S6100 Operators BSA1016C101 D26 052 EN

Reference manual
REGISTRONR S 6100-HDI
FLEXIBLE MATERIALS VERSION
D26
BSA1016C101_D26 052 −
TRANSLATION OF THE ORIGINAL INSTRUCTIONS
 Bobst Mex SA 2013 1016C1 2652 0100 00199579 13.11.2013 A00 00 1

REGISTRONR S 6100-HDI FLEXIBLE MATERIALS VERSION
D26 D26 D26
BSA1016C101_D26
052 −
BSA1016C101_D26 BSA1016C101_D26
052 − 052 −
MANUAL NUMBER
BSA1016C101_D26
052 −
1016C1 2652 0100 00199580 13.11.2013 A00 00 2A  Bobst Mex SA 2013 2

REGISTRONR S 6100-HDI =>0736 2552 02 edt 14/ <= FLEXIBLE MATERIALS VERSION
Summary
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety and environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Job programming screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Startup screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Individual unit supervision screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Machine global supervision screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Register diagnosis screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
User options and machine settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Summary
1016C1 2652 0100 00199581 13.11.2013 Somm  Bobst Mex SA 2013 3
Preface
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Reserve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Reader’s comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Abreviations and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preface
1016C1 2652 0100 00199582 13.11.2013 A00 01 1  Bobst Mex SA 2013 4
General
We reserve all rights in this document and in the subject Reserve
thereof. By acceptance of the document the recipient Some of the items shown in this manual are available as
acknowledges these rights and undertakes not to publish the options. Only those items will be supplied which figure in the
document nor the subject thereof in full or in part, nor to make order confirmation of Bobst Mex SA.
them available to any third party without our prior express
written authorization, nor to use it for any purpose other than Reader’s comments
for which it was delivered to him. Please submit any remarks or suggestions that might help us
to improve this manual.
Safety
When applying to us, please do not omit to mention the
The instructions regarding the safety are described in a chap- manual number.
ter printed on yellow paper. Before proceeding to any opera-
m Make a photocopy of each page concerned, noting your
tion on or with the machine, operators, operator helpers,
remarks or suggestions.
mechanics, electricians, persons responsible of the machine
and its production or anyone else who comes into physical m Send these pages together to the address indicated
contact with the machine are imperatively asked to read this below.
chapter. Abreviations and symbols
cc Operator’s side (os)
coc Opposite operator’s side (oos)
U Keys on the CUBE keyboard
Bobst Mex SA Tel.: +41 21 621 21 11

Document Management Support FAX: +41 21 621 43 95
PO Box E-mail: doctech.bobst@bobst.com
CH-1001 Lausanne WEB: http://www.bobst.com
Preface
EDT 01
1016C1 2652 0100 00106883 17.12.2003 A01 01 1B  Bobst Mex SA 2013 5
Safety and environment

General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Manuals and directions for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General rules for all users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Switch cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fluidic equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1016C1 2652 0100 00199583 13.11.2013 B00 01 1  Bobst Mex SA 2013 6
General safety instructions

Introduction Manuals and directions for use
You should read and understand these instructions if you are The manuals supplied by the manufacturer with the machine
an operator, set-up person, mechanic, maintenance person, or after its delivery contain directions for use and must be
a helper or assistant to any of these people, or anyone else made available to any person working with the machine or
who comes into physical contact with the machine and if you having any responsibility with regard to it.
have administrative or supervisory responsibilities for the Anyone who will be working with the machine must read and
operation, maintenance, and use of the machine. understand the directions before beginning work on the
If there is anything about the instructions or about the machine. The directions must be followed by all workers.
machine that you do not understand, speak to your The manuals must be kept in a clean location and available
supervisor before you touch the machine. to anybody dealing with the machine. Everybody dealing with
YOUR FAILURE TO FOLLOW THESE INSTRUCTIONS the machine must be notified of all revisions.
MAY CAUSE SERIOUS INJURIES TO YOU OR TO To prevent injuries to people or damage to the machine,
SOMEONE ELSE. make sure that the whole machine receives regular
maintenance as described in the manual.

1016C1 2652 0100 00064305 28.10.1999 B01 01 1  Bobst Mex SA 2013 7
General rules for all users

To prevent injuries, you must:
m read and comply with the directions supplied with the m never put your hands, feet or any other part of your body
machine. Make sure the machine is operated only by inside the machine or near moving parts while the
people who have been trained according to manufactur- machine is in operation.
er’s directions. m never climb onto the machine while the machine is in
m not use the machine unless it is in good working condition operation.
and unless all safety guards and devices as well as all m make sure the work area around the machine and the
machine functions work properly. machine itself are clean and neat. Grease, oil, and other
m check whether safety devices are working properly. slippery substances are dangerous and should be
m never void any safety device and never prevent or stop cleaned up immediately. Do not leave any tools or other
a safety device from doing what it is supposed to do. objects on the floor, platform or in other working areas.
m immediately report any trouble compromising safety at m make sure that the machine is serviced according to
work to your supervisor and warn any person likely to manufacturer’s directions given in the maintenance
work with the machine of the trouble. manual.
m make sure before every start-up, that no one is inside the m make sure that the worker is not putting himself in such
machine, that everybody is standing away from the a state (alcohol, narcotics, etc.) that he might put himself
machine, and that no one is touching the machine. or other workers in danger.
Switch cabinets
Only a qualified person is authorized to intervene inside the
switch cabinets.

1016C1 2652 0100 00104743 12.09.2003 B01 02 1  Bobst Mex SA 2013 8
Fluidic equipment
Only a qualified person is authorized to intervene on the
fluidic equipment of the machine.
In fluidics, flexible conduits have a limited service life. A regu-
lar visual control, under the responsibility of the users, is nec-
essary to determine whether or not conduits must be
replaced.

1016C1 2652 0100 00125559 29.04.2005 B01 03 1  Bobst Mex SA 2013 9
General
Opening screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
General
1016C1 2652 0100 00199584 13.11.2013 C00 01 1  Bobst Mex SA 2013 10
Opening screen
The S 6100 operator interface includes eight main screens,

accessible with the following tabs:
Job programming screen

14
Startup screen
29
Individual unit supervision screen

42
Machine global supervision screen

55
Register data analyzer screen (not

available)
General
1016C1 2652 0100 00199586 13.11.2013 C01 00 1  Bobst Mex SA 2013 11
Register diagnostic screen

57
User options and machine settings

61
Embedded documentation (not

available)
General
1016C1 2652 0100 00199587 13.11.2013 C01 00 2  Bobst Mex SA 2013 12
Caution
Use
Only use your fingers when using the touch screen 1 and this
without using excessive pressure. Do not use any sharp or
cutting object.
Cleaning
In order to clean the touch screen, use a clean and soft cloth
with a neutral detergent or ethanol. The use of any other
product is prohibited.
Important: When cleaning the touch screen, assure that no
cleaning liquid penetrates between the glass and the film
which could cause malfunctions.
General
1016C1 2652 0100 00188839 18.07.2012 C02 01 1  Bobst Mex SA 2013 13

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Job creation wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Step ”Set the general properties” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Step ”Define the units options” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Step ”Choose the layout” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Step ”Job summary” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Job management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Jobs import . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1016C1 2652 0100 00199588 13.11.2013 E00 01 1  Bobst Mex SA 2013 14
General
The Job tab is used to display the parameters of the current

running job 1 and,
To create a new recipe. 1
To manage existing recipes:

load, edit, copy, delete.
To import recipes (not available yet).
The job programming wizard is used for all operations in the job
management and the following buttons are available to navi-
gate between the different pages:
Next to validate your choice and continue.
Previous to return to the previous page.
Cancel to quit the programming wizard.

1016C1 2652 0100 00199589 13.11.2013 E01 00 1  Bobst Mex SA 2013 15
Job creation wizard
Step ”Set the general properties”

The Job Name 1 and the Repeat length 2 are mandatory for the 1 2
register control (field highlighted in red on the screen). Enter
them by using the alphabetical and numerical keyboard.
It is possible to give optional information 3, but this is not neces-
sary for the register control. These informations, stored within
3
the recipe, are :
m Customer Name
m Product Name
m Reference
m Comments
Press Next when OK.
Note: If the job name 1 or the repeat length 2 is incorrect, the

Next button is disabled.
On the top of the screen, the displayed data are related to the
job currently in use by the Registron software. The data of the
new job will be displayed only after being loaded.

1016C1 2652 0100 00199591 13.11.2013 E02 01 1  Bobst Mex SA 2013 16
Step ”Define the units options”

Starting from the beginning of the press, first select a printing
unit controlled by the Registron system 1 and then select the
corresponding color by choosing it on the palette 2. Do the
same for each printing unit.
A printing unit is selected for the new job only 1

when a color has been set and this choice
automatically activates the register control.
Use this button to cancel the choice of a color

and to disable a printing unit. 2
This removing is confirmed with a button
switching from blue to grey.
Enables to switch the corresponding printing

unit in mark-cylinder mode which is indicated
by the symbol displayed in the machine lay-
out.
Enables to switch the corresponding printing
unit in mark-mark mode which is indicated by
the symbol displayed in the machine layout.

1016C1 2652 0100 00199592 13.11.2013 E02 02 1  Bobst Mex SA 2013 17
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 web

reverter (turning bar) of a unit which is indi-
cated by the symbol used in the machine lay-
out.
Optional button: button to enable the revers-
ible mode of a unit which is indicated by the
symbol used in the machine layout.
Optional button: button to enable the 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 (this button switches from
blue to grey).

1016C1 2652 0100 00199593 13.11.2013 E02 02 2  Bobst Mex SA 2013 18
Optional button: toggle button to switch

between mono scanning mode and dual
scanning mode.
Press Next when OK.
Note: At least, one printing unit must be activated in order to be

allowed to continue on the next screen.

1016C1 2652 0100 00199594 13.11.2013 E02 02 3  Bobst Mex SA 2013 19
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 further down).
To have separate groups of register marks,
each with a reference mark (not used in flex-
ible printing industry).
To have maximum of flexibility in modifying
the mark layout.
Pre-defined mark layout
To choose a pre-defined mark layout (no
modification possible). A pre-defined mark
layout is set by the Bobst technician accord-
ing to the informations given by the customer
and corresponding to the standard mark lay-
out used in the production. Several pre-de-
fined mark layouts can be prepared if neces-
sary.
Select the type of pre-defined mark layout in
the list, corresponding to the production to be
run.
Press Next when OK.

1016C1 2652 0100 00199595 13.11.2013 E02 03 1  Bobst Mex SA 2013 20
”Define the layout”

This menu is used:
m To select :
D the type and orientation of register marks,
D the type of opening codes for the Easystart function (if
several are available),
D the type of TAPS code for the automatic start-up of the
job (if several are available).
m To invert or rotate the layout.
m To modify the reference color for any printing unit.
Under the tab Insert, 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 and choose the correct register mark
type.

1016C1 2652 0100 00199596 13.11.2013 E02 03 2  Bobst Mex SA 2013 21
Under the same tab Insert, it is also possible to modify the

opening codes (only if several are available).
Press on the button Code and choose the correct opening code
for the Easystart function and the correct TAPS code (if several
are available).
Under the tab Layout, 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 the full layout vertically.
To modify the orientation of the register

marks: press several time to get one of the
four possible orientation.
Under the tab Colors, 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.
Press Next to continue to the ”Job summary”

(see further down).

1016C1 2652 0100 00199597 13.11.2013 E02 03 3  Bobst Mex SA 2013 22
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 lay-
out sequence as seen in the printed job.
Press Next to continue to program the semi
flexible layout.
Note: in this case, do not touch any pre-defined layout before
pressing Next.

1016C1 2652 0100 00199598 13.11.2013 E02 03 4  Bobst Mex SA 2013 23
Under the tab Units, set the colors inside the layout exactly as
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.
An exclamation mark above a printing unit in

the machine layout means that the corre-
sponding color is not yet set in the layout.
The button Next will be enabled only after all
colors have found a place in the layout.
Under the tab Insert, 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 and choose the correct register mark
type.

1016C1 2652 0100 00199599 13.11.2013 E02 03 5  Bobst Mex SA 2013 24
Under the same tab Insert, it is also possible to add either an

opening code for Easystart or a TAPS code:
To add the code(s), first choose the opening code (it is possible
to have several different codes) and then press the button Add.
Then choose the correct TAPS code (if several are available)
and press the button Add.
To delete the codes, press the button Delete.
Under the tab Layout, it is possible:

m to arrange the mark layout vertically or horizontally,
m to invert the complete mark layout around an horizontal
axis.
Under the same tab Layout, it is also pos-

sible to modify the orientation of the register
marks. Press several time to get one of the
four possible orientation.
Once the mark layout is ready and in full con-
cordance with what will be printed on the
web, press Next to go to the next step.

1016C1 2652 0100 00199600 13.11.2013 E02 03 6  Bobst Mex SA 2013 25
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 con-
tinue :
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 the press is running, it is not possible
to load the new job, except if it is a modifica-
tion of the current job.
To cancel the newly created job.

1016C1 2652 0100 00199601 13.11.2013 E02 04 1  Bobst Mex SA 2013 26
Job management
Jobs management page allows you to perform different func-

tions on the memorized recipes:
To search for 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 functions
described below can be activated.
Note: The current job is always
the first one in the list.
To load the selected job.
To modify the selected job.
To copy (clone) the selected job.

Note: The name given automatically by the
system can be modified.
To delete the selected job.
Note: The current job can not be deleted.
To return back to the main Job programming
screen.

1016C1 2652 0100 00199602 13.11.2013 E03 01 1  Bobst Mex SA 2013 27
Jobs import
Jobs import page is used to transfer recipes from one S 6100

Registron system to another one.
This function is not yet available.

1016C1 2652 0100 00199604 13.11.2013 E04 01 1  Bobst Mex SA 2013 28
Startup screen
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Job startup with TAPS function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Troubleshooting for TAPS sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Job startup withEasystart but without TAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Job startup without TAPS or Easystart functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Startup screen
1016C1 2652 0100 00199605 13.11.2013 F00 01 1  Bobst Mex SA 2013 29
Description
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 two functions 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.
Note: If the mark layout contains only an opening code, go to
”Job start with Easystart but without TAPS”.
If the mark layout contains no code (TAPS or opening code), go
to ”Job startup without TAPS or Easystart functions”.
Startup screen
1016C1 2652 0100 00199606 13.11.2013 F01 00 1  Bobst Mex SA 2013 30
Job startup with TAPS 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 1st
color.
Register marks
Note: The 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.
Startup screen
1016C1 2652 0100 00199607 13.11.2013 F01 01 1  Bobst Mex SA 2013 31
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, for any reason,

cannot run the TAPS sequence by pressing on the correspond-
ing check-box 1.
Note: The units working in mark-cylinder mode and all the units
following it, or following a disabled unit, are automatically dis- 1
abled.
Startup screen
1016C1 2652 0100 00199608 13.11.2013 F01 01 2  Bobst Mex SA 2013 32
Wait for the Start button to become green

and then press it to continue the TAPS Limitations for TAPS function
sequence. TAPS is not working for the following web or job configura-
tion:
This button will become green only if all machine conditions m TAPS code with incorrect dimensions and distances.
required for the TAPS sequence are present:
m Web turned over more than one time in the press for the
m Cylinders running in inking mode.
same job.
m Web stopped.
m Mark to pulse register mode (absence of the TAPS pat-
m All doctor blades in printing position on cylinders. tern or the register mark for this color).
m Exhaust fans and burner switched ON. m ”Insetting” unit.
Once the Start button is pressed, the press will start automat- m One unit working in register (cold seal) after a laminat-
ically and begin to print. Once the web is moving, the operators ing unit.
have to set the side register of all printing units and adjust all m Register marks layout not suitable for TAPS.
scanners sideways on the register mark track in order to be able
m Different TAPS pattern from job to job.
to scan the marks.
Startup screen
1016C1 2652 0100 00199609 13.11.2013 F01 01 3  Bobst Mex SA 2013 33
Explanation of the different symbol for the TAPS sequence :
To start the TAPS sequence: the nip rollers

will go down and up in sequence until all reg-
ister 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.
Startup screen
1016C1 2652 0100 00199610 13.11.2013 F01 01 4  Bobst Mex SA 2013 34
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 indi-

cation is given on the screen:
Scanner too far on the left.
Scanner too far on the right. At the end of the TAPS sequence, all units will be in auto-
matic mode and operators can proceed with the next
screen called Unit.
If it is not the case, see some troubleshooting tips on the
In this case, correct the position manually. next page.
Startup screen
1016C1 2652 0100 00199611 13.11.2013 F01 01 5  Bobst Mex SA 2013 35
Troubleshooting for TAPS sequence

Problem Solution
m The access to the TAPS screen is not possible. m Check that a layout allowing TAPS has been selected.
m The TAPS sequence does not start. m Check that all machine conditions are respected:
D Cylinders running in inking mode.
D Web stopped.
D Doctor blades in position.
D Exhaust fans and burner switched ON.
m The TAPS pattern cannot be found. m Check that the scanners are correctly located sideways
on the track of the TAPS pattern.
m Check that the dimensions and position of the TAPS pat-
tern are correct (including the distance between the TAPS
pattern and the corresponding register mark of the same
color).
m Check that nothing is printed between the TAPS pattern
and the corresponding register mark.
Startup screen
1016C1 2652 0100 00199612 13.11.2013 F01 02 1  Bobst Mex SA 2013 36
Problem Solution
m The opening code (Easystart) cannot be found. m Check that the scanners are correctly set sideways on the
track of the opening code.
m Check that the dimensions and position of the opening
code are correct (including the distance between the last
line of the code and the first register mark).
m Check that the opening code is printed with the same color
as the following register mark.
m A unit does not go into automatic mode. m Check that the scanners are correctly located on both reg-
ister marks.
m Check that the side register is better than +/− 1 mm.
m One or more printing units are not in register. m Manually correct the misregister by using the joystick and
bring the reference mark inside the gate.
Startup screen
1016C1 2652 0100 00199613 13.11.2013 F01 02 2  Bobst Mex SA 2013 37
m If the mark layout contains a TAPS code and an opening

code for the Easystart function, you do not need to go Opening code (Easystart) printed with the
through the next three pages. same color as the 1st register mark in the
m If the mark layout contains only an opening code for the layout.
Easystart function, you need to follow the instruction below.
Job startup withEasystart but without TAPS
For the Easystart function, all the colors must be brought manu-
ally in register with a precision better than +/− 5 mm in length Register marks.
register and +/−1 mm in side register.
Note: Dimensions and position of the
opening code must be strictly respected.
Several opening codes can be pro-
grammed in the system depending on
customer needs (to be done by Bobst
If the mark layout does not contain any TAPS code, the TAPS technician).
menu will show that all units are blocked for the TAPS function,
which indicate 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.
Startup screen
1016C1 2652 0100 00199614 13.11.2013 F01 03 1  Bobst Mex SA 2013 38
If, for any reason, a printing unit cannot run the Easystart func-
tion, disable it by pressing on the button 1 below the unit.
Press the Start button to start the Easystart

sequence.
Unit searching for opening code.
Opening code found. 1
Register marks found and accepted, unit in

automatic mode.
Register marks found and not accepted.
Startup screen
1016C1 2652 0100 00199615 13.11.2013 F01 03 2  Bobst Mex SA 2013 39
If the scanners are not centered on the register marks, an indi-

cation is given on the screen:
Scanner too far on the left.
Scanner too far on the right.
In this case, correct position has to be set manually.
The Easystart function can be stopped any

time with this button.
Startup screen
1016C1 2652 0100 00199616 13.11.2013 F01 03 3  Bobst Mex SA 2013 40
m If the mark layout contains neither a TAPS code, nor an

opening code, all the job start-up procedure must be done
manually.
Job startup without TAPS or Easystart functions
First adjust the length and the side register manually with a pre-
cision better than +/− 5 mm in length register and +/−1 mm in
side register.
Then go to the main screen Unit and 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.
Startup screen
1016C1 2652 0100 00199617 13.11.2013 F01 04 1  Bobst Mex SA 2013 41

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Unit selection zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Control unit setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Scope window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Register control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Unit management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

1016C1 2652 0100 00199618 13.11.2013 G00 01 1  Bobst Mex SA 2013 42
Description
The third tab Unit 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:
1 Unit controls and machine layout. 1
2 Control unit setting.
3 Scope window.
4 Register control.
5 Unit management.
All the four zones 2, 3, 4 and 5 are linked to the chosen unit in
zone 1.
2 3 4 5

1016C1 2652 0100 00199619 13.11.2013 G01 00 1  Bobst Mex SA 2013 43
Unit selection zone

The unit selection zone contains the machine layout with all the 1
machine elements linked to the register control system for the
current job.
Each element has a little colored point 1 which gives the status
of the corresponding control unit.
The same information is repeated in the job data area at the top
of the screen (big point).
The meaning of the colors is as follows:
Green: Everything is OK, unit in automatic
mode.
Orange: Register error above tolerance set

by operators, unit in automatic mode.
Red: Fail safe mode or unit in manual mode.
Blue: Software is being loaded after switch-

ing on.
Grey: No communication between Registron

computer and Registron control units in cabi- Note: Other colors (white, black, yellow, brown, violet) may
net. Call maintenance. appear. Refer to the maintenance manual to know the
meaning.

1016C1 2652 0100 00199620 13.11.2013 G01 01 1  Bobst Mex SA 2013 44
Control unit setting
Unit configuration menu:
Oscilloscope zoom factor (4 steps) between

complete repeat length and detailed view
(1/3 of repeat length).
Gate width (from 6 to 60 mm; standard value
= 18 mm).
Note: Always use the largest possible value
by ensuring that there is no other mark in the
Gate than the one expected.
Mark-mark: The reference mark is
compared with the control unit printed mark.
One or two scanners are needed to work in
this mode.
Mark-pulse: Only the optical fibre of channel
1 is used. The reference mark is compared
with the cylinder position.
Dual scanning: The system must be
equipped with two scanners in each unit.
Mono scanning: The system can be
equipped with one or two scanners in each
unit, but only scanner Nr.1 is used.

1016C1 2652 0100 00199621 13.11.2013 G01 02 1  Bobst Mex SA 2013 45
Scanning configuration menu:
Sensitivity of the scanners for very pale col-

ors (in case of low contrast between print and
background).
The bar graph displays a contrast threshold value between 5
and 10%.
The minimum contrast threshold for the acceptance of the reg-
ister marks can be set 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!
Blue, orange or green light source for

scanners Nr. 1 (left) or 2 (right).
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
the light source color automatically in order to
have the best possible contrast.

1016C1 2652 0100 00199622 13.11.2013 G01 02 2  Bobst Mex SA 2013 46
Pulse type selection in the gate.
Automatic: Phasing mode on any kind of

pulse for scanner 1 or 2.
Phasing only on a negative pulse for scan-

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

1 or 2.

1016C1 2652 0100 00199623 13.11.2013 G01 02 3  Bobst Mex SA 2013 47
Scope window
This window displays the signal received from the scanner(s)
of the chosen printing unit:
m In dual scanning mode, two traces (one for each scanner
1 and 2) and two gates (one for each trace) are displayed.
m 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.
m 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 as the color set for
the corresponding unit.
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 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 the mark again
in order to bring it to the middle of the gate (plus sign is
grey).

1016C1 2652 0100 00199624 13.11.2013 G01 03 1  Bobst Mex SA 2013 48
Register control
This section is divided in two parts:
m Chart recorder.
m Register adjustment
Chart recorder
This area displays the length and the side (if available) register
for the last 400 cylinder revolutions.
Symbolyzes the length register.

Symbolyzes the side register.
The two orange lines in each chart represent the tolerance

value set by the operators (in this example: +/− 0.1 mm).

1016C1 2652 0100 00199625 13.11.2013 G01 04 1  Bobst Mex SA 2013 49
Register adjustment
The area displays the visualization of the length and side regis-
ter errors by means of a moving ball inside a target.
This element corresponds exactly to the observations of the
scanner(s). On the screen, the web moves from bottom to top.
This display also gives the possibility to correct the length and
side register errors manually, either in manual mode or in auto-
matic mode.
In manual mode, the buttons 1 (0.1 mm steps) and 2 (1 mm
steps) will change the angular position of the cylinder (advance/
retard of the printed color) or its sideways position.
In automatic mode, the buttons 3 (0.01 mm steps) and 4 1 2 3 4
(0.1 mm steps) will change the offset value to partially compen-
sate 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 colored ball represents
the tolerance set by the operator. When the ball touches this
orange circle, the movement of the printed color has reached
the tolerance.
When the ball touches the grey circle, the movement of the
printed color has reached 10x the tolerance.

1016C1 2652 0100 00199626 13.11.2013 G01 04 2  Bobst Mex SA 2013 50
The four corner zones are used to display different infromations

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

1016C1 2652 0100 00199627 13.11.2013 G01 04 3  Bobst Mex SA 2013 51
In this zone, we find the following information:

m The absolute values for the length offset and the side offset.
m The last offset modifications for the length and side register.
In this zone, we find the out of tolerance register errors when the
register errors are above the tolerance set by the operators.
In this zone, we find all the status icons:
No mark in the gate or mark not accepted.

Need to clean the scanner’s front lens.
Nip open.
Scanner too far on the big size of the mark.
Scanner too far on the small size of the mark.

1016C1 2652 0100 00199628 13.11.2013 G01 04 4  Bobst Mex SA 2013 52
Unit management
This section is divided in two zone with the two tabs:
m Unit control.
m Tolerance management.
Unit control
In the first zone, it is possible to:
m Set the zero point of the length and side

register error before going into automatic
mode.
m Set the manual/automatic mode for
length register control.
m Set the manual/automatic mode for side
register control.
m Set the manual/automatic mode of the
AutoTrack system (optional).
m Move the scanner to the left with the
AutoTrack motor (only in manual mode).
m Move the scanner to the right with the
AutoTrack motor (only in manual mode).

1016C1 2652 0100 00199629 13.11.2013 G01 05 1  Bobst Mex SA 2013 53
Tolerance management
In the second zone, it is possible to set the tol-

erance needed for the required quality.
By means of the +/− button, this tolerance can be set from

0.05 mm to 2 mm by the operator.
For example, a typical value for color register in mark-mark
mode is 0.1 mm.
This will set the distance between the moving colored ball and
the first orange circle in order to give a good information to the
operators.

1016C1 2652 0100 00199630 13.11.2013 G01 05 2  Bobst Mex SA 2013 54

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

1016C1 2652 0100 00199631 13.11.2013 H00 01 1  Bobst Mex SA 2013 55
Description
The fourth tab Supervision 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, representing 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. All status icons are also displayed.
However, to change regulation parameters or states, it is nec-
essary to return to the page Unit.
The explanation of each unit module is the same as the one
already given in the chapter regarding the page Unit.

1016C1 2652 0100 00199632 13.11.2013 H01 00 1  Bobst Mex SA 2013 56
Register diagnosis screen

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Regulation status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Scanning status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

1016C1 2652 0100 00199633 13.11.2013 J00 01 1  Bobst Mex SA 2013 57
Description
The sixth tab Diagnostic of the main screen is used during the
production phase of a job in case something is not working as
usual.
This screen gives valuable information in order to help the oper-
ators 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 bar 1 can also give other error messages than
the status displayed above. Touch this bar to open the field and
read the error messages. Touch it again to close it.

1016C1 2652 0100 00199634 13.11.2013 J01 00 1  Bobst Mex SA 2013 58
Regulation status
In this area, we can find the status related to the regulation: 11 Web speed too low: web speed too low for register
1 Pulses per revolution: number of encoder pulses per cylin- control in automatic mode.
der revolution. Refer to the technical files to know the cor- 12 Machine stop: press is stopped.
rect value to be read and if another value is displayed, it 13 Web speed equal zero: web is not moving anymore.
means that the unit encoder has a problem. 14 Pressor up: indicates status of nip.
2 Web break detected: not used with film.
3 Nip roller down: should reflect the exact situation in the
press (true = nip closed; false = nip open).
4 Longitudinal and lateral offset: should be between
+/− 1 mm. If it is bigger, check why it is so. 1
5 Control unit state: gives a status regarding the current state 2
of the regulation board hardware. 3
6 Mark not accepted: red if register mark out of dimension,
mark missing or contrast too low. 4
7 AGC error: red if scanning system has a problem. 5
8 Waiting reference: red during search of reference. 6
7
9 Manual longitudinal: automatic mode not set for length reg-
ister. 8
9
10 General no correction: complete Registron system in fail
safe. 10
11
12
13
14
1016C1 2652 0100 00199635 13.11.2013 J01 01 1  Bobst Mex SA 2013 59
Scanning status
In this area, we can find the status related to the scanning (in 10 Contrast too low: not enough contrast to scan the
mono scanning mode or in mark-cylinder mode, only the data register mark.
of scanner 1 are displayed):
1 Mark height: value should stay inside the two limit values
indicated on top of the image (see maximal and minimal
mark height, depends on mark width and mark angle).
2 Contrast of the mark: should be above 10%. If between 5%
and 10%, reduce the threshold manually and try to scan.
1
3 Selected color used: indicates which light source color has
2
been chosen by the system to get the highest possible con-
trast for the register mark. 3
4 Too many transitions: more than one pulse inside the gate 4
(maximum: two transitions). 5
5 Not enough transition: no pulse or only one transition (mini-
6
mum: two transitions).
6 Warning: limit min. closed; too close of minimum height for 7
register mark (small edge of mark). 8
7 Alarm: limit min. reached; under minimum height for regis-
9
ter mark (small edge of mark).
8 Warning: limit max. closed; too close of maximum height for 10
register mark (big edge of mark).
9 Alarm: limit max. reached; over maximum height for register
mark (big edge of mark).

1016C1 2652 0100 00199636 13.11.2013 J01 02 1  Bobst Mex SA 2013 60

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
General parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

1016C1 2652 0100 00199637 13.11.2013 K00 01 1  Bobst Mex SA 2013 61
Description
The seventh tab Settings of the main screen is used to set the
general parameters of the software.
This screen is used:
m to set the general software and hardware parameters of the
Registron computer or, 1
m to exit the Registron software.
Different tabs 1 are available to set the general parameters.

1016C1 2652 0100 00199638 13.11.2013 K01 00 1  Bobst Mex SA 2013 62
General parameters
With tab General, we can set only the checkbox ”Restitute the
last user action” in order to avoid unnecessary repetition.
With tab Keyboard, it is possible to connect another type of
keyboard than the one supplied by Bobst.
With tab Languages, it is possible to change the language
used on the screen (feature not yet available).
With tab Physical system, it is possible to modify the measure-
ment units between international metric system (MKSA) and
english system.
With tab Backup/Restore, it is possible to backup the data 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 storing
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.

1016C1 2652 0100 00199639 13.11.2013 K01 01 1  Bobst Mex SA 2013 63
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 cor-
recting (manual mode).
To change this limit speed, touch the field, introduce the new
value and press the button Send.

1016C1 2652 0100 00199640 13.11.2013 K01 01 2  Bobst Mex SA 2013 64

S6100 Operators BSA1016C101 D26 052 EN

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

S6100 Operators BSA1016C101 D26 052 EN

Uploaded by

Copyright:

Available Formats

Reference manual

TRANSLATION OF THE ORIGINAL INSTRUCTIONS

 Bobst Mex SA 2013 1016C1 2652 0100 00199579 13.11.2013 A00 00 1

D26 D26 D26

FLEXIBLE MATERIALS VERSION

FLEXIBLE MATERIALS VERSION

1016C1 2652 0100 00199580 13.11.2013 A00 00 2A  Bobst Mex SA 2013 2

Bobst Mex SA Tel.: +41 21 621 21 11

Safety and environment

Safety and environment

General safety instructions

Safety and environment

General rules for all users

Safety and environment

Safety and environment

The S 6100 operator interface includes eight main screens,

Job programming screen

Individual unit supervision screen

Machine global supervision screen

Register data analyzer screen (not

Register diagnostic screen

User options and machine settings

Embedded documentation (not

Job programming screen

Job programming screen

The Job tab is used to display the parameters of the current

To create a new recipe. 1

To manage existing recipes:

To import recipes (not available yet).

Next to validate your choice and continue.

Previous to return to the previous page.

Cancel to quit the programming wizard.

Job programming screen

Job creation wizard

Step ”Set the general properties”

Press Next when OK.

Note: If the job name 1 or the repeat length 2 is incorrect, the

Job programming screen

Step ”Define the units options”

A printing unit is selected for the new job only 1

Use this button to cancel the choice of a color

Enables to switch the corresponding printing

Job programming screen

Optional button: toggle button to indicate the

Optional button: button to enable the web

Job programming screen

Optional button: toggle button to switch

Press Next when OK.

Note: At least, one printing unit must be activated in order to be

Job programming screen

Step ”Choose the layout”

To modify some parameters of a mark layout

Job programming screen

”Define the layout”

Under the tab Insert, it is possible to select or change the type

Job programming screen

Under the same tab Insert, it is also possible to modify the

To invert the full layout vertically.

To modify the orientation of the register

Under the tab Colors, it is possible to modify the reference for

Press Next to continue to the ”Job summary”

Job programming screen

Semi Flexible mark layout