Mercury THD Operator Manual English 141982762

MERCURY T-HD
MERCURY T-HD
OPERATOR MANUAL
Kodak
Mercury Plate Processor
Serial Number ___________________________
Year of Manufacture __________________
Date of Installation ___________________
Service Key Number_______________________
731-01655A-EN
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MERCURY T-HD
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MERCURY T-HD
CONTENTS
ENGINEERING CHANGE NOTES TO OPERATOR MANUAL .............................. 5

SAFETY .................................................................................................................. 6
INSTALLATION ...................................................................................................... 9
POWER SUPPLY CONNECTIONS ...................................................................... 10
SPECIFICATION, SETTINGS & DEFAULTS ....................................................... 11
MACHINE LABEL KEY ........................................................................................ 13
INTRODUCTION ................................................................................................... 15
DESCRIPTION ...................................................................................................... 17
Plate Path .................................................................................................... 18
Developing System .................................................................................... 19
Developer Tank…………………………………………………………………...20
Developer Cooling System ........................................................................ 21
Rinse System .............................................................................................. 22
Gum System ............................................................................................... 24
Drying System ............................................................................................ 25
Wash Down System ................................................................................... 26
OPERATION ......................................................................................................... 28
Operating Controls & Safety Switches ..................................................... 28
Starting Procedure ..................................................................................... 30
Processing a Plate ..................................................................................... 31
Re-entry Operation ..................................................................................... 32
OPERATOR CONTROL PANEL .......................................................................... 33
Display Trees ............................................................................................... 34
Screen Displays ........................................................................................... 41
CONSUMABLES / FILTERS ................................................................................ 90
SHUTTING DOWN................................................................................................ 91
PERIODIC CLEANING ......................................................................................... 92
TROUBLESHOOTING .......................................................................................... 93
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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 EN 61326:1998 Electrical equipment for measurement, control and

Standards, especially: 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
ENGINEERING CHANGE NOTES TO OPERATOR MANUAL
Rev Changes Made

Logo & machine name
G Main power connection instructions
Chiller type and description
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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 N. America 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 T-
HD 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. 200 – 230V Single Phase + GND

2. 200 – 230V 2-Wire + GND
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
N PE
ELECTRICAL TECHNICAL INFORMATION

Full Load Protected Device
Specification Minimum Cable Size
Current Rating
200-230V L+N+PE/GND
or 2W+PE/GND 16A 20A * 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
MERCURY T-HD SPECIFICATION
850 1250 1550

Maximum Plate Width 850mm 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
MERCURY T-HD SETTING RANGE & DEFAULTS
Parameter Range Default *

Brush Speed 10 - 60 rpm 40 rpm
Dev Temp 5 - 26 °C 22 °C
Plate Speed 1 0 - 1500mm 750mm
Developer Replenishment 30 – 600ml 100ml
Dosing Rate Time Setting 30 secs
Dryer Output 0 - 100% 75%
Entry Sensors 1 or 2 1
Exit Sensor 1 1
Conductivity 5 – 130 mS N/a
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MERCURY T-HD
Customers Individual Settings (please complete on installation)
Parameter Range Default *

Brush Speed rpm 40 rpm
Dev Temp °C 22 °C
Plate Speed 1 mm 700mm
Developer Replenishment ml 100ml
Dosing Rate secs 30 secs
Dryer Output % 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
DEVELOPER FILL &

REPLENISHMENT
GUM FILL GUM RETURN
GUM FILL GUM RETURN SERVICE KEY SWITCH
WASH DEVELOPER GUM
BOTTLE OVERFLOW
WASH DEVELOPER GUM

BOTTLE OVERFLOW
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MERCURY T-HD
MACHINE LABEL KEY (cont)
DRAIN POINT WASH DOWN

1 1/2" BSP ON / OFF
DRAIN POINT WASH DOWN

1 ½ BSP ON / OFF
MAINS WATER
3/4" BSP
MAINS WATER
¾” BSP
DEV FILTER WASH FILTER
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MERCURY T-HD
INTRODUCTION
GENERAL VIEW – FRONT
2
7
1
8
12
11
10
3 5
1. Top Front Cover 7. Re – entry Position

2. Top Rear cover 8. Operator Panel
3. Removable front cover 9. Developer Filter
4. Chiller Access Cover 10. Washdown Hose
5. Adjustable feet & wheels (if fitted) 11. Gum Flush Bottle
6. In - feed cover 12. Removable Side Cover
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MERCURY T-HD
GENERAL VIEW - (REAR)
12
13
11
10
3
9
4
6
5 7
8
1. Gum Flush Bottle 8. Water Inlet

2. Wash Down Hose Tap 9. Drain Taps/Hoses
3. Biocide Dose Hose 10. Rear Exit Cover
4. Gum Feed Hose 11. Emergency Stop Button
5. Gum Return Hose 12. Exit Wheels
6. Wash Filter 13. Exit Sensor
7. Rear Direct to Drain Manifold
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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. The unit automatically develops, rinses, gums and then dries
the plate. Provision is made for automatic re-entry. 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 carry over 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 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.
Dev Flow Switch
Dev Bulk Fill

Dev Replenishment Pump Dev Circulation Pump
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 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
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
Fault Indicator Lamp
Access
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

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 Inlet / Replen Solenoid

and Spray Bar Solenoid
Drain Taps & Hoses
Water Recirculation Pump
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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 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
OPERATION
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. Check that all removable
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.
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. 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 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 infeed table. Ensure that the plate is within the plate
guides moulded into each side of the infeed table and that part of the plate passes above
the infeed sensor.
(Dual Plate Feeding – this is only possible on machines fitted with dual infeed sensors.
Plates should have a gap of at least 30mm between them).
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MERCURY T-HD
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.
Re-entry Operation
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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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
Operator Settings
1 Exit 2
3 Developer
Menu
Manual Dev 4
Replen
5 Wash Menu Manual Wash

Replen
6
Dryer Menu Save
7 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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Operator Control Panel Operation Trees

Rev 01.05.07
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MERCURY T-HD
Turn M/c ON
A Select Conveyor
Startup Display Speed
Plate Counter
Go To Operation Display Re-Set
L
Guard Switch Override
Main Menu Active Alarms
Operator Settings Change System Summary Close Down Conveyor Engineering

Menu Menu Menu Menu Menu Menu
Go To Go To Go To Go To Go To
B C D E F
This screen is
password protected.
Go To
G
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MERCURY T-HD
Operator Settings
B From
A Menu
Developer Menu Wash Menu Dryer Menu Screen Save Settings

Saver Menu
Plate Speed Wash Replen Dryer Warm Up Save Settings

Menu Type
Developer Biocide Dosing Dryer O/P Restore Settings

Temperature
Brush Speed Manual Dose Restore Cons

Data
Dev Replen Manual Wash

Type Replen
NOTE
Set Plate Sizes The wash related
screens are only
displayed when the
Manual Dev wash section type is
Replen selected as
recirculation
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MERCURY T-HD
From Change
C A Menu
Change Change developer Change wash Change Wash Fill Tanks

Developer Filter Filter 1 Menu
Cleaning Developer
Cycle
From System Summary Wash

D A Menu
Summary Summary Alarm

Processing Consumables Menu
Note
Alarms The Wash related

screens are only
displayed when
Alarm History the wash section
type is selected as
recirculation
Open Alarms
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From Close Down

E A Menu
Flush Set Set Warmup End Set

Gum Closedown Time Closedown Clock
From Conveyor
F A Menu
Stop Restart Inch Inch

Conveyor Forward Back
Cancel
Plate
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MERCURY T-HD
From Guard Switch

L A Override
Exit/ Inch Inch Fill Tanks Hold to Cancel Engineering

Restart Back Forward Menu Run Plates Menu
Go To
Developer G
Wash NOTE
The wash related
screens are only
displayed when the
wash section type is
selected as
recirculation
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MERCURY T-HD
Start up Screen
HT PRO, 205
1 [Software Version] 2
[Date & Time software was compiled]
Heater system
3 DC Drive system 4
ADC system
Read Clock – Done
Read PT Cal - OK
5 6
Any Key To Start

7 8
[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 pre-
set. 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 8
Any Key To Stop
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.
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MERCURY T-HD
• 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
Alarms
Alarms
1 Exit Restart Circ 2
3 Dev Temp Low 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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Main Menu
Main menu
1 Exit 2
3 Operator Close Down 4

Settings
5 Change Menu Conveyor 6
System Engineering 8
7
Summary
1. Returns to Operator
2. No selection Available
Display
3. Moves to the Operator
4. Moves to the Close Down menu
Settings menu
5. Moves to the Change
6. Moves to the Conveyor menu
menu
7. Moves to the System 8. Moves to the Engineering menu
Summary 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 Select Speed 2

600 mm/m
Plates:0000 01 Jan 00
3 00:00:00 4
Reset
Entry: READY
5 Re-Entry: READY 6
Act Set
Developer 22.0C 26.0C
7 8
Dev Conductivity 100.1mS
1. Moves to the Main Menu / 2. Allows Selection of 3 different

Active Alarms (if any exist) programmable conveyor speed
3. Shows the current plate 4. Date and Time – from this
count. When pressed it will information the processor can
allow the operator to reset the be set to automatically start up
Plate Counter to Zero or shut down.
5. No Selection Available 6. 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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Operator Settings
Operator Settings
1 Exit Screen Savers 2
3 Developer Wash Menu 4

Menu
5 6
Save
7 Dryer Menu Settings 8
2. Allows the selection of the

1. Returns to previous menu
screen saver
4. Moves to the Wash Menu
3. Moves to the Developer (this is only displayed when
Menu the machine is configured
for recirculation wash)
8. Moves to the Save Settings
7. Moves to the Dryer Menu
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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Developer Menu
Developer Menu
1 Exit 2
Plate Speed Dev Replen 4

3
Developer Manual Dev

5 6
Temperature Replen
Set Plate
7 Brush Speed 8
Sizes
This screen provides access to all the other screens which control the development of the plate.
1. Returns to previous menu 2. No Selection Available

3. Moves to the plate speed 4. Moves to the developer
setting screen replenishment type selection screen
5. Moves to the developer 6. Moves to the manual developer
temperature setting screen replenishment screen
7. Moves to the brush speed 8. Moves to the plate size data input
setting screen screen
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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 4. No Selection Available
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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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
6. Moves the cursor right
value
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.
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Developer Temperature
Dev Temperature
1 Exit Default 2
22.0 C
7 8
2. Restores the temperature to

the default value.
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.
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Brush Speed
Brush Speed
1 Exit Default 2
5 Decrease Developer Menu

Right Digit 6
40RPM
7 8
2. Restores the brush speed to

the default value.
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Developer Replenishment
Dev Replenish
1 Exit 2
3 Level Sense 4
Per Area
None
5 Up 6
7 Down 8
1. Returns to previous menu* 2. No Selection Available

5. Moves Cursor Up 6. No Selection Available
7. Moves Cursor Down 8. No Selection Available
* When None or Level Sense is selected - exits to previous menu. When Per Area is selected
the Dev Replenish Rate screen (next page) is displayed.
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Dev Replenish Rate
Dev Replenish Rate

1 Exit Default 2
75ml / sq m
7 8
1. Returns to previous menu 2. Resets to the default value

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MERCURY T-HD
Manual Dev Replenishment
Manual Dev Replenish

1 Exit 2
3 4
1200 ml *
5 Start 6
7 8

5. Initiates Manual Dev
6. No Selection Available
Replenishment
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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Set Plate Sizes
Plate Size Table

1 Exit Next 2
Length Width mm
3 1 0 0 4
2 0 0
3 0 0
4 0 0
5 5 0 0 6
6 0 0
7 0 0
8 0 0
7 8
Decrease Increase
1. Returns to previous menu 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
Manual Wash Wash Replen

3 4
Replen
Biocidal
5 Manual Dose 6
Dosing
7 8
2. Moves cursor to next

position
3. Initiates Manual Wash 4. Moves to the Wash Replen
Replenishment Type screen
5. Initiates Manual Biocidal 6. Moves to the Biocidal Dosing
Dosing screen
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.
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Wash Replenishment
Wash Replenish Type

1 Exit 2
3 Level Sense 4
Per Area
None
5 Up 6
7 Down 8
1. Returns to previous menu* 2. No Selection Available

5. Moves Cursor Up 6. No Selection Available
* 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
Wash Replenish Rate

1 Exit Default 2
100ml / sq m
7 8

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Biocidal Dosing
Biocidal Dosing
1 Exit Advance 2
Sunday 00:00 00:00

3 Monday 00:00 00:00 4
Tuesday 00:00 00:00
Wednesday 00:00 00:00
Thursday 00:00 00:00
5 Friday 00:00 00:00 6
Saturday 00:00 00:00
7 Next Time Next Day 8
1. Returns to previous menu 2. Increases the numeric value

7. Moves to the next time slot for
8. Moves to the Next Day
that 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
Dose Pump Run Time

1 Exit Default 2
10 sec
7 8

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Screen Saver
Screen Saver
1 Exit 2
3 OFF 4
ON
Up
5 6
Down
7 8
1. Returns to previous menu and

updates screen saver status
5. Moves cursor up 6. 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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Dryer Menu
Dryer Menu
1 Exit 2
3 Dryer Warm Up Dryer O/P 4
5 6
7 8

3. Moves to Dryer Warm up 4. Moves to the Dryer Power
menu menu
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Dryer Warm Up Time
Dryer Warm Up
1 Exit Default 2
7 10 Seconds 8

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Dryer Power
Dryer Power
1 Exit Default 2

75%
7 8

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Save Settings
Save Settings
1 Exit 2
3 Save 4
Settings
5 Restore 6
Settings
7 Restore 8
Cons Data

3. Updates EPROM 4. No Selection Available
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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Closedown Menu
Close Down
1 Exit 2
3 Flush Gum 4
5 End 6
Set Closedown
Closedown
Set Warm-up 8
7 Set Clock
Time

3. Flush gum section – gum
flushing stopped by pressing any 4. No selection available
key
6. This will manually take the
5. This will manually put the
machine out of closedown mode
machine into 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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Set Clock
Set Clock
1 Exit 2
3 Advance 4
YY/MM/ DD hh:mm
5 Next 00/ 00 / 00 00:00 6
^
7 Previous 8

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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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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Set Warm-up Times
Set Warmup Time

1 Exit Next 2
On Off
Sunday - -
3 Monday - - 4
Tuesday - -
Wednesday - -
5 Thursday - - 6
Friday - -
Saturday - -
7 Increase Decrease 8
2. This will move the cursor to the

next field
7. This will increase the number 8. This will decrease the number
above the cursor 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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Developer/Wash Change Menu
Developer / Wash Change

1 Exit Change Wash 2
3 Change Change Wash 4

Developer Filt
5 Change Dev 6
Filt
7 Cleaning Fill Tanks 8

Cycle
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
3. Moves to the Change Developer Filter screen (this is only
screen. displayed when the machine is
configured for recirculation wash)
5. Moves to the Change Developer
6. No selection Available
Filter screen.
7. Moves to Cleaning cycle menu 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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Change Developer or Developer Filter or Wash or Wash Filter
Change Developer
1 or 2
Change Dev Filt
or
Change Wash
3 or 4
Change Wash Filt
5 6
7 Quit Continue 8

7. This will quit the selection and 8. This will record the change and
return to previous menu 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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Fill Tanks
Fill Tanks
1 Exit 2
3 Developer Wash 4
5 6
7 8

4. Runs the Wash Fill (this is only
3. Runs Developer Fill pump - displayed when the machine is
Press to run configured for recirculation
wash). Press to run
5. No selection available 6. No Selection Available
7. 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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Cleaning Cycle
Cleaning Cycle
1 2
Drop Dev Tank Contents

3 Remove Filters Clean 4
Deposits From Tanks
5 6
7 Quit Continue 8

7. Returns to developer/wash 8. Moves to Second cleaning
menu – No action taken cycle instruction screen
This instruction screen lists tasks to be performed to fully complete the cleaning of the plate
processor.
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Cleaning Cycle
Cleaning Cycle
1 2
Add Water
And concentrate
3 4
850 Machine use 35 Litre
1550 Machine Use 65 Litre
5 6
7 Quit Continue 8

7. Returns to developer/wash 8. Moves to cleaning process
menu menu
This screen gives the instruction to add water and concentrate and lists the quantities for each
machine type.
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Cleaning Process (Cleaning Cycle)
Cleaning Process
1 Exit 2
3 Start Circ Time 4

10 Min
Temperature
5 Set 30.0C 6
Actual 15.0C
7 Time Remaining* 10:00 8

4. Moves to circulation times
3. Initiates Cleaning Process
menu
6. Moves to Temperature set
menu
* Time remaining in wash process is displayed here.
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Temperature (Cleaning Cycle)
Temperature
1 Exit 2
30 C 8
7

3. Increase the numeric value 4. Moves the cursor left
For a recommended clean temperature, please contact your local Kodak representative.
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Circulation Timer (Cleaning Cycle)
Circ Time
1 Exit 2

10 Mins
7 8

3. Increase the numeric value 4. Moves the cursor left
Values shown in Bold Italics are examples only.
For a recommended circulation time, please contact your local Kodak representative.
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Water Rinse (Cleaning Cycle)
Water Rinse
1 2

Add Water
3 4
1550 Machine Use 65 Litre
5 6
7 Quit Continue 8

7. Returns to developer/wash 8. Moves to next cleaning
menu process menu
This screen prompts you to fill the tanks with water for rinsing out the developer section.
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Water Rinse Cleaning Cycle)
Cleaning Process
1 Exit 2
3 Start Circ Time 4

20 min
5 6
7 Time Remaining* 10:00 8

4. Moves to circulation times
3. Initiates Cleaning Process
menu
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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Developer Flush (Cleaning Cycle)
Developer Flush
1 2

Add Developer
3 4
850 Machine use 7-10 Litre
1250 Machine use 10-15 Litre
1550 Machine Use 15-20 Litre
5 6
7 Quit Continue 8

7. Returns to developer/wash 8. Moves to next cleaning
menu 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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Final Screen (Cleaning Cycle)
1 2

3 4
Fit New Filters
Add Developer
For Normal Use
5 6
Any Key To Finish
7 8
Press any key to return to the Developer/Wash Change menu.
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System Summary
System Summary
1 Exit 2
Summary: Summary:
3 4
Processing Consumables
5 6
7 Alarm Menu 8
Change Menu

3. Moves to the Summary: 4. Moves to Summary: Consumables
Processing Screen Screen
7. Moves to the Alarm Menu 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 Dev Temp Set 22.0 C 2
Plate Speed 750 mm/m
Brush Speed 40 RPM
3 Dryer O/P 75 % 4
Dev Replenish Per Area

Type 75 ml
5 Rate 6
0
Total Plates 0.0 sq m
Total Area
7 KPG V-6 850 CTP 8
V02.05.00
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.
0231M383 REV G 18/09/07
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MERCURY T-HD
Summary Consumables (page 1)
Summary Consumables
1 Developer 2
Since Change 0 Plt
0.0 sq m
Change At 1000 sq m
3 Max Period 30 days 4
Remaining 30 days
5 Developer Filter 6
Since Change 0 Plt
0.0 sq m
Change At 250 sq m
Remaining 30 days
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 2
Since Change 0 Plt
0.0 sq m
Change At 100 sq m
Remaining 10 days
5 Wash Filter 1 6
Warn Level 75 %
Stop Level 85 %
Current Level 20 %
Remaining 30 days
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 2
Alarms Alarm
3 4
History
5 Open Alarms 6
7 Cancel Alarm 8

3. Moves to a list of current 4. Moves to a list of past and
alarms present alarms
6. Sorts the Alarm History for
Open Alarms
7. Moves to the Alarm Menu 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 2
3 Stop Inch Forward 4
5 Restart Inch Back 6

Conveyor
Cancel
7 8
Plates

4. If a plate is jammed, pressing
3. Stops the conveyor this key will inch the plate
forward.
6. If a plate is jammed, pressing
5. This will restart the
this key will inch the plate
Conveyor motor
back.
7. If a plate has been
removed from the
processor while 8. No Selection Available
processing, this cancels
the rest of the cycle.
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

1 Exit / Fill Tanks 2
Restart
3 Inch Back Hold to Run 4
Inch Forward Cancel 6

5
Plates
Cleaning Engineering
7 8
Cycle
1. If the top cover is in place

and the key switched back to
run position this will restart 2. Moves to fill tanks menu.
the machine and return to
main menu.
3. Pressing this key will inch 4. Will simulate the processor
the conveyor back (reverse). cycle while kept pressed.
6. If a plate has been removed
5. Pressing this key will inch from the processor while
the conveyor forward. processing, this cancels the
rest of the cycle.
7. Moves to the Cleaning Cycle 8. Moves to engineering menu
menu (described earlier on). (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.
0231M383 REV G 18/09/07
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MERCURY T-HD
Consumables / Filters
Variations in machine size, water quality, plate, chemistry and regular machine maintenance
may affect filter life.
It is in the interests of the customer to optimise processor operating conditions to maximise

further performance by changing the developer filter at the same time as developer.
Changing Filters
1. Close the inlet and outlet taps on top of the filter unit.
2. Drain contents via drain tap.
3. Unscrew the filter bowl from the top part of the unit by turning clockwise (a special spanner
is supplied).
4. Fit a new filter element – make sure it locates correctly in the bowl.
5. Check ‘O’ ring seal in the filter bowl for damage and ensure that it is seated correctly in the
groove. If in doubt fit a new seal.
6. Replace the filter bowl and open the inlet valve then slowly open the outlet valve so that any
trapped air is pushed out.
7. Reset software at the control panel using the Change Menu (See Operator Control Panel).
0231M383 REV G 18/09/07
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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 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. Press any key to display the Main Menu.
2. Select the Close Down display from the Close Down Menu.
3. Press the Set Closedown button.
4. The screen will display Flushing Gum System.
5. The display returns to the Main Display. The machine is now closed down.
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
that all the tanks should be drained and the whole machine should be cleaned.
Points to Remember
1. Regularly check the contents of the external developer replenish developer waste, gum
flush and gum bottles. Empty or replace as necessary.
2. The service key must be kept in a safe place away from the machine and 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
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

Covers not correctly positioned
No mains power
Fuse blown or MCB tripped
Machine does not start
Emergency stop button depressed
Sensor faulty
Developer Float not covered
Excessive brush pressure
Plates not feeding correctly Infeed roller wet
Not enough roller pressure
Free by using drive reverse function
Plate jammed in machine
On operator display
Filter blocked
Filter tap partially closed
Insufficient/no developer flow Air lock in hose
Spray bar blocked with deposit
Faulty pump
Developer set point setting wrong
Developer temperature low Heater faulty
MCB tripped
Ambient temperature too high
Chiller not functioning- Cooling circulation flow
Developer temperature too high switch (no flow), high pressure or low pressure
switches on the chiller not closed
Developer set point incorrect
Supply turned OFF
Rinse taps closed
No water flow. Type (direct to drain)
Faulty solenoid valve
MCB tripped
Rinse water runs continuously Dirt under solenoid valve diaphragm
Gum bottle empty
Gum spray bar blocked
No gum flow
MCB tripped
Faulty pump
Plate jammed in machine.
Manually feed the plate out of the machine .
Machine switches off before plate exited
Infeed or exit sensors dirty.
Contact KPG Service.
Developer replenish bottle empty
Developer level slowly falls Developer replenish faulty
(Make sure there are no leaks) Developer float faulty
Developer temperature too high (evaporation)
Drive speed too fast
Developer too old and weak
Developer replenish bottle empty
Plate not fully developed
Developer replenish faulty
Developer brushes not correctly set
Developer temperature not reached
Emergency stop not reset
Emergency Stop Signal
Lids not on correctly
Unit will not start
Guard switch strikers not located
0231M383 REV G 18/09/07
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MERCURY T-HD
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0231M383 REV G 18/09/07
Page 90 of 90

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MERCURY T-HD

Mercury Plate Processor

Serial Number ___________________________

Year of Manufacture __________________

Date of Installation ___________________

Service Key Number_______________________

Page Left Intentionally Blank

0231M383 REV G1 18/09/07

ENGINEERING CHANGE NOTES TO OPERATOR MANUAL .............................. 5

0231M383 REV G1 18/09/07

Type of Equipment: Plate Processor

Authorised application: Processing of Lithographic Plates

Serial Number(s): MB1001 & Subsequent

Relevant EC Regulations: Machinery Directive 98/37/EC

Applied Harmonised EN 61326:1998 Electrical equipment for measurement, control and

Notified Body Certificates: TRLEMC

Manufacturer: Heights UK Ltd. Wainstalls, Halifax,

Date: 01/07/2004 Original Signatures on File

0231M383 REV G1 18/09/07

ENGINEERING CHANGE NOTES TO OPERATOR MANUAL

Rev Changes Made

0231M383 REV G1 18/09/07

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

0231M383 REV G1 18/09/07

2. Top Cover Switches

4. Service Key Switch

b) Do not cover the ventilation slots on the covers of the machine.

0231M383 REV G1 18/09/07

KODAK CANNOT ACCEPT RESPONSIBILITY FOR ANY DAMAGE TO PERSONS OR

This product has been designed and tested in accordance with

SAFETY COMPLIANCE to:-

CAN/CSA-C22.2 No. 60950-1-03 Information Technology Equipment - Safety – Part 1: General

Note N. America only:

0231M383 REV G1 18/09/07

The machine is suitable for connection to the following mains supply:

1. 200 – 230V Single Phase + GND

All versions require an earth line.

0231M383 REV G1 18/09/07

POWER SUPPLY CONNECTIONS

ELECTRICAL TECHNICAL INFORMATION

Installation Cable Recommendation

*SUPPLY TO EQUIPMENT TO BE PROTECTED BY A 2 POLE 20A CIRCUIT BREAKER TYPE C

0231M383 REV G1 18/09/07

MERCURY T-HD SPECIFICATION

850 1250 1550

MERCURY T-HD SETTING RANGE & DEFAULTS

Parameter Range Default *

0231M383 REV G1 18/09/07

Customers Individual Settings (please complete on installation)

Parameter Range Default *

0231M383 REV G1 18/09/07

MACHINE LABEL KEY

DEVELOPER FILL & REPLENISHMENT

DEVELOPER FILL &

GUM FILL GUM RETURN SERVICE KEY SWITCH

WASH DEVELOPER GUM

WASH DEVELOPER GUM

0231M383 REV G1 18/09/07

MACHINE LABEL KEY (cont)

DRAIN POINT WASH DOWN

DRAIN POINT WASH DOWN

DEV FILTER WASH FILTER

0231M383 REV G1 18/09/07