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 02/25/2020
PE
Z4 CONTROLLER REV#
(C) 20XX MONTALVO
5857565554535251504948474645444342414039383736353433323130
2928272625242322212019181716151413121110987654321
Z4XXXXX
11XXXXXX
Made In USA
R6 R1R2R3R4R5
Run Mode AUTO
|||||||||||||||||||||||||||
SERXXXXXX
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|||||||||||||||||||||||||||
SERXXXXXX
SUPPLY
100-240 VAC
ONLY
(Fuse: 3.15A Slow Blow)
 Communication 
(Ethernet I/P)

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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 Ethernetm 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:
https://www.montalvo.com/document-libraries/product-manual-library/tension-control-
ler-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 Port
CPU
Power
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
Lorem ipsum

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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 and most inputs can be streamed to a PLC or other device on the network
Connecting to the Z4 via the Ethernet Interface 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 ethernet interface 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. Details for changing the IP address can
also be found in the section "Conguring the Z4 Network Settings" later in this manual.
Parameter Setting
IP Address 192.168.1.202 (Editable)
Vendor ID 824
Product ID 11000839
Product Name Z4 Controller
Assemblies
Refer to the EIP Instance Assembly chart in Appendix 2 to determine the parameters capable of
READ/WRITE access in the Remote (PLC).
Z4 Managed Control
The PLC can only write to parameters in the Z4 that are mapped to physical connections
(analog and digital) if they are congured rst in the Setup Menu/Com Menu/Remote Menu/
Enable Menu in the Z4. The individual parameters' remote access is set to NO if remote control
is not allowed (default), YES if it is.
These parameters are shown on the following pages.
10.2 Ethernet (option)

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10.2-3
10.2 Ethernet (option)
Analog Input Signals
Documentation
Name
Wired
Terminal
Source Selection
(Write Parameter)
System Value
(Read Parameter)
Ethernet Provided
(Input Parameter)
AI1 19 AI1_Managed System_AI1 Remote_AI1
AI4 48 AI4_Managed System_AI4 Remote_AI4
AI5 51 AI5_Managed System_AI5 Remote_AI5
AI6 25 AI6_Managed System_AI6 Remote_AI6
AI7 54 AI7_Managed System_AI7 Remote_AI7
Aux1 In (AI5 ltered) 51 (processed) n/a Aux1 Input n/a
Aux2 In (AI7 ltered) 54 (processed) n/a Aux2 Input n/a
Analog Output Signals
Documentation
Name
Wired
Terminal
Source Selection
(Write Parameter)
System Value
(Read Parameter)
Ethernet Provided
(Input Parameter)
Aux1 Output 57 AO4_Managed Aux1_Output Remote_AO4
Aux2 Output 23 n/a Aux2_Output n/a
Digital Input Signals
Documentation
Name
Wired
Terminal
Source Selection
(Write Parameter)
System Value
(Read Parameter)
Ethernet Provided
(Input Parameter)
DI1 31 DI1_Managed Di1_State Remote_DI1
DI2 2 DI2_Managed Di2_State Remote_DI2
DI3 32 DI3_Managed Di3_State Remote_DI3
DI4 3 DI4_Managed Di4_State Remote_DI4
DI5 34 DI5_Managed Di5_State Remote_DI5
DI8 6 DI8_Managed Di8_State Remote_DI8
Digital Output Signals
Documentation
Name
Wired
Terminal
Source Selection
(Write Parameter)
System Value
(Read Parameter)
Ethernet Provided
(Input Parameter)
DO1 38 n/a Do1_State n/a
DO2 9 n/a Do2_State n/a
DO3 39 n/a Do3_State n/a
DO4 10 n/a Do4_State n/a
Managed Parameters
(Physical I/O on Z4 and associated System Parameters)

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10.2-4
Conguring the Z4 Network Settings
Introduction
While the Z4 comes preset with static IP of 192.168.1.202 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 set to
the users’ intended subnet. There are a number of utilities available to do this, but a simple and
effective one is 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).
Note: One alternate method of setting the Z4 EIP IP address is by using the Rockwell Software
RSLinx classic as outlined in Appendix 1 under Details of the conguration steps to perform.
Another is to use the Z4’s built-in website. This method can be read in the following section
“Using the Z4 Controller’s Internal Website”
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)

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10.2-5
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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10.2-6
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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10.2-7
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)

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10.2-8
Using the Z4 with Remote Interfaces
Using Multiple Interfaces with a Single Z4
The Z4 with Ethernet/IP now works with 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
!!!! IMPORTANT !!!!
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)

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10.2-9
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 can be changed 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. This will put the controller into tension off mode
and the controller will no longer attempt to regulate tension.
• The PLC can only write to parameters in the Z4 that are mapped to physical connections
(analog and digital) if they are congured rst in the Setup Menu/Com Menu/Remote
Menu/Enable Menu in the Z4. See the section Z4 Managed Control in this manual for details.
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)

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10.2-10
Appendix 1
Z4 with Ethernet I/P Interface for Rockwell Logix5000-based
controllers
This is a guide to conguring your Rockwell Logix PLC to recognize and communicate with the
Monalvo Z4 Ethernet I/P interface. Throughout the remainder of this document the interface
protocol Ethernet I/P will be referenced by its common acronym EIP.
This guide is a supplement to the Montalvo user manuals (all obtainable documents are
accessible at https://www.montalvo.com/document-libraries/product-manual-library/tension-
controller-manuals/) and is not intended as a training document for Rockwell software nor for
their hardware. Methods and steps referenced are usually not the only way to accomplish the
task at hand but rather have been found to work and are the easiest known ways to do it. The
user must understand the RSLogix5000/Studio5000 programming environment and RSLinx
Classic to congure the communication. Understanding CIP explicit messaging is a plus but
using the sample Logix le as a guide will sufce.
Different versions of RSLogix 5000 and Studio 5000 will require conguration steps in different
orders, such as when to register the eds le. If you have any problems speak to the Montalvo
controls engineer for assistance or contact your Rockwell Software representative, as this type
of issue is due to a Rockwell environment change.
Overview of the steps to perform
Brief descriptions of the following detailed sections of this document.
1. Obtain the latest versions of the following les in your language choice (all references here
are for English-US). Download here or contact customer service.
a. One of the technical manuals Z4NL-NIP, Z4RL, Z4UD, Z4UI, Z4UL depending on
your specic application.
b. The suite of support les in RSLogix_Z4 _EIP_support.zip
It contains:
i. Z4-Ethernet-IP-option-manual-us-e.pdf - a copy of this manual.
ii. Montalvo_Z4v20.L5K le. This is an RSLogix 5000 import/export text
le, usable to create a new PLC program of one RSLogix version from an
exported le of a different version. For Logix 5000 Import/Export help reference
Rockwell manual 1756-RM084Y-EN-P.
ii. Z4Controller_v11.eds and Z4-board.ico.
iv. Z4 EIP Instance Assemblies.xlsx - a guide to the Z4 EIP parameter list in
order of occurrence, the respective descriptors, data types, notes and CIP
messaging requirements.
2. Familiarize yourself with the data you wish to access in the Z4 EIP Instance Assemblies.xlsx
spreadsheet and how these will be accessed either directly or via explicit messaging.
3. Open the Montalvo_Z4v20.L5K le and convert it to your version of RSLogix 5000 or
RSLogix Studio, your processor type and your Z4 EIP module address and save it as a new
.ACD le. Open this new le.
a. Modify the I/O conguration of the Z4_EIP in your new .ACD le.
b. You can copy any of the program routines, the Add-On Instruction AOI_Z4_IO and the
Z4_EIP I/O conguration if you desire.
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10.2-11
c. You can also export the routines, UDTs and AOIs from this sample le to a temporary
storage location and then import them to a separate Logix 5000 program if you prefer.
When doing this import the AOIs an UDTs rst, then the routine.
4. Temporarily change your network Interface port that will connect to the Z4 EIP module to a
subnet of 192.168.1.xxx (the EIP module address is 192.168.1.202 by default).
5. Install the Z4Controller_v11.eds using RSLinx Classic tool EDS Hardware Installation Tool.
6. Access the Z4 EIP module via the network port just changed and set its network address to
that of your controls network. To further access the Z4 EIP module you must set your
network interface port to the new address subnet.
7. Edit any of the network addresses necessary to download your application to your A-B Logix
processor. Download the application and check the status of the Z4 EIP module to assure it
is communicating.
8. Live test the Z4 parameter access.
Details of the conguration steps to perform
Only the steps requiring specic interaction with the RSLogix, RSLinx and EDS le are detailed here.
If not already done, open the Montalvo_Z4v20.L5K le directly by selecting it from your explorer
folder or from the Logix Designer File/Open menu tab. Once open you must select one of
your currently installed Logix Designer platform versions. The .L5K le was constructed using
Logix5000 version 20 to make it upward and downward compatible with most every current
version being used. If you are using version 20 then leave it as such. Modify the le name to
something of your choosing; do not overwrite your template le!!!
See Figure 1.
Figure 1. Z4 sample les
10.2 Ethernet (option)

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10.2-12
When the import is complete ignore the warning message and continue to save the le:
Warning: Line 29: A warning occurred while setting 'CompatibilityMode' property of
cong 'Z4_Template' (Unexpected attribute will be ignored.)
Complete - 0 error(s), 1 warning(s)
Place the Z4Controller_v11.eds and Z4-board.ico together in a folder on your computer. Run
the RSLinx Classic tool EDS Hardware Installation Tool, select Add and either Register a single
le or Regiser a directory of EDS les. Enter your path to the Z4Controller_v11.eds le, press
Next and accept all the defaults. If the icon le is not found press the Change icon button and
browse to the path for your Z4 eds and icon les.
Once registered the Z4_EIP component can be accessed from your RSLogix program I/O
Conguration tab. If you are using the sample .ACD le you may need to re-register it in the I/O
Conguration, but that is not typical (see image below). If so, perform the eds registration within
RSLogix, save the .ACD le, close it then reopen it. The registered EDS should show correctly
afterwards. See Figure 2 for registering the EDS le from the Logix I/O conguration.
Figure 2. Registering the EDS le from the Logix I/O Conguration
Also, some eds additions to RSLogix 5000 will not be read into the Studio 5000 data set and
vice-versa. You may need to do this only once you have selected your nal program version.
View of the registered icon (Figure 3):
10.2 Ethernet (option)
Figure 3. Registering the EDS le (icon symbol shown)

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10.2-13
Rename your module conguration if desired and describe it as in the next picture (Figure 4).
Assign the IP address.
General tab for Z4_EIP module conguration (Figure 4):
Figure 4. Properties of the Z4 module in the I/O onguration
Select “Change” in the “Module Denition” area. Module denition should be (Figure 5):
Make sure if you are going to use Exact
Match or Compatible Module keying you
type the revision numbers EXACTLY as
shown.
Major Rev: 1
Minor Rev: 002
Leave the Connections defaults as shown.
Figure 5. Z4 Module denition - Connections
10.2 Ethernet (option)

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10.2-14
Connection tab (Figure 6). Avoid reducing the RPI below the value of 10ms. 20ms should be
adequate. Keep the Unicast connection selection and cyclic triggering settings as shown.
None of the other conguration tabs’ data are accessible until the program is online.
At this point you have all the basics in place to communicate to the Z4.
Using the sample RSLogix program
The Z4 EIP module v1.002 has implicit CIP direct I/O, 62 direct Input SINTs from the Z4 to the
PLC and 12 direct Output SINTs from the PLC to the Z4. It also has many internal parameters
accessible only by explicit CIP messaging.
The sample program shows how to access the Input and Output data directly and the internal
parameters via CIP explicit messaging. Direct I/O will be explained rst.
The sample program uses an Add-On Instruction AOI_Z4_IO* to parse the data parameters to/
from direct tag attributes. To explain its purpose and use, the sample program has the Z4_EIP
module named Z4_EIP and thus has the direct I/O tag for it is as shown in Figure 7.
These “raw” I/O tag attributes are not very useful since the data words within the Z4 are read
in as all SINTs but their original formats are not all SINTs and do not aligned evenly with 16 bit
boundaries. Also, the boolean data in the Z4 is transmitted to the EIP and subsequently to the
PLC as a SINT per boolean.
* With user dened data types (UDTs).
Figure 6. Z4 Connection tab
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10.2-15
Figure 7. Z4 raw I/O data
The end programmer would have to perform separate COP instructions for the analog variables
and reference the [SINT].0 boolean to get a single bit reference.
In the routine Z4_Mapping, AOI_Z4_IO rst reads some of the I/O data into meaningful attributes. It
has UDTs associated with it to do a clean data parsing into a single parameterized tag of your
choosing. The parsed tag containing all the conversions is called "Z4", a controller tag, and
browsing the attributes of this tag will show all the converted parameters. The routine further
contains all CIP message instructions to access the parameters via local INT tags. (Figure 8):
If the AOI routine AOI_Z4_IO is copied from the sample program to a different program it will
bring the UDTs along with it so no copying of the UDTs is needed.
Any device or tag name in this sample le can be modied to suit the users' conventions. It is
recommended:
• not to change the name nor modify the contents of the UDT or AOI les unless
experienced in doing so.
• not to change the name of the Z4_EIP I/O object since all the MSG instructions will lose
reference to it and point to the Ethernet address instead. There is no harm in this but
descriptive identity is lost.
Notes of parameter parsing/mapping:
• All REAL tag types are READ from a x10 SINT value to a directly usable REAL value.
• All signed or unsigned integers READ are stored as DINT tags.
• All BOOLEAN parameters are mapped within the Z4 as single integers, value 0 or 1. To
make their logic use practical they are read into BOOLEAN tags by READing just bit 0.
• The WRITE operations are just the reverse procedure of the READs.
Figure 8. AOI usage for parsing Z4 raw data to user tags
10.2 Ethernet (option)

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10.2-16
Parameterized Results – All Word attributes, including Boolean UDTs:
10.2 Ethernet (option)

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Parameterized Results – Boolean attribute details:
10.2 Ethernet (option)

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10.2-18
Parameterized Results – Extended Parameter details:
10.2 Ethernet (option)

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10.2-19
The attribute descriptions depict what the default values and meanings are, but just as
importantly whether the attribute is READable or WRITEable. For more clarication of parameter
usage view Appendix 2 – Z4 EIP I/O Interface Parameters and CIP Instance Assemblies.
One drawback of the direct IO access method is that WRITEable attributes/parameters do not
provide a way to read back what has been written. Explicit messaging allows this.
The Z4_Mapping routine provides all the MSG instructions to access the remaining Z4 I/O
parameters. All the READ MSG instructions are cascaded and looped back automatically to
reduce concurrent MSG activity. At the end of the routine is a provision to pause the cascading
scan of the READ MSGs for one CPU scan to allow any overlapping READ MSGs due to
manual triggering to be cleared (discussed below).
The WRITE MSG instructions act on a command/disagree basis. If the WRITE value is not
echoed in the READ value reply, when the WRITE MSG completes it will attempt to write again
on the next scan. The WRITE MSG instructions are not cascaded.
Using Remote System and Extended Parameter Settings
The Z4 System and extended parameters can be accessed to and from the EIP interface but
care must be taken in their interpretation. These parameters are buffered and will not necessarily
show the currently active values.
1. Any WRITE command in the PLC will write the extended parameter data to the Z4 buffer.
From the buffer the Z4 will check the data range validation before sending it to the active
parameters. If the written value is out of range it will not be passed to the active
parameter. Any READ command will read from the buffer and not the active value. This
can cause a mismatch between PLC values and active Z4 values. The user must take
care to observe the range limitations for these parameters and set limit checking in the
user program before writing them to the Z4.
2. If extended parameter data to be written has previously been written to the Z4 buffer, re-
writing that parameter will not change the buffer contents and will not trigger a transfer of
data to the active buffer. It is best to retrigger a WRITE data by READing the data,
resending that data then resending the new data.
3. On Z4 powerup or reboot the available extended parameter data is previously stored
buffer data and not necessarily active values. If the user intends for the PLC to control
extended parameter values then these values should be written with the intent to
override those active Z4 values at all times. At no time should the user attempt to set
extended parameters via the Z4 conguration touch pad if the EIP interface is enabled
and active extended parameters are to be written from the PLC.
The extended parameters affected by this condition are:
GAIN_BOOST
GAIN_MAX
GAIN_MIN
GAIN_SLOPE
PID_D_LEVEL
PID_I_TIME
PID_P_LEVEL
PID_SYS_GAIN
SPLICE_LEVEL
TAPER_BEGIN
10.2 Ethernet (option)