Ltromat: Operation Manual For The DRC 200 - System

eltromat
Operation manual
for the
DRC 200 - System
© eltromat GmbH 07/95
Herforder Straße 249 - 251

33818 Leopoldshöhe
Germany
Table of contents
Warnings and safety instructions ____________________________________________________ 4
1.0 Introduction __________________________________________________________________ 6

1.1 How to use the operating manual ______________________________________________ 7
2.0 Theoretical bases _______________________________________________________________ 8

2.0.1 Construction and function of the register control ______________________________ 8
2.1 Printing marks _____________________________________________________________ 9
2.2 Measurement method ______________________________________________________ 10
2.2.1 Web-web method (Web-Web) ___________________________________________ 10
2.2.2 Web-web method with side register (Web-Web-S) ____________________________ 10
2.2.3 Web-cylinder method (Web-Cyl) __________________________________________ 11
2.2.4 Web-cylinder method with side register (Web-Cyl-A) _________________________ 11
2.3 Register adjustment ________________________________________________________ 11
2.3.1 Register roller (pivoting or ruling rollers) ___________________________________ 11
2.3.2 Differential gearing ____________________________________________________ 11
2.4 Insetter (option)___________________________________________________________ 12
2.4.1 Basic information ______________________________________________________ 12
2.4.2 Format adaptation and instantaneous corrections via the servomotor at the
pull & brake __________________________________________________________ 12
2.4.3 Format adaptation via a pull & break, instantaneous correction via an additional
Slo-Syn-Motor at the printing unit (or tool) __________________________________ 13
2.4.4 Format adaptation via pull & break, instantaneous correction via an additional ______ 13
Slo-Syn-Motor to shift a linear roller _______________________________________ 13
2.4.5 Format adaptation and instantaneous correction via a servomotor at the tool _______ 14
2.4.6 Settings for format adaptation ____________________________________________ 14
2.4.7 Control process of the insetter ____________________________________________ 15
3.0 Additional hardware components of the register control _____________________________ 16

3.1 Optical fibre sensing head ___________________________________________________ 16
3.2 Digitizer _________________________________________________________________ 17
3.3 Tachogenerator ___________________________________________________________ 17
4.0 Menu structure and operating of the DRC 200 system_______________________________ 18

4.0.1 Operating elements ____________________________________________________ 19
4.0.2 Operating elements insetter (Option) _______________________________________ 20
4.0.3 Types of variables _____________________________________________________ 20
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4.1 Main menu with register control display ________________________________________ 21
4.1.1 Main menu with register control display (with insetter) _______________________ 24
4.1.2 Register control status and error messages __________________________________ 26
4.2 Keyboard legend (in general) _______________________________________________ 27
4.3 Keyboard functions (display- and input mode) ___________________________________ 30
4.4 Oscilloscope _________________________________________________________ 31

4.4.1 Description of typical signal constellations and error situations __________________ 35
4.5 Register control set-up _________________________________________________ 40

4.5.1 Parameter definitions ___________________________________________________ 41
4.6 Register control parameters _____________________________________________ 46

Brief description of the individual register control parameters ________________________ 48
4.7 Service set-up ____________________________________________________ 49

Brief description of the individual service parameters ______________________________ 50
4.8 Output parameters _________________________________________________ 56

4.8.1 Analogue motors ______________________________________________________ 57
4.8.2 Step motors __________________________________________________________ 58
4.8.3 ELR / Single phase synchronous motors ____________________________________ 60
4.9 Insetter parameters ________________________________________________ 61

Brief description of the individual insetter parameters ______________________________ 61
5.0 Start up and adjustment without insetter option ___________________________________ 64

5.1 Start up and adjustment with insetter option _____________________________________ 65
6.0 Error messages and counter messages (trouble shooting) ____________________________ 66

Appendix A1 Side register measurement _________________________________________ 69
Appendix A2 Error display ____________________________________________________ 70
Appendix A3 Register error ___________________________________________________ 71
Appendix B Status messages of the DRC 200 (in "Service set-up" screen) _______________ 72
Appendix C _________________________________________________________________ 73
Assignment of DIP-switches on CPU- and base board _____________________________ 73
Assignment of test sockets and LEDs on base board _______________________________ 73
Appendix D _________________________________________________________________ 74
DIP-switches on board of the DRC 200-INS.0 ___________________________________ 74
LED-display at the frontside of the DRC 200-INS.0 _______________________________ 74
Adjustment of the measurement pins at the frontside of the DRC 200 INS.0 ____________ 74
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Warnings and safety instructions
General information This user manual describes the functions and procedures for safe and practical
operation with the register control system DRC 200.
The study of this user manual is indispensable for ensuring effective and faultfree
handling of this system.
Please note that an incorrect parameter setting can at the worst have an effect
on the printing press itself. This particularly applies to parameters which may
only be set by authorized ELTROMAT technical personnel. These parameters
are protected by a password. The respective sections of this user manual point
out as well that the user may not alter these parameters.
For technical safety reasons, observe the following, abridged instructions with
headwords.
Qualified personnel • Only allow qualified personnel to operate the system.

Within the meaning of this documentation, these are persons who:
• are familiar with the general safety regulations,
• have been instructed in handling the printing press,
• have familiarized themselves with the operating manual accordingly.
Designated use • The system may only be operated in a way specified by the documentation.
Exceptions are to be expressly agreed with ELTROMAT.
• The system described in the documentation has been developed, manufactured,
tested and documented in accordance with the pertinent safety standards.
Therefore, the system does not normally present any hazards with regard to the
health of persons or damage to property.
• The operator does not normally have access to particular configuration
parameters which may not be changed by him. The authorized ELTROMAT
technical personnel reserve the right to alter these parameters.
• Prerequisite for the perfect and safe operation of the system are correct
transport, assembly and installation, as well as careful operation and
maintenance.
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Warning of residual
hazards • After housings have been opened or devices to protect against accidental
contact have been removed, certain system components will be exposed which
may carry dangerously high voltage.
• Interaction with these machines/systems may only be undertaken by
appropriately qualified technical personnel.
• This system allows control of movable machine parts (e.g. compensators).
Ensure that no parts of the body enter the machine danger zone, otherwise
there is a danger of injury.
• When operating the machine, observe the safety and accident prevention
regulations valid in each specific case.
Work on the
system hardware • Repairs and conversions may only be performed by ELTROMAT technical
personnel or suitably instructed personnel.
• Inexpert repairs and/or unauthorized opening of components can lead to
serious injuries and/or substantial damage to property.
• The general maintenance work may only be performed by suitably instructed
personnel in accordance with the documentation.
• Do not make any modifications to the machine components (e.g. 19" slides)
in standard operation. Similarly, do not alter the setting of DIP switches
accommodated in the front panels of some of the slides. Such manipulations
directly affect the system and possibly the connected printing press. This may
lead to unforeseeable hazardous situations.
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1.0 Introduction
The manual for the DRC 200 system enables the user to have an overview of the
system's functions and capabilities.
Construction, control panels, functions and commands are described so that the
user is able to operate the system correctly.
Operating instructions for the system are explained in detail in order to eliminate
errors. A function description and a permitted value range is given for every
input parameter.
Further on error messages and appropriate corrective measures are explained.
In two more chapters theoretical backgrounds and additional hardware compo-

nents are described.
© Copyright ELTROMAT GmbH, 1995
This documentation is protected by copyright and must neither be copied or

duplicated nor made available to a third party or company or translated into
another language if not necessary for internal use.
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1.1 How to use the operating manual
Page layout The page is divided into two columns. The left-hand column contains headings,
key symbols, notes and parameter names. They directly relate to the contents of
the respective paragraph in the right-hand column. The left-hand column enables
specific text to be found quickly.
The right-hand column contains the text itself and, possibly, headings for
particular passages.
The chapters which describe menus or masks are structured according to the
following set pattern:
• Overview with function description (Overview)
• Figure (Fig. x)
• Commands in display mode (Display mode)
• Commands in input mode (Input mode)
• Description of parameters (Parameters)
Styles The following styles and symbols have been used to improve the legibility of the
operating manual:
Bold type
• Texts in the left-hand column
• Headings
Bold italic type

• Particular emphasis
• Important details
Key symbols (e.g. )

• To describe the actions to be performed with the key
• To actuate the represented key
Notes
• Notes are marked with the symbol
Cross references
• Specification of the chapter or page number (e.g. see 4.5.3)
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2.0 Theoretical bases
2.0.1 Construction and function of the register control
The following block diagram shows the conception of the digital register
control system with schematic marking of inputs and outputs as well as the
connection of sensors, motorized adjusting elements and diagnostic devices in
order to illustrate the hardware setup. Optional the DRC 200-system can be
equipped with an insetter.
Printing characteristics Depending on the regulation mode, the digital register control work as 3 - point
control with internal feedback (gravure characteristics) or as a control without
feedback (offset characteristics). In a both regulating modes, a closed loop is
set up enabling exact and steady control of the print. The DRC 200-system is
able to control the print for one control unit (printing unit) for length and side
register.
Further on there is the possibility to control a standalone tool (e.g. cross cutters
or perforator units) with the DRC 200-system.
Figure 1: Block
diagram DRC 200
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2.1 Printing marks
The register control of a printing process requires certain reference marks,
which supply the register control mechanism with corresponding information.
Register control is generally not possible without such a reference point or a
comparison of the nominal value entered and the measured actual value.
The following illustration (Fig. 2) explains the usable printing marks with their
application, characteristic values and special features. It must be noted that a
side register regulation can only be performed with certain marks (wedge or
double wedge marks).
Fig. 2: Printing marks
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2.2 Measurement method
In order to undertake a register control of the print, the registration deviations
must be measured with the aid of printed register marks. Position and arrangement
of these marks for conventional web sensors are dependent upon the measurement
method (web-web or web-cylinder), as well as the type of register adjustment
(differential registration, roller adjustment).
The printing marks used for the individual measuring methods are listed in
chapter 2.1
The web- cylinder method used in the DRC 200-system offers the possibility to
control also standalone tools such as cross cutters or perforator units. Generally
tools do not print their own register marks. Therefore a digitizer, directly
coupled with the tool, gives the required position values.
A sensing head detects the printing or cutting marks on the web and supplies the
second measure value necessary for controlling the tool. It is also possible to use
a printing edge for controlling.
2.2.1 Web-web method (Web-Web)

With the web-web method two register marks each are sensed and their position
measured in relation to each other. The spacing parallel to the printing direction
is decisive, in order to undertake a length register control based on this
information. For this a register mark must be printed by each printing unit. For
machines with a register roller adjustment (adjustment sum) the register marks
are printed one behind the other or beside the other in the sequence of the printing
unit.
Sum adjustment For machines with a register roller adjustment (adjustment sum) the register
marks are printed one behind the other or beside the other in the sequence of the
printing unit.
Further informations see chapter 2.4.4
Individual adjustment For machines with differential gearing (individual adjustment) always print the
register marks of the standard unit and the printing unit to be register controlled
neighbouring each other using the conventional web sensing. This is not
required when using correspondingly constructed optical fibre web sensing.
Further informations see chapter 2.4.3
2.2.2 Web-web method with side register (Web-Web-S)

In addition to the above described web-web method, a side register measurement
is performed. The use of wedge or double marks forms is prerequisite for the
application of this method. The information for the side register measurement
is obtained from the edge of the register mark which is not at right angles to the
printing direction. Set the mark angle correctly when using this method,
otherwise when calculating the side register error incorrect values will result.
Further informations chapter 4.5 Register control set-up
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2.2.3 Web-cylinder method (Web-Cyl)
As opposed to the above mentioned measuring method the web- cylinder
method only uses one register mark of the sensing head. The second information
required for the measurement is derived from the position of the print cylinder.
A digitizer is located directly on the drive axis of the printing cylinder and
supplies pulses, which clearly define the position of the printing cylinder. The
digitizer is mechanically connected to the print cylinder so that it makes
adjustments in the same manner as the print cylinder, i.e. the reference between
digitizer and print cylinder position remains. The web-cylinder method is
suitable whenever no register mark can be printed on the printing unit to be
register controlled or when the print of a very low contrast colour is to be register
controlled.
2.2.4 Web-cylinder method with side register (Web-Cyl-A)

In addition to the above described web-cylinder method a side register
measurement is also performed. The use of wedge or double marks forms the
prerequisite for the application of this method. The information for the side
register measurement is obtained from the register mark which is not at right
angles to the print direction. Ensure that the mark angle is correctly set when
using this method, otherwise incorrect values will result when calculating the
side register error.
Refer to chapter 4.5 Register control set-ups
2.3 Register adjustment

For correcting register errors an adjustment mechanism is required, which can
displace the print format with reference to a position on the print web. This
register adjustment can be carried out according to the methods described in the
following.
2.3.1 Register roller (pivoting or ruling rollers)

Sum adjustment Register rollers change the web path between printing units. A length change
resulting from an adjustment of the register rollers (e.g. by a spindle drive) has
the effect of an overall adjustment for the complete print. This means that all the
colours printed in the previous printing units are adjusted in relation to the now
following colour as an aggregate amount.
2.3.2 Differential gearing

Differential adjustment A register adjustment using a differential gearing only affects the individually set
printing unit. With the aid of this gearing the position of an individual printing
cylinder can be changed in relation to all other printing cylinders. By way of such
a differential adjustment the position of each colour print can be changed
individually, i.e. individual adjustment takes place.
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2.4 Insetter (option)
2.4.1 Basic information
The insetter can be used if an already printed web has to be again printed,
stamped, pressed or cut in register (offline).
Tasks of the insetter • Controlling of current register errors with the help of instantaneous correc
tions.
• Format adaptation of the already printed web to the format of the processing
machine.
Measured quantities • Time difference between the web pulses (register marks are fed in by the
sensing head, SH) and the reference pulse (digitizer DG) in view of the web
speed (line speed reference or tacho generator).
• Sequence of these pulses (leading and lagging)
The insetter control has two different contactless outputs unlike other measur-
ing and regulating amplifier:
Outputs • To control a servo motor (DC-disk amature motor) while instantaneous
commands can superimpose a variable base speed.
• Instantaneous commands alternatively via a slowly running synchronous
motor (Slo-Syn-Motor).
2.4.2 Format adaptation and instantaneous corrections via the

servomotor at the pull & brake
Fig. 3:
Insetter variant 1
In figure 3, the DRC 200-system is controlling a servomotor connected with the

drive of the pull & brake via a differential gear.
For a format adaptation the speed of the servomotor superimposes the speed of
the pull & brake. The speed of the servomotor has then to be changed until the
format of the incoming web corresponds to that of the machine.
In order to adjust current register errors short instantaneous commands are sent
by the same servomotor. They superimpose the base speed of the servomotor
and increase or decrease shortly its speed. By using this configuration, the web
is fed in format and in register into the following printing unit or tool.
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2.4.3 Format adaptation via a pull & break, instantaneous correction
via an additional Slo-Syn-Motor at the printing unit (or tool)
Fig. 4:
Insetter variant 2
In figure 4, the format adaptation is effected by a servomotor at the pull & break
which is also shown in the figure before. This time, however, the instantaneous
commands are sent via a second insetter output to a further synchronous motor
(Slo-Syn). This synchronous motor is connected via a differential gear with the
drive of the printing unit or tool.
Differential adjustment The printing unit or tool is directly controlled by instantaneous commands to
adjust current register errors (differential adjustment).
2.4.4 Format adaptation via pull & break, instantaneous corr-

ection via an additional Slo-Syn-Motor to shift a linear roller
Fig. 5:
Insetter variant 3
In figure 5, the format adaptation is effected by a servomotor at the pull & break,
already shown in the previous figures. The instantaneous commands are sent
via the second insetter output to a further Slo-Syn-Motor.
Sum adjustment In this case the Slo-Syn-Motor shifts a linear roller. The Shifting of the linear
roller enables a direct influence of the web length and thus an adjustment to the
current register errors (sum adjustment).
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2.4 Insetter (option)
2.4.1 Basic information
The insetter can be used if an already printed web has to be again printed,
stamped, pressed or cut in register (offline).
Tasks of the insetter • Controlling of current register errors with the help of instantaneous correc
tions.
• Format adaptation of the already printed web to the format of the processing
machine.
Measured quantities • Time difference between the web pulses (register marks are fed in by the
sensing head, SH) and the reference pulse (digitizer DG) in view of the web
speed (line speed reference or tacho generator).
• Sequence of these pulses (leading and lagging)
The insetter control has two different contactless outputs unlike other measur-
ing and regulating amplifier:
Outputs • To control a servo motor (DC-disk amature motor) while instantaneous
commands can superimpose a variable base speed.
• Instantaneous commands alternatively via a slowly running synchronous
motor (Slo-Syn-Motor).
2.4.2 Format adaptation and instantaneous corrections via the

servomotor at the pull & brake
Fig. 3:
Insetter variant 1
In figure 3, the DRC 200-system is controlling a servomotor connected with the

drive of the pull & brake via a differential gear.
For a format adaptation the speed of the servomotor superimposes the speed of
the pull & brake. The speed of the servomotor has then to be changed until the
format of the incoming web corresponds to that of the machine.
In order to adjust current register errors short instantaneous commands are sent
by the same servomotor. They superimpose the base speed of the servomotor
and increase or decrease shortly its speed. By using this configuration, the web
is fed in format and in register into the following printing unit or tool.
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The manual setting of the speed level can be made by pressing the keys beside
to set base speed.
The digital display of the insetter is indicating this base speed concerning the
control range of the insetter. If the medium speed of the servomotor is used the
digital display will show 000, in case of maximum speed +999 and using the
minimum speed - 999.
With this manual settings of the speed it is possible to make a presetting if the
format deviation is known before. This assures a quick processing (short make-
ready-time and less waste).
The possible setting range of the speed is depending on the conditions of the
machine and material.
In the automatic mode (AUTO) for the length register the base speed is
controlled permanently and adjusted by the DRC 200-system if necessary. The
altered speed is then shown on the digital display.
2.4.7 Control process of the insetter

The control process of the insetter is basically a key regulation. The incoming
web is controlled in register regarding a key unit (printing or processing unit).
The real insetting, however, is the most important procedure which means the
correct adjustment of the web in format and in register. Consequently, the
insetting is an independent controlling process.
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3.0 Additional hardware components of the register control
3.1 Optical fibre sensing head
The sensing head is an optical sensor, which records the printing marks and
converts them to electrical impulses. These are transmitted to the register
control system and form the input signals for the register controls together with
the digitizer pulses.
The printed web to be sensed is illuminated by a transmitter lamp in the sensing
head housing via a fibre optic cable. Printing web and printing marks reflect this
light which is led back by the sensor to the sensing head housing by means of a
second fibre optic wave guide. At this point it contacts a photo detector, which
to a considerable degree corresponds to the human eye as far as sensitivity and
spectral range are concerned. Contrast conditions, however, are differently
evaluated by the photo detector in comparison to the human eye. An electronic
module creates the electrical pulses necessary for the register controls from the
photo detector signals.
For the correct function of the sensing head it is important that the photo detector
records brightness fluctuations within a certain range, without being overcon-
trolled.
For this reason the sensor head of the sensing head must be precisely adjusted
to the print web to be sensed (focusing). The recognition of a print mark is based
on a reflection change with reference to the unprinted web or the differently
printed background. If a printing mark reflects less light than the background
(unprinted web), then this results in a positive pulse at the sensing head output,
and vice-versa.
The printing marks used must be of the same size or larger than the light point
used or sensing, in order to achieve a wide range of reflection differences
(improvement to the signal amplitude). The tracing is made vertically to the
printed web (reflection angle = 0) or at an angle of 15° to the web. Printing marks
are to be sensed on a tracing bar or precisely above the vertex of a guide roller.
Guide the printed web beneath the individual sensing point so as to exclude
mechanical fluttering.
This sensing method developed by ELTROMAT offers the considerable advan-

tage as compared with standard explosion protected web sensors that only the
sensor heads require fitting within the explosion protected area. The web tracing
housing with the electronic modules can be easily located outside of the
explosion protected area on the printing unit. For this the optical fibre web
sensors are supplied for fixed spacings and intermediate spaces between printing
marks as double sensors in a holder or as a combination of two individual
sensors. This enables sensing the printed web even on non neighbouring points,
e.g. for web-web method.
On the sensor head the pulse channel C1 is marked with a ring, the pulse channel
C2 with two rings. Both sensors are supplied from one light source.
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3.2 Digitizer
The digitizer is used to determine the angle position of the print cylinders. A
certain number of pulses (e.g. 250 or 1000) and a zero pulse (indicating a full
rotation) are supplied by the digitizer.
These pulses are available independent of the print speed for each rotation of the
cylinder. These pulses generated by the digitizer are available for printing speed
calculation. Furthermore, the gate sensing the register mark and the measure-
ment pulse for the web-cylinder method can be established.
3.3 Tachogenerator
The tachogenerator can be optionally connected to the DRC 200-system. It
serves to monitor the machine speed and is automatically used for various fail-
safe function (e.g. automatic, machine stoppage).
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4.0 Menu structure and operating of the DRC 200 system
The complete operation of the DRC 200-system is made via a membrane
keyboard used as the input unit and a screen used as output unit. Based on the
screen menus the user is shown the current information of the system in a clear
form. By means of the user surface, incorrect operations are securely prevented
and the exceeding of certain parameter values avoided, so that the printing cycle
is to a large extent protected from the effect of possible incorrect operation.
The screen division of the DRC 200-system user surface has the following
layout:
Header Display of the selected screen or the active function, keeping the user constantly
informed about his position in the system.
Display screen The actual screen contents (e.g. table listing of the register control parameters)
is displayed. If necessary it is also changeable.
Base line Displayed in the base line of the individual masks are commands and operation
possibilities.
In addition, further keys of the membrane keyboard can be admitted (e.g. mark
centering), which are not referred to in the base line.
Fig. 8: Main menu
For more detailed information refer to the description of the individual menus
or masks.
The nominal value, auto/manual and the gate setting buttons are active
independent other selected screen as well as in other masks. In order to avoid
incorrect operation, these keys are only to be actuated in the masks, which allow
the reactions to be displayed on the screen !
Incorrect operation (e.g. the pressing of an invalid key) is also displayed in the
base line by briefly masking in of a error message.
Data inputs in the input plane are in all cases checked for correctness by the
system.
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For this the data entered for a certain parameter is compared with the attendant
upper or lower limit. If a range is exceeded or gone below, the system replaces
this input by the individually permissible maximum or minimum value. In this
manner possible machine critical incorrect settings are avoided.
The menu structure of the DRC 200-system is of a tree construction. From the
menu screen with register control display (main screen) further masks, such as
the oscilloscope or register control parameter screen, can be invoked. In
addition to the standard display level, these sub-menus often include another
one designated as an input. In this, if necessary, password protected level the
system settings and operating parameters can be changed.
.. The function keys are always used for switching over into menus (if necessary,
in combination with the SHIFT key).
Leaving the menu is possible by pressing the ESC button. The input mode is
also completed by the ESC key.
4.0.1 Operating elements

As mentioned above, the DRC 200-system is operated with the aid of a
membrane keyboard. The grey highlighted key symbols are simultaneously the
actuation surface. The keyboard is divided into three functional blocks.
On the right hand side is a number keyboard, which also contains the function
keys (F1 ... F4) and the input register control keys (such as, e.g. Cursor, ENTER
or ESC keys).
The membrane keyboard centre features five keys for gate positioning. Their
functions are represented symbolically in the form of pictograms.
In the left hand section of the keyboard are tnominalint value/motor command
keys, which also contain the "AUTO" / "MANU" keys, the nominal value
acceptance key and the SHIFT key.
Fig. 9:
Keyboard layout
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4.0.2 Operating elements insetter (Option)
Fig. 10:
Operating elements
insetter
The operating elements of the insetter consists of:
Niveau display
main menu Display range from -999 to +999, corresponding to the adjustment of the level
of the servo-motor controlled by the insetter.
Niveau adjustment Manual adjustment of the revolution level.
Manual motor
commands Manual execution of motor commands.
The principle function of the insetter is described in chapter 2.4
4.0.3 Types of variables
There are three variables types, of which two can be changed.

Switching variables Switching variables are marked by a value, which is given out as a text (e.g.
"normal" or "type 1").
Numerical variables They are marked by number values (e.g. 340). The value of this variable type can
be changed using the numerical keyboard. A value allocation is made by
selecting the required numerical variable with the cursor keys and by entering the
new value via the numerical keys (0 ... 9) the old value being erased and replaced
by the new one.
Display variables The third type of variables cannot be changed by the system user. These
variables are showing, the system conditions, current values (measurement of
the printing speed) or values calculated by the system.
If an invalid key is pressed the error message "— Invalid key — "or" — Function
not available —" appears. The invalid input is ignored.
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4.1 Main menu with register control display
Review This main screen is the top of the menu tree (top level). It is displayed directly
after switching on the system and after completing the start phase. It combines
two functions:
Firstly the register control cycle is displayed, and secondly it serves as a
selection menu for further functions (e.g.: oscilloscope).
Fig. 11: Main menu with

register control display
Screen contents Due to the double function of this screen, the screen is also divided into two
areas. The upper section is provided to display the register cross, register errors,
actual and nominal values, auto/manual settings and motor commands, in each
case for the length register and the side register. Furthermore status and error
messages of the register control are also displayed here. Function keys are
masked in the bottom screen section, which serve the selection of further masks
or further functions.
Register control display The construction of the register control display is dependent on the register
control operating mode selected in the screen "register control set-up". If a
measuring method is used without side register control (e.g. web-web method
"Web-Web"), then all displays referring to the side register are masked out. In
the following description all possible displays are described, without taking
account of this operating mode setting.
Register cross with

scaling and waste frame The register cross is the optical reference point for print setting. The register
errors are displayed in this coordinate system obtained from the length and side
direction (direction and prefix definition refer to supplement A). The axis for
the length register runs in the vertical direction, that for the side register in the
horizontal direction. The measurement orientation for the register error is
defined in the picture "Register control set-up". Here the measurement orien-
tation can be changed for length and side register measurement. If such a change
is made, then the display in the register cross changes correspondingly.
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Register error display
in register cross A register error is displayed in the register cross separately for length and side
register and dependent upon the direction of the error (error wedge). The start
point for this error display is the origin of the axis cross. The site of the error
wedge is proportional to the register error occurred.
Tolerance border dis-

play in register cross In the register cross the tolerance values which are set in the register setting are
displayed as a frame.
AUTO/MANU
Display side register Beneath the side register symbol on the left hand side of the register cross the
operating mode of the side register control is displayed. This can either be on
"MANU" or "AUTO".
In manual operation the actual register control is switched off. The adjustment
of the side register is made with the manual adjustment commands. The register
control is active in the automatic operating mode and register controls the side
register automatically.
If an external disabling signal is set (e.g. roll change ) the operation mode is
changing automatically to a mode similar to the manual mode. No motor
commands will be given from the register control. The display turns to "auto"
respectively "manu". (Small letter in opposite to "AUTO" / "MANU".)
AUTO/MANU
Display length register The operating mode of the length register control is displayed under the length
register symbol on the right hand side of the register cross. This can either stand
on "MANU" or "AUTO".
of the length register is made with the manual adjustment commands. The
register control is active in the automatic operating mode and register controls
the length register automatically.
If an external disabeling signal is set (e.g. roll change ) the operation mode is
Actual and nominal dis-

play of the side register In the left hand bottom corner of the register cross the actual and nominal values
of the side register are masked in as numerical values. These values are given in
1/100 mm.
The actual value is formed from the measurement of the printing marks and
corresponds to the current conditions of the print running. If it is not possible to
calculate an actual value (alarm, machine stoppage) there will be lines displayed.
The nominal value entered by the user is the reference point to which the register
control regulates.
If the system is working in insetter mode the level display will be monitored, see
chapter 4.1.1
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play of length register In the right hand bottom corner of the register cross the actual and nominal
values of the length register are masked in as numerical values. These values are
entered in 1/100 mm.
The actual value is formed from the measurement of the printing marks and
corresponds to the current behaviour of the print running. If it is not possible to
calculate an actual value (alarm, machine stoppage) there will be lines displayed.
The nominal value entered by the user is the reference point to which the register
control regulates.
Display of the register

control settings com-
mands To maintain the nominal values set the register control determines the deviations
and eventually forms the motor commands. These are supplied to the setting
elements (analogue servo motors or step motors) and initiate a positioning of the
print.
In order to permit an optical register control on the register control display
screen of these motor commands, small, light triangles (arrows) are masked in
at the end of the register cross scale. They readily indicate the direction of a
setting command and the register which it is intended for.
When the motors are traversed using manual adjustment commands (refer to
operating instructions and error messages), these arrows are also masked in for
register control purposes.
Display of the
printing speed The printing speed is displayed in the head line on the right- hand section of the
screen. This is given in [m/min] (max. 3 digits). In the event of a machine
stoppage lines appear in the display.
The display of the printing speed is derived from the digitizer signals.
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4.1.1 Main menu with register control display (with insetter)
Review This menu displays nearly the same as the main menu shown in chapter 4.1.
Instead of the normal register cross only the length register axis (insetter) is
shown.
Fig. 11A :
Main menu with regi-
ster display with Inset-
ter option) Due to the double function of this screen, the screen is also divided into two
areas. The upper section is provided to display the register axis, register errors,
actual and nominal values, auto/manual settings and motor commands.
The lower section is corresponding with the functions described in chapter 4.1.
Register control display

Register axis with scal-
ing and waste frame The register axis is the optical reference point for print setting. The register
errors are displayed on this insetter axis system (direction and prefix definition
refer to supplement A). The measurement orientation for the register error is
defined in the picture "Register control set-up". Here the measurement orien-
tation can be changed. If such a change is made, then the display in the register
axis changes correspondingly.
Register error display

in register axis A register error is entered in the above described register axis and dependent
upon the direction of the error (error wedge on the register cross). The start point
for this error display is the middle of the axis. The site of the error wedge is
proportional to the register error occurred.
Tolerance border display

in register axis (insetter) On the register axis the tolerance values which are set in the register setting are
displayed as a frame.
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AUTO/MANU Display
length register (insetter) The operating mode of the length register control is displayed under the length
register symbol on the right hand side of the register axis. This can either stand
on "MANU" or "AUTO".
of the side register is made with the manual adjustment commands. In the
automatic operating mode the register control is active and controls the length
register automatically.
If an external disabling signal is set (e.g. roll change ) the operation mode is

play of length register In the right hand bottom corner of the register axis the actual and nominal values
of the length register are masked in as numerical values. These values are entered
in 1/100 mm. The actual value is formed from the measurement of the printing
mark(s) and corresponds to the current conditions of the print running. If it is not
possible to calculate an actual value (alarm, machine stoppage) there will be lines
displayed. The nominal value entered by the user is the reference point to which
the register control regulates.
Level display In the left bottom corner of the register axis the actual insetter level is displayed.
Values can be shown in a range between -999 and +999. This values corresponds
with the level adjustment of the controlled servo motor.
Display of the register

control settings com-
mands To maintain the nominal values set, the register control determines the deviations
and eventually forms the motor commands. These are supplied to the setting
elements (analogue servo motors or step motors) and initiate a positioning of the
print. In order to permit an optical register control on the register control display
screen of these motor commands, small, light triangles (arrows) are masked in
at the end of the register axis scale. They immediately indicate the direction of
a setting command and the register which it is intended for. When the motors are
traversed using manual adjustment commands, these arrows are also masked in
for register control purposes.
Display of
printing speed The printing speed is displayed in the head line on the right hand section of the
screen. This is given in [m/min] (max. 3 digits). In the event of a machine
stoppage lines appear in the display. The display of the printing speed is derived
from the digitizer signals.
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4.1.2 Register control status and error messages
Register OK Reason Register control is operating normally in all functions.
Register ALARM Reason Register control process is malfunctioning, multi-input
error (flashing).
Example Printing speed below minimum speed.
Counter measure Remove disturbance, increase speed.
When "ALARM" is displayed as a register control status no further register

adjustment is performed by the register control.
Speed Reason Printing speed goes below the minimum speed.

Example Machine stop
Counter measure • Check tacho-signal
• Start the machine
Acceleration Reason Calculated acceleration exceeds upper limit.

Example Extreme conditions, occurs when starting or stopping the
machine.
Counter measure This alarm is cancelled, if the acceleration upper limit for
the number of digitizer rotation goes below the set value.
Mark 1 missing Reason • Mark level of mark 1 is recognized as too low.

• One of the two measuring timers for C1 is not started.
Mark 2 missing Reason • Mark level of mark 2 is recognized as too low.

• One of the two measuring timers for C2 is not started
Malfunction pulses Reason More than two signal flanks are recognized in the gate by
the measuring hardware.
Mark of gate edge Reason If a mark is too close to the gate edge (less than 1/16 of the
gate width), an alarm is triggered.
The last four alarm messages ("Mark 1 missing" to "Mark on gate edge") appear
simultaneously if the gate timer is not started. To avoid and overcome errors,
which are in conjunction with the last four alarm messages, please refer to the
illustrations in chapter 4.4.1. Based on oscilloscope picture examples are shown
of the correct setting of sensing head signals and gate width.
Mark 1 missing and
malfunction pulse Reason During measuring of mark C1 it is established that the
minimum mark length of 2/10 mm is gone below.
Mark 2 missing and
malfunction pulse Reason During measuring of mark C2 it is established that the
minimum mark length of 2/10 mm is gone below.
Status display of
gate tracking Reason If the gate tracking function is active the text "Gate
tracking active" will be displayed.
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4.2 Keyboard legend (in general)
Key Function Meaning

Oscilloscope Display function for both sensing head signals, for gate
position, gate width, zoom factor and web speed. These
functions serve for recording and analysing the mark
signals and gate settings.
Register control set-up Display and input screen for the register control set-up.
The system can be configurated for the required operating
conditions in this screen.
Register control para-

meter Display function for the register control parameters.
Dependent upon the application three parameter records
can be selected for one photo-gravure printing unit or one
offset register control characteristic. The input mode for
changing certain values remains reserved for ELTROMAT
service personnel.
Gate tracking The gate tracking is used in OFF-LINE procedures to

guide the gate automatically if marks are eventually
running out of the gate.
Change-over (NOT AVAILABLE WITH INSETTER OPTION)

side register AUTO : Automatic operation, the register control
assumes all register control tasks.
MANU: Manual operation, the user controls the
process, the register control is inactive.
Change-over
length register AUTO : Automatic operation, the register control
assumes all register control tasks.
MANU: Manual operation, the user controls the
process, the register control is inactive.
Takeover nom. value By pressing this key the current actual value for length and
side register is taken over as new nominal value. New
reference point for the register control system!
/ Single / tenfold step Increase of length register nominal value (display unit)
/ 1 / 10 step Decrease of length register nominal value (display unit)
/ 1 / 10 step Increase of side register nominal value // of the level
/ 1 / 10 step Decrease of side register nominal value // of the level

( Description without // with insetter )
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Displacing the gate
centre position (1 Digit) Displacing the gate centre position by 1 digit (smallest
unit with reference to the digitizer resolution) to the right.
Using this function a mark can be manually brought into
the gate. This can also be used for searching for the mark.
As the gate display is always held centrally to the
oscilloscope screen, a displacement of the mark(s) to the
left is optically noticed. The gate position changed due to
the displacement is masked into the head line of the
screen.
Displacing the gate

centre position (10Digits) The gate position can be displaced in leaps of 10 digits to
the right
Displacing the gate

centre position (1Digit) As above, direction of displacement is to the left.
Displacing the gate

centre position (10Digits) As above, direction of displacement is to the left..
Change gate width The gate width increases by 1 mm. The gate display on the
oscilloscope indicates these changes by a wider gate. The
enlarged gate width is masked into the head line of the
screen. The gate width can be enlarged to a maximum
value of 1/4 the cylinder circumference. If an attempt is
made to increase the gate width above this value, the error
message "— gate width limited! —" appears in the base
line. Simultaneously the gate width is set to the maximum
value.
Change gate width As above, however decreasing gate width
Change gate position Automatic centering of the own mark in the gate. This
function optimally moves already corrected set gate widths
and positions into the gate. Here certain edge conditions
must be noted.
Adjusting the length

register control motor Manual adjustment of the register controls with slow
adjustment speed in positive direction. The motors are
traversed in the given direction for the duration of the
button depression. (Only possible in combination with the
step- or analogue motor output unit.)

register control motor Fast adjustment speed in positive direction.

register control motor Slow adjustment speed in negative direction.
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register control motor Fast adjustment speed in negative direction.
Adjusting the side

register control motor Slow adjustment in positive direction.
(With insetter option: Increase level slow)
Adjusting the side

register control motor Fast adjustment in positive direction.
(With insetter option: Increase level fast)
Adjusting the side

register control motor Slow adjustment in negative direction.
(With insetter option: Decrease level slow)
Adjusting the side

register control motor Fast adjustment in negative direction.
(With insetter option: Decrease level fast)
Exit menu screen By pressing this key the actual screen is left and the
"main menu with register control display" is returned to.
Further / previous
base line Switching forwards / backwards to the next / previous
base line.
Clear input Removes the actual numerical value.
Store value The actual value selected with the block cursor is taken
over into the system as a valid value. In this manner the
previously present value is written over.
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4.3 Keyboard functions (display- and input mode)
Display mode
Input Switching over to the input mode (if necessary enter the correct code number).
In this mode setting values can be selected and their can be value changed.
Exit menu screen By pressing this key the actual screen is left and the "main menu with register
control display" is returned to.
Input mode
Toggle Provided that the inverse block cursor stands on a switching variable, all values
permissible for this switching variable can be run through by repeatedly
pressing the key (sign: value = text)
Store value The actual value selected with the block cursor is taken over into the system as
a valid value. In this manner the previously present value is written over.
Cursor To select the changeable parameters an inverse block cursor appears on the
screen, which marks the input field of the parameter concerned. Inputs can be
made within these fields (num. variables), switching variables permits to toggle
through permissible values. Before leaving this menu, store changed values.
/ Moving the block cursor for parameter selection up / down. Switching contin-
ues to the input field of the previous / following input variables. If you are on
the first / last parameter in the screen, you are switched forward / back to the last
/ first parameter pressing this key (loop end).
Clear input With this key the values can be corrected in the event of an input error. The
contents of a complete input field is erased, permitting a new value to be
entered.
Exit input mode By pressing this key the input mode is left. The block cursor is switched off, no
further inputs are possible and the system returns to normal display mode.
If an invalid key is pressed the error message "— Invalid key —" or "—
Function not available —" appears in the base line. The invalid input is
ignored.
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4.4 Oscilloscope
Review With the aid of the functions offered here, the input pulses of the two register
control points (length and side register control) and the gate oscilloscope can
be represented. There are functions for gate positioning and for automatic
centering the marks in the gate. The information from the oscilloscope display
is entered in a screen memory, which is updated every two cylinder rotations.
Resulting from this, is a static picture on the oscilloscope.
Fig. 12 : Oscilloscope
Screen contents The screen layout is similar to an oscilloscope. Two display channels are
available, which are displayed in an analogue or digital form dependent upon
the setting of the sensing head signals. The gate is masked in under these two
display channels. Its duty is to precisely cut-out pulses from the sensing head
signals which are required for the register control. Only those signals which are
clearly within this gate can be taken as reference values for the register control.
At the end of this chapter some typical signal constellations and error situations
are shown as examples.
Gate position Display of the actual gate position in digits, based on the gate middle. This
position is formed from the pulses supplied by the digitizer and thus refers to
the cylinder circumference. Changes of the gate position exceeding the digitizer
range (i.e. less than 0 or greater than the digitizer resolution-1), results in a loop
end in the display, the gate position is then either set to (digitizer resolution -
1) or to 0. The gate position is also displayed in the "Register control set-up"
screen. Changes thus affect both masks.
Gate width Display of the set gate width in [mm]. In accordance with the definition the gate
width measured from the gate middle to the gate edge. The resulting gate width
thus doubles. The gate width is also displayed in the "Register control set-up"
screen. Changes thus affect both masks.
Printing speed Display of the printing speed in [m/min]. This display is analogue to the speed
information in the "menu screen with register control display".
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Zoom factor This factor is a measure for the range of the oscilloscope display. For zoom
factor = 0 the complete cylinder circumference can be seen on the oscilloscope.
If the zoom factor is increased in steps (maximum value is 10), the screen shows
an increasingly smaller section of the cylinder circumference displayed in a larger
scale (section enlargement). The gate position serves as a reference point for the
enlargement (gate centre). This means that the gate centre is always at the centre
of the oscilloscope screen.
Display mode
ZOOM Reduce the zoom factor by one stage (minimum value is 0). A larger section of
the cylinder circumference is displayed. The gate centre is positioned in the
centre of the oscilloscope display.
ZOOM Enlarge the zoom factor by one stage (maximum value is 10). A smaller section
of the cylinder circumference is displayed. The gate centre lies in the centre of
the oscilloscope display.
Gate tracking Switch on respectively off the automatic gate tracking. If the gate tracking is
active the gate position that is scanned by the C2-sensing head will be tracked
automatically. This tracking will be repeated after every register measuring. In
the Web-Cylinder mode the gate tracking is cancelled ! For gate tracking
procedure it is important that the digitizer direction is "O.K." (see Fig. 31,
Register control set-up).
Display Toggle between several signals shown on the oscilloscope with its two display
channels. Two sensing head signals can be used. They can either be shown as
analogue signals (directly from input unit) or as digital signals (behind digitizing,
at the comparator).
For the assignment of signals and display channels the following is valid:
• Sensing head C1 is always scanning the reference mark
• Sensing head C2 is scanning the mark of it's own printing unit, if using web-
web procedure.
• By using web-cylinder procedure the signal is coming from the digitizer of the
own printing unit.
• If a reverence signal and an own signal is shown on the oscilloscope at the same
time, the reference signal C1 is always shown on the upper display channel.
The own signal is shown in the lower display channel.
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So you can choose between the following possibilities.
Web-web method • Upper display channel: analogue signal from sensing head C1.
Lower display channel: analogue signal from sensing head C2.
• Upper display channel : analogue signal from sensing head C1.
Lower display channel: digital signal from sensing head C1.
• Upper display channel: analogue signal from sensing head C2.
• Upper display channel: digital signal from sensing head C1.
Web-cylinder method • Upper display channel: analogue signal from sensing head C1,
Lower display channel: cylinder impulse.
• Upper display channel: digitized signal from sensing head C1,
Lower display channel: cylinder impulse.
Switch the base line Switch the base line to the next / previous command line.
Further information see chapter 4.2 keyboard legend (in general).
Procedures
Web-web method The mark of the own printing unit is masked in the lower display channel
(channel 2). When centering the middle of the own mark is brought into the gate
centre. The reference mark (channel 1) is correspondingly displaced.
Web-cylinder method The active edge of the cylinder pulse supplied by the digitizer (display channel
2, below) is always in the centre of the gate. A reference mark originating from
another printing unit is displaced in accordance with the centering in relation
to the "own mark", so that the active edge is located as precisely as possible in
the gate centre.
Automatic centering can lead to the following errors:
• If an alarm condition is present (e.g. no correct measured values), no

automatic centering can be performed. The message "— not possible in
this state of the alarm —" appears in the base line.
• A centering cycle itself can become the cause of an error, in that a mark is
pushed out of the gate when centering. In this case the error message
"— ALARM! Centering not possible —" appears.
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Gate tracking The gate tracking can be switched on resp. off in the main menu or in the
oscilloscope menu with the function key. If the gate tracking is active a message
"Gate tracking active" is displayed in the status display.
If the gate position have to be changed manually by active gate tracking the gate
tracking have to be cancelled if necessary to operate well. The automatic gate
tracking will center the mark from the C2-sensing head in the middle of the gate,
so it works against the gate positioning.
After system start up of the DRC 200-system the automatic gate tracking is
always switched off.
If there is one of the following alarms the gate tracking will not work:
• MARK 2 MISSING
• MARK 2 AT GATE EDGE
• SIGNAL DISTURBED AT C2
The automatic gate tracking is possible only in the procedures Web-Web (Web-
Web) or Web-Web with side register measuring (Web-Web-S). If Web-
Cylinder procedure is used the gate tracking is cancelled. In Web-Cylinder
procedure the gate tracking is cancelled because the gate is centered to the
cylinder pulse.
The digitizer direction must be "O.K." (see figure 31, register control set-up).
In other case the marks are running out of gate if the automatic gate tracking is
activated
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4.4.1 Description of typical signal constellations and error situations
The illustrations show examples of the signal forms similar to those appearing
in practice. Here in all cases the mark signals are seen in relation to the gate
width and gate position. Signal description and, if necessary, the error provides
a classification of the situations displayed distinguishing between "correct" and
"incorrect" setting. For all masks with the exception of Fig. 22 measurement is
made in accordance with the web-web method. Fig. 22 indicates a measurement
using the web-cylinder method.
Figure 13 Correct:
Ideal illustration of a "positive"
register mark. Base line relatively
straight, mark contrasts strongly
with the base material (higher
pulse) and is located in the mid-
d l e
of the gate.
Figure 14 Correct:
Ideal illustration of a "negative"
register mark, the pulse is inverted
in comparison to figure 13.
Figure 15 Correct:
The front edge of a print pattern
is used for sensing, thus a positive
signal edge can be seen.
Necessary, if, for example, the
necessary register mark is very
poorly printed or fully missing.
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Figure 16 Correct:
As figure 15, however, with a ne-
gative signal edge. (e.g. gold
surface)
Figure 17 Correct:
As figure 13, in addition a 2nd
mark is located behind the mark
to be sensed. This is not an error
situation because the gate width
was selected such that only the
1st mark is within the gate.
Figure 18 Correct:
Corresponds to figure Figure 14.
By using strongly reflecting base
material (e.g. aluminium) further
positive pulses are visible in add-
ition to the register mark Not an
error because the width is set
correctly.
Figure 19 Correct:
A colour marking is used as a
register mark. Outside of the gate
several cut-outs are visible as
negative pulses.
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Figure 20 Correct:
As figure 17, however the print
pattern follows the register mark.
Not an error because only the
mark lies within the gate.
Figure 21 Correct:
Corresponds to figure 20, how-
ever, as a negative display. Nega-
tive marks with the following
"negative" printing pattern
(e.g. printed gold surfaces after a
gold mark).
Figure 22 Correct:
Display of a cylinder pulse when
using web-cylinder method. The
position of the cylinder pulse
is always the same in this method.
The active impulse edge is in gate
centre, the cylinder pulse has
the length of half the gate width.
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Figure 23: Incorrect: (Figure 23 + 24)
Heavy structure in the base line
with very small "positive" or
"negative" mark. No or only an
incorrect register control is possi-
ble.
Causes of error:
• insufficient light at the sensing
position (e.g. pressure on the
paper, but switch is set to
aluminium (in "register control
set-up" screen)
Figure 24: • sensing head not precisely ad

justed the spacing from the print
web is too large or too small, or
the sensing head is not at right
angles to the web (no reflected
light enters the lens system).
• Sensing head glass lenses are
soiled (clean with solvent solu-
tion.
Exception:
The light conductor of a sensing
head is kinked.
Figure 25 Incorrect:
Optimum mark pulse, however,
gate width set too small (register
control area too small).
Possible cause of error:
Incorrect gate width setting.
Counter measure:
Enlarge the gate width until the
mark (channel 2) is located
approximately in the middle of
the gate area and the gate edges
surround the mark on both sides.
An extreme example from prac-
tice. The register mark in a weak
colour is located in the cut-out of
an intense colour (aluminium
material).
Counter measure:
Reduce gate width, until only the
register mark is within the area.
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Register mark is too far to the left
fig. 27) or even outside (fig. 28)
of the gate (in the last case auto-
matic register control is no longer
possible).
Possible causes:
Inaccuracy when positioning the
register marks register dis-
placement, during a machine em-
ergency stop (cutters disengage,
cylinder slip).
Figure 28 Help:
Move the register back into regis-
ter or use the mark search se-
quence to bring the web pulse
back into the middle of the gate
(absolutely necessary with the
web-cylinder method, because the
cylinder also lies in the centre of
the gate with its active flank).
Figure 29 Increase the zoom factor by press-

ing the -key. The illustration
is stretched so that with a maxi-
mum zoom stage (10) the com-
plete gate area is displayed on the
screen. Always increase the zoom
factor when signals or signal
forms are to be precisely observed.
Figure 30 Reduce the zoom factor by press-

ing the -key. The illustration
is pressed together, so that with
the smallest zoom stage (0)
the full cylinder circumference
becomes visible with its signal.
This zoom factor setting is
practical in order to obtain an im-
pression of all signals, in particu-
lar of those lying outside of the
gate (sensing area)
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4.5 Register control set-up
Review On the screen a table listing appears of the register control set-up values and
their current values. In this screen the properties, operating modes and register
control methods of the system as well as the requirements of the individual
printing order can be matched.
Figure 31:
Register control set-up
Screen contents The screen indicates four groups of parameters with their actual values.
The description of the individual parameters is made in chapter 4.5.1.
Further information on permitted keys see chapter 4.3. In this screen in the
display mode the - key is defined in a different way, as it is described in
chapter 4.3.
Clear state The message "gate set" appears in the bottom left hand display field if the gate
acceptance of the sensing head is correctly performed (optical control).
Operation sequence for take over of the gate position:
• Switch over to the "Register control set-up" screen
• In the "register control set-up" screen clear the message "gate set"
• stop the printing machine, then slowly move the print web forward until the
register mark to be sensed is located in the light point of the sensing head
optics.
• Press the "store" push button on the sensing head housing, take over the gate
position.
• The message "gate set" must light up in the bottom left hand display field,
when the gate is correctly taken over by the DRC 200 system. In the event
of an error, repeat this operating sequence.
The web speed during the gate take over must be less than the bottom speed
limit. If this is not the case, the error message "Gate take over whilst machine
is running is not possible !" appears in the base line.
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4.5.1 Parameter definitions
Measuring mode Type Switch variable
Description Adjustment of the operation mode and measurement
method.
Requirements Wedge- or double mark
Attention Ensure the correct setting of mark angle and mark type!
Web-Web: Length register measurement using the web-web method,
i.e. measuring the mark printed by the printing unit in
relation to a previously printed reference mark. All dis-
plays which refer to the side register are masked out in the
"screen with register control display".
Web-Web-S: As Web-Web, with additional side register measurement
Web-Cyl: Only length register measurement using the web-cylinder
method, i.e. register control of the printing cylinder posi-
tion (cylinder pulse) in relation to the printing pattern. All
displays concerning the side register are masked out in
"Main menu screen with register control display". Auto-
matic gate tracking is not possible.
Web-Cyl-A: As Web-Cyl with additional side register measurement
Control dir. L. Type Switch variable

Description Change the measurement orientation of the length register.
normal: Measurement orientation defined in supplement A.
revers: Measurement orientation exchanged (to be used when
changing web sensors (C1 and C2) or changed over mark
arrangement)
Param. type L. Type Switch variable

Description Select one of the three length register control characteris
tics. The register control behaviour must allow matching
within certain limits to the special features of the print.
Preset values Type 1,2, or 3
The parameter setting required for this (chapter 4.6 "Register control param-
eter") should only be undertaken by ELTROMAT service personnel.
Register tol. L. Type Numerical variable

(1/100 mm) Description Definition of the tolerance borders for the register error of
the waste detection from the length register measurement.
Value range 0 - 600
The input value "0" stops the waste detection of the length register control
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Control dir. S. Type Switch variable
Description Change the measurement orientation of the side register
measurement.
normal: Measurement orientation as defined in supplement A.

revers: Measurement orientation exchanged. (to be used for turned
wedge marks)
Param. type S. Type Switch variable

Description Select one of the three side register control characteristics
(switching variables). The register control behaviour must
allow matching within certain limits, to the special features
of the print.
Preset values Type 1, 2 or 3
The parameter setting required for this (chapter 4.6 "Register control param-
eter") should only be undertaken by ELTROMAT service personnel.
Register tol S. Type Numerical variable

Description Definition of the tolerance borders for the register error of
the waste detection from the side register measurement.
Value range 0 - 600
The input value "0" stops the waste detection of the side register control.
Fibre optic Type Switch variable

Description Switch over/matching the sensing head light intensity.
The sensing head recognizes marks based on their contrast
difference between the mark and the background. With
highly reflective material this can lead to an overcontrol of
the sensing head input stage, making an evaluation of the
contrast differences impossible. In order to avoid an
overcontrol, the sensing head light intensity must be matched
to the material.
Paper: For normal reflecting material, normal light intensity.
Aluminium: For strongly reflecting material (when the mark signal
merges with the limitation), reduced light intensity.
Mark shape Type Switch variable

Description Selection of the mark shape
Wedge: Wedge or bar shaped mark, the bar shaped mark only
allows length register control.
Double: Double mark, measurement of the rising signal flanks.
Print: If a separate mark is not available for the register control,
then as an alternative a notable point (high contrast print
edge) can be register controlled in the print.
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Each measuring procedure needs certain printing marks (see chapter 2.1).
The parameter "mark shape" has to be identical to the mark shape used in the
printing process.
Edge used Type Switch variable

Description Selection of the active signal edge for measurement
Leading: For length register measurement the two first flanks are
used.
Trailing: For the length register measurement the two second flanks
are used (for double marks the two third flanks). To be
used when the sloped side of the mark is printed first, seen
in the direction of flow.
As described in chapter 2.1 "Printing marks", the printing marks are recognized
based on their signal flanks caused by their contrast distinctly varying. The
parameter to be set here establishes the flanks to be highlighted for measurement.
This setting is applicable in the operating mode "Web-Web" as well as "Web-
Web-S" both for the reference mark as well as the "own" mark, with "Web-Cyl"
and "Web- Cyl-A", however, only for the reference mark.
Mark angle (degree) Type Numerical variable

Description Input of the mark angle in degrees for wedge and double
marks.
Value range 17 to 45 degree
As described in chapter 2.1 "Printing marks" for the calculation of the side
register errors, marks are required which run angled to the web running
direction. The mark angle to be entered here must be in agreement with the marks
used in the print, because this is a calculation basis for the side register control.
In the event of too large or too small values being entered, an error message
appears in the base line and the mark angle is set to 45 or 17 degrees.
Gate position Type Numerical variable

Description Positioning the gate centre with reference to the cylinder
circumference
Value range 0 to (digitizer resolution-1)

When entering a gate position, which is larger than the
(digitizer resolution -1), the gate position is set to the
permissible maximum value (digitizer resolution -1).
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Gate width (mm) Type Numerical variable
Description Input of the gate width in mm.
Range Middle of the gate to the gate edge.
Value range 1 mm to up to 1/4 of the cylinder circumference are
permissible. When entering a zero the gate width is set to
1 mm. When entering a value which is too large the gate
width is then set to the maximum possible admissible value
or to 325.
Format Type Numerical variable
Description Entering the cylinder circumference. This value should be
exact, because it is the calculation base for the register
control system.
Value range 10 to 5000 (Units)
When entering a value which is too large / small the
maximum / minimum value is set.
Speed limit Type Numerical variable

Description Entering the speed limit in m/min, beneath which the
register control should not control
Value range 1 to 100 m/min
When entering a value which is too large / small the
maximum / minimum value is set.
Accel. switch off Type Switch variable

Description When exceeding the acceleration limit the register control
is switched off. It is practical to switch on this automatic
mode when the print is frequently started or stopped.
Register control during the acceleration phase is not
practical due to the instable web condition (e.g. web
tension) at this time, as this will lead to an increase in the
buildup time of the control system.
ON: Register control switches to alarm above the set accelera-
tion limit and does not transmit any further command.
OFF: Register control always functions, independent of the
acceleration.
Acceleration limit Type Numerical variable

Description Entry of the limit, from which point the register control
ceases operation
Value range 1 to 99
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Accel. delay (rev) Type Numerical variable
Description Enter the number of cylinder rotations for which the
register control remains inactive after completing the
acceleration phase, prior to regulating again (numerical
variable). This delay serves to settle the machine or the web
tension during machine acceleration.
Value range 0 to 99
Accel. speed limit Type Numerical variable

Description Enter a speed in m/min above the register control indepen-
dent of the acceleration
Value range 100 to 600 m/min
The correct setting of this parameter can reduce waste
under the corresponding conditions with high web speeds,
because the web tension is relatively constant at high
speeds. When entering a too high value a maximum value
of 600 m/min is set in the other case the limit value is set
to a minimum value of 100 m/min.
Digitizer position Type Display variable

Description Display of the current digitizer position as a numerical
value from 0 to (digitizer resolution -1).
Digitizer Direction Type Display variable

Description Display of the cylinder rotational direction. The cylinder
and digitizer rotational directions must be in agreement,
otherwise the formation of the measurement gate does not
function.
O.K.: Rotational direction is correct, do not undertake a change.
revers: Change digitizer direction in screen "service set-up".
Digitizer ref. Impulse Type Display variable

Description Status message about the zero pulse
O.K.: Zero impulse correct
Missing: Zero impulse not present
Acceleration Type Display variable

Description This value forms the calculation basis for the running up
automatic.
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4.6 Register control parameters
Review Here the preset values (presets) for the register control behaviour is shown.
Depending on the control mode the settings for the length register control and
the side register control are displayed.
This screen is conceived as register control screen. The input mode is protected
by a password and inputs may only be undertaken by ELTROMAT service
personnel.
Figure 32: Register con-

trol parameter "Offset"
Figure 33: Register

control parameters
"Gravure"
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Figure 34: Register pa-
rameter "Gravure PIV"
resp. "PIVi"
Screen contents The register control parameters are shown separately in a table form. For each
control (length, side, PIV) three predefined parameter records are provided,
belonging to either gravure-, offset- or PIV-characteristics.
The selection of one of these records is made in the "Register control set-up"
screen (refer to chapter 4.5). For each register only one parameter record is
active.
Further information on permitted keys see chapter 4.3. keyboard legend.

(display and input mode)
Dependent upon the area of application of the DRC 200-system a choice can be
made between four register control behaviours:
On the one hand the register control can be operated with an offset behaviour
or on the other hand as a gravure print register control.
As a third possibility a combination of gravure- and PIV- control can be chosen.
In thus mode one control works as a normal gravure-control, the other serves
to control a PIV-gear system. A PIV-gear system is a continuously adjustable
gear, that transmits torques without loss of power. Special parameters are
required to control this type of gear (see figure 34).
As the fourth possibility for the control mode the "Gravure/PIVi" setting can be
chosen. This mode is similar to the third mode, where the PIV-control is based
on an integral behaviour. The PIV parameter records however do not differ.
For these four basic register control properties the parameter "Register control"
is set to one of these four possibilities in the "Service set-up" screen. Dependent
upon this the corresponding values are masked in the "Register control
parameter" screen. Based on the following illustrations the difference between
offset, gravure and gravure/PIV printing parameters can be clearly seen.
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Only a brief description of the individual parameters is made, because in this
register control screen no changes have to be made under normal conditions
All in this operation mode permitted keyboard functions and their meaning are
described in chapter 4.3.
Brief description of the individual register control parameters

Offset parameter Amplification: permissible value range: 1...60000
Dead zone: permissible value range: 1...20 [1/100 mm]
Time const. low pass: permissible value range: 1...33
Web length: permissible value range: 1...65 [m]
Doubling cycles: permissible value range: 1...20 [rev.]
Measuring cycle: permissible value range: 1...20 [rev.]
Gravure parameter Feedback constant: permissible value range: 0...32767

Feedback amplification: permissible value range: 0...32767
Hysteresis: permissible value range: 1...10 [1/100 mm]
D-portion: permissible value range: 0...32767
Gravure/PIV-Parameter
Gravure Feedback constant: permissible value range: 0...32767
Feedback amplification: permissible value range: 0...32767
Hysteresis: permissible value range: 1...10 [1/100 mm]
D-portion: permissible value range: 0...32767
PIV Switching level: permissible value range: 1...99 [rev.]

Switching period: permissible value range: 2...10000 [50 ms]
Dead band permissible value range: 1...50 [1/100 mm]
Dead period permissible value range: 1...99 [rev.]
If the value input for the listed parameters is gone below or exceeded with invalid
values, the message appears in the base line "— Entered value too low ! —" or
" — Entered value too high ! —". Subsequently the parameter concerned is set
to the permissible minimum or maximum value.
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4.7 Service set-up
Review In this screen the system parameters are listed which contain hardware
coupling, display settings and direction definitions. This screen has been
conceived as a setting screen for the commissioning (by ELTROMAT service
personnel) and as a control screen, i.e. in normal operation of the system this
is a pure display screen, not allowing any changes to be made.
Figure 35:
Service set-up
Screen contents This screen contains the important parameters for the installation of the system.
At the top of screen the serial number appears of the software used in the unit.
This number is important in the event of any questions intended for ELTROMAT.
Further information, to permitted keys in this operation mode, are shown in

chapter 4.3.
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Brief description of the individual service parameters
Language Type Switch variable
Description Switching over the language German/English/French.
After switching over to another language and leaving the
service screen the system makes a warm start, the new
masks and texts are created.
Digitizer Type Switch variable

Description Switch over the digitizer divider to one of the following
division ratios.
1:1, 2:1, 3:1, 4:1, 5:1, 6:1.
Digitizer direction Type Switch variable

Description A/B, B/A Switch over the count direction of the gate
formation. Switching over is necessary if the displayed
variable "Rotational direction" in the "Register control
set-up" screen is on "reverse".
Digitizer clock Type Switch variable

Description Switching over the gate formation between direct coupling
of the digitizer to the printing cylinder (format) and
coupling the digitizer to one cylinder the circumference
(mm) remains constant.
Digitizer resolution Type Numerical variable

Description The number of digitizer pulses (if necessary, following
pulse quadrupling) per format length. Normal setting with
a digitizer with 250 pulses/track is 1000. If the digitizer
clock is configured to "mm", the amount of web travel
between two consecutive encoder pulses must be entered.
The input is effected in 1/1000 mm so that e.g. for a
millimeter clock the input of 1000 is required.
Value range 100 ... 9999
Digitizer mode Type Switch variable

Track A+B: Digitizer with separate tracks A and B (track A+B, pulse
quadrupling).
Clock+Dir: One track supplies the clock, the other the direction signal
The operating mode mentioned last is to be aimed for when operating with
millimetre steps and the Web-Cyl measuring method, because in this case the
cylinder pulse jumps less.
In the mode "Clock+Dir" the jumper J4 has to separated on the REGBAS

board! In the mode "Trace A+B" it must be connected!
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Sensing head Type Switch variable
Description SH2 DGC-/DRC sensing head
SH2-E Special DGC-/DRC sensing head
SH2-K Correlation sensing head
Output Type Display variable

Description Display of output card available in the system set:
Slo-Syn: Output card REG-ELR for Slo-Syn motors.
Step-M: Output card REG-STEP for selecting the step motors.
Analogue: Output card REG-INS for selecting the servo drive.
AnaIns: Output card REG-INS for selecting the analogue insetter.
In the screen "Output parameters" the screen matching this setting is automati-
cally displayed.
Control Type Switch variable

Description Selection of the register control method (register control
core):
Gravure print: Gravure printing register control behaviour.
Offset: Offset register control behaviour.
Grv / PIV: One control with gravure characteristic, the other one with
PIV characteristic (for controlling the gear system)
Grv / PIVi: One control with gravure characteristic, the other one with
integral PIV characteristic (for controlling the gear sys-
tem)
Insetter: The side register is switched off completely. Additional
the level is displayed in the main menu. With this switch-
ing variable the register control screen is switched
automatically. The PIV- and the PIVi- characteristic
don' t differ with regard to the register parameter screen.
Format unit Type Numerical variable

Description This variable indicates the scaling of the cylinder
circumference in (n * 1/100 mm). The display variable
"Format (mm)" indicates the cylinder circumference
calculated with this factor
Cyl-division Type Numerical variable

Description Size of the cylinder division in teeth.
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Error limit Type Numerical variable
Description Internal error limitation of the control kernel (in 1/100mm).
It is adjusted in 1/100 mm an will guarantee that the
register error seen by the register control will not be bigger
than chosen limit. This limit will not have any influence on
the register error display, recorder output and waste
control. This prevents by big register errors an
overregulation of the insetter. If the error limit chosen is
"0" there will be no boundary. This value have to be set if
an error limit is not useful. (normal register control,
insetter without limitation) !
Value range 0....1000
Display Type Switch variable

Description This variable serves for scaling the units of the register
cross display in the "Menu screen with register control
display". Each division of the axis cross can be selected
with 1/10 mm, 5/10 mm and 1 mm as scaling.
- delay Type Numerical variable

Description Display settling for the register display. Small value
> increased settling, big value > small settling
(with 32767 direct display).
Value range 1000 ... 32767
Edge No. Type Switch variable

Description Function selection of the error message "malfunction
pulses".
OFF: Malfunction pulses on C1 and/or C2 do not trigger an
alarm
ON: Malfunction pulses on C1 and/or C2 only trigger an alarm
when they have occurred with 3 measurements following
one after the other.
direct: Malfunction pulses on C1 and/or C2 immediately trigger
an alarm
M.b.g. Type Switch variable

Description Selection of the error message functions "mark on gate
edge".
OFF: "Mark on gate edge" on C1 and/or C2 do not trigger an
alarm.
ON: "Mark on gate edge" C1 and/or C2 only trigger an alarm
when they have occurred with 3 measurements following
one after the other.
direct: "Mark on gate edge" C1 and/or C2 immediately trigger an
alarm.
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NV keys Type Switch variable
Description Allocation of nominal value keys and directions
+L /+S: Normal (L+ above, S+ right)
- L /+S: Side direction exchanged (L+ below, S+ right)
+L /-S: Side direction exchanged (L+ above, S+ left)
- L /-S: Length and side direction exchanged (L+ below, S+ left)
MotOut Type Switch variable

Description Allocation of the motor directions to the adjustment keys
and the register control commands (during installation
initially set to +L/+S).
+L / +S: Normal (L+ above, S+ right)
-L / +S: Length direction exchanged (L+ below, S+ right)
+L / -S: Side direction exchanged (L+ above, S+ left)
-L / -S: Length and side direction exchanged (L+ above, S+ left)
JmpErr. Type Switch variable

Description Release of the jump error function.
ON: The jump error recognition responds if the register error
of one measurement to the next amounts to 150% of the
maximum possible adjustment, however, at least 0.5 mm.
OFF: It then blocks the register control for the duration of a
measurement. However, no alarm is triggered.
MoWC Type Switch variable

Description "Measuring only web-cylinder" blocks the operating mode
switch in the "Register control set-up" screen, so that
work is only possible in Web-Cyl mode. If the MoWC
switch is switched to "ON", the operating mode switch
must be changed once prior to being clamped to "Web-
Cyl".
Refer to chapter 4.5 "Register control set-up" and figure 25.
Tacho Type Switch variable

Description This switch determines whether the speed value for the
register control threshold is calculated from the digitizer or
via a tachometer voltage.
OFF: Speed of digitizer
ON: Speed of tachometer input
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If the speed is measured via the tachometer input, the
display indicates the measured value in m/min (max. 255)
at the right next to the tachometer switch. This display
serves for comparing the tachometer inputs for actual
machine speed ("0" is displayed with the tachometer
switched off). The speed display in "Menu screen with
register control display" and in the oscilloscope are always
taken from the digitizer!
LSi Type Switch variable

Description Using the LSi switch in "ON" position, the automatic
setting and the motor commands of the side register
control are blocked. It can then only be used as a display
unit (in the menu screen with register control display).
With LSi = "ON" the "AUTO/MANU" display of the side
register control in the main screen is masked out.
Sync Type Switch variable

MANU: The zero pulse is ignored. The gate formation operates
freely. The display "zero pulse" in the "Register control
set-up" screen indicates "Missing".
AUTO: With each zero pulse arriving the gate formation is reset to
zero. If the zero pulse does not arrive, the system counts
to the value "resolution -1" and the zero pulse display in
the "Register control set-up" screen switches to "miss-
ing".
Using this key combination, actuated in the "Oscilloscope"
screen a synchronization cycle can be triggered, whilst the
gate formation is synchronized to the mean value of the
next four zero pulses. Following this it runs freely again.
This operating mode is to be recommended when the zero
pulse supplied by the machine is not stable enough.
Waste Type Switch variable

Description Separate control of the waste outputs for the length and
side register control.
OFF: Waste output is not active
L: Waste output will be activated if the tolerance limit is exceeded
and the register control is set to "AUTO".
LM: Waste output will be activated if the tolerance limit is exceeded
and the register control is set to "AUTO" or the register control
is set to "MANU" (MANU = output always active)
LA: Waste output will be activated if the tolerance limit is exceeded
and the register control is set to "AUTO" or if one of the four
alarm messages "mark 1 missing, mark 2 missing, malfunction
pulse, mark of gate edge" is displayed.
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LMA: Waste output will be activated if the tolerance limit is
exceeded and the register control is set to "AUTO" or to
"MANU" (MANU = output always active) or if one of the
four alarm messages "mark 1 missing, mark 2 missing,
malfunction pulse, mark of gate edge" is displayed.
LAG: Waste output will be activated if the tolerance limit is
exceeded and register control is set to "AUTO" or if one
of the messages "mark 1 missing, mark 2 missing,
malfunction pulse, mark of gate edge, speed, acceleration"
is displayed.
LMAG: Waste output will be activated if the tolerance limit is
exceeded and the register control is set to "AUTO" or the
register control is set to "MANU" (MANU = output
always active) or if one of the six alarm messages "mark 1
missing, mark 2 missing, malfunction pulse, mark of gate
edge, speed, acceleration" is displayed.
DAC A Type Switching variable with 2 parameters

Description 1 C1/L, C2/S, RAM
Description 2 Meas. direct, meas. delayed, actual direct, actual delayed,
int. feedback, motor command, length mark, tachometer
DAC B Type Switching variable with 2 parameters

Description 1 C1/L, C2/S, RAM
Description 2 Meas. direct, meas. delayed, actual direct, actual delayed,
int. feedback, motor command, length mark, tachometer
Scal. A 1V/mm => 10mV/Digit, 3V/mm => 30mV/Digit, Adjust 1..100

Scal. B 1V/mm => 10mV/Digit, 3V/mm => 30mV/Digit, Adjust 1..100
For these scaling values result the following output voltages:

motor command: +/-100: with 1V/mm => +/-1V, with 3V/mm => +/-3V
web speed: 0 ... 600: with 1V/mm => 0 ... 6V
Digitizer limit The digitizer limit shown here is dependent upon the set digitizer resolution:
Digitizer limit = Digitizer resolution - 1.
Format Display of the format length in the units set under "display".
Mark length (1/100)

channel 1 and channel 2 These two display variables indicate the measured mark lengths in 1/100
millimetres.
Status Various state messages of the system are displayed here. The complete list of all
state messages can be found in appendix B.
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4.8 Output parameters
Review Here the decisive parameters for the setting elements used on the machine
concerned are set. There are three possible output configurations, which can be
et by equipping the system with the appropriate hardware modules.
Output circuits • Control of analogue servo motors
• Control of step motors
• Switching electronic load relays (ELR’s)
For the first both controls separate parameter masks are available, for the ELR’s
no screen is provided.
In the following identical points are described for both screens, each of the
specific parameters are explained in the sections 4.8.1 to 4.8.3.
Figure 36: Analogue

output set-up
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Figure 37:
Stepmotor set-up
4.8.1 Analogue motors

Screen contents The analogue output screen contains the table listing of the motor parameters
for the selection of analogue servo motors. Two separate parameter records are
available, one of which is for the length register, the other for the side register.
Motor data Type Numerical variable
Description This variable indicates the voltage to be applied to the input
of the servo power stage, so that the servo motor runs with
a rotational speed of 1000 rpm.
Value range 1 ... 60000 mV/1000 Rpm
Gear ratio Type Numerical variable

Description This factor indicates the print offset when the motor
undertakes one revolution.
Value range 1 ... 60000 µm/rev.
Speed 1 Type Numerical variable

Description Input of the adjustment speed for the register control
operation and for slow manual adjustment.
Value range 1...10000µm/s
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Description Input of the adjustment speed for a fast manual adjustment.
Value range 1..10000µm/s
Output voltage 1 Type Display variable

Description Calculated output voltage for adjustment speed 1.
Value range 0 ... 10000 mV
Output voltage 2 Type Display variable

Description Calculated output voltage for adjustment speed 2.
Value range 0 ... 10000 mV
From the entered values for motor factor, gearing factor and the individual
adjustment speeds, the system automatically calculates the required output
voltage, required for servo motors accessing.
Auto-Boost Type Switch variable

ON: Once the set response time has elapsed (see below) the
system switches automatically from slow to fast adjust-
ment speed with external manual adjustment.
OFF: For external manual adjustment only slow adjustment
speed is used.
Reaction time Type Numerical variable

Description Setting the response time for the auto-boost function. If
the response time is zero, the adjustment is made
immediately at high speed.
Value range 0 ... 10 s
4.8.2 Step motors

Screen contents The step motor parameter screen contains the table listing of the motor
parameters for the selection of step motors. Two separate parameter records are
present, one of which is for the length register and the other for the side register.
Start-/Stop frequency Type Numerical variable
Description When accelerating or decelerating the area is run through
up to the start/stop frequency without ramp (i.e. in leaps).
Value range 20 ... 10000 Hz
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Acceleration Type Numerical variable
Description This parameter indicates the steepness of the acceleration
or deceleration ramp for frequencies above the start/stop
frequency.
Value range 10 ... 9999 Hz/ms
Timeout Type Numerical variable

Description Input of the waiting time, which lies between a rotational
direction change of the motor.
Value range 10 ... 1000 ms
Motor data Type Numerical variable

Description The motor factor indicates how many steps (= input pulses
of the step motor end stage) the step motor requires for one
rotation of the motor shaft (dependent upon the motor
type and upon semi- or full step operation).
Value range 10 ... 9999 Step/rev.
Gear ratio Type Numerical variable

Description This factor indicates how far the print offsets when the
motor undertakes one revolution.
Value range 10 ... 9999 µm/rev.

Description Input of the adjustment speed for register control opera-
tion and for slow manual adjustment.
Value range 1 ... 10000 µm/s

Description Input of the adjustment speed for fast manual adjustment.
Value range 1 ... 10000 µm/s
Output frequency 1 Type Display variable

Description Calculated output frequency for register control operation
and for slow adjustment.
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Output frequency 2 Type Display variable
Description Calculated output frequency for fast adjustment.
The system automatically calculates the individually required output frequency

from the entered values for motor factor, gearing factor and the individual
adjustment speed, with which the step motors are selected.
Auto-Boost Type Switch variable

ON: Once the set response time has elapsed (see below) the
system switches automatically from slow to fast adjust-
ment speed with external manual adjustment.
OFF: For external manual adjustment only one slow adjustment
speed is operated.
Reaction time Type Numerical variable

Description Setting the response time for the Auto-Boost function. If
the response time is zero, the adjustment are made
immediately at a higher adjustment speed.
Value range 0 ... 10 s
4.8.3 ELR / Single phase synchronous motors

As mentioned above, for the selection of the electronic load relays (ELR) or
single phase synchronous (Slo-Syn) no output parameter screen exist. This type
of output stage of the DRC 200 -system permits a pure switching on or off of
the outputs, for which no special parameters are to be set.
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4.9 Insetter parameters
Review Here the insetter parameters are listed. This screen has been conceived as a
setting screen for the commissioning (by ELTROMAT service personnel) and
as a control screen, i.e. in normal operation of the system this is a pure display
screen, not allowing any changes to be made.
Figure 38:
Insetter parameters
Screen contents This screen contains the important parameters for the installation of the insetter.
Settings for hardware and register control components for the insetter mode are
undertaken here.
Further information on permitted keys see chapter 4.3. "Keyboard legend"
(display and input mode).
Brief description of the individual insetter parameters

Level cont. infl. Type Numerical variable
Description Influence of the level control to the base revolution.
Value range 0 .. 1000
P cont. infl. Type Numerical variable

Description Influence of the register error to the adjustment of the
servo motor.
Value range 0...1000
Motor comm. infl. Type Numerical variable

Description Influence of the momentary motor commands to the
adjustment of the servo motor.
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Manual com. slow / fast Type Numerical variable
Description Influence of the manual command to the adjustment of the
servo motor.
Dead band P control Type Numerical variable

Description If the register deviation is within the dead band, there will
be no influence from the P-controller to the servo.
Div. ratio level c. Type Numerical variable

Description Defines the influence of the register deviation to the level
control adjustment speed .0 = No influence, 99= Maximum
influence.
Value range 0...99
Cutoff pt level control Type Numerical variable

Description If the register deviation is bigger than the adjusted value,
the adjustment speed of the level controller is no longer
increased, but stays constant.
Measuring gate Type Numerical variable

Description Defines the width of the measuring gate , inwith the p-
control is operating. The measuring gate is just behind the
actual gate.
Time const P-LP Type Numerical variable

Description Shows the RC-constant of the PT-1 section in P-con-
troller.
Time const level LP Type Numerical variable

Description Shows the RC-constant of the PT-1 section preceding the
level control.
Value range 1...60
Servo zero point (mv) Type Numerical variable

Description Shows the line speed reference at the servo motor.
Value range +/-0...6000
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Servo motor Type Switch variable
Description (On / Off)
Stops the influence of P-controller and momen-
tary motor commands. Only the base revolution and the
level are controlling the motor.
Tach direction Type Switch variable

Description (forward / backward)
Defines tacho direction, toggle if needed.
Algorithm Type Switch variable

Description MUST BE SWITCHED TO STANDARD!
Level direct. Type Switch variable

invert: Inverts the direction of the register control niveau
normal:
Level display Type Switch variable

invert: Inverts the sign of the niveau and the direction of the
manual adjustment commands
normal:
Display parameters
Level cont share Actual portion of niveau control at servo motor revolution. No input field.
P-cont. share Actual portion of proportional control at servo motor revolution. No Input field.
Motor comm. shar Actual portion of momentary motor commands at servo motor revolution.
Register error Displays the actual register error (congruent to the display "act" in the main
menu.).
Level Displays the actual level (congruent to display "Lev" in Main menu.)
Actual format Number of the actual format. This value is send via four control lines to the DRC
200-system (in BCD code). Ten selectable formats. No input field.
Format values 1...10 The right base revolution to match the actual format is entered. Value range from
0 (minimal base revolution) to 999 (maximal base revolution).
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5.0 Start up and adjustment without insetter option
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5.1 Start up and adjustment with insetter option
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6.0 Error messages and counter messages (trouble shooting)
Error Init gate generation
Reason New initialising demanded by micro controller.
Counter measure None, because of fatal error.
Error Wrong code number

Reason Input of a wrong code number.
Counter measure Repeat input with the correct code number.
Inquiry Sure ? (F1=Yes Else=No)

Reason Safety question e.g. before putting digitizer offset to zero.
Counter measure F1-key = positive confirmation, other key termination.
Error Only numbers allowed

Reason Only digits are allowed.
Counter measure Repeat input correctly.
Error Entered value too low

Reason Input of an numerical value is too low.
Counter measure Repeat input with allowed value.
Error Entered value too high

Reason Input of an numerical value is too high.
Counter measure Repeat input with allowed value.
Error Gate position limited

Reason Appears upon input of a cylinder dimension, which is too small for the gate
position in systems with millimetres clock (cylinder dimension is coupled with
the digitizer resolution).
Counter measure None, the gate position is limited automatically to the allowed maximum value
(digitizer resolution - 1).
Error Only HEX-numbers allowed

Reason If in screen "service setup" at parameter ‘DAC-source’ the input was not done
in HEX-format.
Counter measure Repeat input in HEX-format.
Error Output voltage too high

Reason The parameters in the "Analogue output"-screen are adjusted in a way, that the
10V output voltage is exceeded.
Counter measure Check and correct the parameter settings (the maximum control voltage for
servos is 10,00V !).
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Error No function while machine is running
Reason Attempt to reset digitizer during machine is not in standstill.
Counter measure Stop machine or only move slowly (min. speed limit) and repeat reset.
Error Invalid key

Reason An invalid key has been pressed.
Counter measure Check the input and repeat correctly.
Error Cylinder circumference value too high

Reason The format unit in the "Service set-up-screen is too big. The calculated cylinder
circumference exceeds the allowed max. value.
Counter measure Check the input and repeat correctly.
Error Rounding error occurred! Please check input

Reason Refers to systems with millimeter clock. A cylinder circumference or a digitizer
resolution has been entered in, of which the digitizer resolution cannot be
calculated without balance. If it is carried on with this adjustment, the gate can
eventually not be stable and a drift occurs.
Counter measure Check the input of the cylinder circumference and the digitizer resolution and
repeat correctly.
Error Function not available

Reason An invalid function key was pressed.
Counter measure Check input and repeat correctly.
Error No toggle function available

Reason Attempt to toggle a numerical variable.
Counter measure On a numerical input field it is only possible to put in digits. A change-over is only
possible with switch variables. Check the input and repeat correctly.
Error Illegal setting

Reason It was tried to dial a locked switch condition.
Counter measure Cancel the blocking by appropriate parameter setting and repeat the input.
Error Gate transfer not possible while machine is running

Reason Attempt of taking-over gate during the machine is in operation.
Counter measure Stop the machine or only run slowly (min. speed limit !) and repeat gate taking
over.
Error ALARM ! Centring not possible

Reason Alarm after gate centring. Because of the centering an error condition occurred
(e.g. register mark is not placed within the gate).
Counter measure None, the system resets the centering automatically.
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Error Not possible at this state of ALARM
Reason An alarm is preset. Within this state a centering is not possible.
Counter measure Elimination of the alarm condition, then repeat the centering
Error AUTOMATIC ! Transfer not possible

Reason The taking over of a nominal value is not possible when the register control
system is in "automatic"-mode.
Counter measure Switch the corresponding register control to "manual" and repeat the takeover.
Error ALARM ! Transfer not possible

Reason The taking over of a nominal value is not possible in an alarm state.
Counter measure Elimination of the alarm state and repeat the taking-over.
Error Not possible in automatic mode

Reason Attempt of a centering during the system is in automatic mode and the system
is operated in the "web/cylinder"-mode (nominal values would be changed).
Counter measure First switch the register control system to "manual"-mode and repeat the
centering.
Error Gate width limited
Reason Input of such a small cylinder circumference, that the gate width ow might be
bigger than 1/4 of the cylinder circumference.
Counter measure None, the system sets the gate width automatically to the maximum value of
1/4 of the cylinder circumference.
Error Keyboard interface not ready

Reason Communication with the keyboard is disturbed.
Counter measure None, fatal error message of the operating software (eventually it might help to
switch the system off and turn it on again).
Error Register control is not switched on

Reason Attempt to switch an off-switched register control to "automatic" (e.g. if only
a length register control is active and the side register control should be switched
to "automatic").
Counter measure The corresponding register control first has to be switched on (correct choosing
of measurement mode) before it can be switched to "automatic".
Error Function is not available in Web-Cyl mode

Reason Attempt to switch on the automatic gate tracking in Web-Cyl mode.
Counter measure None. In Web-Cyl mode the automatic gate tracking is not possible and is in fact
of this locked by the system.
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Appendix A1 Side register measurement
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Appendix A2 Error display
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Appendix A3 Register error
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Appendix B Status messages of the DRC 200 (in "Service set-up" screen)
A1 overflow gate measurement

A2 overflow at 2. edge C2 -measurement
A6 Disturbance C1
A7 Disturbance C2
A8 Speed limit exceeded
B1 1. edge C1 to close to gate edge
B5 Mark C1 missing
B6 Mark C2 missing
B7 Acceleration limit exceeded
B8 —
C1 Jump error length
C2 Jump error side
C3 Mark C1 to short
C4 Mark C2 to short
C5 1. edge C1 -measurement not started
D1 Gate measurement is not working
D2 —
D3 —
D4 —
D5 —
D6 —
D7 —
D8 —
E1 Overflow Osko-RAM
E2 No date in Osko-RAM
E3 Osko-RAM is not optimal used
E4 Track A / Clock
E5 Track B / direction
E6 Write error EEPROM
E7 Read error EEPROM during operation
E8 Read error EEPROM after RESET
F1 —
F2 —
F3 —
F4 —
F5 —
F6 —
F7 —
F8 —
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Appendix C
Assignment of DIP-switches on CPU- and base board
CPU-board: ON OFF
1 Auto-Boot
(only with Boot-Software)
2 n.c.
3 n.c.
4 n.c.
5 n.c.
6 6:OFF 7:OFF 8:OFF > REG-ELR-output
7 output stage: 6: ON 7:OFF 8:OFF > REG-STEP-output
8 6:OFF 7: ON 8:OFF > REG-INS.0-output
6: ON 7: ON 8:OFF > REG-INS.0 for insetter
9 Watch dog enabled Watch dog disabled
10 n.c.
Basis-board: ON OFF
1 INT 3 disabled INT 3 enabled

2 diagnostic mode enabled diagnostic mode disabled
(only with test outputs gate software=ON)
3 test pins on scope sensing head signals on scope
(only with test outputs gate software=ON)
4 new gravure printing kernel old gravure printing kernel
5 n.c.
6 n.c.
7 n.c.
8 diagnostic mode customer mode
Assignment of test sockets and LEDs on base board
So1.1 Ground LED41.1 (red) wrong DG direction

So1.2 Chart recorder output A LED41.2 (red) Zero pulse missing
So2.1 Ground LED42.1 (red) Watch dog disabled
So2.2 Chart recorder output B LED42.2 (red) diagnostic mode ena-
bled
So3.1 Test pin 10 LED43.1 (red) EEPROM reading error
So3.2 Gate LED43.2 (red) EEPROM writing error
So4.1 Zero pulse LED44.1 (red) n.c.
So4.2 Tacho volt. a. adjustment poti LED44.2 (red) n.c.
LED45.1 (green) Gate tracking active
LED45.2 (green) gate interrupt occured
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Appendix D
DIP-switches on board of the DRC 200-INS.0
Key ON OFF
1 Diagnose: DA converter DA converter active

not activated (serving mode)
2
3 free
4 free
5 free
6 free
7 free
8 free
LED-display at the frontside of the DRC 200-INS.0

top left side Measurement gate active
top right side DA converter selected (glows if in use)
bottom left side Manual motor command forward
bottom right side Manual motor command backwards
Adjustment of the measurement pins at the frontside of the

DRC 200 INS.0
Voltage range -10V...........+10V (Ground is at the left side)
SO1 (down) Standardized tacho voltage
SO2 Base revolution influence
SO3 Register level influence
SO4 Infl. manual commands, manual motor command, P-register
SO5 (up) Servo control voltage
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eltromat

© eltromat GmbH 07/95

Herforder Straße 249 - 251

Warnings and safety instructions ____________________________________________________ 4

1.0 Introduction __________________________________________________________________ 6

2.0 Theoretical bases _______________________________________________________________ 8

3.0 Additional hardware components of the register control _____________________________ 16

4.0 Menu structure and operating of the DRC 200 system_______________________________ 18

eltromat Page 2 DRC_200_GB V1.11

4.4 Oscilloscope _________________________________________________________ 31

4.5 Register control set-up _________________________________________________ 40

4.6 Register control parameters _____________________________________________ 46

4.7 Service set-up ____________________________________________________ 49

4.8 Output parameters _________________________________________________ 56

4.9 Insetter parameters ________________________________________________ 61

5.0 Start up and adjustment without insetter option ___________________________________ 64

6.0 Error messages and counter messages (trouble shooting) ____________________________ 66

Qualified personnel • Only allow qualified personnel to operate the system.

Further on error messages and appropriate corrective measures are explained.

In two more chapters theoretical backgrounds and additional hardware compo-

© Copyright ELTROMAT GmbH, 1995

This documentation is protected by copyright and must neither be copied or

Bold italic type

Key symbols (e.g. )

Fig. 2: Printing marks

2.2.1 Web-web method (Web-Web)

2.2.2 Web-web method with side register (Web-Web-S)

2.2.4 Web-cylinder method with side register (Web-Cyl-A)

2.3 Register adjustment

2.3.1 Register roller (pivoting or ruling rollers)

2.3.2 Differential gearing

2.4.2 Format adaptation and instantaneous corrections via the

In figure 3, the DRC 200-system is controlling a servomotor connected with the

2.4.4 Format adaptation via pull & break, instantaneous corr-

2.4.2 Format adaptation and instantaneous corrections via the

In figure 3, the DRC 200-system is controlling a servomotor connected with the

2.4.7 Control process of the insetter

This sensing method developed by ELTROMAT offers the considerable advan-

eltromat Page 17 DRC_200_GB V1.11

Fig. 8: Main menu

4.0.1 Operating elements

The principle function of the insetter is described in chapter 2.4

4.0.3 Types of variables

There are three variables types, of which two can be changed.

Fig. 11: Main menu with

Register cross with

Tolerance border dis-

Actual and nominal dis-

Display of the register

Register control display

Register error display

Tolerance border display

Actual and nominal dis-

Display of the register

When "ALARM" is displayed as a register control status no further register

Speed Reason Printing speed goes below the minimum speed.

Acceleration Reason Calculated acceleration exceeds upper limit.

Mark 1 missing Reason • Mark level of mark 1 is recognized as too low.

Mark 2 missing Reason • Mark level of mark 2 is recognized as too low.