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0231M383 1 C (1) .Issue2
0231M383 1 C (1) .Issue2
MERCURY
V6
OPERATOR MANUAL
Kodak Polychrome Graphics
CONTENTS
INTRODUCTION................................................................................................... 14
DESCRIPTION...................................................................................................... 16
Plate Path .................................................................................................... 17
Developing System .................................................................................... 18
Developer Tank…………………………………………………………………...19
Developer Cooling System ........................................................................ 20
Rinse System.............................................................................................. 21
Gum System ............................................................................................... 23
Drying System ............................................................................................ 24
Wash Down System ................................................................................... 25
OPERATION ......................................................................................................... 27
Operating Controls & Safety Switches ..................................................... 27
Starting Procedure ..................................................................................... 28
Processing a Plate ..................................................................................... 30
Re-entry Operation..................................................................................... 30
OPERATOR CONTROL PANEL .......................................................................... 31
Display Trees ............................................................................................... 32
Screen Displays........................................................................................... 38
CONSUMABLES / FILTERS ................................................................................ 85
SHUTTING DOWN................................................................................................ 86
PERIODIC CLEANING ......................................................................................... 87
TROUBLESHOOTING.......................................................................................... 88
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 suitable 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.
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 alternatively
use 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 run the machine when the top
covers are removed.
NOTE:
The safety switches merely 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.
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 Kodak
plate processors. The wearing of gloves, goggles and protective clothing is recommended
when working in the water section of the Kodak 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.
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 button is mounted at each corner of the machine; (except the 850 which has two
buttons fitted on opposing corners). 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.
This can be used to bypass the safety switches on the top cover. The conveyor drive can
be inched only 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.
c) Do not insert a plate into the machine unless the display indicates “READY”.
d) The machine must NOT be connected to an IT electrical supply, unless it is fitted with a
mains power transformer.
IMPORTANT
BS EN 61326:1998 Electrical equipment for measurement, control and laboratory use. EMC
requirements.
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 Polychrome Graphics in
the country of installation.
INSTALLATION
The installation, connection of services and commissioning of the machine must be carried out
by Kodak Polychrome Graphics approved equipment service engineers, or qualified
representatives.
The installation site must be clean, dry and strong enough to support the unit (See Mercury V6
Processor specification).
Contact your Kodak polychrome graphics 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 V6 Processor specification minimum water
pressure).
ELECTRICAL
The electrical cabinet is located at the left hand side of the machine when viewed from the
operator panel, and is secured by two 5mm screws and 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.)
1. 220 – 240V 1ph + N + E or 2ph + E (where the 2 phase equal 220 ~ 240 VAC)
All versions require an earth line and a neutral line unless two phase.
For Europe and International countries, H05VVF3 VDE Approved Type cable to be used.
Notes
BOTTLE OVERFLOW
MAINS WATER
3/4" BSP
MAINS WATER
¾” BSP
INTRODUCTION
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5 7
8
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 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 a stop pushbutton or opening of a guard will cause the mains power to be
removed from the pumps and drives.
For removing jammed plates, maintenance and cleaning operations (by authorised personnel
only) a service key switch is provided in the control panel door. This allows an authorised
person to remove the guards and by-pass the safety switch circuit.
PLATE PATH
DEVELOPING SYSTEM
A pump draws developer fluid from the tank, and pumps it continuously through a filter to the
spray bars.
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 a 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.
DEVELOPER TANK
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 there respective mounting points.
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
header tank or the auto reset high-pressure switch
Water Filler
Digital Temperature
Readout
Warning Indicator
Water Level
NOTE 1: THE CHILLER MAY NOT BE RUNNING DUE TO THE COMPRESSOR START
SEQUENCE LIMITING THE NUMBER OF STARTS PER HOUR, THIS IS NORMAL AND
THEREFORE THE FAULT INDICATOR WOULD NOT BE ILLUMINATED.
NOTE 3: THE WATER FILLER CAP HAS A PIECE OF TAPE COVERING A BREATHER
HOLE THIS IS FOR SHIPMENT PURPOSES ONLY AND SHOULD BE REMOVED
BEFORE USE.
RINSE SYSTEM
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.
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.
GUM SYSTEM
Gum is contained in an external container. It is fed by a pump to a spray 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.
Gum Return
Hose
Gum Feed
Hose
Gum Nozzle
Bar
Spiral
Applicator
Roller
Gum Pump
Gum Flush
Pump
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
Be Careful when using the spray gun. Water must be contained within the tank area
Spray Gun
OPERATION
NOTE: Before using the processor the operator must read the safety notes.
Two switches are moulded to the top cover; they stop the machine if the top cover is 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.
This can be used to bypass the safety switches on the top cover and is located adjacent to the
electrical control cabinet. The machine can then be operated. It must always be set to
automatic and the key removed when in normal operation.
The Mercury processor is totally controlled by the Operator Control Panel. Using a special
service menu which is automatically displayed. Plates cannot be made in this condition and is
only intended for use when maintaining or servicing is carried out. All data is inputted via the
LCD screen and the conditions of the machine is outputted on the LCD screen.
Alarm Displays
These are accompanied by an audible warning tone, and the message is superimposed on the
current LCD screen display.
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.
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 with show the
main operation screen.
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 after rollers filling can also cause a
splashing hazard.
To fill the developer section select the fill menu, developer and press the button developer
– This will start the auto fill pump. The fill menu can also be accessed through the service
menu. Place a full container of developer at the front of the machine and insert into it the
feed pipe into it. 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 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.
Remember 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.
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”.
NOTE:
The pump will switch on automatically when there is sufficient water in the rinse
section. This will fill the filter bowls. When the correct level is reached the EMS
will give an audible tone. Turn off the tap.
Remove the spiral applicator roller and gum nozzle bar and pour in gum from a bottle into
the tank. Fill until the level is within 2mm of the top of the overflow stack pipe.
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.
Starting
1. Wait until the developer temperature has reached the required set value.
2. The LCD display will show the word “READY” when the machine is ready to process
plates.
2. To reset the plate counter to zero, if required, press RESET 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).
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 out-feed 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.
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.
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
Note:
For purpose of this information, numbers have been assigned to the buttons on the display to
aid in the following explanations of their functions.
Operation
Display
Main
Guard Switch Override Menu
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
Go To Go To Go To Go To Go To
B C D E F
This screen is
password protected.
Go To
G
Operator Settings
B From
A Menu
From Change
C A Menu
Cleaning Developer
Cycle
From Conveyor
F A Menu
Cancel
Plate
Go To
Developer G
Wash NOTE
The wash related
screens are only
displayed when the
wash section type is
selected as
recirculation
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
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 FLP850 uses a digital control system. The software parameters are factory pre-set and
can only be changed by approved personnel using a secure password.
Exercise Machine
1 2
3 4
5 6
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
Alarms
Alarms
1 Exit Restart Circ 2
5 6
7 8
In normal operation these alarms will be 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 Men
Main Menu
Main menu
1 Exit 2
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)
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.
Operator Display
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
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 conductively is displayed in milli siemens (<5 mS and there will be no display)
The current plate count is displayed with the ability to zero or Reset it if required.
Operator Settings
Operator Settings
1 Exit Screen Savers 2
5 6
Save
7 Dryer Menu Settings 8
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.
Developer Menu
Developer Menu
1 Exit 2
Set Plate
7 Brush Speed 8
Sizes
This screen provides access to all the other screens which control the development of the plate.
3 Speed 1 4
5 Speed 2 6
7 Speed 3 8
Developer Menu
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.
7 8
All 3 speed settings have there own Set Pate 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.
Developer Temperature
Dev Temperature
1 Exit Default 2
22.0 C
7 8
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.
Brush Speed
Brush Speed
1 Exit Default 2
40RPM
7 8
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.
3 Level Sense 4
Per Area
None
5 Up 6
7 Down 8
* When None or Level Sense is selected - exits to previous menu. When Per Area is selected
moves to the Dev Replenish Rate screen (next page).
75ml / sq m
7 8
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.
3 4
1200 ml *
5 Start 6
7 8
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.
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
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 calculates 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 release, 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.
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
Wash Menu
(This screen is only available when the machine is configured for Recirculation Wash)
Wash Menu
1 Exit 2
Biocidal
5 Manual Dose 6
Dosing
7 8
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.
(This screen is only available when the machine is configured for Recirculation Wash)
3 Level Sense 4
Per Area
None
5 Up 6
7 Down 8
* When None or Level Sense is selected - exits to previous menu. When Per Area is selected
moves to Wash Replenish Rate screen (next page).
(This screen is only available when the machine is configured for Recirculation Wash)
100ml / sq m
7 8
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.
Biocidal Dosing
(This screen is only available when the machine is configured for Recirculation Wash)
Biocidal Dosing
1 Exit Advance 2
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. Press Exit to go to the Dose
Pump Run Time screen.
(This screen is only available when the machine is configured for Recirculation Wash)
30 sec
7 8
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.
Screen Saver
Screen Saver
1 Exit 2
3 OFF 4
ON
Up
5 6
Down
7 8
Dryer Menu
Dryer Menu
1 Exit 2
5 6
7 8
Dryer Warm Up
1 Exit Default 2
7 10 Seconds 8
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.
Dryer Power
Dryer Power
1 Exit Default 2
7 8
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.
Save Settings
Save Settings
1 Exit 2
3 Save 4
Settings
5 Restore 6
Settings
7 Restore 8
Cons 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:
EEROM 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
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
To Set Warm-up / Closedown times first check that the processor clock is reading the correct
time. To Adjust - Press Set Clock
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
Closedown Mode
In most cases it is preferable to leave the power on and put the processor into a Closedown
Mode when not required. This allows replenisher to be added to the developer and gum
sections to maintain the activity.
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.
On Off
Sunday - -
3 Monday - - 4
Tuesday - -
Wednesday - -
5 Thursday - - 6
Friday - -
Saturday - -
7 Increase Decrease 8
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 release, 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 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.
5 Change Dev 6
Filt
The Change Wash and Change Wash Filter items are only displayed when the machine is
configured for recirculation wash.
Change Developer
1 or 2
Change Dev Filt
or
Change Wash
3 or 4
Change Wash Filt
5 6
7 Quit Continue 8
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.
Fill Tanks
Fill Tanks
1 Exit 2
3 Developer Wash 4
5 6
7 8
Developer fill.
• Make sure that the fill and overflow pipes are placed in a container of fresh developer.
• 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 should be run until developer is seen to flow from the overflow pipe.
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.
Cleaning Cycle
Cleaning Cycle
1 2
5 6
7 Quit Continue 8
This instruction screen lists tasks to be performed to fully complete the cleaning of the plate
processor.
Cleaning Cycle
Cleaning Cycle
1 2
Add Water
And concentrate
3 4
850 Machine use 35 Litre
1250 Machine use 50 Litre
1550 Machine Use 65 Litre
5 6
7 Quit Continue 8
This screen gives the instruction to add water and concentrate and lists the quantities for each
machine type.
Cleaning Process
1 Exit 2
Temperature
1 Exit 2
7 30Set 8
For a recommended clean temperature, please contact your local KPG representative.
Circ Time
1 Exit 2
7 8
For a recommended circulation time, please contact your local KPG representative.
Water Rinse
1 2
7 Quit Continue 8
This screen prompts you to fill the tanks with water for rinsing out the developer section.
Cleaning Process
1 Exit 2
5 6
To set the circulation time is the same as previously described for the Cleaning Cycle
For a recommended circulation time, please contact your local KPG representative
Developer Flush
1 2
7 Quit Continue 8
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 KPG representative
1 2
7 8
System Summary
System Summary
1 Exit 2
Summary: Summary:
3 4
Processing Consumables
5 6
7 Alarm Menu 8
Change Menu
This screen gives the operator information on the pre-set parameters and a record of the
consumables used.
Alarm Menu – shows active alarms, open alarms and an alarm history. There is also a button
to cancel any active alarms.
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
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 right hand corner of the
software will vary with each different version of machine.
Summary Consumables
1 Developer 2
Since Change 0 Plt
0.0 sq m
Change At 100 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 100. sq m
7 Max Period 30 days 8
Remaining 30 days
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 100 sq metres. Also
the timer has been set to issue a warning at 30 days (whichever comes first) to change the
developer and their 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.
Summary Consumables
1 Wash 2
Since Change 0 Plt
0.0 sq m
Change At 100 sq m
3 Max Period 30 days 4
Remaining 30 days
5 Wash Filter 1 6
Warn Level 75 %
Stop Level 85 %
Current Level 20 %
7 Max Period 30 days 8
Remaining 30 days
This screen will only be displayed if the machine has been configured to recirculation wash.
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 developer at 100 sq metres. Also
the timer has been set to issue a warning at 30 days (whichever comes first) to change the
developer and their are 30 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.
Alarm Menu
Alarm Menu
1 Exit 2
Alarms Alarm
3 4
History
5 Open Alarms 6
7 Cancel Alarm 8
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.
Conveyor Menu
Conveyor
1 Exit 2
Cancel
7 8
Plates
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.
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.
Cleaning Engineering
7 8
Cycle
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.
Consumables / Filters
Variations in machine size, water quality, plate, chemistry and regular machine maintenance
may affect filter life.
Changing Filters
1. Close the inlet and outlet taps on top of the filter unit.
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 inlets 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).
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.
2. Select the Close Down display from the Close Down Menu.
5. The display returns to the Main Display. The machine is now closed down.
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.
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.
Machine Cleaning
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.
6. Clean all the rollers. Consult you local Kodak Polychrome Graphics 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.
TROUBLESHOOTING
Any problems that arise are likely to be of a minor nature and easily rectified. The
following is a brief guide: