Montalvo S3100 Service manual

S3100/3110
Version 2.0 Pub. date: 12/5/02 v2
Digital Tension Controller
OPERATOR’S HANDBOOK

12/5/02 3
S3100/3110: Table of Contents
1 General Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
2 Front Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
2.1 Description of Front Panel and Keyboard - - - - - - - - - - - - - - - - - - - - 6
2.2 Status Indicator Lights - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
2.3 Digital Display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
3 Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
3.1 Manual Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
3.2 Auto Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
3.3 Auto/Manual Switching - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
3.4 Changing the Auto Tension Setpoint- - - - - - - - - - - - - - - - - - - - - - - 10
3.5 New Roll - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
3.6 Installing new roll (unwind)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
3.7 Help - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
3.8 Operator’s Message Table- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
4 Before you call maintenance- - - - - - - - - - - - - - - - - - - - - 12
4.1 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12

1 General Description
12/5/02 5
1 General Description
The Montalvo S3100/3110 digital controller provides precise automatic control of web tension. The S3100/3110 is
used in a closed loop, of which the load cell roll and brake are a part. Please refer to the diagram of a typical
pneumatic system below.
Load Cell Function
Two load cells (or transducers) are normally used. The signals from the load cells are summed together to give the
total web tension across the entire web.
Converter Function
The I/P converts the 4 to 20 mA regulator output to a proportional 0 to 75 PSI (0 to 6 bar) to control the brake.
Brake Function
One or more brakes may be controlled, converting the pneumatic output pressure from the I/P into torque. This torque
in turn changes the web tension.
Auto Mode Function (closed loop)
The operator sets the desired tension with the keypad and the digital display. The feedback from the load cells is
calibrated to display the actual web tension on both the digital display and the analog meter. This signal is compared
with the desired tension (setpoint) and the microprocessor automatically adjusts the output to make the actual tension
the same as the desired tension. Because the web itself is part of the feedback loop, the controller can quickly
compensate for speed and diameter changes as well as other factors that may affect tension.
Manual Mode Function (open loop)
The operator sets the desired brake pressure with the keypad and digital display. The web tension is still measured
and displayed on the web tension meter and the digital display, but no automatic regulation is done in this mode. The
operator must make constant adjustments to maintain tension.

6 12/5/02
2 Front Panel
2 Front Panel
2.1 Description of Front Panel and Keyboard
Analog Meter (S3100 only)
Displays the actual total tension at all times.
Note: because of the sensitivity of the transducers, minor fluctuations during operation are common and no cause
for alarm.
Keypad
The following diagram shows the keypad with a brief explanation of the function of the keys:
Scrolls through
the list of
messages.
Increases or
decreases
value of
number under
which the
cursor is
positioned.
Toggles between auto and manual mode. When in
auto, Auto or Softstart LED is illuminated.
Toggles between Tension on and off. When off,
no air is applied to the brake. When Tension on
LED is illuminated.
Places cursor
under number to
be changed.*
Enters
displayed value
into memory.
Scrolls to the setpoint message so that Auto
Tension can be changed.
* The cursor is a line underneath a digit in the display, marking the position of the character that can be edited or
entered.
If the cursor appears, each time the cursor key is pressed, the cursor moves one position to the left. When it has gone
as far left as possible for the particular message, it will return to the least significant digit. If the cursor is not showing
on a message that can be edited, pressing the cursor key will make it appear.
SOFT
START
ANTI-
COAST
TENSIONAUTO
0
20
40 60
80
100
www.montalvo.com
Analog meter
Digital display
Status LEDs
Help key
Keypad

2.2 Status Indicator Lights
12/5/02 7
Help Key
Pressing this key causes a brief help message to scroll across the display. This feature is especially helpful for
describing messages that have been abbreviated to fit in the 16 character display. (Refer to keypad diagram.)
2.2 Status Indicator Lights
A. Auto. Indicates that the controller is in automatic mode. (Controller
will adjust output as needed to maintain the setpoint value.) To change
the tension in auto mode, change the setpoint. The auto light should only
be on when the machine is running.
B. Tension On/Off. Indicates that an output is being applied to
the brake. If only the tension light is on, the controller is in manual
mode. In manual mode, a change in output changes tension.
Pressing Tension On/Off key turns tension on and off.
C. AntiCoast. Indicates that the controller is in the anticoast mode.
Should only light up when the stop button on the machine is pushed and
should remain on until the machine has come to a complete stop.
D. Softstart. Indicates that the controller is in softstart mode. Should
only be on when machine has stopped. When the run button on the
machine is pushed, this light will blink for a set time, then go out, and the
auto light will come on.
SOFT
START
ANTI-
COAST
TENSIONAUTO
AB C D

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2 Front Panel
2.3 Digital Display
A limited number of messages appear on the digital display. Most of them are "read
only" messages, which cannot be changed. To view the messages, use the scroll
up and down keys. Some messages are only available in certain operating modes.
For the scrolling principle, see the diagram below:
NewRoll? Yes
ManoutSet 20p
Manout 20p
Material 1
Tension 27.5#
Output 42.3p Message currently displayed
Use the Scroll keys to view
other screens

3 Operation
12/5/02 9
3 Operation
3.1 Manual Mode
From the ManOut message, the output can be set to any value in its operating range.
The output in manual can be previewed and preset from the ManOutSet message.
• Use the CURSOR key to position the cursor under the digit you wish to
change.
• Use the INCREASE or DECREASE key to change the digit to the desired
value.
• Press ENTER to store the value.
• To activate the manual mode, press the TENSION ON / OFF key.
The tension LED will come on and the message will change to ManOut. Once in
manual, the output can be changed using the same procedure. Since no automatic
regulation is done in manual, the operator must make constant adjustments to
maintain tension.
3.2 Auto Mode
If the start/stop contact has been wired in and Soft Start or Inertia Comp Start has
been selected, the S3100/3110 provides “set it and forget” operation. At machine
start, tension will automatically be turned on and the controller will cycle through Soft
Start /Inertia and switch into automatic. At machine stop, depending on application,
the controller will either switch into Anticoast/Inertia Comp Stop mode, or remain in
automatic until the line has stopped. For unwinds, it will then switch into Holdmode
until the line is restarted. For rewind applications, it willremain in auto.If the
start/stop contact is not used,the controller can beswitched into closed loop
automatic regulation by pressing the AUTO/MANUAL key once tension is on. In
automatic, the actual web tension is compared with the desired tension (setpoint) and
the output is adjusted to maintain that setpoint. The output changes proportionally
with roll diameter and other factors which may affect web tension. To change the
Setpoint, SCROLL to SetPoint or press the SETPOINT key. Change the appropriate
digits and press ENTER to save the new value.
3.3 Auto/Manual Switching
When switching from manual to auto, the controller starts at the manual output, then
regulates to the output required for automatic control. When switching from auto to
manual, the controller changes the manual set value to the level it was in auto, so that
there is a smooth transfer in either direction.

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3 Operation
3.4 Changing the Auto Tension Setpoint
This procedure for changing the setpoint also serves as a short exercise in editing
and changing displayed messages.
Recommended: practice the following procedure a few times to learn how to use
the keypad.
3.5 New Roll
If Soft Start, Inertia Compensation or Taper are programmed, this message appears
automatically each time tension is turned off. It is necessary to reset the diameter
calculation whenever the roll is changed. The default message for unwind
applications is NewRoll? Yes, so if the roll is being changed, these functions are
automatically reset. If tension is turned off without changing the roll, press ENTER to
change to NewRoll? No. For rewinds, the default is NewRoll? No. If the roll is
changed, press ENTER to change to NewRoll? Yes.
1. If
Setpoint xx.x#
is not displayed, press setpoint key.
2. Position cursor under digit to be changed with the cursor key.
3. Use increase or decrease keys to change digits to the desired value.
4. When desired value is reached, press enter key to store value in
permanent memory.

3.6 Installing new roll (unwind)
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3.6 Installing new roll (unwind)
3.7 Help
For a short explanation of a displayed message, press the Help key, and a brief description will scroll across the
display. This feature is especially helpful in describing messages abbreviated to fit the 16 character display.
3.8 Operator’s Message Table
Below is a list of standard messages that are available to the operator and the modes in which they will be displayed.
Note: some messages are for information (read only) and cannot be changed. Other messages may appear in the
operator’s list if certain options are activated (for example Taper, Multiple Calibrations, Tension Per Unit Width).
Note 1: This message is displayed only if Soft Start, Taper, or Range Expander is selected by supervisor.
Turning tension off automatically brings up the NewRoll? Message because the controller must be reset when the
roll is changed.
Note 2: This message is displayed if more than one material has been saved by supervisor during setup.
Press:
Tension on/off key to turn tension off. Display reads:
New Roll? Yes
Install new roll.
Tension on/off key . Tension LED lights and display reads:
ManOut xx.xp
Auto/manual key. SoftStart or Auto LED lights. Display reads:
Output xx.xp
Message
Mode
Tension Off (no LEDs on) Tension On (Manual)
(tension LED on)
Auto (tension & Auto or
Soft Start LEDs on)
ManOutSet 22.0 p
Output when tension is turned on
(can be changed) Not displayed Not displayed
ManOut 22.0 p Not displayed Output that is being
applied (can be changed) Not displayed
Output 0.0 p
Displays 0.0 as a reminder that
tension is off Not displayed in this mode Output in automatic
SetPoint 75.0# Desired operating tension while in Auto mode (can be changed)
Tension 0.0#
Displays total web tension (cannot be changed).
Should agree with analog meter reading.
Material 3 Displays current material selection (can be changed). See Note 2 below.
New Roll? Yes See Note 1 below. Not displayed.

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4 Before you call maintenance
4 Before you call maintenance
Below is a list of common problems often attributed to tension control. Many, however, are not caused by a controller
malfunction and may just require a slightly different operating procedure.
If use of the S3100/3110 is no longer required, dispose of it according to the regulations in force at the time. For
service, please contact:
4.1 Troubleshooting
Instability
Indicated by large variation of the analog meter.
Small variations, however, are quite common (3 to 5 divisions of the meter scale).
If large variations occur while the meter is running, switch the S3100/3110 into the manual
mode by pressing the Auto/Manual key.
If meter continues to indicate a large fluctuation, fluctuation is not caused by the tension
controller.
Look for mechanical problem, examples: egg-shaped rolls, slipping or worn chucks or
airshafts, surging nip drives, etc.
Cannot adjust
tension (setpoint)
Tension cannot be adjusted above current meter scale setting. See your supervisor.
Web break or
stretching on
startup
Check that the controller is in softstart mode when starting. (Softstart usually works off the
start button on the machine.)
If start button is pressed with the speed potentiometer turned all the way down, the softstart
will time out and the controller will go into the auto mode.
If controller goes into the auto mode before the web starts moving, the air pressure on the
brake will start to increase. (See section on soft start.)
Roll coasting
when stopping
If anticoast is used, coasting should not occur.
Note: anticoast is activated by the stop button.
If speed is adjusted downward by turning the pot quickly to zero, coasting can occur.
If coasting still occurs after the stop button has been pressed, check that anticoast LED
remains on until the machine comes to a stop.
If machine does not come to a complete stop, supervisor must increase the time that unit
stays in anticoast.
If the LED remains lit after the machine stops and coasting still occurs, supervisor should
contact Montalvo customer service representatives.
The Montalvo Corporation
50 Hutcherson Drive
Gorham, ME 04038 USA
Tel: [phone]
Fax: [phone]
E-mail: [e-mail]
Web Site: www.montalvo.com
Danarota Technic A/S
GI. Skartved 5, DK-6091
Bjert, Denmark
Tel: [phone]
Fax: [phone]

The Montalvo Corporation • 50 Hutcherson Drive, Gorham, Maine 04038 USA • E-mail: [e-mail] / www.montalvo.com
Tel: [phone] Fax: [phone] Toll Free Tel: [phone] Toll Free Fax: [phone]
Technical details subject to change without notice. Printed in U.S.A. S-3100/3110CE-OH © 2002 MONTALVO