ARIS SCU5 User manual

SCU5: Controller
Product and User Manual
Firmware Version 3.6

Copyright Information
All of the information herein is the exclusive proprietary property of Roll-2-Roll Technologies LLC, and is
disclosed with the understanding that it will be retained in confidence and will neither be duplicated or
copied in whole or in part nor be used for any purpose other than for which it is disclosed.
Information in this document is believed to be reliable and accurate. However no responsibility is assumed
as a result of its use nor for any inaccuracies, infringement of patent or other rights of third parties resulting
from its use.
The information in this document is subject to change without any notice.
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CONTENTS
INTRODUCTION 6
Web Guiding Application 6
Web Position Sensor 7
Web Guide Controller 7
Guide Mechanism 7
Measurement and Sensing Application 7
Sensor and Web Guide Controller Specification 7
Controller Options 8
Physical Dimensions of SCU5 9
Power Input (Port 1) 10
Switchcraft DC Connector 10
Industrial DIN Rail Power Supply 10
Grounding 10
Sensor Interface 10
Motor Communication (Port 2) 11
Analog Output (Port 2) 12
Industrial Ethernet Interface (Port 3) 12
Opto-Isolated Output (Port 3) 13
SAFETY INSTRUCTIONS 14
Instructions for Use 14
Proper Use 14
Improper Use 14
Static Discharges and Grounding 14
OPERATION AND OPERATOR INTERFACE 15
Main Operator Interface Screen 15
Heartbeat Indicator 15
Web Detected Indicator 16
Web Position Indicator 16
Sensor Orientation Indicator 17
Find Edge Button 17
Automatically find the sensor orientation 17
Enable and disable the sensors 17
Automatic/Manual Icon 18
Servo Center Icon 18
Jog-left/Jog-right Icon 19
Guide Point 20
Guide Point Indicator 20
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Guide Point Offset 20
Guide Point Adjustment 20
Fine Guide Point Adjustment 21
Gross Guide Point Adjustment 21
Reset Guide Point 22
Actuator Position Bar 22
Advanced Settings Menu 24
Operator Settings Screen 25
Operator Sensor Screen 25
Sensor Mode 25
Thresholding Mode 25
Sensor Selection 27
Minimum Contrast Gauge 27
Brightness Gauge 27
Brightness Control 27
Live Processed Image Preview 28
Selected Feature 28
Feature Navigation 28
Teaching 28
Contrast Mode 28
Right edge of a color 29
Edge created by two colors 30
Color of a line 30
Left Edge of a color 31
Operator Width Screen 32
Nominal Width 32
Upper Limit 33
Lower Limit 33
Measured Width 33
One Sensor 33
Two Sensors 33
Teaching 34
Output Type 34
Absolute 34
Error 35
Display Screen 35
Power User Screen 35
Actuator Setting 36
Stroke 36
Pitch 37
Motor Polarity 37
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Servo Center Polarity 37
Speed 37
Acceleration 37
Sensor Setting 38
Automatic Brightness Control 38
Brightness Value 38
Enable/Disable Sensor 38
Sensor Position/Orientation Setting 39
Controller Setting 40
Gain 40
Deadband 40
Reverse Error Polarity 40
Lock on Lost Edge 41
Servo Center 41
Limit Switches 42
Analog Output Setting 42
Output range selection 42
Analog mode 42
Analog setup 43
Password Setting 43
Communication Setting 43
Ethernet 43
DHCP 43
FTP 44
IP 44
Subnet Mask and Gateway 44
MAC address 45
Module Type 45
Network IC Type 45
REMOTE CONTROL AND MONITORING 46
EtherNet/IP Connection Parameters 46
PROFINET Connection Parameters 46
EtherCAT Connection Parameters 46
Controller Output and PLC Input 47
Sensor status and fault registers 47
Sensor 1/Sensor 2 Left Edge 49
Sensor 1/Sensor 2 Right Edge or Contrast 49
Sensor 1/Sensor 2 Coverage 50
Quality Factor Registers 50
Web guide status and fault registers 51
Guide point percentage 52
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Actuator speed percentage 52
Actuator acceleration percentage 52
Sensor 1 Thread Count 52
Sensor 2 Thread Count 52
Sensor 1 /Sensor 2 Web Width 52
Controller Input and PLC Output 54
Sensor Command Register 54
Sensor Brightness Command Register 56
Remote Light Control (RLC) 56
Remote Brightness Limit (RBL) 56
Maximum and Minimum Brightness Limit 56
Sensor 1/Sensor 2 Automatic Brightness Control (S1A and S2A) 57
Sensor 1/Sensor 2 Brightness Override (S1BO and S2BO) 57
Sensor 1/Sensor 2 Brightness Override Value 57
Web guide command register 58
Guide point offset register 59
Actuator speed register 60
Actuator acceleration register 60
COMMISSIONING 61
Sensing and Measurement Application 61
Web Guiding Application 61
Edge Guiding 61
Center Guiding Application 62
Standard Operating Procedure 62
General Maintenance 62
TECHNICAL SUPPORT AND SERVICE 63
Contact information 63
Return shipping instructions 63
REVISION HISTORY 64
Hardware Revision 64
Firmware Revision 65
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INTRODUCTION
This product manual provides information about installation, use and maintenance of SCU5 controller. The
controller includes an operator interface that is used for both measurement and control applications within
converting lines. For installation of the sensor and web guide please refer to the respective product manuals.
The controller is designed for use in indoor industrial and laboratory equipment that process materials in
web form as they move through a converting or raw material manufacturing process.
The controller can be used in closed loop control applications such as web guiding applications for edge,
contrast and center guiding. The controller can also be used for other standalone sensing applications such
as width measurement, thread counting, mark detection, contrast position measurement, gap detection and
the like.
Web Guiding Application
A web guiding system is a fully automatic mechatronic system used to accurately align/steer web materials
within roll-to-roll machines. The web guide is used at critical locations where accurate alignment of web is
necessary. Typical locations include at the unwind section, before process sections, such as before printing,
coating, laminating, slitting, and rewind section. Accurate web guiding will improve productivity by enabling
high speed transport and manufacturing.
There are three main components to a web guiding system:
1. Web position sensor
2. Web Guide Controller
3. Guide mechanism
Fig. 1: Components of a web guiding system
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Web Position Sensor
The web position sensor provides the vision for the control system. The sensor captures the image of the
web position (edge or a contrasting feature on the web) and sends that information to the controller for
further processing.
Web Guide Controller
The controller is the brain for the control system. Based on the image captured by the sensor controller
processes the image and determines the corrective action necessary to accurately align the web material.
The web guide controller encloses the electronic hardware for the sensor processing, operator interface and
the control algorithm for the web guide/actuator.
Guide Mechanism
The web guide mechanism is the muscle for the control system. The guide mechanism actuated by a motor
physically steers the web to the required position based on the command from the controller.
Measurement and Sensing Application
The controller along with an appropriate sensor head can be used for standalone sensing applications such
as edge detection, contrast position detection, width measurement, web centerline position measurement,
thread counting, gap detection, etc. The sensor and the controller perform the same functions, however
further processing is carried out by the controller to provide higher level measurement information.
Sensor and Web Guide Controller Specification
The general specifications of the SCU5 controller are listed below. Depending on the application one of more
of the output options would be available.
Operator Interface
Color touchscreen
Output (Voltage)
± 10 V or 0 to 10 V
Languages
Language independent
Output (Current)
0 to 20 mA or 0 to 10 mA
Motor Driver
Microstepping or servo drive
Connectivity
EtherNet/IP, PROFINET
Motor
Servo or Linear hybrid stepper
Input Supply
24 V DC
Controller Frequency
50 to 200 Hz
Current
5 A
The most basic controller is the SCU5 D which has the operator interface integrated within the controller.
The controller is used for standalone measurement and sensing applications. Analog output of the sensor
measurement is provided so that the controller can be connected to legacy systems (legacy web guide
controllers, servo valves, pneumatic valves, etc.) for closed loop control. The analog output can also be
connected to a PLC for measurement monitoring application. Advanced measurement and sensing
applications can utilize either the EtherNet/IP or PROFINET industrial Ethernet connectivity option.
For a web guide controller, the analog output option is replaced with an RS485 communication option to
drive a web guide actuator driver manufactured by Roll-2-Roll Technologies LLC.
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Controller Options
Following table shows the capabilities of the different controller option
Options
SCU5 D
SCU5 C4(X)D
SCU5 MD
SCU5 MC4(X)D
Input
24 VDC
24 VDC
24 VDC
24 VDC
Application
Sensing
Sensing
Web Guiding
Web Guiding
Analog output
YES
YES
NO
NO
Voltage output options
± 10 V2
± 10 V2
NONE
NONE
Current output
0 to 20 mA3
0 to 20 mA3
NONE
NONE
Motor Controller
YES
YES
Current Consumption
< 2.5 Amps
< 3 Amps
< 5 Amps
< 5 Amps
Controller Frequency
50 - 200 Hz
50 - 200 Hz
50 Hz
50 Hz
Industrial Ethernet
YES
YES
Web browser
dashboard
YES
YES
Remote Control
YES
YES
Diagnostics/Fault Info
YES
YES
Process two sensors
YES
YES
YES
YES
GO/NO GO
YES1
NO
YES1
NO
Standalone System
YES
YES5
YES
YES5
1Two digital 24 V NPN GO/NO GO output are available upon request. This is not a standard.
2can be programmed to be ± 10 V or 0 to 10 V or ± 5 V or 0 to 5 V based on application requirement
3can be programmed to be 0 to 20 mA or 4 to 24 mA or 0 to 10 mA based on application requirements.
4the industrial ethernet has two options C(E) for EtherNet/IP and C(P) for PROFINET
5can be made standalone when not connected to a remote controller (PLC) or when set by remote
controller (PLC)
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Physical Dimensions of SCU5
Fig. 2: SCU5 M Controller Physical Dimensions (All dimensions are in mm); Subject to change without notice.
The SCU5 M controller has the following ports for connections to the sensor, motor driver and other devices.
Fig. 3: SCU5 MD Connector Ports
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Power Input (Port 1)
The SCU5 M operates under 24 VDC (± 5%) power with a maximum current requirement of 5 Amps. The
power is supplied through a Switchcraft DC power connector.
WARNING: Supplying more than 24 VDC would damage the controller permanently.
WARNING: A reverse polarity connection may also damage the controller permanently.
Switchcraft DC Connector
Sealed Switchcraft L712AS power jack port option is available on the SCU5. A mating Switchcraft 761KS12
plug connector or a pre-assembled Switchcraft CARA761KS07984 or a pre-assembled Switchcraft
CA761KS07984 can be used to supply power. For the plug connector the 24 VDC power should be supplied
to the tip/center pin and electronic ground on the sleeve pin. For the pre made cable assembly from
Roll-2-Roll the 24 VDC should be connected to the red cable and the electronic ground connected to the
black cable.
Pin
Signal
Center Pin
+24 V
Sleeve
GND
Industrial DIN Rail Power Supply
Industrial DIN rail mountable power supply such as Mean Well SDR-75-24 can be used to supply 24VDC
power. This is an available purchase option.
Grounding
For safety and for normal operation, the SCU5 M controller, the equipment to which the controller is installed
must be properly grounded. The metal enclosure surface or the mounting screws may be used to properly
ground the controller to the protective earth.
WARNING: Please use all possible options to safely earth ground the controller. Improper grounding may
result in static buildup that can potentially result in malfunction of the controller.
Sensor Interface
Two sensor ports labeled Sensor 1 and Sensor 2 have industry standard 12-pin M12 connectors to connect
the 12-pin connector on the sensor cable. Either sensor ports can be used to connect the sensor(s) and the
controller will automatically recognize the connection.
WARNING: The connectors are keyed and please DO NOT force the connectors. Forcing the connector may
damage the pins and eventually can damage the sensor and or the controller.
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NOTE: If two sensors are connected and configured for edge mode, the controller will automatically
configure the appropriate guiding method based on the orientation of the edges. If both the left and the
right edge is seen by the sensor, the center guiding mode will be enabled. If both the sensors see the same
edge of the web then an average of the sensor measurement will be used to guide the web.
NOTE: If two sensors are connected and configured for contrast mode, only the sensor that is selected will
be used for guiding.
NOTE: The sensors can be enabled or disabled electronically within the controller even if they are physically
connected with cables.
NOTE: If two sensors are connected and configured for edge mode, the analog output can be configured
for left edge, right edge, centerline web position or web width.
NOTE: If two sensors are connected and configured for contrast mode, the analog output can be configured
for left edge, right edge, centerline web position or web width.
WARNING: Only the sensors and cables provided by Roll-2-Roll Technologies LLC should be connected to
the sensor ports. Third-party cables and sensors may damage the controller and will void the warranty.
Please consult with the factory before adding any patch cords.
Motor Communication (Port 2)
The SCU5 controller with “M” suffix includes a 4-pin Male M8 connector to connect the controller to a motor
driver (supplied by Roll-2-Roll Technologies LLC) used for web guiding applications. A pre-wired motor
communication cable with the 4-pin M8 female connectors on both ends is used to connect the controller
and the motor driver. The motor communication cable carries the power and the communication signals
between the SCU5 M controller and the motor driver.
Pin
Color
Signal
1
Brown
+24 V
2
White
RS 485 B-
3
Blue
RS 485 A+
4
Black
GND
WARNING: Never connect or disconnect the motor communication cable while the SCU5 controller is
powered or connected to a power supply. Always power down the SCU5 controller during the
connection/disconnection of the motor communication cable.
WARNING: Only the cables provided by Roll-2-Roll Technologies LLC should be connected to the motor
communication port. Third-party cables and sensors may damage the controller and will void the
warranty.
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Analog Output (Port 2)
The SCU5 controller without the motor suffix will include a 3-pin Male M8 connector for analog output. The
pinouts for the connector are shown below.
Pin
Color
Signal
1
Brown
Voltage
3
Blue
Current
4
Black
Ground/Common
The outputs can be chosen via the touchscreen interface to any of the following available output options:
Voltage
Current
0 - 5 V, 0 - 10 V, ± 5 V, ± 10 V
4 - 20 mA, 0 - 20 mA, 0 - 24 mA
WARNING: These pins are isolated outputs. Do not connect a power source to these pins. Some analog
input cards on PLC might have a voltage source to power sensors. Please do not connect the voltage source
to these pins. This might permanently damage the controller.
Industrial Ethernet Interface (Port 3)
An optional industrial ethernet connection is available on models with suffix C(E) or C(P). A 4-pin D-coded
M12 socket connect is provided for ethernet connection. Standard network cables such as Phoenix Contact
NBC-MSD/ 1,0-93E/R4AC SCO - 1407360 or VS-MSD-IP20-93E/5,0 - 1403500 can be used to connect the
SCU5 M to an ethernet network using RJ45 plug.
Pin
Color
Signal
1
White/Orange
+TX
2
White/Green
+RX
3
Orange
-TX
4
Green
-RX
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Opto-Isolated Output (Port 3)
For some applications two opto-isolated outputs are available from the SCU5 controller. These outputs are
available on a 4-pin M12 female pin connector. A standard M12 4-pin A coded male connector or a pre-wired
M12 cable can be used for the connection. The pin functions for the connector are shown in the table below.
Pin
Color
Signal
1
Brown
VDD
2
White
OUT2
3
Blue
GND
4
Black
OUT1
The outputs can be used as NPN output by providing a VDD (5 - 24 VDC) and GND from a PLC and the signal
through the two outputs OUT1 and OUT2. Custom programing can be done to provide a GO/NO GO type of
output or a digital ON/OFF signal.
When the respective output
signal is enabled then that
signal would go low. And
normally the signal would be
high if wired as shown in the
schematic on the left.
Note that the outputs are
normally closed. If wiring a
relay, wire to the NC side of
the circuit so that the
appropriate output from the
relay is provided to the device.
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SAFETY INSTRUCTIONS
The SCU5 controller is an electronic device that operates on low voltage (24 V DC). However, it does
present a few safety requirements that must be followed in order to assure safe and effective operation of
the system.
Instructions for Use
The SCU5 controller must be properly transported, stored before being installed professionally. The
controller should not be installed or commissioned for operation if any visible damage is observed. Only
persons who have the necessary qualifications should work on the installation, commissioning, operation,
and maintenance of the system.
Notes:
●Please read the product manual and properly follow its instructions
●Please read and follow the warning labels on the device
●Be aware of all national, state, and local requirements for accident prevention and environmental
protection.
Proper Use
The SCU5 M controller is intended for indoor use only for use in industrial and lab equipment that process
materials in web form as they move through a converting or raw material manufacturing process.
Improper Use
●Outdoor use or exposure to direct sunlight is considered improper.
●Any use outside the general specifications shall be considered improper use and voids any warranty
of the equipment.
●Any replacement parts or modification necessities should be made by Roll-2-Roll Technologies LLC.
Static Discharges and Grounding
●Web, especially plastic webs, when transported over rollers can create significant static voltage
potential. This static may discharge to the controller through the sensor cables. The static potential
needs to safely discharged by proper grounding of the controller.
●Ensure that the sensor, the controller and all other devices connected to the SCU5 controller are
properly grounded as well.
●Proper grounding can be ensured by checking for the continuity from any of the connectors on the
controller and the earth ground.
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OPERATION AND OPERATOR INTERFACE
Main Operator Interface Screen
The main operator screen provides relevant information and operator access for both the sensing and
guiding application. The web guiding operations are accomplished using the web guide operation buttons on
the bottom of the screen.
The capacitive touchscreen on the SCU5 controller uses a language independent icon based screen that
allows ease of operation.
Never use sharp or pointed tools of any kind to operate the interface. Best practice is to have operators use
their fingers to press the different icons. Care must be taken to clean the touch screen surface periodically.
Its icon based design allows for a language independent operation without the need of translation of the
screen for setup and operation in different countries.
Heartbeat Indicator
A round indicator at the bottom left of the operator interface indicates the heartbeat or the communication
between the electronic controller board and the operator interface.
●This indicator is used for troubleshooting purposes.
●During normal operation this indicator will toggle between red and green at about 1 Hz.
NOTE: Slow heartbeat may indicate communication delay between the main motherboard and the
touchscreen display/operator interface.
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Web Detected Indicator
A small square indicator on the bottom left part of the screen indicates the presence and absence of the web
as seen by the sensor in the respective mode of operation. When in edge mode the indicator turns green
whenever the sensor sees a web edge. When in contrast mode the indicator turns green when the desired
contrast is seen by the sensor.
This web detect indicator can be used for troubleshooting purposes. If this indicator turns off intermittently
while a web is in front of the sensor it may indicate that the sensor is finding it difficult to accurately sense
the web edge or the contrasting feature. This indicates a low contrast condition. Such a condition may occur
for optical grade clear webs with low scattering in the infrared spectrum or when the desired contrast
feature is not seen by the sensor.
Web Position Indicator
A horizontal bar graph, white bar in a black
background, in the main operator interface is used
to indicate the relative position of the web within
the sensor range. The edge position or the contrast
position is displayed using the white horizontal
bar. The white portion indicates the web,
specifically representing the light
reflected/scattered back from a web, while the
black background indicates the absence of web,
specifically the darkness because of no reflection
or scattering from the web.
Depending on the position and orientation of the
sensor the white bar graph may move:
●from left to right for a sensor located on
the right side of the web edge
●from right to left for a sensor that is
located on the left side of the web edge.
When a wide sensor is connected and if the
sensor is set to see both the edges, then both left
and right edges of the web will be shown using the
web position indicator. The vertical green line in
the middle indicates the centerline position of the
web.
When two sensors are connected, the bar graph
will split in two, with the left half indicating the left
edge of the web and the right half indicating the
right edge of the web. If both sensors are the same
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orientation, then web position from the sensor connected to Sensor 1 port will be displayed on the left and
the right half indicating the web position from the sensor connected to Sensor 2 port.
When in contrast mode the white bar graph may turn into gray segments representing the various contrasts
on the web and the contrast position indicated by a vertical green line.
Sensor Orientation Indicator
The four sensor orientation indicators provide quick feedback on the orientation of each sensor. Each
sensor can be oriented to pick the left edge, right edge or both edges. The two indicators on the left
correspond to the left orientation for Sensor 1 and Sensor 2 while the two on the right correspond to
the right orientation for the two sensors. When a particular orientation is chosen for a particular sensor the
corresponding indicator will turn green; if not the indicator would appear gray.
Find Edge Button
The find edge button is used by the operator to set the job appropriately based on the desired edge
that is used for sensing and guiding purposes. The find edge button serves dual purpose based on the
sensor configuration in the power user screen.
1. Automatically find the sensor orientation: When one or both sensors are set to detect the orientation
automatically, pressing the find edge button will detect the correct orientation for the sensor(s) with
respect to the web in the sensor’s field of view.
2. Enable and disable the sensors: When both sensors are set a predefined orientation pressing the
find sensor button will successively enable and disable the connected sensors electronically
Automatically find the sensor orientation
The sensor orientation with respect to the web can be automatically detected in this mode when the find
edge button is pressed. This allows for quick job changes when the sensor is repositioned within the
machine. This is especially useful while using a single sensor that is repositioned to pick either the left edge,
right edge or both edges.
This functionality is used whenever the sensor orientation with respect to the web is changed. For example,
if the sensor is moved from the operator side to the drive side for a job, then as soon as the repositioning
happens the find edge button can be pressed to switch the sensor mode from left edge to right edge (or vice
versa). If both edges of the web are seen within the field of view of the sensor then the sensor orientation
would change to center mode.
Enable and disable the sensors
When the orientation of the sensors are fixed then the find edge button allows the user to quickly enable and
disable the sensors for easy job change. For example, when two sensors are connected to the controller and
are configured for a respective sensor orientation, then successive press of the find edge button would have
the following effect:
●Enable sensor 1 and disable sensor 2
●Enable sensor 2 and disable sensor 1
●Enable both sensor 1 and sensor 2
●Disable both sensor 1 and sensor 2
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Automatic/Manual Icon
Manual Automatic
The SCU5 controller, for web guiding applications,
can be put into manual or automatic operation mode
by pressing this icon. The press of the icon will toggle
the controller between manual and automatic
operation. When the controller is connected to an
actuator and a web guiding system, the automatic
mode will move the web guide structure based on
the position of the web.
A few icons on the operator interface are enabled or
disabled as the web guide is switched between
manual and automatic mode based on the available
options in each mode. Figure on the right shows the
operator interface while the controller is in automatic
mode. The advanced setup and the find sensor buttons are disabled.
WARNING: Changing from one mode to another can result in a change in the web guide position causing
process upsets. Caution must be exercised when changing the operating mode and should be done by
those who completely understand the consequence of this change.
WARNING: No personnel should be manually handling the web guide or the material around the web guide
when the guide is in automatic operation. Failure to follow this warning could result in crushing of body
parts at pinch points around and within the web guiding system.
WARNING: Care must be taken that only one person is working on the guide when it is in manual operation.
Failure to follow this warning could result in crushing of body parts at pinch points around and within the
web guiding system.
NOTE: This functionality has no meaning for sensing applications. However, some custom applications with
custom firmware may use the functionality.
Servo Center Icon
Default/normal state Servo-centering ON
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Pressing the servo center icon will initiate the servo centering operation for web guiding applications. This
operation can be performed only when the SCU5 controller is in manual mode. Pressing this momentary
switch will initiate the servo centering operation which would toggle the icon to green. When the controller
is in servo centering mode, the actuator connected to the SCU5 controller will move towards the home
position or center position which is provided by the servo center sensor, typically an inductive proximity
switch. As soon as the actuator reaches the home or the center position, the actuator will stop and the state
of the momentary switch will change from Servo-centering (Green) to Default/normal state (Red).
The servo center feature allows the guide to be centered quickly to facilitate threading of the web during
changeover.
WARNING: Servo centering operation results in a change in the web guide position causing process upset.
Caution must be exercised when performing this function and should be done by those who completely
understand the consequence of this change.
WARNING: Servo centering can be performed only when the web guiding system is in manual mode.
Pressing the servo center icon during automatic operation will perform a different function.
WARNING: This is an automatic procedure of the web guiding system. No personnel should be performing
manual work on or around the guide during the servo-centering procedure. Failure to follow this warning
could result in crushing of body parts at pinch points around and within the web guiding system.
NOTE: This functionality has no meaning for sensing application. However, some custom applications with
custom firmware may use the functionality.
Jog-left/Jog-right Icon
Jog-left OFF Jog-right OFF
Jog-left ON Jog-right ON
The Jog-left/Jog-right icons allow the operator to manually move an actuator connected to the SCU5
controller in either direction. These operations can be performed only when the controller is in manual
mode. Both these icons act as a momentary switch that will turn ON (Green) when pressed and turn OFF
(Red) when released.
The Jog operation will continue as long as the button is pressed and will stop as soon as the button is
released. This operation can only be performed when the guide is in manual setting.
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