Montalvo Z4-UD User manual

[email protected] / www.montalvo.com / Technical details subject to change without notice. Z4-UD-technical manual-us © Montalvo
Montalvo
Z4-UD
Unwind Tension Controller for Dancer Feedback
EST. 1947
TECHNICAL MANUAL
Z4-UD Unwind (for Dancer feedback)
PID Web Tension Controller
Controller Firmware Version 1.8.x
Publication Date 06/29/2020
Circuit Board Version
Enclosure Version
PE
Z4 CONTROLLER REV#
(C) 20XX MONTALVO
5857565554535251504948474645444342414039383736353433323130
2928272625242322212019181716151413121110987654321
Z4XXXXX
11XXXXXX
Made In USA
R6 R1R2R3R4R5
Run Mode AUTO
|||||||||||||||||||||||||||
SERXXXXXX
NL
|||||||||||||||||||||||||||
SERXXXXXX
SUPPLY
100-240 VAC
ONLY
(Fuse: 3.15A Slow Blow)
ADJUST TREND DATALOG SCALING CONFIGDISPLAY
Diameter
28.0 in
Aux
0.0 %
Manual
36.0 psi
Do 1234
Di 1 2 34 58
Rng1
Di
12
3
4
5
8
Man / Auto
AUTOMODE
Cal2
Ten Off / On
-100.0
0.000
0.250
0.500
0.750
1.000
-80.0
-60.0
-40.0
-20.0 20.0
0.0
40.0
60.0
80.0
100.0
Output
x100 psi
Dancer
3.5
%

[email protected] / www.montalvo.com / Technical details subject to change without notice. Z4-UD-technical manual-us © Montalvo
Table of Contents
Table of Contents
1 General Description..........................................................................................1-1
1.1 Overview..........................................................................................................1-1
1.2 Models*, Options* and Compatibility*...............................................................1-2
1.3 How It Works...................................................................................................1-3
1.4 Function and Standard Operation ....................................................................1-4
2 Mechanical Installation...................................................................................2-1
2.1 Circuit Board (controller) Dimensions................................................................2-1
2.2 HMI (remote interface) Dimensions...................................................................2-2
2.3 Enclosure Dimensions......................................................................................2-3
3 Electrical Installation........................................................................................3-1
3.1 Warning, EMC, and Safety ...............................................................................3-1
3.2 Basic Diagrams Z4b Model (circuit board only).................................................3-2
3.3 Basic Diagrams Z4r Model (circuit board with remote HMI*) .............................3-3
3.4 Basic Diagrams Z4e Model (circuit board and HMI* in enclosure) .....................3-4
3.5 Terminal Blocks................................................................................................3-5
3.6 Installation - Dancer Sensor .............................................................................3-6
3.7 Installation - Dancer Calibration........................................................................3-7
3.8 Installation – Regulated Output ........................................................................3-8
3.9 Installation – Power Supply (VAC and VDC)....................................................3-10
3.10 Digital Input (24V)...........................................................................................3-11
3.11 Digital Output (24V)........................................................................................3-14
3.12 Analog Input (0-10V) ......................................................................................3-15
3.13 Analog Output ...............................................................................................3-17
3.14 Analog Output (AUX1 Output) ........................................................................3-17
3.15 Voltage to Current Converter..........................................................................3-18
4 Tuning ........................................................................................................................4-1
4.1 Tuning of Z4.....................................................................................................4-1
5 Conguration and System Setup.............................................................5-1
5.1 Conguration Menu Cong Menu ...................................................................5-1
5.2 Options Selection Menu Options Menu ..........................................................5-2
5.3 Regulator Parameter Regulator Menu ............................................................ 5.3
5.4 Roll Change Roll Change Menu .....................................................................5-5
5.5 Starting the Machine Start Menu ....................................................................5-7
5.6 Stopping the Machine Stop Menu ..................................................................5-9
5.7 Machine at Stop Hold Menu ........................................................................5-12
5.8 Diameter Diameter Menu .............................................................................5-13
5.9 Taper Taper Menu ........................................................................................5-15
5.10 Digital Output Digital Output Menu ...............................................................5-16
5.11 Splice Splice Menu ......................................................................................5-18
5.12 Range Expander Range Exp Menu ..............................................................5-23

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Table of Contents
Table of Contents
5.13 Aux1 Input Aux1 Input Menu ........................................................................5-31
5.14 Aux2 Input Aux2 Input Menu ........................................................................5-32
5.15 Aux1 Output Aux1 Output Menu ..................................................................5-33
5.16 Aux2 Output ..................................................................................................5-33
6 Operation of the Controller Menu........................................................... 6-1
6.1 Operation of the Controller Menu .................................................................... 6-1
6.2 Menu Tree Status Menu ................................................................................ 6-2
6.3 Description Run Mode .................................................................................. 6-2
6.4 Menu Tree Setup Menu ................................................................................. 6-3
6.5 Menu Tree / Parameter Settings...................................................................... 6-4
7 Hardware Adjustment and LEDs............................................................. 7-1
7.1 LEDs............................................................................................................... 7-1
7.2 Potentiometers ............................................................................................... 7-1
8 Troubleshooting.................................................................................................. 8-1
8.1 Block Diagram ................................................................................................ 8-1
8.2 Symptom / Causes ......................................................................................... 8-2
9 Technical Data..................................................................................................... 9-1
9.1 Specications ................................................................................................. 9-1
9.2 Declaration of Conformity................................................................................ 9-2
10 Communication............................................................................................... 10-1
10.1 HMI (option) (separate manual*) .................................................................... 10-1
10.2 Ethernet (option) (separate manual*).............................................................. 10-2
*Hard copies of appropriate additional manuals along with this controller manual ship
with product. All manuals are available as pdf downloads from: www.montalvo.com

[email protected] / www.montalvo.com / Technical details subject to change without notice. Z4-UD-technical manual-us © Montalvo
General Description
1
1
1-1
The Montalvo Z4 Unwind dancer controller provides precise automatic control of web tension.
The progressive PID regulator automatically compensates for roll diameter. The controller is used
in a closed loop, of which the dancer and a brake (or other tension-affecting device) are part.
To properly set up and operate the controller and to take advantage of all its available features, it
is important to have a general understanding of the controller and its place in the tensioning
system (please refer to the diagram on the following page). A typical pneumatic system is
displayed; however, the same principles apply to any other closed-loop control system. The
controller outputs of 4 to 20mA and 0 to 10V enable the controller to interface with a variety of
output devices to control web tensioning brakes, clutches, or motors.
Dancer Function A dancer with one or more wrap rollers can be applied. The controller
receives a signal from a potentiometer that is placed at the pivot point of the dancer. The
resulting change in voltage is amplied and calibrated at the controller.
Converter Function (Brake)
The Z4 can regulate either pneumatic or electric brakes. An I/P converter, used with pneumatic
brakes, converts the 4 to 20mA regulator output to a proportional 0 to 75 PSI (0 to 6 bar)
output. Electric brakes require a voltage converter. Other converters may be used, depending
on the application.
Brake Function
One or more brakes may be controlled, converting the pneumatic output pressure from the I/P
into torque. This torque in turn determines the web tension.
Diameter Signal (recommended)
To optimize the tension system, a diameter signal is recommended. Diameter can be calculated
by signals from two proximity switches or it can be received from an analog device such as an
ultrasonic sensor or other device.
Auto Mode Function (Closed Loop)
The controller receives a signal from the position of the dancer potentiometer and automatically
regulates the pressure to the brake in order to maintain the dancer in center position. The
dancer indicates the difference in speed between the machine and the unwind roll. The brake
creates the web tension. Weights or the air cylinder (the tension set point) determines how
much torque the brake needs to create in order to keep the dancer in the middle.
Manual Mode Function (Open Loop)
No automatic regulation is done in manual mode. To set the brake pressure, and to maintain
the dancer in the center position, the operator must make constant adjustments with the
manual potentiometer.
1.1 Overview

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General Description
1
1
1-2
1.2 Models, Options and Compatability
MODELS
The Z4 Tension Controller is available in three separate models:
Circuit Board Only - Z4b
Connect to machine via communication links or discrete I/O.
Circuit Board with HMI*- Z4r
Install the circuit board and HMI in separate locations.
Circuit Board and HMI*in Enclosure - Z4e
IP54, industrial enclosure can be installed as either panel or surface mount.
OPTIONS
The Z4 Circuit Board can be factory congured for the following options:
No Communication
Basic protective cover plate when no HMI or Ethernet communication is required.
HMI*Communication
Standard module has HMI connectivity required for connunication with Z4e and Z4r models.
Also available for Z4b.
Ethernet*Communication
Ethernet/IP communication module includes HMI communication. Available on all models.
COMPATIBILITY
The Z4 Circuit Board is a drop-in replacement/upgrade for earlier Montalvo controllers:
CB64, CB63 and DRT6 Replacement*
The Z4 design allows for easy customer swap, full compatibility and increased functionality.
*Hard copies of appropriate additional manuals along with this controller manual ship
with product. All manuals (as pdf) and software tools are available from: www.montalvo.com

[email protected] / www.montalvo.com / Technical details subject to change without notice. Z4-UD-technical manual-us © Montalvo
General Description
1
1
1-3
1.3 How It Works
Unwind
INPUT
Z
INPUT Z
Y Regulated Air (single line - one torque range)
Y Regulated Air (2, 3 or 4 lines - multiple torque ranges)
Air Supply
Z
Y Air Supply
Y OUTPUT
Pneumatic
Brake
Web Direction
Z
I/P Converter
(Option)
Automatic
Range Expander
(Option)
Z4-UD
Dancer
Potentiometer
(Option)
Proximity
Switches
(Option)
Ultrasonic
Sensor
(Option)
DPS-1 Position Sensor (Option)
PE
Z4 CONTROLLER REV#
(C) 20XX MONTALVO
5857565554535251504948474645444342414039383736353433323130
2928272625242322212019181716151413121110987654321
Z4XXXXX
11XXXXXX
Made In USA
R6 R1R2R3R4R5
Run Mode AUTO
|||||||||||||||||||||||||||
SERXXXXXX
NL
|||||||||||||||||||||||||||
SERXXXXXX
SUPPLY
100-240 VAC
ONLY
(Fuse: 3.15A Slow Blow)
Y
Communication
Z
Ethernet plus HMI
(Option)
HMI
(Option)

[email protected] / www.montalvo.com / Technical details subject to change without notice. Z4-UD-technical manual-us © Montalvo
General Description
1
1
1-4
PE
Z4 CONTROLLER REV#
(C) 20XX MONTALVO
5857565554535251504948474645444342414039383736353433323130
2928272625242322212019181716151413121110987654321
Z4XXXXX
11XXXXXX
Made In USA
R6 R1R2R3R4R5
Run Mode AUTO
|||||||||||||||||||||||||||
SERXXXXXX
NL
|||||||||||||||||||||||||||
SERXXXXXX
SUPPLY
100-240 VAC
ONLY
(Fuse: 3.15A Slow Blow)
ADJUST TREND DATALOG SCALING CONFIGDISPLAY
Diameter
28.0 in
Aux
0.0 %
Manual
36.0 psi
Do 1234
Di 1 2 34 58
Rng1
Di
12
3
4
5
8
Man / Auto AUTOMODE
Cal2
Ten Off / On
-100.0
0.000
0.250
0.500
0.750
1.000
-80.0
-60.0
-40.0
-20.0 20.0
0.0
40.0
60.0
80.0
100.0
Output
x100 psi
Dancer
3.5
%
ADJUST TREND DATALOG SCALING CONFIGDISPLAY
Diameter
28.0 in
Aux
0.0 %
Manual
36.0 psi
Do 1234
Di 1 2 34 58
Rng1
Di
12
3
4
5
8
Man / Auto AUTOMODE
Cal2
Ten Off / On
-100.0
0.000
0.250
0.500
0.750
1.000
-80.0
-60.0
-40.0
-20.0 20.0
0.0
40.0
60.0
80.0
100.0
Output
x100 psi
Dancer
3.5
%
Enclosure version
1.4 Function and Standard Operation
Remote version
Item Description
Manual Setpoint
Sets controller output at a constant level when the controller is in
manual mode. (Manual setpoint on a 0 to 100% scale produces
0 to 100% output). Once scaled, the output can be PSI, volts or mA.
Controller Output Meter Displays controller/regulator output on a scale of 0 to 100% or
user assignable output range.
Manual / Auto Button Toggles between manual and auto mode.
Tension On/Off Button Turns tension on and off. Output is zero when off.
Yellow Power LED Indicates that power is on.

2-1
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Mechanical Installation
2
2
2.1 Circuit Board (controller) Dimensions
Avoid mounting the controller close to drive controllers or any
other equipment producing large amounts of EMI.
PE
Z4 CONTROLLER REV#
(C) 20XX MONTALVO
5857565554535251504948474645444342414039383736353433323130
2928272625242322212019181716151413121110987654321
Z4XXXXX
11XXXXXX
Made In USA
R6 R1R2R3R4R5
Run Mode AUTO
|||||||||||||||||||||||||||
SERXXXXXX
NL
|||||||||||||||||||||||||||
SERXXXXXX
SUPPLY
100-240 VAC
ONLY
(Fuse: 3.15A Slow Blow)
6.97 (177)
4.72 (120) 1.30
(33)
2.64
(67)
6.65
(169)
5.81
(147.5)
Standoffs for installation in customer cabinet
Standoffs used in Montalvo enclosure are different length.

2-2
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Mechanical Installation
2
2
2.2 HMI (remote interface) Dimensions
5.35 (136)
1.47 (38)
8.00 (203)
7.44 (189)
1.85 (47)
5.43
(137.92)
0.118 (3) max. radius
7.00 (178)
7.6
(193.04)
Cut Out
+0.020
-0.000
+0.5
-0.0
+0.020
-0.000
+0.5
-0.0

2-3
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Mechanical Installation
2
2
2.3 Enclosure Dimensions
Avoid mounting the controller close to drive controllers or any
other equipment producing large amounts of EMI.
10.86 (276)
8.23 (209)
9.42
(239.5)
4.30
(110)
8.94
(227)
10.50
(267)
0.16 (4)
HMI Door Pull
1/4 Turn Compression Latch

Electrical Installation
3
3
3-1
[email protected] / www.montalvo.com / Technical details subject to change without notice. Z4-UD-technical manual-us © Montalvo
3.1 Warning, EMC and Safety
Warning: Electrical installation must be done by skilled personnel. Wiring must meet all
applicable codes and standards.
Refer to the appropriate wiring and terminal descriptions for external connections.
The maximum external fuse on the input is 10A.
Note: 0V and PE are internally connected.
Note: Double-check the accuracy of all wiring connections before applying power to the
controller. Damage caused by improper wiring is not under warranty.
EMC Requirements: Connect the protective ground wire to the terminal marked PE. Ground
wires should be as short as possible. Connect the controller PE terminal and enclosure to a
common ground.
Use only shielded cables for all external connections. For analog signals, terminate the shield at
the controller end; for digital signals, terminate the shield at both ends.
Keep signal cables away from supply cables or any wires that conduct high current. For the
best noise immunity, run signal cables close to the machine frame, mounting plates, or other
grounded structures.
SAFETY INFORMATION
The following safety symbols appear in this manual.
Caution
Failure to follow installation and
setup instructions in this
manual may result in equipment
damage or personal injury.
Electrical Hazard
Failure to follow wiring
instructions in this manual may
result in equipment damage,
personal injury, or death.

Electrical Installation
3
3
3-2
[email protected] / www.montalvo.com / Technical details subject to change without notice. Z4-UD-technical manual-us © Montalvo
3.2 Basic Diagrams B Version (circuit board only)
PE
Z4 CONTROLLER REV#
(C) 20XX MONTALVO
5857565554535251504948474645444342414039383736353433323130
2928272625242322212019181716151413121110987654321
Z4XXXXX
11XXXXXX
Made In USA
R6 R1R2R3R4R5
Run Mode AUTO
|||||||||||||||||||||||||||
SERXXXXXX
NL
|||||||||||||||||||||||||||
SERXXXXXX
SUPPLY
100-240 VAC
ONLY
(Fuse: 3.15A Slow Blow)
NL PE
PE
N (COM) L (24V) PE
PE
Power Connections
100-240 VAC (standard)
24 VDC (factory option)
Circuit Board
Manual SetpointFunction Switches Machine Input
Regulated OutputDancer Input (use only one type)
Voltage
0-10V
I/P Converter
(Current 4-20mA)
12 13 14 11 13533 536 15 16 17 50 51
31 33 32 47 48 49 34 36 6
0-10v
(Aux1 Input)
0Vregulated
output
(0-10V)
regulated
output
(4-20mA)
0V0V 24V
*
(connect if
converter uses
24V power supply)
-2.5V dancer
potentiometer
+input
dancer
position
+input
+2.5V
fast stop
(DI 8)
24V*
run
(DI 5)
(10V)
manual
setpoint
(0-10V)
0V
manual
(DI 1) tension off (DI 3)
24V*
Diameter
or
Web Pulse
Proximity Switch
Roll Pulse
Proximity Switch
roll pulse
(DI 7)
web pulse
(DI 6) 0V24V
*
24V
*
10K
Terminals 1-58
PNP
Analog
Input
0-10V
PNP
10 K
CW
DPS-1
Dancer Position
Sensor
MDP-6
Dancer
Potentiometer
* Any of the three 24V terminals (4, 33 and 36) can be used as available. Caution - connecting too many devices to the 24V terminals will cause the
controller’s digital circuit breaker to trip. A separate 24V power supply may be required if this happens.

Electrical Installation
3
3
3-3
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3.3 Basic Diagrams R Version (circuit board with remote HMI)
NL PE
PE
N (COM) L (24V) PE
PE
Power Connections on PCB
24 VDC (factory option)
100-240 VAC (standard)
Circuit Board HMI (showing back side) Standard HMI Cables
Part# Module
Type
Length
(m)
19000618 HMI 0.6
19000619 HMI 5
19000620 HMI 10
19000621 HMI 15
19000652 Ethernet/HMI 0.6
19000669 Ethernet/HMI 5
19000670 Ethernet/HMI 10
19000671 Ethernet/HMI 15
PE
Z4 CONTROLLER REV#
(C) 20XX MONTALVO
5857565554535251504948474645444342414039383736353433323130
2928272625242322212019181716151413121110987654321
Z4XXXXX
11XXXXXX
Made In USA
R6 R1R2R3R4R5
Run Mode AUTO
|||||||||||||||||||||||||||
SERXXXXXX
NL
|||||||||||||||||||||||||||
SERXXXXXX
SUPPLY
100-240 VAC
ONLY
(Fuse: 3.15A Slow Blow)
PE
Z4 CONTROLLER REV#
(C) 20XX MONTALVO
5857565554535251504948474645444342414039383736353433323130
2928272625242322212019181716151413121110987654321
Z4XXXXX
11XXXXXX
Made In USA
R6 R1R2R3R4R5
Run Mode AUTO
|||||||||||||||||||||||||||
SERXXXXXX
NL
|||||||||||||||||||||||||||
SERXXXXXX
SUPPLY
100-240 VAC
ONLY
(Fuse: 3.15A Slow Blow)
GND FGDC24
ON
1 2
DO NOT use these ports!
Use USB and COM only.
RESET
If HMI must be RESET,
make sure machine is
NOT RUNNING!
USB COM
Z4
TYPE
www.montalvo.com
Tension Controllers
PN
VOLTS
®
HMI Interface - Z4i
24V
11000851
Assembled in USA
GND FGDC24
ON
1 2
DO NOT use these ports!
Use USB and COM only.
RESET
If HMI must be RESET,
make sure machine is
NOT RUNNING!
USB COM
Z4
TYPE
www.montalvo.com
Tension Controllers
PN
VOLTS
®
HMI Interface - Z4i
24V
11000851
Assembled in USA
R6 R1R2R3R4R5
HMI
Communications
Module 6 pin Molex connector
5 pin M12 connector
Ethernet/HMI
Communications
Module
HMI Module Cable
Ethernet / HMI Module Cable
Machine Input
Regulated OutputDancer Input (use only one type)
Voltage
0-10V
I/P Converter
(Current 4-20mA)
12 13 14 11 13533 536 15 16 17 50 51
34 36 6
0-10v
(Aux1 Input)
0Vregulated
output
(0-10V)
regulated
output
(4-20mA)
0V0V 24V
*
(connect if
converter uses
24V power supply)
-2.5V dancer
potentiometer
+input
dancer
position
+input
+2.5V
fast stop
(DI 8)
24V*
run
(DI 5)
Diameter
or
Web Pulse
Proximity Switch
Roll Pulse
Proximity Switch
roll pulse
(DI 7)
web pulse
(DI 6) 0V24V
*
24V
*
Terminals 1-58
PNP
Analog
Input
0-10V
PNP
10 K
CW
DPS-1
Dancer Position
Sensor
MDP-6
Dancer
Potentiometer
* Any of the three 24V terminals (4, 33 and 36) can be used as available. Caution - connecting too many devices to the 24V terminals will cause the
controller’s digital circuit breaker to trip. A separate 24V power supply may be required if this happens.

Electrical Installation
3
3
3-4
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NL PE
PE
N (COM) L (24V) PE
PE
Power Connections
100-240 VAC (standard)
24 VDC (factory option)
Enclosure
3.4 Basic Diagrams E Version (circuit board and HMI in enclosure)
ADJUST TREND DATALOG SCALING CONFIGDISPLAY
Diameter
28.0 in
Aux
0.0 %
Manual
36.0 psi
Do 1234
Di 1 2 34 58
Rng1
Di
12
3
4
5
8
Man / Auto
AUTOMODE
Cal2
Ten Off / On
-100.0
0.000
0.250
0.500
0.750
1.000
-80.0
-60.0
-40.0
-20.0 20.0
0.0
40.0
60.0
80.0
100.0
Output
x100 psi
Dancer
3.5
%
Machine Input
Regulated OutputDancer Input (use only one type)
Voltage
0-10V
I/P Converter
(Current 4-20mA)
12 13 14 11 13533 536 15 16 17 50 51
34 36 6
0-10v
(Aux1 Input)
0Vregulated
output
(0-10V)
regulated
output
(4-20mA)
0V0V 24V
*
(connect if
converter uses
24V power supply)
-2.5V dancer
potentiometer
+input
dancer
position
+input
+2.5V
fast stop
(DI 8)
24V*
run
(DI 5)
Diameter
or
Web Pulse
Proximity Switch
Roll Pulse
Proximity Switch
roll pulse
(DI 7)
web pulse
(DI 6) 0V24V
*
24V
*
Terminals 1-58
PNP
Analog
Input
0-10V
PNP
10 K
CW
DPS-1
Dancer Position
Sensor
MDP-6
Dancer
Potentiometer
* Any of the three 24V terminals (4, 33 and 36) can be used as available. Caution - connecting too many devices to the 24V terminals will cause the
controller’s digital circuit breaker to trip. A separate 24V power supply may be required if this happens.

Electrical Installation
3
3
3-5
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3.5 Terminal Blocks
2928272625242322212019181716151413121110987654321
5857565554535251504948474645444342414039383736353433323130
DI 2 Splice
DI 4 Standby
24V
DI 6 Web Pulse
DI 8 Fast Stop
24V Input for DO
DO 2 Range 1
DO 4 Range 3
0V
Tension Off DI 3
24V
24V
Run DI 5
Roll Pulse DI 7
Range 2 DO 3
- 2.5V
- 2.5V
+2.5V
+2.5V
+Dancer Input (DPS-1 Dancer Position Sensor
or MDP-6 Dancer Potentiometer)
10V
10V
10V
10V
- 10V
4 to 20mA Regulator Output
0 to 10V Regulator Output
0 to 10V Auto Setpoint
Calibrated Aux 3 Output ±10V ±10V Aux3 Input
4 to 20mA Output from U/I Converter
Input for Extra U/I Converter 0 to 10V
Aux 1 Output 0 to 10V
Manual Setpoint 0 to 10V
Dancer Position -10 to +10V
Dancer Position -100 to +100µA
0V
0V
0V
0V
0V
0V
0V
0V
0V
0V
0V
0V
0V
0V
0V
Web Break or Range 4 DO 1
0 to 10V Aux2 Output
Taper Trim
Aux 2 Input 0 to 10V
Aux 1 Input 0 to 10V
Manual DI 1

Electrical Installation
3
3
3-6
[email protected] / www.montalvo.com / Technical details subject to change without notice. Z4-UD-technical manual-us © Montalvo
3.6 Installation – Dancer Sensor
# Description
12 -2.5V Supply
13 Dancer Input
14 +2.5V
# Description
36 24V Supply
13 Dancer Input
11 0V
The controller requires the use of a dancer arm position sensor. Montalvo offers two types:
• DPS-1 - Solid state. Reacts to changes in angle/tilt.
• MDP-6 - Potetiometer. Located at the dancer arm pivot point.
The signal from either device is calibrated to measure the full expected swing of the dancer arm.
That signal is used by the controller to continuously calculate tension, based on the dancer arm
position, and to output a signal, based on tension setpoint, to a tension brake.
DPS-1 (Dancer Position Sensor) MDP-6 (Dancer Potentiometer)
Wiring
14131211
39383736353433323130
24V
0V
+ INPUT
TEACH
PE
Z4 CONTROLLER REV#
(C) 20XX MONTALVO
5857565554535251504948474645444342414039383736353433323130
2928272625242322212019181716151413121110987654321
Z4XXXXX
11XXXXXX
Made In USA
R6 R1R2R3R4R5
Run Mode AUTO
|||||||||||||||||||||||||||
SERXXXXXX
NL
|||||||||||||||||||||||||||
SERXXXXXX
SUPPLY
100-240 VAC
ONLY
(Fuse: 3.15A Slow Blow)
Wire colors refer to standard cables supplied by Montalvo
MDP-6 Cable
DPS-1 Cable
§
PE
Z4 CONTROLLER REV#
(C) 20XX MONTALVO
5857565554535251504948474645444342414039383736353433323130
2928272625242322212019181716151413121110987654321
Z4XXXXX
11XXXXXX
Made In USA
R6 R1R2R3R4R5
Run Mode AUTO
|||||||||||||||||||||||||||
SERXXXXXX
NL
|||||||||||||||||||||||||||
SERXXXXXX
SUPPLY
100-240 VAC
ONLY
(Fuse: 3.15A Slow Blow)
§
+2.5V
+INPUT
-2.5V
BN
WH
BU
GY
BK
BN
WH
BK
14131211
10K
Use White wire if DPS-1 is mounted closer to horizontal (Y position)
Use Black wire if DPS-1 is mounted closer to vertical (X position)
Y
Y
Y
X
X

Electrical Installation
3
3
3-7
[email protected] / www.montalvo.com / Technical details subject to change without notice. Z4-UD-technical manual-us © Montalvo
Zeroing the DPS-1
1. Place the dancer in center position and attach the DPS-1 +/-15° of level (see DPS-1
manual for more details on mounting). Connect to the controller via the supplied cable. See
Wiring on previous page.
2. With power applied to the DPS-1, momentarily (2 seconds) touch the Gray (GY) conductor
to the Blue (BU) conductor. This "teaches" the DPS-1 a new ZERO (center) position based
on its current mounting position relative to the dancer arm at "center". Hold the Gray "teach"
conductor to the Blue conductor for >6 seconds to restore the default setting.
Calibrating the Dancer
3. Apply power to the controller and let it warm up for at least 10 minutes. Scroll to the
Dancer X.X% parameter in the Status Menu .
4. Place the dancer in center position and adjust potentiometer R1 until the digital display
shows Dancer 0.0% .
Note: R1 and R2 are 25-turn potentiometers; so many rotations may be required.
5. Place the dancer in maximum position. If a negative value is displayed, rotate the DPS-1
mounting position 180° using the same mounting holes, and repeat step 2. Adjust
potentiometer R2 until Dancer 100.0% appears. If the value is below 100%, turn R2
clockwise; if above, turn counter clockwise.
6. Move the dancer to minimum position. The display should show -100%.
• If the value is under -100%, move center position towards minimum position.
• If the value is over -100%, move center position towards maximum position.
• To readjust center position, return to step 4.
3.7 Installation – Dancer Calibration
Z
1
2
C
3
Status Menu
Version
Dancer
Setpoint
Output
Flt Out
I-Level
Gain Level
Manual
Diameter
Aux1 In
Aux2 In
Aux3 In
Aux1 Out
Aux2 Out
IO Terminal Menu
Ext Status Menu
NOTE: Not all menus / items
display all the time. Relevant
menus / items display when
correct password is entered.
Max. 100%
Center 0%
Dancer
Min. -100%
403938373635
R6 R1R2R3R4R5
Max. 100%
Center 0%
Dancer
Min. -100%
403938373635
R6 R1R2R3R4R5
1211
BU
GY TEACH

Electrical Installation
3
3
3-8
[email protected] / www.montalvo.com / Technical details subject to change without notice. Z4-UD-technical manual-us © Montalvo
3.7 Installation – Dancer Calibration
Zeroing the MDP-6
1. Check for correct installation of the dancer potentiometer.
2. Place the dancer in center position, loosen the potentiometer coupling, and turn the
potentiometer shaft until it is approximately in center position (5K between the two
wires on terminals 13 and 14). Tighten the coupling.
Calibrating the Dancer
3. Apply power to the controller and let it warm up for at least 10 minutes. Scroll to the
Dancer X.X% parameter in the Status Menu .
4. Place the dancer in center position and adjust potentiometer R1 until the digital display
shows Dancer 0.0% .
Note: R1 and R2 are 25-turn potentiometers; so many rotations may be required.
5. Place the dancer in maximum position. If a negative value is displayed, switch the two wires
at terminals 12 and 14 coming from the potentiometer, and repeat step 2. Adjust
potentiometer R2 until Dancer 100.0% appears. If the value is below 100%, turn R2
clockwise; if above, turn counter clockwise.
6. Move the dancer to minimum position. The display should show -100%.
• If the value is under -100%, move center position towards minimum position.
• If the value is over -100%, move center position towards maximum position.
• To readjust center position, return to step 4.
Z
1
2
C
3
Status Menu
Version
Dancer
Setpoint
Output
Flt Out
I-Level
Gain Level
Manual
Diameter
Aux1 In
Aux2 In
Aux3 In
Aux1 Out
Aux2 Out
IO Terminal Menu
Ext Status Menu
NOTE: Not all menus / items
display all the time. Relevant
menus / items display when
correct password is entered.
Max. 100%
Center 0%
Dancer
Min. -100%
403938373635
R6 R1R2R3R4R5
Max. 100%
Center 0%
Dancer
Min. -100%
403938373635
R6 R1R2R3R4R5
Ohm Meter
(to read 5K)
Z4 Controller
(terminals 13 and 14)
5K
MDP-6 Cable MDP-6
(rotate shaft)
Dancer Arm
(at center of swing)
BN
WH
BK
14131211
10K

Electrical Installation
3
3
3-9
[email protected] / www.montalvo.com / Technical details subject to change without notice. Z4-UD-technical manual-us © Montalvo
3.8 Installation – Regulated Output
Circuit Board Terminals
# Description Function
15 0V Common signal (0V) for regulated voltage or current output.
Connects to input ground of the converter.
16 Regulated Current Regulated 4 to 20mA current signal to an I/P or other converter.
17 Regulated Voltage
Regulated 0 to 10V output. Can be used for a 0 to 10V E/E or
other converter. Can control motor drives operating in torque
mode. Maximum load: 5 mA.
PE
Z4 CONTROLLER REV#
(C) 20XX MONTALVO
5857565554535251504948474645444342414039383736353433323130
2928272625242322212019181716151413121110987654321
Z4XXXXX
11XXXXXX
Made In USA
R6 R1R2R3R4R5
Run Mode AUTO
|||||||||||||||||||||||||||
SERXXXXXX
NL
|||||||||||||||||||||||||||
SERXXXXXX
SUPPLY
100-240 VAC
ONLY
(Fuse: 3.15A Slow Blow)
0 to 10V
4 to 20mA
0V
Montalvo I/P Converter Wiring
• Signal = 4 to 20mA
Montalvo I/P Converter Wiring
• Signal = 0-10V
§
§
17
16
15
1615
0 to 10V
4 to 20mA
0V
Montalvo I/P Converter Wiring
• Signal = 4 to 20mA
• I/P requires 24V supply
171615
24V
10987654321
NOT USED
NOT USED
GND
0 to 10V
4 to 20mA
0V
17
17
15
1615
NOT USED
GND
MPC-4
0-10V Model
MPC-4
4-20mA Model
MPC-5
1516
MPC-3
1234

Electrical Installation
3
3
3-10
[email protected] / www.montalvo.com / Technical details subject to change without notice. Z4-UD-technical manual-us © Montalvo
3.9 Installation – Power Supply (VAC and VDC)
NNeutral (COM)
LSupply Voltage 100/240 VAC
PE Ground
N0V
L24 VDC
PE Ground
PE
Z4 CONTROLLER REV#
(C) 20XX MONTALVO
5857565554535251504948474645444342414039383736353433323130
2928272625242322212019181716151413121110987654321
Z4XXXXX
11XXXXXX
Made In USA
R6 R1R2R3R4R5
Run Mode AUTO
|||||||||||||||||||||||||||
SERXXXXXX
NL
|||||||||||||||||||||||||||
SERXXXXXX
SUPPLY
100-240 VAC
ONLY
(Fuse: 3.15A Slow Blow)
N (COM) L (24V) PE
PE
NL PE
PE


VAC Circuit Boards
VDC Circuit Boards
N
(COM) L 24V PE
Z4 CONTROLLER REV#
(C) 20XX MONTALVO
5857565554535251504948474645444342414039383736353433323130
2928272625242322212019181716151413121110987654321
Z4XXXXX
11XXXXXX
Made In USA
R6 R1R2R3R4R5
Run Mode AUTO
|||||||||||||||||||||||||||
SERXXXXXX
|||||||||||||||||||||||||||
SERXXXXXX
SUPPLY
24 VDC
ONLY
(Fuse: 1.0A)