Montalvo Z4 User manual

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Montalvo
Z4 Web Tension Controller
With Ethernet Communications Option
EST. 1947
TECHNICAL MANUAL
Z4 Web Tension Controller
With Ethernet Communications Option
Firmware Version 1.2 / Publication Date 01/21/2019
PE
Z4 CONTROLLER REV#
(C) 20XX MONTALVO
5857565554535251504948474645444342414039383736353433323130
2928272625242322212019181716151413121110987654321
Z4XXXXX
11XXXXXX
Made In USA
R6 R1R2R3R4R5
Run Mode AUTO
|||||||||||||||||||||||||||
SERXXXXXX
N L
|||||||||||||||||||||||||||
SERXXXXXX
SUPPLY
100-240 VAC
ONLY
(Fuse: 3.15A Slow Blow)
 Communication 
(Ethernet I/P)

Communication 10
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10.2-1
10.2 Ethernet (option)
The Montalvo Z4 Controller, with Ethernet Option, can provide communication capability within
an industrial Ethernet network (e.g. Ethernet/IP). The module for this option is factory installed.
Existing controllers without the option can be upgraded by replacing the HMI Module (or cover
plate) with the Ethernet Module. Factory replacement highly recommended.
Note: The HMI Module or Ethernet Module is necessary for connection to the HMI.
New controllers with HMI get HMI module (standard) or Ethernet module (optional).
The Ethernet communications option consists of the following:
• Ethernet Module - factory installed on the controller board
• Ethernet Technical Manual (hard copy). Also available as a pdf download:
http://www.montalvo.com/document-libraries/product-manual-library/ten-
sion-controller-manuals/
Technical Specications for Ethernet interface
• Support for all required administration protocols (DHCP, ICMP, IGMP)
• Support for TCP and UDP application protocols per ODVA Ethernet/IP requirements
• Future support for additional Ethernet based protocols
PE
Z4 CONTROLLER REV#
(C) 20XX MONTALVO
5857565554535251504948474645444342414039383736353433323130
2928272625242322212019181716151413121110987654321
Z4XXXXX
11XXXXXX
Made In USA
R6 R1R2R3R4R5
Run Mode AUTO
|||||||||||||||||||||||||||
SERXXXXXX
N L
|||||||||||||||||||||||||||
SERXXXXXX
SUPPLY
100-240 VAC
ONLY
(Fuse: 3.15A Slow Blow)
Z4 Controller
 Communication 
HMI (RS232)
Ethernet
Power
CPU
I/O I/O I/O I/O I/O I/O
 Communication 
Ethernet (e.g. Ethernet/IP)
Customer
USB Drive
Z4 HMI
ADJUST TREND DATALOG SCALING CONFIGDISPLAY
Diameter
28.0 in
Aux
0.0 %
Manual
36.0 psi
Setpoint
556. lb
Do 1 234
Di 1 2 3 4 58
Rng1
Man / Auto
AUTOMODE
Cal2
Ten Off / On
0.000
0.000
0.250
0.500
0.750
1.000
0.100
0.200
0.300
0.400 0.600
0.500
0.700
0.800
0.900
1.000
Output Setpoint
X1000 lb
x100 psi
Tension
561.
lb
PWR
CPU
COM
Web Tension Controller
Z4
Z4®

R6 R1R2R3R4R5
HMI comes standard
with USB port for
copying stored data
(see section 10.1
of full manual)
Ethernet
HMI RS232
HMI RS232
Option - Ethernet Module
R6 R1R2R3R4R5
R6 R1R2R3R4R5
Cover Plate
HMI Module
No Connectors

Communication 10
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10.2-2
Features
• ODVA certied industrial Ethernet
• Provides assemblies for streaming data to and from the controller
• Provides a series of tuning parameters to allow adjusting performance on the y
• Load cells or dancer position sensor are the only input that needs to be wired to the controller
• All outputs can be streamed to a PLC or other device on the network
Connecting to the Z4 board
The Z4 Ethernet communications board is pre-programmed with the static IP address of
192.168.1.202. This can be changed by connecting both the Z4 and a computer to a local
network and using a browser (Firefox, Chrome, etc) to navigate to address 192.168.1.202 and
changing the IP address, which can be found under the ‘Conguration’ tab. The module can
also be congured to support DHCP.
Parameter Setting
IP Address 192.168.1.202
Vendor ID 824
Product ID 11000839
Product Name Z4 Controller
Assemblies
Originator -> Target
Parameter Size (bytes) Data Type Index Min Value Max Value
REMOTE_AI6 2 INT 0 0 1000
REMOTE_AI7 2 INT 2 0 1000
REMOTE_AO4 2 INT 4 0 1000
REMOTE_DI2 2 UINT 6 0 1
REMOTE_DI5 2 UINT 8 0 1
REMOTE_DI8 2 UINT 10 0 1
10.2 Ethernet (option)

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10.2-3
Target -> Originator
Parameter Size (bytes) Data Type Index Min Value Max Value
AI1_MANAGED 1 BOOL 0 0 1
AI4_MANAGED 1 BOOL 1 0 1
AI5_MANAGED 1 BOOL 2 0 1
AI6_MANAGED 1 BOOL 3 0 1
DI1_MANAGED 1 BOOL 4 0 1
DI2_MANAGED 1 BOOL 5 0 1
DI3_MANAGED 1 BOOL 6 0 1
DI4_MANAGED 1 BOOL 7 0 1
DI5_MANAGED 1 BOOL 8 0 1
AI7_MANAGED 1 BOOL 9 0 1
DI8_MANAGED 1 BOOL 10 0 1
AO4_MANAGED 1 BOOL 11 0 1
SYSTEM_AI1 2 INT 12 0 1000
SYSTEM_AI2 2 INT 14 0 1000
SYSTEM_AI3 2 INT 16 0 1000
SYSTEM_AI4 2 INT 18 0 1000
SYSTEM_AI5 2 INT 20 0 1000
SYSTEM_AI6 2 INT 22 0 1000
SYSTEM_AI7 2 INT 24 0 1000
SYSTEM_AI8 2 INT 26 0 1000
AUX1_OUTPUT 2 INT 28 -1000 1000
AUX2_OUTPUT 2 INT 30 -1000 1000
RUNMODE 2 UINT 32 0 15
CTRLSUBTYPE 2 UINT 34 0 2
CTRLTYPE 2 UINT 36 0 5
RANGE 2 UINT 38 0 4
SETPOINT 2 INT 40 0 1000
TAPERED_SETPOINT 2 INT 42 0 1000
DIAMETER 2 INT 44 0 1000
ALM_WEBBREAK 1 BOOL 46 0 1
ALM_DIAMETER 1 BOOL 47 0 1
ALM_LOWTENSION 1 BOOL 48 0 1
ALM_HIGHTENSION 1 BOOL 49 0 1
ALM_LINESPEED 1 BOOL 50 0 1
MOTOR_ACTIVE 1 BOOL 51 0 1
DO1_STATE 1 BOOL 52 0 1
DO2_STATE 1 BOOL 53 0 1
DO3_STATE 1 BOOL 54 0 1
DO4_STATE 1 BOOL 55 0 1
DI1_STATE 1 BOOL 56 0 1
DI2_STATE 1 BOOL 57 0 1
DI3_STATE 1 BOOL 58 0 1
DI4_STATE 1 BOOL 59 0 1
DI5_STATE 1 BOOL 60 0 1
DI8_STATE 1 BOOL 61 0 1
10.2 Ethernet (option)

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10.2-4
10.2 Ethernet (option)
Tuning Parameters
All of the following parameters are used for tuning the operation of the Z4 controller and can be
accessed using explicit messaging (Class 3 connections).
Parameter Size (bytes) Data Type Read Only Min Value Max Value
DI3_MODE 2 UINT X 0 1
DI4_MODE 2 UINT X 0 3
DI8_MODE 2 UINT X 0 1
MIN_SP 2 UINT X 0 500
TAPER_BEGIN 2 UINT 10 500
SOFTSTRT_REDUX 2 UINT 0 200
PID_GAINLEVEL 2 UINT 0 255
PID_P_LEVEL 2 UINT 0 255
PID_I_TIME 2 UINT 0 255
PID_D_LEVEL 2 UINT 0 255
GAIN_EXP 2 UINT 10 30
GAIN_MAX 2 UINT 0 500
GAIN_MIN 2 UINT 0 50
GAIN_BOOST 2 UINT 0 4
GAIN_LEVEL 2 UINT X 0 100
AUX1IN_VALUE 2 UINT X 0 1000
AUX2IN_VALUE 2 UINT X 0 1000
SPLICE_LEV 2 UINT 0 2000
SPDTRIM_OUT 2 UINT 0 1000
Physical Control Signal Mapping
Documentation Name : The name used in the documentation
Wired Terminal : The physical terminal on the Z4 controller
System Value : The parameter used by Ethernet to obtain the current value
Source Selection : The Ethernet parameter that determines the source of the signal
If 0, the wired connection provides this value
If 1, the Ethernet interface provides this value
Ethernet Provided : If Source Selection is 1, this is the Ethernet Parameter used to provide
the input value

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10.2-5
10.2 Ethernet (option)
Analog Input Signals
Documentation
Name
Wired
Terminal
System Value
(Read Parameter)
Source Selection
(Write Parameter)
Ethernet Provided
(Input Parameter)
AI1 19 System_AI1 AI1_Managed Remote_AI1
AI4 48 System_AI4 AI4_Managed Remote_AI4
AI5 51 System_AI5 AI5_Managed Remote_AI5
AI6 25 System_AI6 AI6_Managed Remote_AI6
AI7 54 System_AI7 AI7_Managed Remote_AI7
Aux1 In (AI5 ltered) 51 (processed) Aux1 Input n/a n/a
Aux2 In (AI7 ltered) 54 (processed) Aux2 Input n/a n/a
Analog Output Signals
Documentation
Name
Wired
Terminal
System Value
(Read Parameter)
Source Selection
(Write Parameter)
Ethernet Provided
(Input Parameter)
Aux1 Output 57 Aux1_Output AO4_Managed Remote_AO4
Aux2 Output 23 Aux2_Output n/a n/a
Digital Input Signals
Documentation
Name
Wired
Terminal
System Value
(Read Parameter)
Source Selection
(Write Parameter)
Ethernet Provided
(Input Parameter)
DI1 31 Di1_State DI1_Managed Remote_DI1
DI2 2 Di2_State DI2_Managed Remote_DI2
DI3 32 Di3_State DI3_Managed Remote_DI3
DI4 3 Di4_State DI4_Managed Remote_DI4
DI5 34 Di5_State DI5_Managed Remote_DI5
DI8 6 Di8_State DI8_Managed Remote_DI8
Digital Output Signals
Documentation
Name
Wired
Terminal
System Value
(Read Parameter)
Source Selection
(Write Parameter)
Ethernet Provided
(Input Parameter)
DO1 38 Do1_State n/a n/a
DO2 9 Do2_State n/a n/a
DO3 39 Do3_State n/a n/a
DO4 10 Do4_State n/a n/a

Communication 10
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10.2-6
10.2 Ethernet (option)
System Signals Mapping
Menu Accessible Signals
Parameter Read/Write Related Menu Entry
RunMode R Run Mode
CtrlType R \ Setup Menu \ Cong Menu \ Ctrl Type
CtrlSubType R \ Setup Menu \ Cong Menu \ RWD Type or
\ Setup Menu \ Cong Menu \ NIP Type
Diameter R \ Status Menu \ Diameter
Tapered_Setpoint R \ Status Menu \ Setpoint
Taper_Begin R \ Setup Menu \ Taper Menu \ Tap Begin
Min_SP R \ Setup Menu \ Dancer Menu \ Ten Min
Splice_Lev R/W \ Setup Menu \ Splice Menu \ Spl Level
Range R \ Setup Menu \ Range Exp Menu \ Active No.
SoftStart_Redux R/W \ Setup Menu \ Start Menu \ Start Lev
Gain_Boost R/W \ Setup Menu \ Cong Menu \ Sensitivity
DI3_Mode R \ Setup Menu \ Options Menu \ DI Mode Menu \ DI-3 Mode
DI4_Mode R \ Setup Menu \ Options Menu \ DI Mode Menu \ DI-4 Mode
DI8_Mode R \ Setup Menu \ Options Menu \ DI Mode Menu \ DI-8 Mode
PID_Gain_Level R/W \ Setup Menu \ PID Menu \ Sys Gain
PID_P-Level R/W \ Setup Menu \ PID Menu \ P Level
PID_I-Time R/W \ Setup Menu \ PID Menu \ I Level
PID_D-Level R/W \ Setup Menu \ PID Menu \ D Level
Gain_Exp R/W \ Setup Menu \ Gain Menu \ Gain Slope
Gain_Max R/W \ Setup Menu \ Gain Menu \ Gain Max
Gain_Min R/W \ Setup Menu \ Gain Menu \Gain Min
Gain_Level R \ Setup Menu \ Gain Menu \ Gain Level
AuxIn1_Value R \ Status Menu \ Aux1 Out
AuxIn2_Value R \ Status Menu \ Aux2 Out
SpdTrim_Out R \ Setup Menu \ Regulator Menu \ Trim Menu \ Trm Level
Internal System Signals
Parameter Read/Write Menu Entry
Setpoint R Internal Un-Tapered Setpoint (system setpoint before taper calculation)
Digital Alarm Signals
Documentation Name Alarm Condition
Alm_WebBreak Web break detected (typically drop in tension)
Alm_Diameter Diameter has passed through specied limit
Alm_LowTension Tension is below pre-dened limit
Alm_HighTension Tension is above pre-dened limit
Alm_Linespeed Linespeed is above specied limit
Motor_Active Signaled when Z4 is on control of motor and shaft is turning

Communication 10
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10.2-7
Conguring the Z4 Network Settings
Introduction
While the Z4 comes set up and ready to operate on a network, there are internal tools that
allow for the customization of the device, including changing the IP address, enabling DHCP
functionality and other network behaviors.
Finding the Z4 on the Network Using IPCong
The rst step to changing the Z4 settings is having the IP address of the Z4 controller in order
to be able to send network trafc to the device. While the Z4 controller should come pre
programmed to use the IP address: 192.168.1.202, it is possible it would have either been
changed or DHCP enabled. In the event that the IP address is unknown, a program called
‘IPCong’ distributed by HMS Industrial Networks (download here) that will detect all Z4
controllers on the network (and any other devices that are using the Anybus module).
Pressing the ‘Scan’ button on the IPCong home screen will cause the software to detect any
modules present on the network and display some basic network settings for that module as
shown in Figure 1.
Figure 1: IPCong home screen after detecting Z4 controller
If you would like to change any of the settings for the module, right-click the device you want to
congure and select ‘Conguration’. As can be seen, you can also open the internal website for
the module from this menu as well by clicking ‘Open Web-Interface’.
10.2 Ethernet (option)

Communication 10
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10.2-8
Figure 2: Selecting the Conguration menu option for the Z4 controller
The Conguration menu for the Z4 will allow for Ethernet conguration, including changing the IP
address and turning DHCP functionality on or off. After making a change to these settings, the
Z4 controller needs to be power cycled in order for the changes to take effect.
Figure 3: IPCong Ethernet conguration window
10.2 Ethernet (option)

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10.2-9
If your computer has both an Ethernet network card and a wireless card, sometimes the
software will need to be explicitly told to use the Ethernet card in order to detect the module.
This can be done by clicking the ‘Settings’ button at the bottom of the home page. On the
screen that appears, check the box labeled ‘Broadcast from a specic network interface
controller’, then, in the drop down menu, select your Ethernet card. If you’re uncertain which
option that is, try each setting until connection is established.
Figure 4: IPCong settings window
Using the Z4 Controller’s Internal Website
The Z4 controller with Ethernet has an internal website built into it that can be used both to
interact with the controller as well as to congure the device’s Ethernet settings. The site can
be accessed by typing the controller’s IP address 192.168.168.202 into a browser for any
computer on the same network as the Z4 controller.
Figure 5: Home page for Z4 controller Ethernet module
10.2 Ethernet (option)

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10.2-10
The internal site can also be used in order to interact with the Z4 controller itself, serving as
a basic HMI over Ethernet. In order to read or write values to the Z4 controller, click on the
‘Parameters’ button on the left side of the screen, which will load the Z4 parameters that can be
accessed using the Ethernet interface.
The internal site will allow for conguration of Ethernet settings for the Z4 controller, including
setting the IP address, port conguration and turning DHCP on or off. In order to access the
conguration options, click on the ‘Conguration’ button on the left side of the screen. Any
changes made to the module will not be set unless the ‘Save Settings’ button is clicked for the
device. After saving the settings, the module will need to be power cycled before the settings
can take effect.
Figure 6: Conguration page for Z4 controller internal website
To change a value for a parameter, type the desired value in the text eld and click on the ‘Set’
button to the right of the eld. The website is a rudimentary tool, and will not help constrain
inputs to valid values, though the Z4 controller will reject them. If setting a parameter isn’t
working, there’s a good chance the desired value is out of the valid range for that particular
parameter.
10.2 Ethernet (option)

Communication 10
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10.2-11
Using the Z4 with Remote Interfaces
Using Multiple Interfaces
The Z4 with Ethernet/IP now works will all of the various remote interfaces possible
simultaneously. It is possible to use USB, HMI and Ethernet/IP communications at the same
time. When using more than one remote interface, the Z4 uses a simple arbitration mechanism
to reduce instances of the various forms of control attempting to change the same parameter
to different desired values. When a parameter is changed, for 3 seconds after that point, no
other remote interface is able to make a change to the value. After this time elapses, any of
the interfaces may be used to change a parameter, and will in turn get a 3 second lock on that
parameter. The notable exception to this arbitration is the LCD screen built onto the face of the
Z4 controller which will always take precedence over remote forms of communication.
Changing Conguration Parameters
There are some parameters in the Z4 controller that can only be changed remotely by putting
the controller into the conguration mode, which puts the controller into standby and keeps it
from attempting to regulate tension. This is done to prevent changing parameters that could
have a negative effect if changed while the machine is running. Attempts to remotely change the
conguration mode parameters will be ignored.
To put the Z4 controller into conguration mode, navigate to ‘Setup Menu > Com Menu’ and
change the Cong Mode setting from ‘No’ to ‘Yes’. This operation can be performed using
either the LCD screen on the face of the Z4 controller or the USB interface. Once done changing
the parameters, the Z4 controller should be taken out of Cong Mode.
10.2 Ethernet (option)

Communication 10
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10.2-12
Troubleshooting
Z4 Isn’t at Default Address
• Use the IPCong software to detect the module on the network. It’s possible the IP
Address has been changed, or DHCP was enabled.
IPCong Software Doesn’t Detect Z4
• It’s possible the module is doing a rmware update. Allow up to a minute for the module
to come online.
• Make sure the Z4 has a working physical connection to the network. The network
indicator lights on the Ethernet socket for the controller should show whether the device
is connected to the network or not.
Unable to Change Parameter Values
• Some parameters are allowed changeable when the Z4 Controller is in conguration
mode, as changing them during operation of the machine could be dangerous. To
put the Z4 controller in conguration mode, navigate to Setup Menu > Com Menu >
Conguration, and set the value to yes. Bear in mind this will put the controller into
tension off and the controller will no longer attempt to regulate tension.
Z4 is not Responding to Packets Sent to its IP Address
• It is possible the Z4 has an IP Address that is shared with another device on the network.
Try changing the IP Address of the module using the IPCong software, and sending
packets again.
10.2 Ethernet (option)

The Montalvo Corporation
50 Hutcherson Drive, Gorham, Maine 04038 USA
Fax: [phone]
1-800-226-8710 / [email protected] / www.montalvo.com
Technical details subject to change without notice. Z4-Enet-technical manual-us © Montalvo
EST. 1947
The Montalvo Corporation
(Corporate Headquarters)
Gorham, Maine 04038
USA
Tel: [phone]
Tel: [phone]
[email protected]
Montalvo Europe ApS
DK-8700 Horsens
Denmark
Tel: [phone]
[email protected]
Montalvo Deutschland
Hannover
Germany
Tel: [phone]
[email protected]
Montalvo (Shanghai) Trading Co., Ltd
Shanghai
China 200062
Tel: [phone]
[email protected]
207-856-2501 / 800-226-8710
[phone]
[phone]
[phone]