TECHNICAL MANUAL. Man / Auto. Ten Off / On x100 psi Tension lb X1000 lb 0.

Transcription

1 Montalvo Z4-RL Rewind Tension Controller for Load Cell Feedback EST. 947 TECHNICAL MANUAL Man / Auto Ten Off / On Cal2 MODE AUTO Output x00 psi Setpoint Tension 56. lb X000 lb Di Setpoint 550. lb Manual 36.0 psi Aux 0.0 % Diameter 28.0 in Do Rng DISPLAY ADJUST TREND DATALOG SCALING CONFIG Run Mode AUTO SERXXXXXX Z4XXXXX XXXXXX Made In USA Enclosure Version SUPPLY VAC ONLY (Fuse: 3.5A Slow Blow) R6 R5 R4 R3 R2 R Circuit Board Version N L Z4 CONTROLLER REV# (C) 20XX MONTALVO Z4-RL Rewind (for Load Cell feedback) PID Web Tension Controller Controller Firmware Version.4.x to.7.x Publication Date 03/05/209

2 Table of Contents General Description...-. Overview Models*, Options* and Compatibility* How It Works Function and Standard Operation Mechanical Installation Circuit Board (controller) Dimensions HMI (remote interface) Dimensions Enclosure Dimensions Electrical Installation Warning, EMC, and Safety Basic Wiring - *Z4RL/CDD (Clutch Direct Drive) Basic Wiring - *Z4RL/CVD (Clutch Variable Drive) Basic Wiring - *Z4RL/MVD (Motor Variable Drive) Terminal Blocks Installation - Load Cells Installation - Tension Calibration Installation - Regulated Output Installation - Power Supply Digital Input (24V) Digital Output (24V) Analog Input (0 to ) Analog Output Analog Output (AUX Output) Voltage to Current Converter Tuning Tuning - Z4RL/CDD (Clutch Direct Drive) Tuning - Z4RL/CVD (Clutch Variable Drive) Tuning - Z4RL/MVD (Motor Variable Drive) Configuration and System Setup Confi guration Menu Confi g Menu Options Selection Menu Options Menu Regulator Parameters Regulator Menu Roll Change Roll Change Menu Shaft Filling (CDD and CVD) Start Rewinder (CVD and MVD) Starting the Machine Start Menu

3 Table of Contents 5.8 Machine at Stop Hold Menu Diameter Diameter Menu Taper Taper Menu Digital Output Digital Out Menu Splice Splice Menu Aux Input Aux Input Menu Aux2 Input Aux2 Input Menu Aux Output Aux Output Menu Aux2 Output Variable Wrap Angle Wrap Angle Menu Operation of the Controller Menu Operation of the Controller Menu Menu Tree Status Menu Description Run Mode Menu Tree Setup Menu Menu Tree / Parameter Settings Hardware Adjustment and LEDs LEDs Potentiometers Troubleshooting Block Diagram Symptoms / Causes Technical Data Specifi cations Declaration of Conformity Communication HMI (option) (separate manual*) Ethernet (option) (separate manual*) *Hard copies of appropriate additional manuals along with this controller manual ship with product. All manuals (as pdf) and software tools are available from:

4 . Overview General Description 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, clutch or motor and motor regulator are a 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 diagrams 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 enable the controller to interface with a variety of output devices to control web tensioning clutches or motors. This manual covers three different types of rewinder systems: CDD - Clutch Direct Driven from main machine CVD - Clutch Variable Driven, clutch driven by a separate motor MVD - Motor Variable Driven, motor is driving rewinder directly 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 confi 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 amplifi ed and calibrated to display actual web tension. Torque Control Z4 is based on torque control for soft regulation and machines with a longer ramp up and down time. Motor Function CVD - the clutch is driven directly by the rewinder motor. MVD - the shaft is driven directly by the rewinder motor. If a gearing is used, the maximum gear ratio recommended is :3. Motor Controller The Z4 has many special features that are required for the optimum rewinder system, allowing use of a simple motor controller for the rewind motor. Line speed The line speed can be used in different ways. For the simple rewinder the line speed is connected directly into the motor controller. For the more advanced system the line speed has to be connected to the Z4 which will then control the speed setpoint for the rewinder as well. 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. -

5 .2 Models, Options and Compatability General Description MODELS The Z4 Tension Controller is available in three separate models: Circuit Board Only - Z4b Connect to machine via communication links or discrete I/O. Circuit Board with HMI* - Z4r Install the circuit board and HMI in separate locations. Circuit Board and HMI* in Enclosure - Z4e IP54, industrial enclosure can be installed as either panel or surface mount. OPTIONS The Z4 Circuit Board can be factory confi gured for the following options: No Communication Basic protective cover plate when no HMI or Ethernet communication is required. HMI* Communication Standard module has HMI connectivity required for connunication with Z4e and Z4r models. Also available for Z4b. Ethernet* Communication Ethernet/IP communication module includes HMI communication. Available on all models. COMPATIBILITY The Z4 Circuit Board is a drop-in replacement/upgrade for earlier Montalvo controllers: CB64, CB63 and DRT6 Replacement* The Z4 design allows for easy customer swap, full compatibility and increased functionality. *Hard copies of appropriate additional manuals along with this controller manual ship with product. All manuals (as pdf) and software tools are available from: -2

6 SERXXXXXX SERXXXXXX SERXXXXXX Z4XXXXX XXXXXX Made In USA Z4XXXXX XXXXXX Made In USA Z4XXXXX XXXXXX Made In USA R6 R6 R6 R5 R5 R5 R4 R4 R4 R3 R3 R3 R2 R2 R2 R R R Z4 CONTROLLER REV# (C) 20XX MONTALVO Z4 CONTROLLER REV# (C) 20XX MONTALVO Z4 CONTROLLER REV# (C) 20XX MONTALVO How It Works General Description CVD - Clutch Variable Drive Rewind Web Direction Z4RL / CVD INPUT (Line Speed) INPUT Run Mode AUTO OUTPUT Motor Motor Pneumatic Clutch Motor Controller Load Cell Regulated Air Air Supply I/P Converter HMI (Option) Communication Ethernet plus HMI (Option) OUTPUT SUPPLY VAC ONLY (Fuse: 3.5A Slow Blow) N L MVD - Motor Variable Drive Rewind Web Direction Z4RL / MVD INPUT (Line Speed) INPUT Run Mode AUTO Load Cell Communication SUPPLY VAC ONLY (Fuse: 3.5A Slow Blow) Motor Motor Motor Controller HMI (Option) Ethernet plus HMI (Option) OUTPUT N L CDD - Clutch Direct Drive Rewind Web Direction Z4RL / CDD INPUT Run Mode AUTO OUTPUT Main Drive Shaft Pneumatic Clutch Load Cell Regulated Air Air Supply I/P Converter HMI (Option) Communication Ethernet plus HMI (Option) SUPPLY VAC ONLY (Fuse: 3.5A Slow Blow) N L -3

7 General Description Z4 CONTROLLER REV# (C) 20XX MONTALVO Function and Standard Operation Remote version Enclosure version Run Mode AUTO SERXXXXXX Z4XXXXX XXXXXX Made In USA 2 3 Man / Auto Ten Off / On Cal2 MODE AUTO x00 psi Tension lb X000 lb Output Setpoint Di Setpoint 550. lb Manual 36.0 psi Aux 0.0 % Diameter 28.0 in Do Rng SUPPLY VAC ONLY (Fuse: 3.5A Slow Blow) N L R6 R5 R4 R3 R2 R DISPLAY ADJUST TREND DATALOG SCALING CONFIG Man / Auto Ten Off / On Cal2 MODE AUTO x00 psi Tension lb X000 lb Output Setpoint Di Setpoint 550. lb Manual 36.0 psi Aux 0.0 % Diameter 28.0 in Do Rng DISPLAY ADJUST TREND DATALOG SCALING CONFIG Manual Setpoint Auto Setpoint Actual Tension Item Description Controller Output Meter Taper % Manual / Auto Roll Reset Button Yellow Power LED Sets controller output at a constant level when the controller is in manual mode. (Manual setpoint on a 0 to 00% scale produces 0 to 00% output). Once scaled, the output can be PSI, volts or ma. In auto mode, output is automatically regulated so that actual tension reaches the Auto tension setpoint. Displays actual tension on a scale of 0 to 00% or user assignable tension range. Displays controller/regulator output on a scale of 0 to 00% or user assignable tension range. Sets the percent (%) for the Taper reduction. Toggles between manual and auto mode. Roll ON - Rewinder is selected on and ready to run (regulate). Roll Reset - Rewinder is zero and all rolldata is Reset. Roll Release - Rewinder is zero and all rolldata is stored and will be used at Roll On. Indicates that power is on. -4

8 2. Circuit Board (controller) Dimensions Mechanical Installation 2 Standoffs for installation in customer cabinet Standoffs used in Montalvo enclosure are different length Run Mode AUTO (69) 5.8 (47.5) SERXXXXXX Z4XXXXX XXXXXX Made In USA SUPPLY VAC ONLY (Fuse: 3.5A Slow Blow) R6 R5 R4 R3 R2 R N L Z4 CONTROLLER REV# (C) 20XX MONTALVO 4.72 (20).30 (33) 6.97 (77) 2.64 (67) Avoid mounting the controller close to drive controllers or any other equipment producing large amounts of EMI. 2-

9 2.2 HMI (remote interface) Dimensions Mechanical Installation (203) 7.44 (89).47 (38) 7.00 (78) 5.35 (36).85 (47) Cut Out 0.8 (3) max. radius (93.04) (37.92)

10 2.3 Enclosure Dimensions Mechanical Installation 2 HMI Door Pull 9.42 (239.5) 0.50 (267) 8.94 (227) 8.23 (209) 0.86 (276) 0.6 (4) 4.30 (0) /4 Turn Compression Latch Avoid mounting the controller close to drive controllers or any other equipment producing large amounts of EMI. 2-3

11 SAFETY INFORMATION The following safety symbols appear in this document. Caution Failure to follow installation and setup instructions in this manual may result in equipment damage and/or personal injury! 3. Warning, EMC, and Safety Electrical Installation 3 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 0A. Note: and 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. Ground wires should be as short as possible. Connect the controller 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. 3-

12 3.2 Basic Wiring - Z4RL/CDD (Clutch Direct Drive) Electrical Installation 3 Model Z4b - Circuit Board Only Run Mode AUTO SERXXXXXX Z4XXXXX XXXXXX Made In USA SUPPLY VAC ONLY (Fuse: 3.5A Slow Blow) R6 R5 R4 R3 R2 R Power Connections VAC (standard) N L 24 VDC (factory option) N (COM) L (24V) N L Z4 CONTROLLER REV# (C) 20XX MONTALVO Tension Output Auto Setpoint Manual Setpoint Machine Input 0 20 Voltage K 0K Run Manual 0 2 Roll -Reset 0-ON 2-Release Terminals -58 tension tension output output (0 to+) (0 to+00μa) 45 () auto setpoint (0-) () manual setpoint (0-) () (DI-5) (DI-) (DI-3) 34 standby (DI-4) 24V BK (-2.5V) WH (+input) BN (+2.5V) BK (+2.5V) WH (-input) BN (-2.5V) *24V regulated output (4-20mA) regulated output (0-) 24V web pulse (DI-6) roll pulse (DI-7) 0-0v (Aux Input) I/P Converter (Current 4-20mA) *Connect if converter uses 24V power supply Voltage 0- Web Pulse Proximity Switch PNP Roll Pulse Proximity Switch PNP OR Analog Input 0- (option) Tension (Load cell) Input Regulated Output Diameter 3-2

13 Z4 CONTROLLER REV# (C) 20XX MONTALVO Z4 CONTROLLER REV# (C) 20XX MONTALVO TY PN VOLTS TY PN VOLTS Basic Wiring - Z4RL/CDD (Clutch Direct Drive) Electrical Installation 3 Model Z4r - Circuit Board with Remote HMI Circuit Board HMI (showing back side) Standard HMI Cables SERXXXXXX SUPPLY VAC ONLY (Fuse: 3.5A Slow Blow) N L Run Mode AUTO Z4XXXXX XXXXXX Made In USA HMI Communications Module R6 R6 R5 R5 R4 R4 R3 R3 R2 R2 R R pin Molex connector DC24 GND FG Z4 Tension Controllers HMI Interface - Z4i V Assembled in USA RESET ON If HMI 2 must be RESET, make sure machine is NOT RUNNING! DO NOT use these ports! Use USB and COM only. USB COM HMI Module Cable Part# Module Type Length (m) HMI HMI HMI HMI Ethernet/HMI Ethernet/HMI Ethernet/HMI Ethernet/HMI 5 Power Connections on PCB N L VAC (standard) Run Mode AUTO Z4 Tension Controllers HMI Interface - Z4i V Assembled in USA RESET ON If HMI 2 must be RESET, make sure machine is NOT RUNNING! SERXXXXXX Z4XXXXX XXXXXX Made In USA DC24 GND FG DO NOT use these ports! Use USB and COM only. SUPPLY VAC ONLY (Fuse: 3.5A Slow Blow) R6 R5 R4 R3 R2 R USB COM N (COM) L (24V) N L Ethernet/HMI Communications Module 5 pin M2 connector Ethernet / HMI Module Cable 24 VDC (factory option) Machine Input Run Terminals -58 (DI-5) 24V BK (-2.5V) WH (+input) BN (+2.5V) BK (+2.5V) WH (-input) BN (-2.5V) *24V regulated output (4-20mA) regulated output (0-) 24V web pulse (DI-6) roll pulse (DI-7) 0-0v (Aux Input) I/P Converter (Current 4-20mA) *Connect if converter uses 24V power supply Voltage 0- Web Pulse Proximity Switch PNP Roll Pulse Proximity Switch PNP OR Analog Input 0- (option) Tension (Load cell) Input Regulated Output Diameter 3-3

14 3.2 Basic Wiring - Z4RL/CDD (Clutch Direct Drive) Electrical Installation 3 Model Z4e - Circuit Board and HMI in Enclosure Man / Auto Ten Off / On Cal2 MODE AUTO x00 psi Tension lb X000 lb Output Setpoint Di Setpoint 550. lb Manual 36.0 psi Aux 0.0 % Diameter 28.0 in Do Rng DISPLAY ADJUST TREND DATALOG SCALING CONFIG Power Connections on PCB N L VAC (standard) N (COM) L (24V) 24 VDC (factory option) Machine Input Run Terminals -58 (DI-5) 24V BK (-2.5V) WH (+input) BN (+2.5V) BK (+2.5V) WH (-input) BN (-2.5V) *24V regulated output (4-20mA) regulated output (0-) 24V web pulse (DI-6) roll pulse (DI-7) 0-0v (Aux Input) I/P Converter (Current 4-20mA) *Connect if converter uses 24V power supply Voltage 0- Web Pulse Proximity Switch PNP Roll Pulse Proximity Switch PNP OR Analog Input 0- (option) Tension (Load cell) Input Regulated Output Diameter 3-4

15 3.3 Basic Wiring - Z4RL/CVD (Clutch Variable Drive) Electrical Installation 3 Model Z4b - Circuit Board Only Run Mode AUTO SERXXXXXX Z4XXXXX XXXXXX Made In USA SUPPLY VAC ONLY (Fuse: 3.5A Slow Blow) R6 R5 R4 R3 R2 R Power Connections VAC (standard) N L 24 VDC (factory option) N (COM) L (24V) N L Z4 CONTROLLER REV# (C) 20XX MONTALVO 0 Tension Output Auto Setpoint Manual Setpoint RW Motor Ctrl Speed Linespeed K 0K Analog Input Voltage 0- Rewind Motor Control Terminals Run Machine Input Manual 0 2 Roll -Reset 0-ON 2-Release Start Rewinder Terminals -58 tension tension output output (0 to+) (0 to+00μa) 45 () auto setpoint (0-) () manual setpoint (0-) (Aux Output) () (0-) (Aux2 Input) linespeed (0-) (DI-5) (DI-) (DI-3) (DI-4) 24V (DI-8) BK (-2.5V) WH (+input) BN (+2.5V) BK (+2.5V) WH (-input) BN (-2.5V) *24V regulated output (4-20mA) regulated output (0-) 24V web pulse (DI-6) roll pulse (DI-7) 0-0v (Aux Input) (DO 2) I/P Converter (Current 4-20mA) *Connect if converter uses 24V power supply Voltage 0- Web Pulse Proximity Switch PNP Roll Pulse Proximity Switch PNP OR Analog Input 0- (option) Rewind Motor Start Terminals Tension (Load cell) Input Regulated Output Diameter RW Motor Start 3-5

16 Z4 CONTROLLER REV# (C) 20XX MONTALVO Z4 CONTROLLER REV# (C) 20XX MONTALVO TY PN VOLTS TY PN VOLTS Basic Wiring - Z4RL/CVD (Clutch Variable Drive) Electrical Installation 3 Model Z4r - Circuit Board with Remote HMI Circuit Board HMI (showing back side) Standard HMI Cables SERXXXXXX SUPPLY VAC ONLY (Fuse: 3.5A Slow Blow) N L Run Mode AUTO Z4XXXXX XXXXXX Made In USA HMI Communications Module R6 R6 R5 R5 R4 R4 R3 R3 R2 R2 R R pin Molex connector DC24 GND FG Z4 Tension Controllers HMI Interface - Z4i V Assembled in USA RESET ON If HMI 2 must be RESET, make sure machine is NOT RUNNING! DO NOT use these ports! Use USB and COM only. USB COM HMI Module Cable Part# Module Type Length (m) HMI HMI HMI HMI Ethernet/HMI Ethernet/HMI Ethernet/HMI Ethernet/HMI 5 Power Connections on PCB N L VAC (standard) Run Mode AUTO Z4 Tension Controllers HMI Interface - Z4i V Assembled in USA RESET ON If HMI 2 must be RESET, make sure machine is NOT RUNNING! SERXXXXXX Z4XXXXX XXXXXX Made In USA DC24 GND FG DO NOT use these ports! Use USB and COM only. SUPPLY VAC ONLY (Fuse: 3.5A Slow Blow) R6 R5 R4 R3 R2 R USB COM N (COM) L (24V) N L Ethernet/HMI Communications Module 5 pin M2 connector Ethernet / HMI Module Cable Rewind Motor Control Speed Rewind Motor Control Terminals 24 VDC (factory option) Linespeed Analog Input 0- Machine Input Run Start Rewinder Terminals -58 (Aux Output) (0-) (Aux2 Input) linespeed (0-) (DI-5) 24V (DI-8) BK (-2.5V) WH (+input) BN (+2.5V) BK (+2.5V) WH (-input) BN (-2.5V) *24V regulated output (4-20mA) regulated output (0-) 24V web pulse (DI-6) roll pulse (DI-7) 0-0v (Aux Input) (DO 2) I/P Converter (Current 4-20mA) *Connect if converter uses 24V power supply Voltage 0- Web Pulse Proximity Switch PNP Roll Pulse Proximity Switch PNP OR Analog Input 0- (option) Rewind Motor Start Terminals Tension (Load cell) Input Regulated Output Diameter Rewind Motor Start 3-6

17 3.3 Basic Wiring - Z4RL/CVD (Clutch Variable Drive) Electrical Installation 3 Model Z4e - Circuit Board and HMI in Enclosure Man / Auto Ten Off / On Cal2 MODE AUTO x00 psi Tension lb X000 lb Output Setpoint Di Setpoint 550. lb Manual 36.0 psi Aux 0.0 % Diameter 28.0 in Do Rng DISPLAY ADJUST TREND DATALOG SCALING CONFIG Power Connections on PCB N L VAC (standard) N (COM) L (24V) 24 VDC (factory option) Rewind Motor Control Speed Rewind Motor Control Terminals Linespeed Analog Input 0- Machine Input Run Start Rewinder Terminals -58 (Aux Output) (0-) (Aux2 Input) linespeed (0-) (DI-5) 24V (DI-8) BK (-2.5V) WH (+input) BN (+2.5V) BK (+2.5V) WH (-input) BN (-2.5V) *24V regulated output (4-20mA) regulated output (0-) 24V web pulse (DI-6) roll pulse (DI-7) 0-0v (Aux Input) (DO 2) I/P Converter (Current 4-20mA) *Connect if converter uses 24V power supply Voltage 0- Web Pulse Proximity Switch PNP Roll Pulse Proximity Switch PNP OR Analog Input 0- (option) Rewind Motor Start Terminals Tension (Load cell) Input Regulated Output Diameter Rewind Motor Start 3-7

18 3.4 Basic Wiring - Z4RL/MVD (Motor Variable Drive) Electrical Installation 3 Model Z4b - Circuit Board Only Run Mode AUTO SERXXXXXX Z4XXXXX XXXXXX Made In USA SUPPLY VAC ONLY (Fuse: 3.5A Slow Blow) R6 R5 R4 R3 R2 R Power Connections VAC (standard) N L 24 VDC (factory option) N (COM) L (24V) N L Z4 CONTROLLER REV# (C) 20XX MONTALVO 0 Tension Output Auto Setpoint Manual Setpoint RW Motor Ctrl Speed Linespeed K 0K Analog Input Voltage 0- Rewind Motor Control Terminals Run Machine Input Manual 0 2 Roll -Reset 0-ON 2-Release Start Rewinder Terminals -58 tension tension output output (0 to+) (0 to+00μa) 45 () auto setpoint (0-) () manual setpoint (0-) (Aux Output) () (0-) (Aux2 Input) linespeed (0-) (DI-5) (DI-) (DI-3) (DI-4) 24V (DI-8) BK (-2.5V) WH (+input) BN (+2.5V) BK (+2.5V) WH (-input) BN (-2.5V) *24V regulated output (4-20mA) regulated output (0-) 24V web pulse (DI-6) roll pulse (DI-7) 0-0v (Aux Input) (DO 2) Current 4-20mA *Connect if converter uses 24V power supply Torque Input to Rewind Drive Web Pulse Proximity Switch PNP Roll Pulse Proximity Switch PNP OR Analog Input 0- (option) Rewind Motor Start Terminals Tension (Load cell) Input Regulated Output Diameter RW Motor Start 3-8

19 Z4 CONTROLLER REV# (C) 20XX MONTALVO Z4 CONTROLLER REV# (C) 20XX MONTALVO TY PN VOLTS TY PN VOLTS Basic Wiring - Z4RL/MVD (Motor Variable Drive) Electrical Installation 3 Model Z4r - Circuit Board with Remote HMI Circuit Board HMI (showing back side) Standard HMI Cables SERXXXXXX SUPPLY VAC ONLY (Fuse: 3.5A Slow Blow) N L Run Mode AUTO Z4XXXXX XXXXXX Made In USA HMI Communications Module R6 R6 R5 R5 R4 R4 R3 R3 R2 R2 R R pin Molex connector DC24 GND FG Z4 Tension Controllers HMI Interface - Z4i V Assembled in USA RESET ON If HMI 2 must be RESET, make sure machine is NOT RUNNING! DO NOT use these ports! Use USB and COM only. USB COM HMI Module Cable Part# Module Type Length (m) HMI HMI HMI HMI Ethernet/HMI Ethernet/HMI Ethernet/HMI Ethernet/HMI 5 Power Connections on PCB N L VAC (standard) Run Mode AUTO Z4 Tension Controllers HMI Interface - Z4i V Assembled in USA RESET ON If HMI 2 must be RESET, make sure machine is NOT RUNNING! SERXXXXXX Z4XXXXX XXXXXX Made In USA DC24 GND FG DO NOT use these ports! Use USB and COM only. SUPPLY VAC ONLY (Fuse: 3.5A Slow Blow) R6 R5 R4 R3 R2 R USB COM N (COM) L (24V) N L Ethernet/HMI Communications Module 5 pin M2 connector Ethernet / HMI Module Cable Rewind Motor Control Speed Rewind Motor Control Terminals 24 VDC (factory option) Linespeed Analog Input 0- Machine Input Run Start Rewinder Terminals -58 (Aux Output) (0-) (Aux2 Input) linespeed (0-) (DI-5) 34 24V 36 (DI-8) BK (-2.5V) WH (+input) BN (+2.5V) BK (+2.5V) WH (-input) BN (-2.5V) *24V regulated output (4-20mA) regulated output (0-) 24V web pulse (DI-6) roll pulse (DI-7) 0-0v (Aux Input) (DO 2) Current 4-20mA *Connect if converter uses 24V power supply Torque Input to Rewind Drive Web Pulse Proximity Switch PNP Roll Pulse Proximity Switch PNP OR Analog Input 0- (option) Rewind Motor Start Terminals Tension (Load cell) Input Regulated Output Diameter Rewind Motor Start 3-9

20 3.4 Basic Wiring - Z4RL/MVD (Motor Variable Drive) Electrical Installation 3 Model Z4e - Circuit Board and HMI in Enclosure Man / Auto Ten Off / On Cal2 MODE AUTO x00 psi Tension lb X000 lb Output Setpoint Di Setpoint 550. lb Manual 36.0 psi Aux 0.0 % Diameter 28.0 in Do Rng DISPLAY ADJUST TREND DATALOG SCALING CONFIG Power Connections on PCB N L VAC (standard) N (COM) L (24V) 24 VDC (factory option) Rewind Motor Control Speed Rewind Motor Control Terminals Linespeed Analog Input 0- Machine Input Run Start Rewinder Terminals -58 (Aux Output) (0-) (Aux2 Input) linespeed (0-) (DI-5) 34 24V 36 (DI-8) BK (-2.5V) WH (+input) BN (+2.5V) BK (+2.5V) WH (-input) BN (-2.5V) *24V regulated output (4-20mA) regulated output (0-) 24V web pulse (DI-6) roll pulse (DI-7) 0-0v (Aux Input) (DO 2) Current 4-20mA *Connect if converter uses 24V power supply Torque Input to Rewind Drive Web Pulse Proximity Switch PNP Roll Pulse Proximity Switch PNP OR Analog Input 0- (option) Rewind Motor Start Terminals Tension (Load cell) Input Regulated Output Diameter Rewind Motor Start 3-0

21 3.5 Terminal Blocks Electrical Installation 3 Input for Extra U/I Converter 0 to Aux Output 0 to Calibrated Aux 3 Output ± Aux 2 Input (Line Speed) 0 to Aux Input (Taper %) 0 to Manual Setpoint 0 to Tension Output 0 to +00μA Tension Output 0 to V Load Cell -Input + 2.5V DO 3 Web Break DO 24V Roll Pulse DI-7 Run DI-5 24V Tension Off DI-3 Manual DI to 20mA Output from U/I Converter - ± Aux3 Input (Diameter) 0 to Aux2 Output 0 to Auto Setpoint 0 to Regulator Output 4 to 20mA Regulator Output + 2.5V + Load Cell Input -2.5V DO 4 DO 2 24V Input for DO DI-8 Start Rewinder DI-6 Web Pulse 24V DI-4 Standby DI-2 Splice 3-

22 Electrical Installation Installation - Load Cells 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 2-2.5V Supply 3 + Load Cell Input V Supply V Supply 42 - Load Cell Input V Supply A - Connections for a Pair of Half Bridge Load -2.5V -INPUT +2.5V +2.5V +INPUT -2.5V Connection Diagrams BN WH BK BN WH BK Load Cell 2 Cable Load Cell Cable Z4 Circuit board B - Connections for Single Full Bridge Load Cell SERXXXXXX SUPPLY VAC ONLY (Fuse: 3.5A Slow Blow) Run Mode AUTO Z4XXXXX XXXXXX Made In USA R6 R5 R4 R3 R2 R V -INPUT +2.5V +2.5V +INPUT -2.5V BL BN WH BK Load Cell Cable N L Z4 CONTROLLER REV# (C) 20XX MONTALVO C - Connection for Single Half Bridge Load Cell Montalvo Load Cells Series Config Diagram ES, T, DR-D & Pair A DR-C (half bridge) U & UPB Pair A F Pair A N & TNT Single B X Single B R Single C -2.5V -INPUT +2.5V +2.5V +INPUT -2.5V BN WH BK 00 ohm resistor 00 ohm resistor Load Cell Cable Wire colors refer to standard cables supplied by Montalvo 3-2

23 3.7 Installation - Tension Calibration Electrical Installation 3 Status Menu Version Tension Setpoint Output Flt Out I-Level Gain Level Manual Linespeed Diameter Aux In Aux2 In Aux3 In Aux Out Aux2 Out LC Gain IO Terminal Menu Ext Status Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered.. 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 0 minutes. 4. Enter Status Menu and scroll to Tension. 5. With web removed and no tension applied to the sensing roller, adjust potentiometer R until tension readout on circuit board is 0%. If value is below zero, turn R clockwise; if above, turn counter clockwise. Note: R 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. Rope fastened to this roller 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 2 & 4 and 4 & 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 (%) BN WH BK BN WH BK Load Cell Roller Known Weight 9. Remove weight and check that tension meter returns to zero. If not, repeat steps 4 to If a second calibration range is used, repeat steps 4 to 8, using potentiometer R3 for calibration of the second range. See 3.0 Digital Input (24V). Calibration Example: Adjust R % Choose Full Scale Apply Known Weight Divide 75/ Convert.375 to % % Adjust R % 3-3

24 Installation Regulated Output Electrical Installation 3 Circuit Board Terminals # Description Function 5 6 Regulated Current 7 Regulated Voltage Common signal () for regulated voltage or current output. Connects to input ground of the converter. Regulated 4 to 20mA current signal to an I/P or other converter. Regulated 0 to output. Can be used for a 0 to I/P or other converter. Can control motor drives operating in torque mode. Maximum load: 5mA. Motor Controller Wiring Signal = 0- For motor driven rewinds 0 to 4 to 20mA Motor Controller SERXXXXXX SUPPLY VAC ONLY (Fuse: 3.5A Slow Blow) Run Mode AUTO Z4XXXXX XXXXXX Made In USA R6 R5 R4 R3 R2 R Current Loop 5 MPC-4 0- Model NOT USED 7 N L Z4 CONTROLLER REV# (C) 20XX MONTALVO Montalvo I/P Converter Wiring Signal = 0- For clutch driven rerwinds Montalvo I/P Converter Wiring Signal = 4 to 20mA For clutch driven rerwinds 0 to 4 to 20mA 0 to 4 to 20mA GND MPC mA Model NOT USED 6 Montalvo I/P Converter Wiring Signal = 4 to 20mA I/P requires 24V supply For clutch driven rerwinds 0 to 4 to 20mA GND MPC V 5 4 NOT USED MPC DC Current Loop Torque Max. Limit 3-4

25 3.9 Installation Power Supply Electrical Installation N L Neutral (COM) Supply Voltage 00/240 VAC Ground VAC Circuit Boards SERXXXXXX Run Mode AUTO Z4XXXXX XXXXXX Made In USA SUPPLY VAC ONLY (Fuse: 3.5A Slow Blow) R6 R5 R4 R3 R2 R N L Z4 CONTROLLER REV# (C) 20XX MONTALVO N L VDC Circuit Boards N L 24 VDC Ground SERXXXXXX Run Mode AUTO Z4XXXXX XXXXXX Made In USA SUPPLY 24 VDC ONLY (Fuse:.0A) R6 R5 R4 R3 R2 R N (COM) L 24V Z4 CONTROLLER REV# (C) 20XX MONTALVO N (COM) L (24V) 3-5

26 3.0 Digital Input (24V) Electrical Installation SERXXXXXX Run Mode AUTO Z4XXXXX XXXXXX Made In USA SUPPLY VAC ONLY (Fuse: 3.5A Slow Blow) R6 R5 R4 R3 R2 R N L Z4 CONTROLLER REV# (C) 20XX MONTALVO Digital Input # Terminal # Function LED Color DI- 3 Manual Red DI-2 2 Splice Yellow DI-3 32 Tension Off Red DI-4 3 Standby Yellow DI-5 34 Run Red DI-6 5 DI-7 35 DI-8 6 Web Pulse Roll Pulse Start Rewinder Yellow Red Yellow Menu Section 5.2 Splice 5.4 Roll Change 5.4 Roll Change 5.7 Start and 5.8 Hold 5.9 Diameter 5.9 Diameter 5.6 Start Rewinder Description 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. This input is used to control the regulator in the splice sequence. 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. When activated by a 24V signal, the output goes to zero. All parameters are still stored in the memory and used again when the 24V input is removed. 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. A proximity switch is mounted to sense the web length/pulse, which is used for diameter calculation. A proximity switch is mounted to sense pulses per revolution on the roll, which is used for diameter calculation. This input is provides rewind motorstart info. Used on CVD and MVD only. 3-6

27 Electrical Installation Digital Input (24V) - continued Setup Menu Confi g Menu Options Menu Use ShftFill Use Taper Use Dig Out Use Splice Use Aux In Use Aux2 In Use Aux 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 Shaft Fill Menu Start Menu Hold Menu Diameter Menu Taper Menu Digital Out Menu Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. Run - Digital Input 5 (terminal 34) The run input serves the following purposes:. 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 5.7 Start Menu and 5.8 Hold Menu. Electrical Wiring Below a typical example of how to connect the run signal: +24V Run DI % Machine Speed Hold Mode 4(NO) 3(COM) K00 Machine START START STOP Run Mode K00 +24V Run DI (NC) (COM) Stop Mode ZERO speed signal from machine K200 Machine Speed ZERO Hold Mode 0% 0 Start Zero 0 Speed Time Hold Delay 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 3-7

28 3.0 Digital Input (24V) - continued Electrical Installation 3 Setup Menu Confi g Menu Options Menu Use ShftFill Use Taper Use Dig Out Use Splice Use Aux In Use Aux2 In Use Aux 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 Shaft Fill Menu Start Menu Hold Menu Diameter Menu Taper Menu Digital Out Menu Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu Start Rewinder - Digital Input 8 (terminal 6) This signal input is used to provide information about when the rewind motor is started. It also activates Digital Output 2 that can be used to enable the rewind motor run signal. Used for CVD and MVD confi gurations only. See 5.70 Start Menu and 5.8 Hold Menu. Electrical Wiring Below is a typical example of how to connect the Start Rewinder signal. +24V START K00 DI 8 Start Rewinder 4(NO) STOP K00 3(COM) Start Rewinder NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. Parameter Descriptions DI-8 Invert Select: NO or YES The Start Rewinder signal is activated with a high (24V) signal. If the inverted function is needed, change the parameter DI-8 Invert to YES. Default is set to NO. 3-8

29 3. Digital Output (24V) Electrical Installation 3 Digital Outputs Keypad Indicator LED Color Terminal # DO Red 38 DO 2 Yellow 9 DO 3 Red 39 DO 4 Yellow DO outputs can be used for web break, diameter alarm or other functions. See 5. Digital Output Menu. SERXXXXXX Run Mode AUTO Z4XXXXX XXXXXX Made In USA SUPPLY VAC ONLY (Fuse: 3.5A Slow Blow) R6 R5 R4 R3 R2 R N L Z4 CONTROLLER REV# (C) 20XX MONTALVO A factory installed jumper between terminals 4 and 7 supplies 24V to the Digital Outputs (DO). If an alternate 24V supply is used, remove the jumper. 24V Input for DO 24V Jumper 2 3-9

30 Z4 CONTROLLER REV# (C) 20XX MONTALVO Analog Input (0 to ) Electrical Installation Run Mode AUTO SERXXXXXX SUPPLY VAC ONLY (Fuse: 3.5A Slow Blow) Z4XXXXX XXXXXX Made In USA R6 R5 R4 R3 R2 R Aux 2 Input 0 to ± Aux3 Input N L Aux Input 0 to Manual Input (0 to ) When the controller is in manual mode, the output level is set from the manual input. A manual input level from 0 to gives 0 to 00% on the output. If the controller is a Enclosure version, this signal is already connected from the HMI. (Note: can only be used at one place.) The manual input can come from a potentiometer or from another external source. (See wiring diagram below.) to 0K Manual 0 to Manual 0 to Aux Input (0 to ) The Aux input is an analog input that can be used for additional purposes. The input level can come from a potentiometer or other external source. (See wiring diagram below). 0 to 0K Aux Input 0 to Aux Input 0 to Note: For parameter set-up, see 5.3 Aux Input. 3-20

31 3.2 Analog Input (0 to ) - continued Electrical Installation 3 Status Menu Version Tension Setpoint Output Flt Menu I-Level Gain Level Manual Linespeed Diameter Aux In Aux2 In Aux3 In Aux Out Aux2 Out LC Gain IO Terminal Menu Ext Status Menu Aux2 Input (0 to ) The Aux2 input is an analog input that can be used for additional purposes. The input level can come from a potentiometer or another external source. (See wiring diagram below.) 0 to Aux2 Input 0 to Note: For parameter set-up, see 5.4 Aux2 Input Menu section NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. Aux3 Input The Aux3 input on terminal 25 can be zero and span adjusted on R4 and R5. Value displays in Aux3 In under Status Menu. (See wiring diagram below.) Input AI-6 to microprocessor Calibrated Aux3 Output R5 SPAN + R4 ZERO Aux3 Input Parameter Descriptions Zero Adjustment (R4) The signal on terminal 25 can be offset adjusted on R4. Span Adjustment (R5) (range: -50) The signal on terminal 25 can be span adjusted on R5. 3-2

32 Z4 CONTROLLER REV# (C) 20XX MONTALVO Z4 CONTROLLER REV# (C) 20XX MONTALVO Analog Output Electrical Installation SERXXXXXX Run Mode AUTO Z4XXXXX XXXXXX Made In USA SUPPLY VAC ONLY (Fuse: 3.5A Slow Blow) R6 R5 R4 R3 R2 R N L Tension Outputs Terminal # Output Description 46 0 to +00μA Proportional to 0 to full scale tension to + Proportional to 0 to full scale tension. 44 Common for tension outputs. 3.4 Analog Output (Aux Output) The Aux Output is an analog output that can be used for various purposes - typically providing 0 to output proportional to diameter, output or line speed. For a CVD or a MVD control, can provide a speed signal to the rewind drive to keep the surface speed of the rewind roll proportional to line speed. The source selection determines the purpose. See 5.5 Aux Output Tension Output 0 to +00μA Tension Output 0 to Run Mode AUTO Aux Output 0 to SERXXXXXX Z4XXXXX XXXXXX Made In USA 55 SUPPLY VAC ONLY (Fuse: 3.5A Slow Blow) R6 R5 R4 R3 R2 R N L 3-22

33 3.5 Voltage to Current Converter Electrical Installation 3 The controller has a voltage to current converter. 0 to input can be converted to 4 to 20mA output. Input 58 Amp 29 Output to 4 to 20mA Volt Terminal Description 58 0 to Input Input for voltage to current converter. Converts 0 to into 4 to 20mA on terminal for analog signal to 20mA Output Output from voltage to current converter. Converts 0 to on terminal 58 into 4 to 20mA. 28 for analog signal. 3-23

34 Tuning 4 4. Tuning - Z4RL/CDD (Clutch Direct Drive) Setup Menu Confi g Menu Options Menu Regulator Menu Gain Menu Gain Min Gain Max Gain Slope Source Gain Level PID Menu Out Alpha Coeff Min Roll Change Menu New Output Cal-2 Scale Core Core 2 M Strt Dia Shaft Fill Menu Start Menu SC DC AutoSet Kick Delay DC Max Kick Time DC Mild Decay Time Hold Menu Hold Delay Hold Level Limit Diameter Menu Taper Menu Digital Out Menu Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. Setup and Adjust - Total Rewinder System. Switch the Z4 into manual and set manual setpoint to Install an empty core on the rewind shaft. With no web in the machine start the machine with the speed set to zero. Increase the speed until the machine drive rolls just start to turn. 3. Go to Start Menu to adjust the static friction SC up until the rewinder shaft just starts to move slowly. 4. Calibrate load cells. See 3.7 Installation - Load Cells. 5. Scroll to Roll Change Menu and adjust the parameters New Output and Core. See 5.4 Roll Change. 6. Scroll to Hold Menu and adjust the parameters Hold Delay, Hold Level and Limit. See 5.8 Machine at Stop. If the system needs to use Taper (see 5.0 Taper) the diameter has to be set up before the system is ready to run. See 5.9 Diameter. The system is now ready to start. 7. Go to the parameter Gain Min under the Regulator Menu. 8. Place a small OD roll in the Rewind stand. 9. Run the machine at low speed and adjust Gain Min until web tension is steady but will still respond to variations. 0. Stop the machine and go down to the parameter Gain Max.. Place a large roll in the Rewind stand. 2. Run machine at low speed and adjust Gain Max until web tension is steady. 4-

35 4.2 Tuning - Z4RL/CVD (Clutch Variable Drive) Tuning 4 Setup Menu Confi g Menu Options Menu Regulator Menu Gain Menu Gain Min Gain Max Gain Slope Source Gain Level PID Menu Out Alpha Coeff Min Roll Change Menu New Output Cal-2 Scale Core Core 2 M Strt Dia Shaft Fill Menu Start Menu SC DC AutoSet Kick Delay DC Max Kick Time DC Mild Decay Time Hold Menu Hold Delay Hold Level Limit Diameter Menu Taper Menu Digital Out Menu Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. Setup - Motor and Motor Controller The motor and motor controller must be setup and adjusted, before running the system. Refer to the motor controller documentation. When all the parameters for the motor controller are setup. Setup and Adjust - Total Rewinder System. Switch the Z4 into manual and set manual setpoint to Thread the web to an empty core on the rewinder shaft, and start the rewinder. 3. Go to Start Menu to adjust the static friction SC up until the rewinder shaft just starts to move slowly. 4. Ramp the machine up to maximum speed and slowly turn up for the manual setpoint to 00%. Measure the speed on the empty core and adjust the speed to be 5% more then the line speed (maximum speed in motor controller). 5. Stop the machine and keep the rewinder started. Measure now the speed on the empty core on rewinder and adjust the minimum speed in the motor controller until 5% of the maximum line speed. 6. Calibrate load cells. See 3.7 Installation - Load Cells. 7. Scroll to Roll Change Menu and adjust the parameters New Output and Core. See 5.4 Roll Change. 8. Scroll to [Hold Menu] and adjust the parameters Hold Delay, Hold Level and Limit. See 5.8 Machine at Stop. If the system needs to use Taper (see 5.0 Taper) the diameter has to be set up before the system is ready to run. See 5.9 Diameter. The system is now ready to start. 9. Go to the parameter Gain Min under the Regulator Menu. 0. Thread the web to an empty core in the Rewind stand.. Run the machine at low speed and adjust Gain Min until web tension is steady but will still respond to variations. 2. Stop the machine and go down to the parameter Gain Max. 3. Thread a large roll in the Rewind stand. 4. Run machine at low speed and adjust Gain Max until web tension is steady. 4-2

36 4.3 Tuning - Z4RL/MVD (Motor Variable Drive) Tuning 4 Setup Menu Confi g Menu Options Menu Regulator Menu Gain Menu Gain Min Gain Max Gain Slope Source Gain Level PID Menu Out Alpha Coeff Min Roll Change Menu New Output Cal-2 Scale Core Core 2 M Strt Dia Shaft Fill Menu Start Menu SC DC AutoSet Kick Delay DC Max Kick Time DC Mild Decay Time Hold Menu Hold Delay Hold Level Limit Diameter Menu Taper Menu Digital Out Menu Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. Setup - Motor and Motor Controller The motor and motor controller must be setup and adjusted, before running the system. Refer to the motor controller documentation. When all the parameters for the motor controller are setup. Setup and Adjust - Total Rewinder System. Switch the Z4 into manual and set manual setpoint to Thread the web to an empty core on the rewinder shaft, and start the rewinder. 3. Go to Start Menu to adjust the static friction SC up until the rewinder shaft just starts to move slowly. 4. Ramp the machine up to maximum speed and slowly turn up for the manual setpoint to 00%. Measure the speed on the empty core and adjust the speed to be 5% more then the line speed (maximum speed in motor controller). 5. Stop the machine and keep the rewinder started. Measure now the speed on the empty core on rewinder and adjust the minimum speed in the motor controller until 5 % of the maximum line speed. 6. Calibrate load cells. See 3.7 Installation - Load Cells. 7. Scroll to Roll Change Menu and adjust the parameters New Output and Core. See 5.4 Roll Change. 8. Scroll to Hold Menu and adjust the parameters Hold Delay, Hold Level and Limit. See 5.8 Machine at Stop. If the system needs to use Taper (see 5.0 Taper) the diameter has to be set up before the system is ready to run. See 5.9 Diameter. The system is now ready to start. 9. Go to the parameter Gain Min under the Regulator Menu. 0. hread the web to an empty core in the Rewind stand.. Run the machine at low speed and adjust Gain Min until web tension is steady but will still respond to variations. 2. Stop the machine and go down to the parameter Gain Max. 3. Thread the web to a large roll in the Rewind stand. 4. Run machine at low speed and adjust Gain Max until web tension is steady. 4-3

37 Configuration and System Setup 5 5. Configuration Menu Confi g Menu Setup Menu Confi g Menu Ctrl Type RWD Type Amplifier Save Config Restore Config Options Menu Regulator Menu Roll Change Menu Shaft Fill Menu Start Menu Hold Menu Diameter Menu Taper Menu Digital Out Menu Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. Confi g Menu consists of fi ve settings. Ctrl Type This parameter displays the factory set controller type: X-RW. RWD Type Select... CDD, CVD] or MVD This parameter displays the rewind type: CDD Clutch Direct Drive - driven from main machine. CVD Clutch Variable Drive - clutch driven by a separate motor. MVD Motor Variable Drive - motor is driving rewinder directly. Amplifi er Select... X or X 0 The amplifi er for the tension input signal can be selected to either X or X0. Typical X0 is used for load cell. X = Gain: to 48 X 0 = Gain: to 480 Save Confi g Select... NO or YES The current confi guration (parameter settings) can be saved. Select YES to save. Restore Confi g Select... NO or YES The saved confi guration (parameter settings) can be restored. Select YES to restore. 5-

38 Configuration and System Setup Options Selection Menu Options Menu Setup Menu Confi g Menu Options Menu Use ShftFill Use Taper Use Dig Out Use Splice Use Aux In Use Aux2 In Use Aux Out Use Var Wrap DI Mode Menu Regulator Menu Roll Change Menu Shaft Fill Menu Start Menu Hold Menu Diameter Menu Taper Menu Digital Out Menu Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. This menu offers a number of optional functions, to be enabled or disabled (choose NO or YES), and as such is building a supplement to the basic functions of the controller. If disabled, an optional function will not appear in the menu tree If enabled, an optional function will appear in the menu tree NO = option is disabled (default) YES = option is enabled Functions Menu Item Use ShftFill Use Taper Use Dig Out Use Splice Use Aux In Use Aux2 In Use Aux Out Use Var Wrap Description If this parameter is set to YES the controller performs a special fi ll pulse. The fi ll pulse is used to fi ll up an empty shaft after roll change. See 5.5 Shaft Filling. Only used in a single zone machine. Used to Taper the tension as roll diameter increases. Requires a diameter signal. Offers the options web break or diameter alarm. Used to control a splice sequence (automatic roll change). When enabled, the analog Aux input is available to use. When enabled, the analog Aux2 input is available to use. When enabled, the analog Aux output is available to use. When enabled, Variable Wrap is available to use. DI Mode Menu Different modes for DI can be set up under this menu. 5-2

39 Configuration and System Setup Regulator Parameters Regulator Menu Setup Menu Confi g Menu Options Menu Regulator Menu Gain Menu Gain Min Gain Max Gain Slope Source Gain Level PID Menu Sys Gain P Level I Time I-lev Smp D Level Out Alpha Coeff Min Roll Change Menu Shaft Fill Menu Start Menu Hold Menu Diameter Menu Taper Menu Digital Out Menu Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. Overview The Z4 is a progressive PID regulator which means the overall system gain is adjusted based on roll size (mass of the roll). The controller uses either the output or the diameter to set the overall system gain. Parameter Descriptions Gain Menu PID Menu Gain Min (range: 0-00) Adjusts the speed of the response of the regulator to errors at the small roll diameter. The higher the value, the faster the reaction towards errors. Parameters lower than 5 are not recommended. Gain Max (range: 0-500) Adjusts the speed of the response of the regulator to errors at the large roll diameter. The higher the value, the faster the reaction towards errors. Parameters lower than 5 are not recommended. Source (DIA / OUTPUT / RPM) Used to select the source for the Gain scaling. Two choices - DIA or OUTPUT (default). RPM used on NIP/Rewind applications. Gain Level (range: 0-00) Shows the current gain level (Read-Only) Sys Gain (range: 0-255) Adjusts overall gain. P Level (range: 0-255) Proportional gain level of the PID regulator. The higher the value, the faster the second will respond. If the response is too large the system may begin to oscillate. I Time (range: 0-255) Integral time of the PID regulator. The higher the value, the longer it will take to adjust, and will slow the speed of response. D Level (range: 0-255) Derivative gain level of the PID regulator. The higher the value, the faster the system will respond to changes. This can increase the overall system response, but can also cause oscillations if too high. Typical Load cell applications require no D component. Out Alpha (range: ) (default: 256) Adjusts how heavily the output signal (used as a reference for range expander) is fi ltered (highly smoothed) to 256 (no smoothing). Note: Status Menu / Flt Out indicates effect of the alpha fi lter applied to the output level. This should help set the Output Alpha level. Coeff Min (range: 0-50) Used only to set a minimum value for the taper when an external input (potentiometer) is not used. This value can be adjusted to set the minimum permissible taper level, but is factor set and typically doesn t require adjustment for use with the HMI or communication inputs. 5-3

40 5.3 Regulator Parameter Regulator Menu - continued Configuration and System Setup 5 Setup Menu Confi g Menu Options Menu Regulator Menu Gain Menu Gain Min Gain Max Gain Slope Source Gain Level PID Menu Out Alpha Coeff Min Roll Change Menu Shaft Fill Menu Start Menu Hold Menu Diameter Menu Taper Menu Digital Out Menu Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu Gain Slope Gain Slope describes the amount of gain the Z4 controller uses to compensate to maintain a constant tension. This works in conjunction with the Gain Min and Gain Max to determine the gain profi le that will be used to make tension adjustments. It is critical that the appropriate gain slope be selected for the application. For load cell systems generally a slope of is required (linear), while a dancer requires a higher initial slope (polynomial), this follows he higher mass of the roll, and then subsides as the roll decreases (becomes less responsive). With a slope of, there's a linear (proportional) correlation between gain min and max. As the roll diameter decreases the gain responsiveness is consistent. With a slope of 2.5, there's a higher order function between min and max. As the roll diameter decreases the gain becomes less responsive. For a dancer system this is important so that large corrections are not made near the core (creating an unstable system). Gain Dia Max Gain Max NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. SLO = Roll Mass Profile Dia Min Gain Min SLO = 2.5 Slope Mass Profile Diameter 5-4

41 Configuration and System Setup Roll Change Roll Change Menu Setup Menu Confi g Menu Options Menu Regulator Menu Roll Change Menu New Output Cal-2 Scale Core Core 2 M Strt Dia Shaft Fill Menu Start Menu Hold Menu Diameter Menu Taper Menu Digital Out Menu Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. Overview How optimal a start-up can be after a roll change depends on the information given by the controller at roll change. The rewinder has a 3 position switch to control the Roll with. The switch is working the following way: Reset ON Release Position Coming from Reset Coming from Release Description The controller output is zero and all the roll data is reset. The controller output is zero and all the roll data is reset. All the stored Roll data is used again to setup the controller. Output from voltage to current converter. Converts 0 to on terminal 58 into 4 to 20mA. The controller is using the following calculation to prepare and set up a new roll after roll change: Output= New Output X Setpoint X Diameter 0000 Output= 00 X 00 X Parameter Setting and Adjustment New Output (range: 0-500%) This parameter is used as a scaling factor for the new output after roll change. The output level with which the controller starts when the Roll switch changes from Reset to ON position. This same output level is also applied after power-up. To set the correct value: a) Set the setpoint at the desired tension setting and web up on a new core. 2 Start the machine and run it at slow speed. Note the output level when tension has become steady. Man / Auto Ten Off / On Cal2 MODE AUTO TENSION OFF / ON OUTPUT LEVEL.000 x00 psi Di Setpoint 550. lb Tension Manual 36.0 psi lb Aux 0.0 % X000 lb Diameter 28.0 in Output Setpoint Do Rng DISPLAY ADJUST TREND DATALOG SCALING CONFIG 5-5

42 5.4 Roll Change Roll Change Menu - continued Configuration and System Setup 5 Setup Menu Confi g Menu Options Menu Regulator Menu Roll Change Menu New Output Cal-2 Scale Core Core 2 M Strt Dia Shaft Fill Menu Start Menu Hold Menu Diameter Menu Taper Menu Digital Out Menu Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. 3 Stop the machine and increase or decrease the New Output parameter to the level noted in step 2. To see the new output level after changing the New Output parameter, switch tension off and then on again. Cal-2 Scale (range: 20-50%) Used to scale the output in the second calibration range. Normally only used in unwind or rewind applications using load cell input with perhaps two web paths or a wide tension range. Active when DI-4 (terminal 3) is set high. Only visible if Setup Menu Options Menu DI Mode Menu DI-4 Mode = Cal2. Cal2 is default for Z4UL and Z4RL. Core (range: 0-00%) The diameter to which, after roll change, the controller is set. Replaced by the calculated diameter when running again. Automatically set to minimum diameter when a new minimum diameter is entered in the Diameter Menu. See 5.8 Diameter. Typically the empty core diameter is used for this parameter. If the application does not require minimum diameter, the parameter can be adjusted. Only used if Setup Menu Diameter Menu Dia Source = OUTPUT or PULSE. 5-6

43 5.5 Shaft Filling (CDD and CVD) Configuration and System Setup 5 Setup Menu Confi g Menu Ctrl Type RWD Type Amplifi er Save Confi g Restore Confi g Options Menu Use ShftFill Use Taper Use Dig Out Use Splice Use Aux In Use Aux2 In Use Aux Out Use Var Wrap DI Mode Menu Regulator Menu Roll Change Menu Shaft Fill Menu Fill Delay Fill Time LS Limit Release Del Start Menu Hold Menu Diameter Menu Taper Menu Digital Out Menu Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. System Descriptions This function is only active if Use ShftFill = Yes in the Options Menu. It is not available when RWD Type = MVD. The Shaft Fill System is specialiy made for fi lling up an airshaft automaticly from the I/P converter that is controlling the clutch u Air Supply (6-8 bar) 2 Air Filter 3 I/P Converter (0-6 bar) 4 Manometer 5 Rotary Union 6 Rewind Clutch 7 Rewind Shaft When Start Rewinder is deactivated (), the output goes to zero and the regulator is reset. If an airshaft is used, it can now manually be exhausted, to be able to change the roll. When Start Rewinder is activated by 24V signal and the delay Fill Delay has run out, the output goes to maximum level for the time Fill Time. This is used to fi ll up the shaft. After fi ll time, the output goes to zero, for the delay [RW start del] and then the output changes to the new output level and gives start signal for the rewind motor (DO 2). The new output level is the Static Compensation SC + (New Output x Setpoint x Diameter) see diagram below. Note: If the rewinder setup is RWD Type = CVD, it will typically be set up to go into auto mode when DO 2 is activated. See 5.8 Machine at Stop. If linespeed (terminal 54) > LS Limit no Fill pulse is applied sec. Air Shaft Exhaust Switch 00%.0 sec. Output 0% 0.5 sec. Hold Level 5-7

44 5.6 Start Rewinder (CVD and MVD) Configuration and System Setup 5 Run Mode Status Menu Password Setup Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. If the application is a CVD, or MVD, the rewinder will be started before the machine starts to RUN. The signal on terminal 6 Start Rewinder is used to give the Z4 information when the rewinder has been started. This information is used to control the mode of the Z4. Following is a description of the modes: Mode TENOFF (and controller reset) AUTO Description The Z4 is in tension off mode and all the parameters are reset, when Start Rewinder is deactivated (). The Z4 is in Run Mode = AUTO when Start Rewinder is activated by a 24V signal and starts to regulate to get the actual tension to be equal with the auto setpoint. Limit and Tension watchdog : When the Z4 is in Auto mode and the machine isn t started, a watchdog is watching the tension level and the limit. Indication Description If Tension < setpoint The regulator will regulate when Run Mode = AUTO. If Tension = setpoint The controller stops the regulator and goes Run Mode = HOLD. If Output < Limit The regulator will regulate when Run Mode = AUTO. If Output = Limit The controller stops the regulator and goes Run Mode = HOLD. Note: Limit is the maximum level that can be applied on the output in Run Mode = HOLD. Electrical Wiring for CVD and MVD An example how the signal is to be connected if the system is using the fi ll pulse option. Motor Controller (Rewind Clutch) START K00 +24V (NO) STOP (COM) K DO 2 Start Clutch DI 8 Start Rewinder START Rewinder A typical example of how to connect the Start Rewinder (terminal 6) START K00 +24V (NO) STOP 2 3 DI 8 Start Rewinder 3(COM) K00 Start Rewinder 5-8

45 5.6 Start Rewinder (CVD and MVD) - continued Configuration and System Setup 5 Setup Menu Confi g Menu Options Menu Regulator Menu Roll Change Menu New Output Cal-2 Scale Core Core 2 M Strt Dia Shaft Fill Menu Start Menu SC DC AutoSet Kick Delay DC Max Kick Time DC Mid Decay Time Hold Menu Diameter Menu Taper Menu Digital Out Menu Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. Parameter Setting and Adjustment. SC (Static Compensation) The static compensation is the fi rst parameter that needs to be set up. The parameter SC is used to compensate for the mechanical inertia in the rewinder system. With this offset on the output signal, the rewinder will always move slowly when the rewinder is started. To set the correct value: a) Switch the controller into manual and set manual setpoint to 0. b) Keep the machine stopped and thread the web to an empty core on the rewinder shaft, and start the rewinder. c) Go to Start Menu to adjust the static compensation SC up until the rewinder shaft just starts to move slowly. 2. New Output (Starting output) New Output is a scaling parameter for the new ouput level when a new output has to be applied. A new output is applied when Tension is ON and Start Rewinder is activated. The output level is depending on, if the controller is in automatic or manual, see the following: Auto selected: A new output is applied when Tension is switched ON and Rewinder Start is activated. The total output is a summation of a scaled new output + static friction. The output level varies in direct proportion to the setpoint and diameter. See following: Total new output = (Start out x Setpoint x Diameter) + Static Friction Manual selected: A new output is applied when Tension is switched ON and Rewinder Start is activated. The total output is a summation of the manual setpoint + static friction. See following: Total new output = manual setpoint + Static Friction Note: The output level on the controller is set to zero when Tension is OFF or Start Rewinder is off. 5-9

46 Configuration and System Setup Starting the Machine Start Menu Setup Menu Confi g Menu Ctrl Type RWD Type Amplifi er Save Confi g Restore Confi g Options Menu Regulator Menu Roll Change Menu Shaft Fill Menu Start Menu Hold Menu Hold Delay Hold Level Limit Diameter Menu Taper Menu Digital Out Menu Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. Starting and Stopping Descriptions Depending on the application type the preparation before start up with machine will be different. RWD Type = CDD (Clutch Direct Driven from main machine) For CDD the rewinder will always be standing still before operator starts the machine. When roll change is done and Tension is selected ON, the controller will be in hold mode and is prepared for start. In hold mode the controller is at a constant level and is waiting for the start signal from the machine. RWD Type = CVD (Clutch Variable Driven, clutch driven by a separate motor) RWD Type = MVD (Motor Variable Driven, motor is driving rewinder directly) For CVD and MVD the rewinder will always be started before the operator starts the machine. When the rewinder is started, it will run in auto mode, or if ½ tension level is reached, the controller will change to hold mode. From one of those two modes it will wait for the start signal from the machine. RUN (Start Machine) Signal activated Description When the Run signal is activated, the regulator goes in to auto mode and a dynamic compensation is applied to the output. The dynamic compensation is needed to be able to get a good tension at start. When the run signal is deactivated, the controller switches to Run Mode STOP. In stop mode the controller is still regulating until time ( Hold Delay setting) has run out. Signal deactivated When time ( Hold Delay setting) has run out, the controller changes to Run Mode HOLD. In hold mode, the controller is not regulating and the desired output is set to a constant level: hold output level = stored output level x Hold Level setting For a rewind there are two important things that have to be controlled to get an optimal system. ) Static compensation Static friction is the mechanical friction in the system (gear transmission, motor, etc.). 2) Dynamic compensation The dynamic compensation refers to the dynamic mass of the (gear, transmission, motor osv ). If compensation for that is not made, the system will be too slow at start up and will lose web tension. 5-0

47 5.7 Starting the Machine Start Menu - continued Configuration and System Setup 5 Setup Menu Confi g Menu Ctrl Type RWD Type Amplifi er Save Confi g Restore Confi g Options Menu Regulator Menu Roll Change Menu New Output Cal-2 Scale Core Core 2 M Strt Dia Shaft Fill Menu Start Menu SC DC AutoSet Kick Delay DC Max Kick Time DC Mid Decay Time Hold Menu Diameter Menu Taper Menu Digital Out Menu Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. Parameter Setting and Adjustment SC (Static Compensation) RWD Type = CDD or CVD The Static Compensation for a CDD and CVD is normally set to the minimum value. RWD Type = MVD The Static Compensation for a MVD is set up as follows: Start the rewinder with the web threaded to an empty core on the rewinder shaft and set tension setpoint at 0%. 2 Go to the parameter SC and increase the Static Compensation until the core starts moving slowly. With your hand, it should be possible to stop the roll and when your hand is removed, the core will start to move slowly again. Note: To do this setup the motor controller has to have a minimum linespeed signal of about 0%. (Dynamic Compensation) The Dynamic Compensation is generated according to the curve shown below. A scaling factor called [Dyn.Factor] is then used to scale the curve up or down in size. The example is shown with [Dyn.Factor 0] and [Dyn.Factor 20]. Note: The New Output parameter in Roll Change Menu, has to be set up before the Dynamic Compensation can be set up correctly. 30 Output% Time (2s/div) Start Machine (Terminal 6) 5-

48 5.7 Starting the Machine Start Menu - continued Configuration and System Setup 5 Setup Menu Confi g Menu Options Menu Regulator Menu Roll Change Menu Shaft Fill Menu Start Menu SC DC AutoSet Kick Delay DC Max Kick Time DC Mid Decay Time Hold Menu Diameter Menu Taper Menu Digital Out Menu Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. To set the correct value: c) Install a empty core on the rewinder shaft and connect the web. Set tension setpoint at about 50%. d) Start the rewinder and let the tension stabilize. e) Start machine and note the tension at start. f) Stop the machine again and decrease [Dyn.factor] if tension rises; increase if tension drops. To set the correct value: d) Switch the controller into manual and set manual setpoint to 0. e) Keep the machine stopped and thread the web to an empty core on the rewinder shaft, and start the rewinder. f) Go to Start Menu to adjust the static friction SC up until the rewinder shaft just starts to move slowly. 3. [Start Out] (Starting output) Start out is a scaling parameter for the new output level when a new output has to be applied. A new output is applied when Tension is ON and Start Rewinder is activated. The output level depends on if the controller is in automatic or manual, see the following: Auto selected: A new output is applied when Tension is switch ON and Rewinder Start is activated. The total output is a summation of a scaled new output + static friction. The output level varies in direct proportion to the setpoint and diameter. See following: Total new output = (Start out x Setpoint x Diameter) + Static Friction Manual selected: A new output is applied when Tension is switched ON and Rewinder Start is activated. The total output is a summation of the manual setpoint + static friction. See following: Total new output = manual setpoint + Static Compensation Note: The output level on the controller is set to zero when Tension is OFF or Start Rewinder is off. 5-2

49 Configuration and System Setup Machine at Stop Hold Menu Setup Menu Confi g Menu Options Menu Regulator Menu Roll Change Menu Shaft Fill Menu Start Menu Hold Menu Hold Delay Hold Level Limit Diameter Menu Taper Menu Digital Out Menu Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. Overview When the machine is running and the run input is deactivated, the output level will be stored and the controller will go into Stop Mode Run Mode = Stop. In Stop Mode the controller is still regulating until time Hold Delay has run out. When time has run out, the controller changes to Hold Mode Run Mode = Hold. In Hold Mode the controller is not regulating and the desired output is held at a constant level = Hold Level. Hold Level = Stored Level + hold% Parameter Setting and Adjustment: Hold Delay (range: ) If there is a delay from the time where the run signal is deactivated until the time where the machine reaches zero speed, enter the time as follows. To set the correct time: Step Run the machine at maximum speed. Step 2 Measure the time from activation of stop to zero speed. Step 3 Enter this time seconds in this parameter. Note: If this time is longer than 0 seconds, use a zero speed signal. Hold Level (range: 0-200%) When the run signal is deactivated, the controller stores the output level, but continues to regulate until Hold Delay has run out. If a longer time is set up, the output will change after that time. In Hold Mode, the output is at a constant hold level. To keep the roll in the same position in Hold Mode, the stored level is increased by hold% to create a holding output Hold Level. Typically Hold Level = stored level +50%. Examples of the output level in Hold Mode: Hold Menu Hold Level 00% => Stored Level Hold Menu Hold Level 50% => Stored Level + 50% 5-3

50 Configuration and System Setup Diameter Diameter Menu Setup Menu Confi g Menu Options Menu Regulator Menu Roll Change Menu Shaft Fill Menu Start Menu Hold Menu Diameter Menu Dia Source P/Rev Roll mm/pulse P Wait Dia Min Dia Max Dia Array Dia Factor DF AutoSet Diameter Dia Raw Taper Menu Digital Out Menu Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. Overview The diameter reference is useful and, in some cases, necessary, in the following instances: Scheduling gain along gain slope Control of tension (taper) on rewinder Not all parameters show depending on Dia Source selection. The diameter can be selected from fi ve different sources. Source Output Pulse Description The processor calculates a diameter from tension and output. This way will not work in applications requiring a wide web tension range. Diameter calculated from two digital input signals (2 proximity switches). Aux Diameter from external analog source, typically ultrasonic, laser, rider arm or other. (Terminal 5). Aux2 Diameter from external analog source (Terminal 54). Aux3 Diameter from external analog source (Terminal 25). OUTPUT (from Tension and Output) The diameter calculated is approximate, not useful in applications requiring precise diameters. To set up parameters enter the Diameter Menu, scroll to Dia Source and select OUTPUT. The following parameters will be available: Parameter Description Dia Min Minimum roll size must be set up in percentages (0-00%). Dia Max Maximum roll size must be set up in percentages (0-00%). Dia Factor DF AutoSet Diameter Calculated diameter constant. Generates Dia Factor based on roll diameter, setpoint and output. Displays current calculated or actual diameter based on previous settings. Scroll to: Dia Min and enter the minimum roll diameter as % (Min. Dia Max. Dia.) Dia Max and enter the maximum roll diameter as % (typically this would be 00%). Place a full or partial roll on the machine. Measure its diameter as % (Roll Dia Max. Dia.). Note: Recommended >50%. Partial rolls already on the machine can be used. ` Measured as mentioned. Scroll to: DF AutoSet and run the machine at low to moderate speed until the machine has stabilized for 0 seconds. Input actual diameter (as %) and press the Enter button (Note that value reverts to.0 but parameter has been accepted). Dia Factor will now display a factor used for diameter calculations. Scroll to: Diameter to verify actual diameter. 5-4

51 Configuration and System Setup Diameter Diameter Menu - continued Setup Menu Confi g Menu Options Menu Regulator Menu Roll Change Menu Shaft Fill Menu Start Menu Hold Menu Diameter Menu Dia Source P/Rev Roll mm/pulse P Wait Dia Min Dia Max Dia Array Dia Factor DF AutoSet Diameter Dia Raw Taper Menu Digital Out Menu Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. PULSE (from 2 proximity sensors) Roll diameter is calculated during running from 2 proximity sensors. One proximity sensor senses roll revolutions at location. See diagram below. The other proximity sensor senses web speed at locations 2, 3 or 4. See diagram below. Roll diameter calculated at start-up after roll change. Calculation is made when controller has received 2 pulses from the new roll. Recommended for applications with a wide web tension range. These calculations improve the fast stop function. To set up parameters enter the Diameter Menu, scroll to Dia Source and select PULSE. The following parameters will be available: Parameter P/Rev Roll mm/pulse Dia Min Dia Max Diameter Roll Pulse Description The number of pulses per revolution on the unwind roll. Millimeters (mm) between pulses on the main machine. Minimum roll size must be set up in millimeters (mm). Maximum roll size must be set up in millimeters (mm). Displays current calculated or actual diameter based on previous settings. Warning: Do not place proximity sensors at a places where they will be overheated by the clutch! 2 Web Pulse Load Cell 3 Web Pulse : Roll Pulse PNP +24 S Web Pulse +24 S PNP Roll Pulse (terminal 35) 2 to 4 pulses (recommended) per revolution during rotation of the roll. Mount on the unwind stand to sense unwind roll revolution. Mount it at a place where it can sense a keyway, screw, or bored hole in the shaft. Other possible sensing locations are at the safety chucks or brake. Note: Maximum input frequency must not exceed 80Hz. Web Pulse (terminal 5) Mount along the web path to sense the web length/pulse. The proximity sensor can be installed in position 2, 3 or 4. Position 4 must turn proportionally with line speed. The recommended web length/pulse is between 0 and 250 mm/pulse. For better resolution, use a short distance between the pulses. Note: The maximum input frequency must not exceed 5KHz. 5-5

52 5.9 Diameter Diameter Menu - continued Configuration and System Setup 5 Setup Menu Confi g Menu Options Menu Regulator Menu Roll Change Menu Shaft Fill Menu Start Menu Hold Menu Diameter Menu Dia Source P/Rev Roll mm/pulse P Wait Dia Min Dia Max Dia Array Dia Factor DF AutoSet Diameter Dia Raw Taper Menu Digital Out Menu Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. Status Menu Version Tension Setpoint Output\ Flt Out I-Level Gain Level Manual Linespeed Diameter Aux In Aux2 In Aux3 In Aux Out Aux2 Out LC Gain IO Terminal Menu Ext Status Menu AUX, AUX2 or AUX3 (from an external analog source) Three analog inputs are available for diameter reference. Depending on the unwind type, however, they can also be used for other purposes. The AUX inputs are default factory setup or adjusted to use a 0 to input signal. If Aux and Aux2 are input, and if other than 0 to signal is needed, software parameter changes must be made for proper scaling. (See 5.3 and 5.4 for Aux and Aux2 input. It is possible to adjust Aux3 with 2 potentiometers, if zero or offset adjustment is needed (see diagram under analog input). Source Aux Aux2 Aux3 Description Free to use (if not used for taper or splice level) Free to use Free to use To set up parameters enter the Diameter Menu, scroll to Dia Source and select AUX, AUX2 or AUX3. Parameter Description Dia Min Min. roll size must be set up in percentages (0 to 00%). Dia Max Maximum roll size must be set up in percentages (0 to 00%). Diameter Displays current calculated or actual diameter based on previous settings. Go to the parameter Aux3 In in Status Menu Place Aux3 input reference at minimum position. Adjust on potentiometer R4 until 0% is displayed (for AUX3 input only) 2 Place Aux3 input reference at maximum position. Adjust on potentiometer R5 until 00% is displayed. 5-6

53 Configuration and System Setup Taper Taper Menu Setup Menu Confi g Menu Options Menu Regulator Menu Roll Change Menu Shaft Fill Menu Start Menu Hold Menu Diameter Menu Taper Menu Type Tap Begin Digital Out Menu Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu Overview The Taper function is typically used on a rewind application to reduce web tension as the roll diameter increases, to make a tension profi le that prevents the roll from center starring and from telescoping. The Taper option is used in a single zone. It will decrease the specifi ed set point value based on the parameters to prevent the roll from being wrapped tighter on the outer layers than it is on the inner layers. Use Taper Taper Menu To enable the Taper option, navigate to Options Menu / Use Taper and select YES. The default setting is NO. NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. ` From the Taper Menu, scroll to Type to choose between LIN or EXP LIN EXP Performs a downward linear ramping function, based on the parameters entered. Performs an exponential decay function, based on the parameters entered; changing slowly near the core and faster as the roll comes closer to it s maximum build. From the Taper Menu, scroll to Tap Begin to enter a value from.0 to This specifi es at what point the effect of tapering will be applied to the roll, it can be set to start anywhere between % and 50% of the roll build. The amount of taper can be controlled either through the Aux channel input, or it can be controlled remotely through the HMI. This is represented as the total amount of taper requested which Note: Aux is user defi nable and may also be used for splice level, but cannot be used for both taper and splice at the same time. Tension Tap Begin Tension Tap Begin Diameter Diameter LINEAR EXPONENTIAL 5-7

54 Configuration and System Setup 5 5. Digital Output Digital Out Menu Setup Menu Confi g Menu Options Menu Regulator Menu Roll Change Menu Shaft Fill Menu Start Menu Hold Menu Diameter Menu Taper Menu Digital Out Menu DO Select Menu Web Break Diameter Lo Tension Hi Tension Linspeed Motor Cntrl Wbr Delay Wbr Level Wbr Time Alarm Dia Lo Level Lo Delay Hi Level Hi Delay LS Level LS Delay Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu All four digital outputs can be selected as either web break or diameter alarm. DO Selection Menu (Digital Output Selection) Web Break or Diameter In those parameters the selection of the digital output is done. Set up one of the following: None, DO, DO2, DO3 or DO4. Web Break Description: The web break function can be used to stop the machine or trigger an alarm if the web breaks. The output will typically activate a customer-supplied relay that stops the machine (maximum 00mA load for the digital output). When the run signal (machine is starting) is activated, the web break function will be active after time Wbr Delay has run out. (default set to 0 sec.) This time period allows start-up with new rolls when little or no tension is present. When Web Break is active, and tension goes below web break level Wbr Level longer than web break time Wbr Time, output will be activated (i.e. go high). See illustration. Machine Speed Wbr Delay Web break function is active Time NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. Tension Wbr Level Time 0 Run/DI-5 Web break 0 Wbr Time 5-8

55 5. Digital Output Digital Out Menu - continued Configuration and System Setup 5 Setup Menu Confi g Menu Options Menu Regulator Menu Roll Change Menu Shaft Fill Menu Start Menu Hold Menu Diameter Menu Taper Menu Digital Out Menu DO Select Menu Web Break Diameter Lo Tension Hi Tension Linspeed Motor Cntrl Wbr Delay Wbr Level Wbr Time Alarm Dia Lo Level Lo Delay Hi Level Hi Delay LS Level LS Delay Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. Electrical Wiring Below is an example of how to connect web break on terminal 38 (DO ): Parameter Setting and Adjustment +24V K00 START STOP 2(NC) K00 (COM) Machine START To set up parameters for Web Break, scroll to DO Select Menu : Wbr Delay (range: sec.). When the run signal is activated, the web break function will be active after this time has run out. Wbr Level (range: %) 2. Tension below this level will activate output after the web break time. The factory setting of 5% applies to most applications. Wbr Time (range: sec.) 3. The time where the tension position is beyond web break level before output is activated (goes high). To adjust this parameter, time should be: long enough to prevent small tension drops from stopping the machine. short enough to minimize material waste before stop. Diameter Alarm Description and Setup: Alarm Dia (range: % or mm) When a diameter is beyond the level set up in this parameter, this will activate the digital output. Note: If the diameter is using PULSE as source, this is in mm. Otherwise the diameter is displayed in %. 5-9

56 Configuration and System Setup Splice Splice Menu This function controls the regulator in the splice sequence. The following sequence diagram shows a fl ying splice:. A new core is ready and in splice position when the operator activates the splice sequence. (Typically, the core will be accelerated up to web speed.) 2. Splice arm moves down; the new roll is spliced onto the running web. 3. Knife cuts the web off the old roll. 4. Knife and splice arm retract. The splice is fi nished. 2 Knife 3 4 In a splice sequence, the output level must change from the regulated output level on the old roll to a new output level for the new core. The output level on the expiring roll will normally be high, while, on the new core, the output will change to a much lower level. If the diameter of core is the same at every splice, the splice level will always be the same. If the core diameter varies to a high degree, the splice level will also vary each time. In a standard application, the splice level in a software parameter is fi xed at the same level for every splice. As an option, the diameter for the core can be set up either from an analog input signal. The option should be used in cases where splice levels vary to a high degree. 5-20

57 5.2 Splice Splice Menu - continued Configuration and System Setup 5 Setup Menu Confi g Menu Options Menu Regulator Menu Roll Change Menu Shaft Fill Menu Start Menu Hold Menu Diameter Menu Taper Menu Digital Out Menu Splice Menu Spl Source Spl Delay Spl Level Spl Time Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. Electrical Wiring Option An example of a splice signal connection. Typically a knife signal is used.. Option 2 If an external diameter is used for the new roll diameter, wire it on Aux Option 4(NO) K200 3(COM) K200 SPLICE KNIFE SIGNAL VALVE SIGNAL 0 to 0 to Option K OR Aux Input Aux Input 0 to In splice mode the regulator is held at a constant level Spl Level for some time Spl Time, and then starts regulating from that level again - see illustration below. Optional: A delay between the knife signal and the cutting of the web can be set up in the parameter Spl Delay, if required. Knife signal or splice button Splice / DI Regulated Output Splice Delay Splice Time Splice Level 0% Time Tension Tension Setpoint 0% Time 5-2

58 Configuration and System Setup Splice Splice Menu - continued Setup Menu Confi g Menu Options Menu Regulator Menu Roll Change Menu Shaft Fill Menu Start Menu Hold Menu Diameter Menu Taper Menu Digital Out Menu Splice Menu Spl Source Spl Delay Spl Level Spl Time Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu Parameter Setting and Adjustment. Spl Source (Splice Source) Set up the source for the splice. Source S.LEV Aux Aux2 or Aux3 Description With S.LEV as the source, the splice level is set up in a menu parameter. Choose this source if the diameter of the core is approximately the same at every splice. With the AUX as source, the splice level comes from an analog signal (0 to ). The analog signal can either be wired on terminal 5, or come from a potentiometer on the HMI. Choose this source for large changes of the diameter of the new roll. The analog input from AUX2 or AUX3 can also be selected as diameter. See Analog Input section. (0 to = 0 to 00% diameter.) NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. Z4 Circuit Board Operator / Control Panel Aux Input 0 to Communications Board K Z4 HMI (Remote or Enclosure Version) Note: The diameter of the HMI and the diameter input on terminal 5 cannot be used at the same time. 2. Spl Delay (Splice Delay) In the event of delay from activation of the knife signal to the cutting of the web, time can be set up within this parameter. 5-22

59 Configuration and System Setup Splice Splice Menu - continued Setup Menu Confi g Menu Options Menu Regulator Menu Roll Change Menu Shaft Fill Menu Start Menu Hold Menu Diameter Menu Taper Menu Digital Out Menu Splice Menu Spl Source Spl Delay Spl Level Spl Time Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu 3. Spl Level (Level from the Splice Menu Parameter) Source Spl Source = S.LEV To set the correct value: 4. Level from Analog Aux Input Description Set up the splice level in this parameter. A new output level is required when the knife cuts the web. This level depends upon the diameter of the new roll. If the diameter of the new roll is approximately identical, the splice level can be set at a constant value. a) Place a roll with a maximum diameter. b) Start the machine at slow speed. Note the output level when tension has stabilized. c) Adjust Spl Level to the output noted in step b). (Note: the output level is scaled with the setpoint.) NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. Setting Spl Source = Aux Description The signal on terminal 5 can either come from the front of the cabinet version or from an analog input signal. 0 to on this analog input will give 0 to 00% diameter. Once the knife cuts the web, a new output level will be needed. The new output level is calculated in the following way: Spl. Level x Setpoint x Diameter Output = x 00 x 00 Output = 0000 To set the correct values: a) Place a full roll with the required tension setpoint. b) Start the machine at slow speed. Note the output level when tension has stabilized. c) Stop the machine and write down the diameter, output level, and setpoint. The noted output level should be the correct splice level for this diameter. d) Perform steps a) to c) with different diameters and list them as well. Production "Tension Setpoint" Splice Level Diameter Paper (40g / 25 lb) 35% 60% 00% Paper (40g / 25 lb) 35% 45% 75% Paper (40g / 25 lb) 35% 30% 50% Paper (80g / 25 lb) 60% 80% 00% 5-23

60 5.2 Splice Splice Menu - continued Configuration and System Setup 5 Setup Menu Confi g Menu Options Menu Regulator Menu Roll Change Menu Shaft Fill Menu Start Menu Hold Menu Diameter Menu Taper Menu Digital Out Menu Splice Menu Spl Source Spl Delay Spl Level Spl Time Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu 5. Spl Time (Splice Time) During this time, output is set to a constant level before returning to automatic regulation. Typical setting for this parameter is about.0 sec. Checking the Splice Settings: NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. 3 2 Regulated Output Splice Time Splice Level Tension Time Tension Setpoint Time 5-24

61 Configuration and System Setup Aux Input Aux Input Menu Setup Menu Confi g Menu Options Menu Regulator Menu Roll Change Menu Shaft Fill Menu Start Menu Hold Menu Diameter Menu Taper Menu Digital Out Menu Splice Menu Aux Input Menu Aux Calc Aux Raw Raw Min Raw Max Calc Min Calc Max Calc Invert Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. Overview This analog input can be used with a potentiometer, an ultrasonic sensor or other output device. Use Rewinder Taper % Analog Aux Input (5) Input 0 to Raw Max Raw Min Description Invert Output Calc Min Calc Max Calc Invert The default input is set to use 0 to = 0 to 00%. If the voltage is with a smaller range, then review the following parameters and confi gure accordingly: Aux Calc (range: %) read-out The calculated result of this input function is shown in this parameter. YES NO [Aux Raw] [Aux Calc] Aux Raw (range: %) read-out The input level on terminal 5 is shown directly in this parameter. (0.0 to 0. = 0.0 to 00.0%.) Raw Min (range: %) Note the minimum level in Aux Raw and set it up in this parameter. (If 0 to signal is used, set up 0.0%.) Raw Max (range: %) Note the maximum level in Aux Raw and set it up in this parameter. (If 0 to signal is used, set up 00.0%.) Calc Min (range: %) Set up the minimum (%) that should be calculated at the Raw Min level. (If 0 to signal is used, set up 0.0%.) Calc Max (range: %) Set up the maximum (%) that should be calculated at the Raw Max level. (If 0 to signal is used, set up 00.0%.) Calc Invert (select: NO / YES) The Analog Input signal can be inverted with this parameter. NO 0 to = 0.0 to 00.0%. YES 0 to = 0.0 to 00.0%. 5-25

62 Configuration and System Setup Aux2 Input Aux2 Input Menu Setup Menu Confi g Menu Options Menu Regulator Menu Roll Change Menu Shaft Fill Menu Start Menu Hold Menu Diameter Menu Taper Menu Digital Out Menu Splice Menu Aux Input Menu Aux2 Input Menu Aux2 Calc Aux2 Raw Raw2 Min Raw2 Max Calc2 Min Calc2 Max Calc2 Invert Aux Output Menu Wrap Angle Menu Com Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. Overview This analog input can be used with a potentiometer, an ultrasonic sensor or other output device. Typical Use Unwinder Analog Aux2 Input (54) Input 0 to Raw2 Max Raw2 Min Line speed Description Invert Output Calc2 Min Calc2 Max Calc2 Invert The default input is set to use 0 to = 0 to 00%. If the voltage is with a smaller range, then review the following parameters and confi gure accordingly: Aux2 Calc (range: %) read-out The calculated result of this input function is shown in this parameter. YES NO [Aux2 Raw] [Aux2 Calc] Aux2 Raw (range: %) read-out The input level on terminal 54 is shown directly in this parameter. (0.0 to 0. = 0.0 to 00.0%.) Raw2 Min (range: %) Note the minimum level in Aux2 Raw and set it up in this parameter. (If 0 to signal is used, set up 0.0%.) Raw2 Max (range: %) Note the maximum level in Aux2 Raw and set it up in this parameter. (If 0 to signal is used, set up 00.0%.) Calc2 Min (range: %) Set up the minimum (%) that should be calculated at the Raw2 Min level. (If 0 to signal is used, set up 0.0%.) Calc2 Max (range: %) Set up the maximum (%) that should be calculated at the Raw2 Max level. (If 0 to signal is used, set up 00.0%.) Calc2 Invert (select: NO / YES) The Analog Input signal can be inverted with this parameter. NO 0 to = 0.0 to 00.0%. YES 0 to = 0.0 to 00.0%. 5-26

63 Configuration and System Setup Aux Output Aux Output Menu Setup Menu Confi g Menu Options Menu Regulator Menu Roll Change Menu Shaft Fill Menu Start Menu Hold Menu Diameter Menu Taper Menu Digital Out Menu Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Source Output Aux Min Aux Max Aux Off Lo Limit Hi Limit Aux Slope Wrap Angle Menu Com Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. Aux output is an analog output 0 to. Parameter Setting and Adjustment: Source Select one of the following parameters. Parameter Description SP The internal setpoint from the controller. (Typically used for controlling the load on a dancer with air cylinder). DIA The internal diameter. Default if RWD Type = CDD. OUTPUT The regulated output level. RPM The RPM for rewind applications. Default if RWD Type = CVD or MVD. ODR The average of the last 4 PID Integrator readings divided by the Diameter Percent. Used in special applications. Output (range: %) The actual output level is shown in this parameter. Aux Min (range: %) The minimum parameter sets the output level at 0%. If set to 0.0%, the output level will be. at 0%. Aux Max (range: %) The maximum parameter sets the output level at 00%. If set to 90.0%, the output level will be 9. at 00%. 5.6 Aux2 Output Aux2 output is an analog output 0 to. This output is always setup to give the actual diameter. 5-27

64 Configuration and System Setup Variable Wrap Angle Wrap Angle Menu Setup Menu Confi g Menu Options Menu Regulator Menu Roll Change Menu Shaft Fill Menu Start Menu Hold Menu Diameter Menu Taper Menu Digital Out Menu Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Enable Wrap Cal Menu K K2 K3 K4 K5 Cal 2 Menu K K2 K3 K4 K5 Com Menu Variable Wrap Angle Technology, a Montalvo exclusive option, improves on conventional web tension measurement and control by eliminating the need for isolation of the tension sensing roll or cantilever load cell with a lead-in or lead-out idler roll, saving money, and valuable machine real estate. Allows tension sensing rollers to be placed immediately off the wound roll when an intermediate roller will not fi t between the wound roll and load cell roller. Compensates for change in wrap angle and angle of force (attack angle) around load cell roller as roll diameter advances from full roll to core. Full Roll Path Core Path Wound Roll Load Cell Roller Common Path Adjacent Roller = Core Wrap Angle = Full Roll Wrap Angle = Full Roll Direction of Force = Core Direction of Force NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. The force applied to the load cell is directly proportional to the wrap angle. As the roll winds from full to core this angle increases; accordingly, the amount of force on the load cell for the same amount of web tension increases. Cantilever load cells are directional in nature, as the force rotates around from applying force directly onto the beam, producing a maximum output, to a less direct angle which produces a much lower output. This is sometimes referred to as the attack angle. There is a mathematical equation, using fi ve constant coeffi cients, that can describe these effects and adjust the load cell readings to compensate given the diameter as an input. On the Z4, these coeffi cients are K through K5 which can be entered into the menu system. These coeffi cients vary greatly due to multiple confi gurations of wrap orientation, roller locations, wound roll locations, angles and distances. The Variable Wrap Angle Calculator application (available for download) takes all of these factors into account and will produce these 5 constants for almost every confi guration (within practical physical limitations). 5-28

65 5.7 Variable Wrap Angle Wrap Angle Menu - continued Configuration and System Setup 5 Setup Menu Confi g Menu Options Menu Regulator Menu Roll Change Menu Shaft Fill Menu Start Menu Hold Menu Diameter Menu Taper Menu Digital Out Menu Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Enable Wrap Cal Menu K K2 K3 K4 K5 Cal 2 Menu K K2 K3 K4 K5 Com Menu Installation and Calibration of Sensing Roll Locate and install a sensing roll or cantilever load cell Follow standard calibration procedures outlined in this manual Position Load direction arrow(s) half way between full roll and core attack angles. The Wrap Angle calculator will calculate a precise angle. Alternatively - Use an Engineering print to measure data points Contact Montalvo for assistance as needed Calculation of Wrap Angle Variables Download the calculator at Collect data points as required and enter into the calculator. The calculator will generate values to be entered for parameters K thru K5. The calculator can also determine the optimum mounting angle of sensing roll or cantilever load cell which is useful during installation. The calculator has a built in user's guide for additional support. NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. 5-29

66 5.7 Variable Wrap Angle Wrap Angle Menu - continued Configuration and System Setup 5 Setup Menu Confi g Menu Options Menu Use ShaftFill Use Taper Use Dig Out Use Splice Use Rng Exp Use Aux In Use Aux2 In Use Aux Out Use Var Wrap DI Mode Menu Regulator Menu Roll Change Menu Shaft Fill Menu Start Menu Hold Menu Diameter Menu Dia Source P/Rev Roll mm/pulse P Wait Dia Min Dia Max Dia Array Dia Factor DF AutoSet Diameter Dia Raw Taper Menu Digital Out Menu Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Enable Wrap Calc Menu K K2 K3 K4 K5 Calc 2 Menu K K2 K3 K4 K5 Com Menu Controller Set Up Wrap Angle Menu is visible and an available option if: Enable Wrap Use Var Wrap = YES and Dia Source = PULSE, AUX, AUX2 or AUX3 Enable Wrap turns the Variable Wrap option off and on. It must be set to NO whenever editing K values. Enter the calculated values under Cal Menu. If a secondary wrap angle is desired such as for another roll diameter, calculate and enter those values under Cal 2 Menu. Set Enable Wrap to YES to save changes made to the controller settings. Enable Wrap can be safely toggled OFF or ON without lost of data entry if no changes have been made. K K2 K3 K4 K5 Values generated by Variable Wrap Calculator. All fi ve values must be entered. 5-30

67 Operation of Controller Menu 6 6. Operation of the Controller Menu Setup Menu Confi g Menu Options Menu Regulator Menu Roll Change Menu Shaft Fill Menu Start Menu Start Lev Hold Menu Diameter Menu Taper Menu Digital Out Menu Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. The controller operates in two modes: and has four types of menu items. Mode Menu Item Scroll Edit (cursor blinks) parent menu submenu numeric parameter textual parameter Menus are arranged in a hierarchical tree structure. The controller starts in scroll mode. A submenu is any menu below the current menu. A parent menu is any menu above the current menu. Scroll moves through the menu items; edit changes the numeric or textual parameter value. Scroll Mode Key Function Edit Mode Key Up Down Back Space Enter Moves to the previous menu item. Moves to the next menu item. Moves to the previous parent menu. Enters the previous parent menu, if a submenu, or changes to edit mode, if a numeric or textual parameter. Function Up Increases the numeric parameter value or moves to the previous textual parameter value. Down Decreases the numeric parameter value or moves to the next textual parameter value. Back Space Cancels edit mode, returning to the previous value*. Enter Stores entered value and changes to scroll mode. * Note: The cancel function of Back Space is not applicable in connection with live edit parameters. Here the value is automatically stored when a change is made, and you cannot return to the previous value. Go to the section Customer Parameter Settings to find out which parameters are live edit parameters. Example: in the following instance, the user increases the value of Start Lev to 80.0%. With the controller displaying Status Menu, the required steps are as follows: (First open Setup Menu with password level 5.) a) Press Down... until Password appears on the display - Press Enter... to open edit mode (the cursor will blink) - Press Up... until 5 appears in the display - Press Enter... to activate password level 5 b) Press Down... until Setup Menu appears in the display Press Enter...to enter the submenu c) Press Down...until Start Menu appears in the display Press Enter...to enter the submenu d) Press Down...until Start appears e) Press Enter... to edit the parameter (the cursor will blink) f) Press Up or Down... until 80.0 appears in the display g) Press Enter...to store the change 6-

68 Operation of Controller Menu Menu Tree Status Menu Status Menu Version Tension Setpoint Output Flt Out I-Level Gain Level Manual Linespeed Diameter Aux In Aux2 In Aux3 In Aux Out Aux2 Out LC Gain IO Terminal Menu Ext Status Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. Submenu Description Version Software version Tension Analog input No. 2, tension -0% to 0% Setpoint Analog input No., setpoint 0% to 0% Output Analog input No. 8, output 0% to 0% Degree of fi ltration applied to terminal 7 (0-) or terminal 6 (4-20mA) Flt Out output, 32 (max) to 256 (min). Allows monitoring the effect of the alpha fi lter applied to the output level. This should help set the Output Alpha level. I-Level Analog input No. 3, integrator 0% to 0% Gain Level Displays gain level 0% to 0% Manual Analog input No. 4, manual level 0% to 0% Linespeed Dispalys line speed from voltage input on terminal 54 Diameter Calculated diameter 0-00% Aux In Displays level on analog auxiliary input Aux2 In Displays level on analog auxiliary 2 input Aux3 In Displays level on analog auxiliary 3 input Aux Out Displays level on analog auxiliary output Aux2 Out Displays level on analog auxiliary 2 output LC Gain Displays load cell gain compensation due to change in wrap angle When parameter Password is entered, access is given to set-up and factory menus. To enter the Setup Menu, use password Description Run Mode Run Mode Status Menu Password Setup Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. Name AUTO MANUAL START FSTOP WAIT HOLD TENOFF STDBY SPLICE Description The controller is in auto mode. The controller compares actual tension to the auto setpoint, and adjusts output until the actual tension and setpoint are equal. The controller is in manual mode. Constant output level is set with manual setpoint. When the run signal is activated and output changes from Hold Level to Start Level. After that the controller goes into auto mode and starts to regulate. When the fast stop signal is activated, the controller applies the fast stop level to the output level and continues to regulate. The start signal (terminal 34) is deactivated and the controller is waiting for Hold Delay to run out. When Hold Delay has run out and the machine has stopped. The output is then set to Hold Level. Tension off is activated and the output level is set to zero. The output level is set to zero. The splice signal (terminal 2) is activated and the controller is performing a splice. 6-2

69 Operation of Controller Menu Menu Tree Setup Menu Setup Menu Config Menu Options Menu Regulator Menu Roll Change Menu Shaft Fill Menu Start Menu Hold Menu Diameter Menu Taper Menu Digital Out Menu Splice Menu Aux Input Menu Aux2 Input Menu Aux Output Menu Wrap Angle Menu Com Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. Submenu Confi g Menu Options Menu Regulator Menu Description Enter to edit confi guration parameters. Enter to edit optional functions and parameters. Enter to edit regulator parameters. Roll Change Menu Enter to edit roll change parameters. Shaft Fill Menu Enter to edit air shaft fi lling parameters when RWD Type = CDD or CVD. Start Menu Enter to edit parameters related to the starting process on the machine. Hold Menu Enter to edit parameters related to hold mode menu where machine is in still stand (stopped). Diameter Menu Enter to edit set-up diameter parameters. Taper Menu Enter to edit taper parameter. Digital Out Menu Enter to edit digital output parameters. Splice Menu Enter to edit splice parameters. Aux Input Menu Enter to edit analog auxiliary input parameters. Aux2 Input Menu Enter to edit analog auxiliary 2 input parameters. Aux Output Menu Enter to edit analog auxiliary output parameters. Wrap Angle Menu Enter to edit variable wrap angle parameters. Com Menu Enter to edit optional communications parameters. 6-3

70 6.5 Menu Tree/Parameter Settings Operation of Controller Menu 6 MENU SETTINGS Actual Default Range Status Menu 5 IO Terminal Menu 5 Ext Status Menu 5 Setup Menu 5 Confi g Menu 5 Amplifi er X 0 X0 X 5 Save Confg NO NO YES 5 Restore Confg NO NO YES 5 Options Menu 5 Use ShftFill (If RWD Type = CDD or CVD) NO NO YES 5 Use Taper YES NO YES 5 Use Dig Out NO NO YES 5 Use Splice NO NO YES 5 Use Aux In NO NO YES 5 Use Aux2 In NO NO YES 5 Use Aux Out NO NO YES 5 Use Var Wrap NO NO YES 5 DI Mode Menu 5 DI-5 Invert NO NO YES 5 DI-8 Invert (If RWD Type = CVD or MVD) NO NO YES 5 DI-3 Mode RESET RESET STDBY 5 DI-4 Mode STDBY CORE2 CAL2 Q-STOP STDBY 5 DI-8 Mode (If RWD Type = CVD or MVD) RESET RESET REGULT 5 Regulator Menu 5 Gain Menu 5 Gain Min 5 0 to 50 5 Gain Max 50 0 to Gain Slope.0.0 to Source OUTPUT DIA OUTPUT RPM 5 Gain level (Read Only) READ 0.0 to PID Menu 5 Sys Gain to P Level 30 0 to I Time 60 0 to I-Lev Smp 0 0 to 20 5 D Level 0 0 to 255 NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. 6-4

71 6.5 Menu Tree/Parameter Settings - continued Operation of Controller Menu 6 MENU SETTINGS Actual Default Range 5 Out Alpha to Coeff Min to Roll Change Menu 5 New Output to Cal-2 Scale (If DI-4 Mode = CAL2) to Core (If Dia Source = OUTPUT or PULSE) to Core 2 (If DI-4 Mode = CORE2 & Dia Source = OUTPUT or PULSE) to M Strt Dia NO NO YES 5 Shaft Fill Menu (If RWD Type = CDD or CVD and Use ShftFill = YES) 5 Fill Delay to Fill Time to LS Limit to Release Del to Start Menu 5 SC (If RWD Type = MVD, Default = 2.0) to DC AutoSet (If RWD Type = MVD, Default = 5) 2 0 to 20 5 Kick Delay to DC Max 5 0 to Kick Time to DC Mild 2 0 to Decay Time to Hold Menu 5 Hold Delay to Hold Level (If RWD Type = MVD, Default = 50) 00 0 to Limit 00 0 to 00 5 Diameter Menu 5 Dia Source PULSE OUTPUT PULSE AUX AUX2 AUX3 5 P/Rev Roll (If Dia Source = PULSE) 4 0 to 8 5 mm/pulse (If Dia Source = PULSE) to P Wait (If Dia Source = PULSE) 0 to 20 5 Dia Min to Dia Max to Dia Array (If Dia Source = PULSE) 0 0 to 50 5 Dia Factor (If Dia Source = OUTPUT) to DF AutoSet (If Dia Source = OUTPUT) to Diameter READ 0.0 to 00.0 NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. 6-5

72 6.5 Menu Tree/Parameter Settings - continued Operation of Controller Menu 6 MENU SETTINGS Actual Default Range 5 Dia Raw READ 0.0 to Taper Menu (If Use Taper = YES) 5 Type LIN LIN EXP 5 Tap Begin to Digital Out Menu (If Use Dig Out = YES) 5 DO Select Menu 5 Web Break NONE NONE DO DO2 DO3 DO4 5 Diameter NONE NONE DO DO2 DO3 DO4 5 Lo Tension NONE NONE DO DO2 DO3 DO4 5 Hi Tension NONE NONE DO DO2 DO3 DO4 5 Linespeed NONE NONE DO DO2 DO3 DO4 5 Motor Cntrl (If RWD Type = CCD, Default = NONE) DO2 NONE DO DO2 DO3 DO4 5 Wbr Delay to Wbr Level to Wbr Time to Alarm Dia to Lo Level to Lo Delay to Hi Level to Hi Delay to LS Level to LS Delay to Splice Menu (If Use Splice = YES) 5 Spl Source S.LEV AUX AUX2 AUX3 S.LEV 5 Spl Delay to Spl Level to Spl Time to Aux Input Menu (If Use Aux In = YES) 5 Aux Calc (Read Only) READ 0.0 to Aux Raw (Read Only) READ 0.0 to Raw Min to Raw Max to Calc Min to Calc Max to Calc Invert NO NO YES 5 Aux2 Input Menu (If Use Aux2 In = YES) NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. 6-6

73 6.5 Menu Tree/Parameter Settings - continued Operation of Controller Menu 6 MENU SETTINGS Actual Default Range 5 Aux2 Calc (Read Only) READ 0.0 to Aux2 Raw (Read Only) READ 0.0 to Raw2 Min to Raw2 Max to Calc2 Min to Calc2 Max to Calc2 Invert NO NO YES 5 Aux Output Menu (If Use Aux Out = YES) 5 Source (If RWD Type = CCD) DIA NONE SP DIA OUTPUT RPM ODR 5 (If RWD Type = MVD) RPM NONE SP DIA OUTPUT RPM ODR 5 (If RWD Type = CVD) RPM (NO OPTIONS) 5 Output (Read Only) READ 0.0 to Aux Min to Aux Max to Aux Off to Lo Limit to Hi Limit to Aux Slope.0.0 to Wrap Angle Menu (If Use Var Wrap = YES and Dia Source = PULSE, AUX, AUX2 or AUX3) 5 Enable Wrap NO NO YES 5 Cal Menu 5 K to K to K to K to K to Cal 2 Menu (If DI-4 Mode = CAL2) 5 K to K to K to K to K to Com Menu 5 Confi g Mode NO NO YES 5 Remote Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. 6-7

74 6.5 Menu Tree/Parameter Settings - continued Operation of Controller Menu 6 MENU SETTINGS Actual Default Range 5 Persistent* NO NO YES 5 Enable Menu 5 Manual (scalable)** NO NO YES 5 Setpoint (scalable)** NO NO YES 5 Aux In (scalable)** NO NO YES 5 Aux In 2 NO NO YES 5 Aux In 3 NO NO YES 5 Aux Out NO NO YES 5 DI- (Auto-Man)** NO NO YES 5 DI-2 NO NO YES 5 DI-3 (Tension On-Off)** NO NO YES 5 DI-4 (Standby)** NO NO YES 5 DI-5 NO NO YES 5 DI-8 NO NO YES 5 Value Menu NOTE: Not all menus / items display all the time. Relevant menus / items display when correct password is entered. * When parameters are assigned to the remote interface, they are set to zero if the controller is reset. If Persistent is set to YES, the controller retains the last monitored setting from the remote prior to reset. ** The controller can only accept Input from a single source. If this source is the HMI / Ethernet interface, the voltage applied is ignored; otherwise, the voltage is monitored and the remote source is ignored. This option is user selectable. Factory default is set to YES on cotrollers configured with an HMI or Ethernet com board. 6-8

75 7. LEDs Hardware Adjustments and LEDs 7 LED Arrays Terminal DO (Digital Output) DO- = Range 4, Web Break or Dia. Alarm DO-2 = Range, Web Break or Dia. Alarm... 9 DO-3 = Range 2, Web Break or Dia. Alarm DO-4 = Range 3, Web Break or Dia. Alarm... DI (Digital Input) DI- = Manual... 3 DI-2 = Splice... 2 DI-3 = Tension Off DI-4 = Cal2 or Standby... 3 DI-5 = Run DI-6 = Web Pulse... 5 DI-7 = Roll Pulse DI-8 = Fast Stop... 6 DO 3 DO DI 7 DI 5 DI 3 DI DO 4 DO 2 DO 24V (Input) DI 8 DI 6 DI 4 DI Run Mode AUTO SERXXXXXX Z4XXXXX XXXXXX Made In USA SUPPLY VAC ONLY (Fuse: 3.5A Slow Blow) R6 R5 R4 R3 R2 R N L Z4 CONTROLLER REV# (C) 20XX MONTALVO Potentiometers 7.2 Potentiometers R6 = Range Calibration...(Aux2 Input) R5 = Range Calibration...(Aux3 Input) R4 = Zero Calibration...(Aux3 Input) R3 = Range Calibration 2...(Tension Input) R2 = Range Calibration...(Tension Input) R = Zero Calibration...(Tension Input) Potentiometer Function Description R6 Range Hardware range adjustment on Aux2 Input R5 Range Used to adjust the maximum level on the Aux3 input R4 Zero Used to adjust the minimum level on the Aux3 input R3 R2 R Calibration Range Calibration Range Zero Range Adjusts tension to show actual web tension on the high scale, when the second calibration is selected Adjusts tension to show actual web tension. See 3.7 Installation Tension Calibration. Used to adjust zero of tension. See 3.7 Installation Tension Calibration. 7-