SmartScan Installation Guide

1- Mount the electrical enclosure so the door can be opened to access the electronics.

2- Mount the encoder assembly. This should be mounted so that the encoder wheel is on
an idler roll. There is an arrow on the encoder wheel, and the arrow must turn in the
correct direction when the web runs for the system to work. It is recommended to
mount the encoder assembly as close as possible to the camera assembly, and have it
run on the surface of the web. The encoder bracket has a spring tension adjustment in
it, adjust the downward pressure so the encoder wheel turns without slipping on the
web.
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3- Mount the monitor.

4- Mount the camera assembly so the arrow on the head by the cable connections, points
in the direction the web will run through the camera. Position the camera head
assembly so there is a 7 to 15 degree wrap angle on the small entry / exit idlers rolls on
the camera assembly. These small idler rolls are only for stabilizing the edges of the web
as it goes by the camera, and maintain a constant distance between the camera and
web. It is important that the assembly is not mounted past the 180 degree line, or
upside down. Once the camera assembly is mounted in place, using a machinist level,
take a reading of one of the other idler rolls on the machine, then adjust the entry / exit
idler rolls on the camera head to match that reading by raising or lowering one side of
the camera assembly.

Note: It is very important that when the web runs, the small entry / exit idler rolls on the
camera assembly turn, and there is not a baggy web edge. A baggy web edge will
cause the system to generate false defects.
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5- Make all the cable connections:

Monitor – 3 cables
(1) HDMI cable for video
(1) Silver USB cable for mouse functions on touchscreen
(1) AC Power supply cable / transformer for the monitor.

Camera Assembly – 3 cables

Encoder – 1 cable
(1) Cable with silver barrel connector for encoder pulses

6- Power the system up. Make sure the backlight in the camera assembly is clean, use
compressed air to blow it out. With the inspection system status reading “Idle”, press
the P2 icon, and enter in the password 2435. Jog the web through the machine. Have a
look at the mounting parameter display. It should be green and have a reading of 0.0 +/-
0.05 degrees. If it is red and reading a higher value, then move either the gear or
operator side of the camera assembly forwards or backwards in web direction until the
display is green and displays a value close to 0.0 If the value does not change when you
move the camera assembly, then check the backlight for dirt of debris on it. Remove the
access door on the camera assembly to gain access to the inside of the housing (This is
the illuminated plate on the operator side held in place with 4 screws).

7- If an interface is required, then determine whether the machine is going to handle the
placement of defects, or the SmartScan inspection system will handle the placement of defects.
The SmartScan signal output is a PLC output of 24 VDC that can be configured for pulsed or
static output. Generally if the machine is handling the defect placement, then a signal is
generated for each defect found and sent to the machine for queuing and placement. This
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interface requires two connections to be made. One connection from PLC digital output 1 in the
SmartScan cabinet to the input for defect found on the machine, and one connection from the
SmartScan 0 Vdc to the machines 0 Vdc. In the P3 menu (password 2435), select signals, then
pulsed signal in “signal options”. Next, enter in the distance (in mm) from the camera assembly
to the placement area (plus the defect found offset value) in the parameter “ camera to stop
distance”. Ie. If the distance from the camera to the placement area is 5000 mm, and the defect
found offset is 1000 mm, then the value to be entered into the parameter camera to stop
distance is 6000 mm

Note: Make sure to press the send button after changing any values to transfer the new
values to the PLC.
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8- If the SmartScan is handling the placement of the defects, then we need to tie into the
stop and jog function of the machine. The defect found output on PLC digital output 1
will now be our Jog signal output, and the digital output 2 will be our stop signal. A
connection from the SmartScan 0 Vdc to the machine 0 Vdc is also required. In the P3
menu under signal option, select “Static signals”. Measure the distance from the camera
assembly to the placement area, and enter this value (in mm) in the “camera to stop
distance “ parameter. Adjust the defect found offset value so that the machine goes into
jog speed mode and stops at the placement area without overshooting.

Note: Make sure to press the send button after changing any values to transfer the new
value to the PLC.

9- The system should now be ready for testing. Refer to the main operator manual on how
to set up a job for inspection, and more detail on the adjustments described above.
10- To test the interface connection, web up the rewinder, make sure that the vison input
option is enabled on the rewinder (if so equipped), then go into the P2 menu of the
SmartScan system, and disable all inspection options except for flag detection. Set the
rewinder speed to about 75 to 100 FPM, then start the rewinder. Press the “Learn”
button on the SmartScan system, after it has learned the web, press the inspect button.
Apply a flag to the operator side of the web before the camera system. The system
should detect the flag and go through it’s defect placement cycle (at a point the
rewinder will slow down to jog speed, then stop when the defect has reached the
placement distance you have entered). Verify that the flag is now at the position where
you want all the defects placed. If not, then adjust the camera to stop distance value if
the SmartScan system is placing defects, or the defect placement distance in the
rewinder settings if the rewinder is handling the defect placement. Repeat the test
several times to make sure it places the defect in the same spot each time, then
increase the speed and see if the placement is okay, or it overshoots. If the SmartScan is
placing the defects, then you can adjust the defect found offset value to change when
jog speed is initiated. If the rewinder is handling the defect placement, then you will
have to consult the rewind manufacturer on how to make this adjustment.

Note: The SmartScan system can inspect the web up to a speed of 820 feet per minute (250
meters per minute). There needs to be enough web distance between the camera and
placement area for the drive system to ramp down to jog speed before the stop signal
is issued. If there is not enough web distance, then the defect will overshoot the
placement area. The only fix for this is to increase the web distance, reduce the accel /
decel values for the rewind drive, or only run with inspection up to the speed you
have enough web distance for to accurately place the defect.