bar blocked MCB tripped Faulty pump

Machine switches off before plate exited

Plate jammed in machine. Manually feed the plate out of the machine . In-feed or exit sensors dirty. Contact KPG Service.

Developer level slowly falls (Make sure there are no leaks)

Developer replenish bottle empty Developer replenish faulty Developer float faulty Developer temperature too high (evaporation)

Plate not fully developed

Drive speed too fast Developer too old and weak Developer replenish bottle empty Developer replenish faulty Developer brushes not correctly set Developer temperature not reached

Emergency Stop Signal Unit will not start

Emergency stop not reset Lids not on correctly Guard switch strikers not located

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MERCURY T-HD NOTES

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Mercury THD User Manual English

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