Montalvo Z4-UL Bedienungsanleitung
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 Conguration and System Setup.............................................................. 27
5.1 Conguration Menu [Cong 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
[email protected] / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo
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 conguration 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
amplied 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
[email protected] / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo
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
[email protected] / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo
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
[email protected] / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo
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
[email protected] / www.montalvo.com / Technical details subject to change without notice. Z4-UL-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 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.
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