Montalvo Z4-UL User manual

ADJUST TREND CONFIGDISPLAY
Setpoint
Manual
Aux
Diameter
65.0
42.0
62.7
24.5
LB
PSI
%
in
1
2
2
2
2
MAN / AUTO CAL
AUTO
MODE
TENSION
00.0
00.0
25.0
50.0
75.0
100.0
10.0
20.0
30.0
40.0 60.0
50.0
70.0
80.0
90.0
100.0
Output Setpoint
Tension
N
(COM) L 24V PE
Z4 CONTROLLER REV
(C) 2014 MONTALVO
5857565554535251504948474645444342414039383736353433323130
2928272625242322212019181716151413121110987654321
Z4XXXX-X
100/240VAC 0.6A
Run Mode TENOFF
R6 R1R2R3R4R5
|||||||||||||||||||||||||||
SERXXXXXX
SUPPLY
100-240 VAC
ONLY
(Fuse: 3.15A Slow Blow)
MADE IN USA
[email protected] / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo
Montalvo
Z4-UL
Unwind Tension Controller for Load Cell Feedback
EST. 1947
TECHNICAL MANUAL
Z4-UL Unwind (for Load Cell feedback)
PID Web Tension Controller
Version 1.0 / Publication Date 2014-12-16
Circuit Board Version
Enclosure Version

Table of Contents
1 General Description............................................................................................. 3
2 Mechanical Installation...................................................................................... 6
2.1 Circuit Board (controller) Dimensions................................................................... 6
2.2 HMI (remote interface) Dimensions...................................................................... 7
2.2 Enclosure Dimensions......................................................................................... 8
3 Electrical Installation........................................................................................... 9
3.1 Warning, EMC, and Safety .................................................................................. 9
3.2 Basic Diagrams B Version (circuit board only).................................................... 10
3.3 Basic Diagrams R Version (circuit board with remote HMI)................................. 11
3.4 Basic Diagrams E Version (circuit board and HMI in Enclosure) ......................... 12
3.5 Terminal Blocks................................................................................................. 13
3.6 Installation - Load Cell....................................................................................... 14
3.7 Installation - Tension Calibration ........................................................................ 15
3.8 Installation – Regulated Output ......................................................................... 16
3.9 Installation – Power Supply (VAC and VDC)....................................................... 17
3.10 Digital Input (24V).............................................................................................. 18
3.11 Digital Output (24V)........................................................................................... 21
3.12 Analog Input (0 to 10V) ..................................................................................... 21
3.13 Analog Output (0 to 10V) .................................................................................. 24
3.14 Analog Output (AUX1 Output) (0 to 10V) ........................................................... 24
3.15 Voltage to Current Converter............................................................................. 25
4 Tuning ......................................................................................................................... 26
4.1 Tuning of Z4 Controller...................................................................................... 26
5 Conguration and System Setup.............................................................. 27
5.1 Conguration Menu [Cong Menu] .................................................................... 27
5.2 Options Selection Menu [Options Menu] ........................................................... 28
5.3 Regulator Parameter [Regulator Menu] ............................................................. 29
5.4 Roll Change [Roll Change Menu]....................................................................... 30
5.5 Starting the Machine [Start Menu] ..................................................................... 32
5.6 Stopping the Machine [Stop Menu] ................................................................... 34
5.7 Machine at Stop [Hold Menu]............................................................................ 37
5.8 Diameter [Diameter Menu]................................................................................. 38
5.9 Taper [Taper Menu] ........................................................................................... 41
5.10 Digital Output [Digital Output Menu] .................................................................. 42
5.11 Splice [Splice Menu].......................................................................................... 44
5.12 Range Expander [Range Exp Menu].................................................................. 49
5.13 Aux1 Input [Aux1 Input Menu]........................................................................... 54
5.14 Aux2 Input [Aux2 Input Menu]........................................................................... 55
5.15 Aux1 Output [Aux1 Output Menu] ..................................................................... 56
5.16 Aux2 Output ..................................................................................................... 56
5.17 Variable Wrap Angle [Wrap Angle Menu] ........................................................... 56

6 Operation of the Controller Menu.............................................................57
6.1 Operation of the Controller Menu ......................................................................57
6.2 Menu Tree [Status Menu] ..................................................................................58
6.3 Description [Run Mode] ....................................................................................58
6.4 Menu Tree [Setup Menu] ...................................................................................59
6.5 Menu Tree / Parameter Settings........................................................................60
7 Hardware Adjustment and LEDs...............................................................65
7.1 LEDs.................................................................................................................65
7.2 Potentiometers .................................................................................................65
8 Troubleshooting....................................................................................................66
8.1 Block Diagram ..................................................................................................66
8.2 Symptoms / Causes .........................................................................................67
9 Technical Data.......................................................................................................68
9.1 Electrical ...........................................................................................................68
10 Communication...................................................................................................69
10.1 USB (option) .....................................................................................................69
10.2 Ethernet (option) ...............................................................................................70
Table of Contents

3
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General Description
1
1
The Montalvo Z4 Unwind tension 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 load cell roller 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.
Load Cell Function
The Z4 is typically used with a pair of half bridge load cells (transducers). It can also be used
with single half or full bridge type. The signals from the paired load cells are summed together
to indicate total web tension across the entire web. Each load cell contains two strain gauges
connected in a series. The two load cells are connected so that the four strain gauges form a
Wheatstone bridge conguration supplied with ±2.5V. The web tension transfers a force to the
load cell roll, changing the resistance values in the bridge. The resulting voltage change is
amplied and calibrated to display actual web tension.
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. Contact Montalvo for further details.
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
To optimize the tension system, a diameter signal is recommended. Diameter can be calculated
by signals from two proximity switches or it can be connected from an analog device such as an
ultrasonic sensor or other device.
Auto Mode Function (Closed Loop)
The operator sets the desired tension using auto setpoint control. The controller compares
actual tension to the auto setpoint, and adjusts output until the actual tension and setpoint are
equal. Because the web itself is part of the feedback loop, the Z4 can quickly compensate for
speed and diameter changes, and for other factors that affect tension during the process.
Manual Mode Function (Open Loop)
The operator sets the desired brake pressure using manual control. The web tension is still
measured and displayed on the tension meter, but is not regulated in this mode. To maintain
tension, the operator must make continued output adjustments.
Overview

4
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General Description
1
1
How It Works
I/P Converter
(Option)
Y
Communication
Z
Z4UL
Unwind
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
Pneumatic
Brake
Load Cell
Web Direction Z
N
(COM) L 24V PE
Z4 CONTROLLER REV2
(C) 2014 MONTALVO
5857565554535251504948474645444342414039383736353433323130
2928272625242322212019181716151413121110987654321
Z4-BULANS
100/240VAC 0.6A
Run Mode TENOFF
R6 R1R2R3R4R5
|||||||||||||||||||||||||||
SERXXXXXX
MADE IN USA
SUPPLY
100-240 VAC
ONLY
(Fuse: 3.15A Slow Blow)
Y OUTPUT
Automatic
Range Expander
(Option)
INPUT Z
USB to PC
(Option)
Ethernet plus
USB to PC
(Option)

5
[email protected] / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo
General Description
1
1
N
(COM) L 24V PE
Z4 CONTROLLER REV2
(C) 2014 MONTALVO
5857565554535251504948474645444342414039383736353433323130
2928272625242322212019181716151413121110987654321
Z4-BULANS
100/240VAC 0.6A
Run Mode TENOFF
R6 R1R2R3R4R5
|||||||||||||||||||||||||||
SERXXXXXX
MADE IN USA
SUPPLY
100-240 VAC
ONLY
(Fuse: 3.15A Slow Blow)
ADJUST TREND CONFIGDISPLAY
Setpoint
Manual
Aux
Diameter
65.0
42.0
62.7
24.5
LB
PSI
%
in
1
2
2
2
2
MAN / AUTO CAL
AUTO
MODE
TENSION
00.0
00.0
25.0
50.0
75.0
100.0
10.0
20.0
30.0
40.0 60.0
50.0
70.0
80.0
90.0
100.0
Output Setpoint
Tension
ADJUST TREND CONFIGDISPLAY
Setpoint
Manual
Aux
Diameter
65.0
42.0
62.7
24.5
LB
PSI
%
in
1
2
2
2
2
MAN / AUTO CAL
AUTO
MODE
TENSION
00.0
00.0
25.0
50.0
75.0
100.0
10.0
20.0
30.0
40.0 60.0
50.0
70.0
80.0
90.0
100.0
Output Setpoint
Tension
Enclosure version
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.
Auto Setpoint In auto mode, output is automatically regulated so that actual
tension reaches the Auto tension setpoint.
Actual Tension Displays actual tension on a scale of 0 to 100% or user assignable
tension range.
Controller Output Meter Displays controller/regulator output on a scale of 0 to 100% or
user assignable output range.
Manual / Auto 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.

6
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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.
6.97 (120)
4.72 (177) 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.
N
(COM) L 24V PE
Z4 CONTROLLER REV2
(C) 2014 MONTALVO
5857565554535251504948474645444342414039383736353433323130
2928272625242322212019181716151413121110987654321
Z4-BULANS
100/240VAC 0.6A
MADE IN USA
Run Mode TENOFF
R6 R1R2R3R4R5
|||||||||||||||||||||||||||
SERXXXXXX
SUPPLY
100-240 VAC
ONLY
(Fuse: 3.15A Slow Blow)

7
[email protected] / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo
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

8
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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.
10.83 (275)
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
9
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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 covered 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
10
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3.2 Basic Diagrams B Version (circuit board only)
0
20
40 60
80
10 0
Tension Output Auto Setpoint Manual Setpoint Machine Input
Regulated OutputTension Input Function Switches
Voltage
0-10V
Voltage
0-10V
I/P Converter
(Current 4-20mA)
12 13 14 41 42 43 415 16 17 31 33 32
44 46 18 19 20 47 48 49 34 36 6
BN
(+2.5V)
WH
(+input)
BK
(-2.5V) tension off
(DI 3)
24Vmanual
(DI 1)
regulated
output
(0-10V)
regulated
output
(4-20mA)
0V24V
(connect if
converter uses
24V power supply)
BN
(-2.5V)
WH
(-input)
BK
(+2.5V)
fast stop
(DI 8)
24V
run
(DI 5)
(10V)
manual
setpoint
(0-10V)
0V
10V
auto
setpoint
(0-10V)
(0V)
tension
output
(0-100µA)
45
tension
output
(0-10V) 0V
10K10K
Terminals 1-58
N
(COM) L 24V PE
Z4 CONTROLLER REV2
(C) 2014 MONTALVO
5857565554535251504948474645444342414039383736353433323130
2928272625242322212019181716151413121110987654321
Z4-BULANS
100/240VAC 0.6A
MADE IN USA
Run Mode TENOFF
R6 R1R2R3R4R5
|||||||||||||||||||||||||||
SERXXXXXX
SUPPLY
100-240 VAC
ONLY
(Fuse: 3.15A Slow Blow)
N (COM) L (24V) PE
PE
N (COM) L (24V) PE
PE
Power Connections
100-240 VAC (standard)
24 VDC (factory option)
Circuit Board

Electrical Installation
3
3
11
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Machine Input
Regulated OutputTension Input Function Switches
Voltage
0-10V
I/P Converter
(Current 4-20mA)
12 13 14 41 42 43 415 16 17 31 33 32
34 36 6
BN
(+2.5V)
WH
(+input)
BK
(-2.5V) tension off
(DI 3)
24Vmanual
(DI 1)
regulated
output
(0-10V)
regulated
output
(4-20mA)
0V24V
(connect if
converter uses
24V power supply)
BN
(-2.5V)
WH
(-input)
BK
(+2.5V)
fast stop
(DI 8)
24V
run
(DI 5)
Terminal Strip 1-58
3.3 Basic Diagrams R Version (circuit board with remote HMI)
N (COM) L (24V) PE
PE
N (COM) L (24V) PE
PE
Power Connections on PCB
100-240 VAC (standard)
24 VDC (factory option)
Circuit Board HMI (showing back side)
N
(COM) L 24V PE
Z4 CONTROLLER REV2
(C) 2014 MONTALVO
5857565554535251504948474645444342414039383736353433323130
2928272625242322212019181716151413121110987654321
Z4-BULANS
100/240VAC 0.6A
MADE IN USA
Run Mode TENOFF
R6 R1R2R3R4R5
|||||||||||||||||||||||||||
SERXXXXXX
SUPPLY
100-240 VAC
ONLY
(Fuse: 3.15A Slow Blow)
USB
HOST
USB
SLAVE
GND FGDC24
COM0 / COM2Ethernet
RESET
ON
1 2
DO NOT use the ports.
Do Not
Remove
Label or
Move
DIP
SWITCHES
If HMI must be RESET,
DO NOT do so while
machine is RUNNING.
DO NOT move DIP switches.
They are factory set to OFF
position and do not require
any further adjustment.
Use USB HOST and
COM0/COM2 only.

Electrical Installation
3
3
12
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Machine Input
Regulated OutputTension Input Function Switches
Voltage
0-10V
I/P Converter
(Current 4-20mA)
12 13 14 41 42 43 415 16 17 31 33 32
34 36 6
BN
(+2.5V)
WH
(+input)
BK
(-2.5V) tension off
(DI 3)
24Vmanual
(DI 1)
regulated
output
(0-10V)
regulated
output
(4-20mA)
0V24V
(connect if
converter uses
24V power supply)
BN
(-2.5V)
WH
(-input)
BK
(+2.5V)
fast stop
(DI 8)
24V
run
(DI 5)
Terminal Strip 1-58
N (COM) L (24V) PE
PE
N (COM) L (24V) PE
PE
Power Connections on PCB
100-240 VAC (standard)
24 VDC (factory option)
Enclosure
3.4 Basic Diagrams E Version (circuit board and HMI in enclosure)
ADJUST TREND CONFIGDISPLAY
Setpoint
Manual
Aux
Diameter
65.0
42.0
62.7
24.5
LB
PSI
%
in
1
2
2
2
2
MAN / AUTO CAL AUTO
MODE
TENSION
00.0
00.0
25.0
50.0
75.0
100.0
10.0
20.0
30.0
40.0 60.0
50.0
70.0
80.0
90.0
100.0
Output Setpoint
Tension

Electrical Installation
3
3
13
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3.5 Terminal Blocks
2928272625242322212019181716151413121110987654321
5857565554535251504948474645444342414039383736353433323130
DI 2 Splice
DI 4 Cal 2
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
+Load Cell Input
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
Tension Output 0 to +10V
Tension Output 0 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
Load Cell
- Input

Electrical Installation
3
3
14
[email protected] / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo
N
(COM) L 24V PE
Z4 CONTROLLER REV2
(C) 2014 MONTALVO
5857565554535251504948474645444342414039383736353433323130
2928272625242322212019181716151413121110987654321
Z4-BULANS
100/240VAC 0.6A
Run Mode TENOFF
R6 R1R2R3R4R5
|||||||||||||||||||||||||||
SERXXXXXX
SUPPLY
100-240 VAC
ONLY
(Fuse: 3.15A Slow Blow)
-2.5V
-INPUT
+2.5V
0V
A - Connections for a Pair of Half Bridge Load
C - Connection for Single Half Bridge Load Cell
100 ohm resistor
100 ohm resistor
Wire colors refer to standard cables supplied by Montalvo
BN
WH
BK
Load Cell 1 Cable
Load Cell Cable
Load Cell Cable
Load Cell 2 Cable
B - Connections for Single Full Bridge Load Cell
§
43424140
+2.5V
+INPUT
-2.5V
0V
BN
WH
BK
14131211
-2.5V
-INPUT
+2.5V
0V
BL
43424140
+2.5V
+INPUT
-2.5V
0V
BN
WH
BK
14131211
-2.5V
-INPUT
+2.5V
0V
43424140
+2.5V
+INPUT
-2.5V
0V
BN
WH
BK
14131211
MADE IN USA
3.6 Installation - Load Cell
The following terminals are for load cell connections. The standard cable from Montalvo is
supplied with a connector for the load cell. Wire the other end into the terminal block of the
circuit board.
PCB Terminals
# Description
12 -2.5V Supply
13 + Load Cell Input
14 + 2.5V Supply
41 + 2.5V Supply
42 - Load Cell Input
43 -2.5V Supply
Montalvo Load Cells
Series Connection Diagram
ES & T Pair A
U & UPB Pair A
F Pair A
N & TNT Single B
X Single B
R Single C
Z4 Circuit Board
Connection Diagrams

Electrical Installation
3
3
15
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1. Check that load cells are mounted and oriented properly, referring to installation instructions.
2. Before applying power to the controller, check that analog tension meter, if used, is set to
zero. If using Montalvo M4 tension meter, mechanically adjust needle with screw at base of
meter scale as needed. Note: If using Z4 HMI, digital display of tension will match circuit
board adjustment.
3. Apply power to the controller and let it warm up for at
least 10 minutes.
4. Enter [Status Menu] and scroll to [Tension] .
5. With web removed and no tension applied to the sensing
roller, adjust potentiometer R1 until tension readout on
circuit board is 0%. If value is below zero, turn R1 clockwise; if
above, turn counter clockwise. Note: R1 and R2 are 25
turn potentiometers, so many rotations may be required.
6. Thread a rope over the center of the tension-sensing roller
following the exact path of the web. Make sure that the rope
extends at least one roller before and one roller after the
sensing roller. Make sure that the rope does not pass over
any dead bars or non-freewheeling rollers. Fasten one end
of the rope securely.
8. Attach a weight of known value to the other end of the
rope. For best results, the weight should be at least 25%
of the analog meter’s full-scale value. A tension value below
0% with the weight hung indicates that the signal from the
load cells is reversed. In the event of such a reversal, switch
wires 12 & 14 and 41 & 43 on the terminal block. To
break friction between the rollers and the rope, rotate rollers
in the direction of the weight.
7. Adjust potentiometer R2 until tension readout on circuit board
is identical to the hanging weight. Scaling on an analog meter
or Z4 HMI is automatic. Tension will appear as a percentage
value (%).
9. Remove weight and check that tension meter returns to
zero. If not, repeat steps 4 to 7.
10. If a second calibration range is used, repeat steps 4 to 8,
using potentiometer R3 for calibration of the second range.
See 3.10 Digital Input (24V).
3.7 Installation - Tension Calibration
Known
Weight
Rope fastened
to this roller
Load Cell
Roller
Calibration Example:
Adjust R1...................................... 0.0%
Choose Full Scale ........................... 200
Apply Known Weight......................... 75
Divide 75/200 ................................ .375
Convert .375 to % ...................... 37.5%
Adjust R2.................................... 37.5%
BN
WH
BK
43424140
BN
WH
BK
14131211
1
2
3
4
5
Status Menu
Version
Tension
Setpoint
Output
I-Level
Gain Level
Manual
Diameter
Aux1 In
Aux2 In
Aux3 In
Aux1 Out
Aux2 Out
IO Terminal Menu
Ext Status Menu
Not all menus appear all
the time. Menus either
irrelevant to the mode
or without the correct
password will not appear.

Electrical Installation
3
3
16
[email protected] / www.montalvo.com / Technical details subject to change without notice. Z4-UL-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 to10V I/P or
other converter. Can control motor drives operating in torque
mode. Maximum load: 5 mA.
N
(COM) L 24V PE
Z4 CONTROLLER REV2
(C) 2014 MONTALVO
5857565554535251504948474645444342414039383736353433323130
2928272625242322212019181716151413121110987654321
Z4-BULANS
100/240VAC 0.6A
Run Mode TENOFF
R6 R1R2R3R4R5
|||||||||||||||||||||||||||
SERXXXXXX
SUPPLY
100-240 VAC
ONLY
(Fuse: 3.15A Slow Blow)
0 to 10V
4 to 20mA
0V
A - I/P Converter Wiring
(signal = 4 to 20mA)
§
§
171615
0 to 10V
4 to 20mA
0V
B - I/P Converter Wiring
(signal = 4 to 20mA and
24V supply)
171615
24V
10987654321
I
P
MADE IN USA

Electrical Installation
3
3
17
[email protected] / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo
3.9 Installation – Power Supply
NNeutral (COM)
LSupply Voltage 100/240 VAC
PE Ground
N0V
L24 VDC
PE Ground
N
(COM) L 24V PE
Z4 CONTROLLER REV2
(C) 2014 MONTALVO
5857565554535251504948474645444342414039383736353433323130
2928272625242322212019181716151413121110987654321
Z4-BULANS
100/240VAC 0.6A
MADE IN USA
Run Mode TENOFF
R6 R1R2R3R4R5
|||||||||||||||||||||||||||
SERXXXXXX
SUPPLY
100-240 VAC
ONLY
(Fuse: 3.15A Slow Blow)
N (COM) L (24V) PE
PE
N (COM) L (24V) PE
PE


VAC Circuit Boards
VDC Circuit Boards
N
(COM) L 24V PE
Z4 CONTROLLER REV2
(C) 2014 MONTALVO
5857565554535251504948474645444342414039383736353433323130
2928272625242322212019181716151413121110987654321
Z4-BULDE
24VDC 0.75A
Run Mode TENOFF
R6 R1R2R3R4R5
|||||||||||||||||||||||||||
SERXXXXXX
SUPPLY
24 VDC
ONLY
(Fuse: 1.0A)
MADE IN USA

Electrical Installation
3
3
18
[email protected] / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo
3.10 Digital Input (24V)
Digital
Input #
Terminal
#Function LED Color
Menu
Section Description
DI 1 31 Manual Red
When activated by a 24V signal, the controller
switches to manual mode. Manual setpoint
then sets the output level. When deactivated,
the controller regulates from the manual level.
DI 2 2 Splice Yellow 5.11
Splice
This input is used to control the regulator during
the splice sequence.
DI 3 32 Tension
Off Red
5.4
Roll
Change
When activated by a 24V signal, the output
goes to zero and the regulator is reset. This
function is used at roll change. When the input
goes low, the regulator is set to the new roll
parameters.
DI 4 3 Cal-2 Yellow
When activated by a 24V signal, the controller
will change to a second calibration range for
the load cell input. This is typically used if a
double tension scale is necessary or if the web
runs two ways with different wrap angles.
DI 5 34 Run Red
5.5
Start
and
5.7
Hold
The Run signal from the machine has to be
connected to this input. This is used to control
the starting sequence, and to release the
regulator when the machine is running. When
the signal is deactivated and the machine is at
zero speed, the regulator is held at a constant
stored level.
DI 6 5Web
Pulse Yellow 5.8 Diameter
A proximity switch is mounted to sense the
web length/pulse, which is used for diameter
calculation.
DI 7 35 Roll
Pulse Red 5.8 Diameter
A proximity switch is mounted to sense pulses
per revolution on the roll, which is used for
diameter calculation.
DI 8 6Fast
Stop Yellow 5.6 Stop
This input is used to control the regulator when
the machine is making a fast stop.
N
(COM) L 24V PE
Z4 CONTROLLER REV2
(C) 2014 MONTALVO
5857565554535251504948474645444342414039383736353433323130
2928272625242322212019181716151413121110987654321
Z4-BULANS
100/240VAC 0.6A
MADE IN USA
Run Mode TENOFF
R6 R1R2R3R4R5
|||||||||||||||||||||||||||
SERXXXXXX
SUPPLY
100-240 VAC
ONLY
(Fuse: 3.15A Slow Blow)


Electrical Installation
3
3
19
[email protected] / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo
Run - Digital Input 5 (terminal 34)
The run input serves the following purposes:
1.To control and release the regulator at start-up.
2.To stop and hold the regulator when the machine is not running.
For set-up, see 5.5 Start Menu and 5.7 Hold Menu.
Electrical Wiring
Below a typical example of how to connect the run signal:
Parameter Descriptions
[DI-5 Invert] Select: [NO] or [YES]
The run signal is activated with a high (24V) signal. If the inverted function is needed, then
change the parameter [DI-5 Invert] to [YES]. Default is set to [NO].
T
E
Setup Menu
Cong Menu
Options Menu
Use Stop
Use Taper
Use Dig Out
Use Splice
Use Rng Exp
Use Aux1 In
Use Aux2 In
Use Aux1 Out
Use Var Wrap
DI Mode Menu
DI-5 Invert
DI-8 Invert
DI-3 Mode
DI-4 Mode
DI-8 Mode
Regulator Menu
Roll Change Menu
Start Menu
Stop Menu
Hold Menu
Diameter Menu
Taper Menu
Digital Out Menu
Splice Menu
Range Exp Menu
Aux1 Input Menu
Aux2 Input Menu
Aux1 Output Menu
Wrap Angle Menu
Com Menu
3.10 Digital Input (24V) - continued
39383736353433323130
+24V
Run DI 5 4(NO)
3(COM)
STOP
K100
Machine START
START K100
39383736353433323130
+24V
Run DI 5 2(NC)
1(COM)
K200
ZERO
speed signal
from machine
Machine Speed ZERO
Run
Mode
Hold
Delay
Time
Stop
Mode
Hold
Mode
Hold
Mode
Machine
Speed
Start
Zero
Speed
100%
0%
0
1
0
1
Not all menus appear all
the time. Menus either
irrelevant to the mode
or without the correct
password will not appear.