s6100d Operator ZNC Bsa1024cxxx d26 052 en

REGISTER CONTROL S 6100-HDI
R E GIS TR O N Rotomec
Tabs
The S6100 operator interface includes six main screens (A),
accessible with the following tabs:
Recipes programming screen
Configuration screen
Machine global supervision screen
Notifications screen
Embedded documentation (not available)
Startup screen
And two fly-out tab:
Change Language
Settings options
Doc26_BUI16_Reference
Copyright 2012 BOBST GROUP. All rights reserved Machine number 1016 EDT 00 Manual_S6100_Rotomec_EDT00_PRELIMINARY.doc 19/05/2017 1 / 48
Recipes programming screen

The “Recipes programming screen” is used :
- to display the parameters of the current running job (A),
- to create a new recipe and
- to manage all the recipes stored on the computer hard A
disk (B), i.e. :
To create a new recipe
To manage existing recipes:

load, edit, copy, delete
B
The job programming wizard is used for every operations in

the job management and the following buttons are available to
navigate between the different pages:
Next to validate your choice and

continue
Previous to return to the previous page
Cancel to quit the programming wizard
Job creation wizard

Step “Set the general properties”:
The Job Name and the Repeat length (see segment A) are
mandatory for the register control (field highlighted in red on
the screen). Enter them by using the alphabetical and
numerical keyboard. A
B
The possibility exists to give optional information (see

segment B), but this is not necessary for the register control.
These information, stored within the recipe, are :
 Customer Name
 Product Name
 Reference
 Comments
Press Next when OK

Remark:
If the job name or the repeat length (A) is incorrect, the Next
button is disabled.
On the top of the screen, the displayed data’s are related to

the job currently in use by the Registron software. The data’s
of the new job will be displayed only after having loaded it.
Job creation wizard

Step “Define the units options”:
Starting from the beginning of the press, select first a printing

unit controlled by the Registron system and then select the
corresponding color by choosing it on the palette . Do the
same for each printing units.
A printing unit is selected for the new

job only when a color has been set
and this choice will automatically
activate the register control.
Use this button to cancel the choice

of a color and to disable a printing
unit.
To switch the corresponding printing

unit in mono scanning mode or dual
scanning mode.
To switch the corresponding printing

unit in mark to mark or mark to pulse
mode.
Optional button: toggle button to

indicate the real length of web inside
the printing unit when using one
dryer, two dryers or no dryer.
Optional button: button to enable the

reversible mode of a unit, with
symbol used in the machine layout.
Optional button: button to select the

source to compute error lat.

web reverter (turning bar) of a unit,
with symbol used in the machine
layout.

register regulation mode or not. If a
printing unit is printing a color without
the need of register control, the
register mode can be deactivated
with this button.
Press Next when OK
Remark:
At least, one printing unit must be activated in order to be
allowed to continue on the next screen.
Job creation wizard

Step “Choose the layout”:
In this menu, there are four possibilities to select the correct

mark layout :
To modify some parameters of a

mark layout (see page 11)
To have separate groups of

register marks, each with a
reference mark (not used in
flexible printing industry)
To have maximum of flexibility in

modifying the mark layout
To choose a pre-defined mark

layout (no modification possible). A
pre-defined mark layout is set by
the Bobst technician according to
the informations given by the
customer and corresponding to the
standard mark layout used in the
production. Several pre-defined
mark layouts can be prepared if
necessary.
Pre-defined mark layout
Select the type of pre-defined mark layout in the list,

corresponding to the production to be run
Press Next to continue
This menu is used :
1) To select :
- the type and orientation of register marks,
- the type of opening codes for the Easystart
function (if several are available),
- the type of TAPS code for the automatic start-up of
the job (if several are available).
2) To invert or rotate the layout.
3) To modify the reference color for any printing unit.
Press on the button “Mark” and choose the correct register

mark type :
Press on the button “Code” and choose the correct opening

code for the EasyStart function and the correct TAPS code (if
several are available).
It is possible to modify the orientation of the layout and the

orientation of the register marks according to what is printed
on the web (as seen by the scanners) :
To invert vertically the full layout
To modify the orientation of the register marks :

press several time to get one of the four
possible orientation.
It is possible to modify the reference for any color :
Touch one mark and then its new reference color (any color
printed before) and press the button “Reference”.
It is possible to modify the distance between mark and

distance code to mark.
Doc26_BUI16_Reference 10 /
Copyright 2012 BOBST GROUP. All rights reserved Machine number 1016 EDT 00 Manual_S6100_Rotomec_EDT00_PRELIMINARY.doc 19/05/2017 48
Press Next to continue to the “Job

summary” (go to page 14 of this document).
Job creation wizard
Step “Choose the layout”:
Semi Flexible mark layout
If the pre-defined mark layout(s) is (are) not adequate for the

new job, it is possible to prepare a special layout.
In this case, select the “Layout Semi Flexible” button to

program the register marks and layout sequence as seen in
the printed job.
Then press Next to continue to program

the semi flexible layout.
Note : in this case, do not touch any pre-defined layout before

pressing on Next.
Under the tab Units List, set the colors inside the layout
exactly as it is seen on the printed layout.
It is possible to change the arrangement of the colors or have
a hole in the layout.
To set the mark color, touch one mark in the layout and then
touch the corresponding printing unit in the machine layout.
The position of any register mark, the link with the printing unit
and the spacing between marks must correspond exactly to
what is printed.
It is possible to select or change the type of register marks

used in the mark layout of this job
Press on the button “Mark type” and choose the correct

register mark type:
Under the same tab Insert, it is also possible to add either an

opening code for EasyStart and a TAPS code :
To add the code(s), first choose the opening code (it is

possible to have several different codes) and then press on the
button “Add”,
Then choose the correct TAPS code (if several are available)
and press on the button “Add”.
To delete the codes, press on the button “Delete”.
It is possible :
- to arrange the mark layout vertically or horizontally,
It is also possible :
To modify the orientation of the register marks : press several

time to get one of the four possible orientation (only available
for wedge marks).
To invert the complete mark layout around an horizontal axis.
Once the mark layout is ready and in full concordance with

what will be printed on the web, press Next
to go to the next step.
Job creation wizard

Step “Job summary”:
At the end of the job creation, verify that all job parameters are
correct. If not, go back with the “Previous” button for
correction.
When everything is correct, there are three possibilities to

continue :
To save the job in the computer and use it

later.
To load the job into the Registron system.

If this button is grey, something is wrong
or missing in the job parameters and
correction must be done to proceed
further.
When press is running, it is not possible to
load the new job, except if it is a
modification of the current job.
To go back in wizard
To cancel the newly created job.
Jobs management
Jobs management page allows you to perform different
functions on the memorized recipes:
To search a job in the library, using

partial or complete recipe name.
List of all the jobs memorized in the

library.
Once a job is selected, the below
described functions can be activated.
To load the selected job.
To modify the selected job.
To copy (clone) the selected job or create new

job.
Remark: the name given automatically by the
system can be modified.
To delete the selected job.

Remark: the current job can not be deleted.
Startup screen
The second tab “Startup” of the main screen is used during
the startup phase of the new job after it has been loaded in the
Registron system.
On this screen it is possible to do two functions which will help

the operators by doing the job startup automatically in typically
less than two web machine lengths:
1) TAPS (Total Automatic Pre-register Setting) to set all

the cylinders in register with the first printed color
2) EasyStart to bring all the register marks inside the
gates.
If the mark layout contains only an opening code for the

EasyStart function, go to page 23.
If the mark layout contains no code (TAPS or opening code),

go to page 25.
TAPS function (optional function)

With this screen, it is possible to start the TAPS function if the
machine is equipped to do TAPS and if the mark layout
contains a TAPS code and an opening code (EasyStart) as :
TAPS code printed with colors 2 to N
Opening code (EasyStart) printed with

same color than first register mark
Register marks
Note : Dimensions and position of the

TAPS pattern and the opening code
must be strictly respected for every job.
Once all engraved cylinders are mounted and the machine is

set to print, the job startup sequence can be activated.
If the new job has a TAPS code, proceed as follows :

:
Press on the TAPS button in the “Startup screen” to go to the
TAPS function screen.
If necessary, disable the printing units which cannot run the

TAPS sequence for any reason by clicking “Off” on the
corresponding check-box
Note : the units working in mark-cylinder mode and all the

units following it or following a disabled unit are automatically
disabled.
Wait for the Start button to become green and then press this
button to continue the TAPS sequence.
This button will become green only if all machine conditions
required for the TAPS sequence are present, i.e. :
- Cylinders are running in inking mode
- Web is stopped Limitations for TAPS function
- All doctor blades are in printing position on cylinders TAPS is not working for the following web or job configuration:
- Exhaust fans and burner are switched ON. - TAPS code with incorrect dimensions and distances,
After having pressed the button Start, the press will start - Web turned over more than one time in the press for the same job,
- Mark to pulse register mode (absence of the TAPS pattern or the register
automatically and begin to print. Once the web is moving, the mark for this color),
operators have to set the side register of all printing units and - Insetting unit,
adjust sideways all scanners on the register mark track in - One unit working in register (cold seal) after a laminating unit,
order to be able to scan the marks. - Register marks layout not suitable for TAPS,
- Different TAPS pattern from job to job.
Explanation of the different symbol for the TAPS sequence :

To start the TAPS sequence :
the impression rollers will go down and up in
sequence until all register marks are in the
gate.
To stop the TAPS sequence
Unit unblocked and ready to search for its

TAPS code on the web (nip open)
Unit blocked and in waiting mode (nip open)

Unit searching for TAPS code (nip closed)
TAPS code found
Unit searching for opening code
Opening code found
Nip opened and cylinder shift in progress
Register marks found and accepted, unit in

automatic mode
Register marks found and not accepted
If the scanners are not centered on the

register marks, an indication is given on the
screen :
Scanner too much on the left
Scanner too much on the right
In this case, correct position has to be set

manually.
At the end of the TAPS sequence, all units will be in automatic If it is not the case, see some troubleshooting tips on the next
mode and operators can proceed with the next main screen page.
called Configuration.
Troubleshooting for TAPS sequence

If the access to the TAPS screen is not possible: Check that a layout allowing TAPS has been selected.
If the TAPS sequence does not start: Check that all machine conditions are respected:
- Cylinders running in inking mode.
- Web stopped.
- Doctor blades in position.
- Exhaust fans and burner switched ON.
If the TAPS pattern cannot be found: Check that the scanners are correctly located sideways on the track of
the TAPS pattern.
Check that the dimensions and the position of the TAPS pattern are
correct (including also the distance between the TAPS pattern and the
corresponding register mark of the same color).
Check that nothing is printed between the TAPS pattern and the
corresponding register mark.
If the opening code (EasyStart) cannot be found: Check that the scanners are correctly set sideways on the track of the
opening code.
Check that the dimensions and the position of the opening code are
correct (including also the distance between the last line of the code and
the first register mark).
Check that the opening code is printed with the same color than the
following register mark.
If a unit does not go into automatic mode: Check that the scanners are correctly located on both register marks.
Check that the side register is better than +/- 1 mm.
If one or more printing units are not in register: Manually correct the misregister by using the joystick and bring the
reference mark inside the gate.
EasyStart function without TAPS (optional function)

Opening code (EasyStart) printed with same
If the mark layout contains a TAPS code and an opening code color than first register mark in the layout
for the EasyStart function, you do not need to go through this
paragraph.
If the mark layout contains only an opening code for the

EasyStart function, you need to follow the instruction below.
In this case, to enable the EasyStart function, all colors must Register marks
be brought manually in register with a precision better than +/-
5mm in length register and +/-1mm in side register.
Note : Dimensions and position of the
opening code must be strictly respected.
Several opening code can be programmed in
the system depending on customer needs (to
be done by Bobst technician).
If the mark layout does not contain any TAPS code, the TAPS
menu will show that all units are blocked for the TAPS
function, which indicates that TAPS function cannot proceed.
In this case, only the EasyStart function can be done if the

mark layout contains an opening code.
To start the EasyStart function, go to Startup page and press

the button :
If, for any reason, a printing unit cannot run the EasyStart
function, disable it by clicking on the button
And select “Off”
Press the Start button to start the EasyStart sequence.
Unit searching for opening code
Opening code found
Register marks found and accepted, unit in

automatic mode
Register marks found and not accepted
If the scanners are not centered on the

register marks, an indication is given on the
screen :
Scanner too much on the left
Scanner too much on the right
In this case, correct position has to be set

manually.
The EasyStart function can be stopped any time with the
button
Job startup without TAPS and EasyStart

functions
If the mark layout contains neither a TAPS code, nor an
opening code, all the job start-up procedure must be done
manually.
First adjust manually the length and the side register with a
precision better than +/- 5mm in length register and +/-1mm in
side register.
Then go to the main screen Unit to phase the register marks of

each unit to set the gate position onto the register marks.
Switch the unit into automatic mode as soon as the register

marks are inside the gate.
The full procedure is explained in the next chapter.
Unit screen
The third tab “Configuration” of the main screen is used
during the startup phase of the new job to adjust all the
parameters and fine tune the register of a chosen unit before
going into production.
This screen is divided into several zones :
A Unit controls and machine layout

B Unit management
C Regulation control
D Visualization and readers settings
All the three zones B, C and D are linked to the chosen unit in
zone A.
Zone D visualization propose some settings and informations

about readers.
The unit selection zone (A) contains the machine layout with all
the machine elements linked to the register control system for
the current job.
“Notifications” and “Job status” in production dashboard, gives

information about units status.
Visualization:
Oscilloscope zoom factor (4 steps) between

complete repeat length and detailed view
(1/3 of repeat length)
Gate width (from 6 to 60 mm with standard

value = 18mm)
Note: Always use the largest possible value
by ensuring that there is no other mark in
the Gate than the one expected.
Blue, orange or green light source for

scanners.
This function can only be used in manual
mode, during the phasing procedure, when
the register marks displayed on the scope
are too weak and difficult to be seen by the
operator.
In automatic mode, the system will choose
automatically the light source color in order
to have the best possible contrast.
sensitivity of the scanners for very pale

colors (in case of low contrast between print
and background).
The bar-graph displays a sensitivity value

between 5 and 10%. The minimum contrast
threshold for the acceptance of the register
marks can be set by the operators with the
+/- buttons.
The default value is set to 10% (bar-graph
full right) and can be reduced in order to
pick up very light colors. Always bear in
mind, however, that reducing the sensitivity
too low will affect the quality of the register !
Note: Never lower the sensitivity more than
necessary !
Pulse type selection in the gate
Phasing on a negative pulse only for

scanner Nr. 1 or 2
Automatic : phasing mode on any kind of

pulse for scanner Nr. 1 or 2
Phasing on a positive mark only for

scanner Nr. 1 or 2
Scope window
This window displays the signal received from the scanner(s)
of the chosen printing unit :
In dual scanning mode, two traces (one for each scanner 1

and 2) and two gates (one for each trace) are displayed.
In mono scanning mode, one trace (for scanner 1) and two
gates (on the same trace) are displayed. The distance between
the two gates corresponds to the distance between the two
corresponding register marks in the layout.
In mark-cylinder mode, one trace (for scanner 1) and one
gate (for reference color only) are displayed.
The gates are colored with the same color than the color set for
the corresponding unit.
This button displays informations under the scope.

(Minimal-maximal mark height, Mark height, contrast) For
readers 1 and 2.
This window is also used when the phasing is done manually.
For manual phasing, the unit must be in manual mode and the
web speed must be lower than 20 m/min.
To find the pulses of the register marks, set the zoom of the
scope to the minimum (minus sign is grey).
Once the pulses of the register marks are visible in the scope
window, touch the area where the register mark of this unit is
seen to bring this zone near the gate.
Set the zoom to the maximum and touch again the mark in
order to bring it at the middle of the gate.
Chart recorder
To change the displayed graphs.
This area displays the length and the side (if available) register
for the last 400 cylinder revolutions.
The length register is symbolyzed by
The side register is symbolyzed by
The two orange lines in each chart represent the tolerance

value set by the operators (in this example: +/-0.1mm)
Register adjustment
The area displays the visualization of the length and side

register errors by means of a moving ball inside a target.
This element correspond exactly to the observations made by
the scanner(s). On the screen, the web moves from bottom to
top.
This display gives also the possibility to correct manually the

length and side register errors either in manual mode or in
automatic mode.
Buttons 1x and 10x

In manual mode, the buttons 1x + (0.1mm steps) and 10x
+ (1mm steps) will change the angular position of the

cylinder (advance/ retard of the printed color) or its sideways
position.
In automatic mode, the buttons 1x + (0.01mm steps)
and 10x + (0.1mm steps) will change the offset value to

partially compensate the length or side register errors if the
calculated error do not correspond to the correct print position.
The four colored segments represent the status of the length

and side register control : red when in manuel mode and green
when in automatic mode.
The orange circle around the moving colred ball represents the
tolerance set by the operator. When the ball touches this
orange circle, it means that the movement of the printed color
has reached the tolerance.
When the ball touches the grey circle, it means that the
movement of the printed color has reached 10x the tolerance.
The four corner zones are used to display different

infromations regarding the unit status :
A Unit configuration
B Register offset values
C Out of tolerance values
D Control unit status
In this zone, we can find the following informations :
Printing unit Nr. in the machine
Color Nr. in the job
Scanning mode : mark-mark
mark-cylinder
mono-scanning
dual-scanning
In this zone, we can find the following informations :
- the absolute values for the length offset and the

side offset
In this zone, we can find the out of tolerance register errors

when the register errors are above the tolerance set by the
operators.
In this zone, we can find all the status icons, i.e. :

No mark in the gate or mark not accepted
Need to clean the scanner’s front lens
Nip open
Scanner too much on the big size of the mark

Scanner too much on the small size of the mark
Unit management
This area is divided in zones with tab dépending to the
configured options.
Monitoring screen
The fourth tab “Monitoring” of the main screen is used during
the production phase of a job to maintain all the parameters
and fine tune the register during the production.
This screen is divided into several zones, which represents all

the printing units used for the current job under production.
All the register fine tuning operations on any printing unit can
be done from this screen. Also all status icons are displayed.
However, to change regulation parameters or states, it is

necessary to come back to the page “Configuration”.
The explanation of each unit module is the same as the one

already given in the chapter regarding the page
“Configuration”.
Diagnostic screen
In flyout menu “settings” we will find “Diagnostic”. It is used
during the production phase of a job in case something is not
working as usual.
This screen gives valuable informations in order to help the

operators and the maintenance people to understand what is
not working correctly, to change some settings for the current
job or to troubleshoot the Registron system.
As it is the case for other screens, all the status are given for
each unit, selected in the machine layout.
The notification tab can give also other error messages than
the status displayed above. Touch this tab to open the screen
and read the error messages.
Regulation status
In this area, we can find the status related to the regulation :

- Pulses per revolution : number of encoder pulses
per revolution : this number is given in the technical
file. Another value means that the unit encoder has
a problem.
- Web break detected : not used with film.
- Nip roller down : should reflect the exact situation in
the press (true = nip closed, false = nip open.
- Longitudinal and lateral offset : should be between
+/-1mm. If it is bigger, check why it is so.
- Control unit state : gives a status regarding the
current state of the regulation board hardware .
- Mark not accepted : red if register mark out of
dimension, mark missing or contrast too low.
- AGC error : red if scanning system has a problem.

- Waiting reference : red during search of reference.
- Manual longitudinal : automatic mode not set for
length register.
- General no correction : complete Registron system
in fail safe.
- Web speed too small : web speed too low for
register control in automatic mode.
- Machine stop : press is stopped.
- Web speed equal zero : web is not moving
anymore.
- Pressor up : indicates status of nip.
Scanning status
In this area, we can find the status related to the scanning (in
mono scanning mode or in mark-cylinder mode, only the data’s
of scanner 1 are displayed) :
- Mark height : value should stay inside the two
above limit values (see maximal and minimal mark
height, depends on mark width and mark angle).
- Contrast of the mark : should be above 10%. If
between 5% and 10%, reduce the treshold
manually and try to scan.
- Selected color used : indicates which light source
color has been chosen by the system to get the
highest possible contrast for the register mark.
- Too many transitions : more than one pulse inside
the gate (maximum: two transitions).
- Not enough transition : no pulse or only one
transition (minimum: two transitions).
- Warning: limit min. closed : too close of minimum
height for register mark (small edge of mark).
- Alarm: limit min. reached : over minimum height for
register mark (small edge of mark).
- Warning: limit max. closed : too close of maximum
height for register mark (big edge of mark).
- Alarm: limit max. reached : over maximum height
for register mark (big edge of mark).
- Contrast too low : not enough contrast to scan the
register mark.
Settings screen
The seventh fly-out tab “Settings” of the main screen is used
during the production phase of a job in case something is not
working as usual.
This screen is used :

- to set the general software and hardware
parameters of the Registron computer or
- to exit the Registron software.
Different tabs are available to set the general parameters.
General parameters
With tab “General”, we can set only the checkbox “restitute the
last user action” in order to avoid unnecessary repetition.
With tab “Region/Languages”, it is possible to change the

language used on the screen, modify the measurement units
between international metric system (MKSA) and english
system, connect another type of keyboard than the one
supplied by Bobst.
With tab “Backup/Restore”, it is possible to backup the data’s

and restore them in case of system crash or change of
computer.
An automatic backup is done every week on the hard disk of
the computer, but only the last 20 backups are available.
It is also possible to store a backup on an external USB

stroring device. If not available, please contact Bobst
technician to do so.
In case a backup is needed, choose the backup according the

date and time, either on the hard disk or on the USB storing
device and then press the button “Restore”.
With tab “Machine Parameters”, it is possible to set the ACR

function and the correction speed limit.
ACR function is a help during job restart where the reference is

automatically switched from the first color to the previous color
in all units. Once all the press is again in automatic, the system
switches back to the first color as reference.
The correction limit speed is normally set between 12 and 15

m/min. Under this web speed, the Registron system is not
correcting (manual mode).
Help screen
The eighth tab “Help” of the main screen is not yet available

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REGISTER CONTROL S 6100-HDI

Recipes programming screen

Machine global supervision screen

Embedded documentation (not available)

And two fly-out tab:

Recipes programming screen

To create a new recipe

To manage existing recipes:

The job programming wizard is used for every operations in

Next to validate your choice and

Previous to return to the previous page

Cancel to quit the programming wizard

Job creation wizard

The possibility exists to give optional information (see

Press Next when OK

On the top of the screen, the displayed data’s are related to

Job creation wizard

Starting from the beginning of the press, select first a printing

A printing unit is selected for the new

Use this button to cancel the choice

To switch the corresponding printing

To switch the corresponding printing

Optional button: toggle button to

Optional button: button to enable the

Optional button: button to select the

Optional button: button to enable the

Optional button: button to enable the

Press Next when OK

Job creation wizard

In this menu, there are four possibilities to select the correct

To modify some parameters of a

To have separate groups of

To have maximum of flexibility in

To choose a pre-defined mark

Pre-defined mark layout

Select the type of pre-defined mark layout in the list,

Press Next to continue

This menu is used :

2) To invert or rotate the layout.

3) To modify the reference color for any printing unit.

Press on the button “Mark” and choose the correct register

Press on the button “Code” and choose the correct opening

It is possible to modify the orientation of the layout and the

To invert vertically the full layout

To modify the orientation of the register marks :

It is possible to modify the reference for any color :

It is possible to modify the distance between mark and

Press Next to continue to the “Job

Semi Flexible mark layout

If the pre-defined mark layout(s) is (are) not adequate for the

In this case, select the “Layout Semi Flexible” button to

Then press Next to continue to program

Note : in this case, do not touch any pre-defined layout before

It is possible to select or change the type of register marks

Press on the button “Mark type” and choose the correct

Under the same tab Insert, it is also possible to add either an

To add the code(s), first choose the opening code (it is

To delete the codes, press on the button “Delete”.

- to arrange the mark layout vertically or horizontally,

To modify the orientation of the register marks : press several

Once the mark layout is ready and in full concordance with

to go to the next step.

Job creation wizard