Montalvo U4 User manual

[email protected] / www.montalvo.com / Technical details subject to change without notice. U4-technical manual-us © Montalvo
Montalvo
U4
Open Loop/Diameter Based Tension Controller
EST. 1947
TECHNICAL MANUAL
U4 Open Loop/Diameter Based Tension Controller
Installation and Set up Instructions
Version 1.2 / Publication Date 8/29/2018
TS
TSC™System Component

3
[email protected] / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo
Warning, EMC, and Safety
Warning: Electrical installation must be done by skilled personnel. Wiring must meet all
applicable codes and standards.
Refer to the appropriate wiring and terminal descriptions for external connections.
Note: Double-check the accuracy of all wiring connections before applying power to the
controller. Damage caused by improper wiring is not under warranty.
EMC Requirements: Connect the protective ground wire to the terminal marked G. Ground
wires should be as short as possible. Connect the controller G 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.

Table of Contents
1 General
1.1 Overview................................................................................................................ 2
1.2 System Operation .................................................................................................. 2
2 Set-up
2.1 DIP Switches.......................................................................................................... 3
2.2 Keypad .................................................................................................................. 4
2.3 Operating Parameters ............................................................................................ 5
3 Montalvo US4 Ultrasonic Sensor
3.1 Mounting................................................................................................................ 6
3.2 Wiring .................................................................................................................... 7
3.3 Calibration..............................................................................................................8
3.4 Set-up.................................................................................................................... 9
4 Proximity Switches
4.1 Mounting.............................................................................................................. 11
4.2 Wiring .................................................................................................................. 12
4.3 Set-up.................................................................................................................. 13
5 Montalvo TS Torque Sensor
5.1 Mounting.............................................................................................................. 15
5.2 Wiring .................................................................................................................. 16
5.3 Calibration When Using an Ultrasonic Sensor....................................................... 17
5.4 Calibration When Using Proximity Switches.......................................................... 18
5.5 Set-up.................................................................................................................. 19
6 Reference
6.1 Advanced Parameters.......................................................................................... 20
6.2 Saving Different Set-ups....................................................................................... 22
6.3 US4 Mode ........................................................................................................... 23
6.4 Proximity Switch Mode......................................................................................... 24
6.5 Start and Stop Operation ..................................................................................... 25
6.6 PC Program ......................................................................................................... 26
6.7 Saved Parameters Log......................................................................................... 27
6.8 Controller Mounting.............................................................................................. 28
6.9 Controller Wiring .................................................................................................. 29
6.10 Quick Start........................................................................................................... 30

2
[email protected] / www.montalvo.com / Technical details subject to change without notice. U4-technical manual-us © Montalvo
General
1
1
●Universal 100-240VAC (Optional 24VDC).
●Display of all Information in either English or Metric units.
●Can be used with ultrasonic or laser diameter sensors, rider arms or proximity switches.
●Programmable Soft Start, Anti-coast, and Hold values allow precise control of starting and
stopping during quick Cycle applications.
●Two different alarm settings can be programmed to alert the operator or can be connected
to machine controls to slowdown and stop machine.
●Set up and programming can easily be done using the keypad and display or with free
software through the USB port.
●Stores and re-calls up to 9 sets of control parameters for different materials.
●Can be used with TS torque sensor to display actual calculated Web Tension.
1.1 Overview
1.2 System Operation
In order to properly set up and program the U4, as well as take advantage of all the available
features, it is important to have a basic understanding of the controller and how it ts into the
tensioning system. Refer to the drawing below.
A typical pneumatic unwind system using an ultrasonic sensor is shown, however the same
principles apply to most open loop tension control systems. The calibrated sensor supplies the
correct diameter to the U4 which applies a proportional output to the brake. The operator sets
the desired amount of tension on the web by increasing or decreasing the trim value to add to
or subtract from the output proportional to the diameter. As the roll diameter decreases, the U4
reduces the output to the brake. Since the output to the brake is proportional to torque, and
since Tension is equal to the Torque divided by the radius, the Tension will automatically remain
the same throughout the roll.
Pneumatic Brake
or Clutch
I/P Converter
Y Web Direction Z
Unwind or Rewind
Y Regulated Air
Air Supply
Z
Y OUTPUT
U4
US4 Ultrasonic Sensor
INPUT
Z
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
G
24 VDC
-+
U4 Controller Rev #
© Montalvo
Serial #
00000
1
U
4
C
ontroller Rev #
©
Montalvo
TENSION ONAUTOSTOP
Controller
U4
OUTPUT
TRIM
DIAMETER
TAPERSTART
TAPER%
TENSION
INCREASE SCROLL
TENSION
ON / OFF
DECREASE AUTO / MAN
12345
000000
TYPE
www.montalvo.com
TensionControllers
SN PN
VOLTS AMPS
®
U4
MADEIN USA
207-856-2501 / 800-226-8710
[phone]
[phone]
[phone]
IP54
CS100
CS130
V250
V300
V400
MPC4
US4
or
PS1
M4
Tension
Controller
Brake
Web
Unwind
I/P
Converter
Torque
Sensor
Ultrasonic or Proximity
Non-Contact Sensors
Tension
Meter
TS U4
Montalvo TSC™System
The Montalvo U4 Open Loop Controller provides
precise, accurate control of web tension by
varying torque based on diameter. The control
outputs of 0-10VDC and 4-20mA enable the
U4 to interface with a variety of torque
output devices to control web tensioning
brakes, clutches and motor Drives. The
TSC™ System utilizing a TS Torque Sensor adds
the ability to monitor actual web tension from full
roll to core. Standard U4 features include:
TS

3
[email protected] / www.montalvo.com / Technical details subject to change without notice. U4-technical manual-us © Montalvo
Set-up
2
2
2.1 DIP Switches
Changes to DIP switch settings require that the U4 be repowered to accept those changes.
By making the following selections on the 5 DIP switches, the U4 will only display parameters
that apply to your specic application:
Switch Default
Settings Description
1 Ultrasonic Select between Ultrasonic Sensor or Proximity Switches.
2 English Select between display of English or Metric units.
3Setup
Enabled
Select between Setup Enabled for initial setup or Setup Disabled to
prevent accidental changing of parameters by operator.
4 Unwind Select between Unwind or Rewind torque device.
5No Torque
Sensor Select between Torque Sensor installed or No Torque Sensor installed.
12345
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
G
24 VDC
-+
U4 Controller Rev #
© Montalvo
Serial #
00000
1
U
4
C
ontroller Rev
#
©
Montalvo
TENSION ONAUTOSTOP
Controller
U4
OUTPUT
TRIM
DIAMETER
TAPER START
TAPER %
TENSION
INCREASE SCROLL
TENSION
ON / OFF
DECREASE AUTO / MAN
12345
Proximity Mode Metric Setup Disabled Rewind No Torque Sensor
Ultrasonic Mode
English
Setup Enabled
Unwind
Torque Sensor
DIP switch (default settings)
8.8.8.8.8.8.8.8.8.8. 8.8.

4
[email protected] / www.montalvo.com / Technical details subject to change without notice. U4-technical manual-us © Montalvo
Set-up
2
2
Digital Display
The rst two (RED) digits are used to display Set-up Parameters when in the Set-up mode. The
next four (GREEN) digits are used to display the values of the Set-up Parameters as well as the
Operating Parameters.
Operating Parameter LEDs
When Operating Parameters are displayed, corresponding LEDs below the display will light up
to indicate the Parameter that is being displayed.
Operating Mode LEDs
2.2 Keypad
LED Color Description
Red ON during STOP time.
Yellow ON when in HOLD mode.
Blinking Yellow BLINKING during START time.
None OFF during all other times.
TENSION ONAUTOSTOP
Controller
U4
OUTPUT
TRIM
DIAMETER
TAPER START
TAPER %
TENSION
INCREASE SCROLL
TENSION
ON / OFF
DECREASE AUTO / MAN
8.8.8.8.8.8.8.8.8.8. 8.8.
Mode Description
AUTO
AUTO and TENSION ON LED lit - The output on the brake can be
set using the and keys to set the TRIM value at full roll and will
automatically decrease as the roll diameter decreases
MANUAL
Only TENSION ON LED lit - Controller output is manually controlled by
using the and keys. If switched to Auto, this value will ramp to the
calculated Auto value. When in Auto, if switched to Manual, the output
will remain the same. This value can then be adjusted with the and
keys.
TENSION ON Output is active.
TENSION OFF Output is set to zero
STOP Mode Indicator LED

5
[email protected] / www.montalvo.com / Technical details subject to change without notice. U4-technical manual-us © Montalvo
Set-up
2
2
2.3 Operating Parameters
Pressing the key cycles through the modes listed below. Starting from the
OUTPUT mode, pressing the key will move in this fashion: OUTPUT / TRIM / DIAMETER /
TAPER% / TAPER START / TENSION / OUTPUT.
The corresponding LED should be lit. The OUTPUT mode is the default mode. OUTPUT,
DIAMETER, and TENSION modes are display values only (not adjustable).
When parameter values are modied, the new value should take effect immediately. This will
allow the output to change as the TRIM value is changed in real time. This also means the main
process will still run while in these modes. Pressing the key saves the new value and moves
to the next parameter.
Parameter Description
Output Percentage of 0-10V or 4-20mA output. Display values can go from 0.0% to
100.0%. This is the default state after power up.
Trim Displays TRIM% value (-100 to +100). In this mode, the TRIM% value can
be changed by the / keys.
Diameter Displays the calculated diameter in inches (0.0 – 99.9) or in mm (0 – 2500).
For Display only. Cannot be changed.
Taper Start
Displays TAPER START value (0-99.9 inches or 0-2500 mm. In this mode,
the TAPER START value can be changed by the / keys. Only
displayed if rewind mode selected by dipswitch.
Taper %
Displays TAPER% value (0 – 100). In this mode, the TAPER value can be
changed by the / keys. Only displayed if rewind mode selected by
dipswitch.
Tension Displays the calculated tension in lb (0-9999) from the torque sensor. Only
displayed if torque input is selected by dipswitch.

Montalvo US4 Ultrasonic Sensor
3
3
6
[email protected] / www.montalvo.com / Technical details subject to change without notice. U4-technical manual-us © Montalvo
3.1 Mounting
Notes
• Beam direction must be perpendicular to the roll diameter and pointing directly at the core.
• The mounting position is free of any vibration that might deect the beam pattern from the roll.
• It is free from interference of any part or surface including the web material itself.
• It is subject to as few temperature changes as possible.
• Refer to the installation instructions that were included with the sensor for specic mounting
distance restrictions and calibration instructions.
To ensure proper operations the US4 must be able to receive a DIRECT linear signal from the
material back to the US4. If the direct signal is altered by any angles created through the unwind
or rewind process the US4 will not receive the intended return signal.
Sensor Position Description
…when unwinding/rewinding from top of roll
The gray zone represents areas of correct installation angles
to ensure the US4 is always receiving an accurate signal
from full roll to core.
…when unwinding/rewinding from bottom of roll
The gray zone represents areas of correct installation angles
to ensure the US4 is always receiving an accurate signal
from full roll to core.
…when unwinding/rewinding from bottom or top of roll
The gray zone represents areas of correct installation angles
to ensure the US4 is always receiving an accurate signal
from full roll to core.

Montalvo US4 Ultrasonic Sensor
3
3
7
[email protected] / www.montalvo.com / Technical details subject to change without notice. U4-technical manual-us © Montalvo
3.2 Wiring
Start/Stop Contact
shown in Run Mode
Dry Contact Only
Power Connections
model options include
VAC or VDC controllers
3
°
4
1
+
2
-
Montalvo MPC-4
I/P Converter
1 Ultrasonic Sensor (0-10VDC input)
2 GND 3 24 VDC (output) 4 5 6 7 8 4-20mA (regulated output to I/P) 9 GND 10 11 GND 12 Start / Stop
G USB (conguration and monitoring)
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
GNL
Serial #
00000
Montalvo US4
Ultrasonic Sensor
G GND
+ 0 VDC - +24VDC
G
24 VDC
-+
GND Neutral 100-240 VAC

Montalvo US4 Ultrasonic Sensor
3
3
8
[email protected] / www.montalvo.com / Technical details subject to change without notice. U4-technical manual-us © Montalvo
3.3 Calibration
1Apply power to the U4 Controller
2To set the distance for the Core and Full Roll, enter the TEACH mode (see below).
• Set the core (maximum) distance rst and the full roll (minimum) distance second.
• Either install an empty core rst and then a full roll, or utilize a sturdy, at piece of
material (ex: cardboard) as a target to set these distances.
Step Proceedure Result
1
Enter TEACH Mode a) Push and hold ANALOG button for > 2 seconds
ANALOG
Power LED: OFF
Output LED: ON
2
Set CORE
(max. distance)
a) Position target repesenting CORE distance Signal LED: Must be
ON Red or Flashing Red
b) Push (d not hold) Analog button
ANALOG
Teach Accepted
Power LED: OFF
Output LED: Flashing
Teach Not Accepted
Output LED: ON
3
Set FULL ROLL
(min. distance)
a) Position target repesenting FULL ROLL distance Signal LED: Must be
ON Red or Flashing Red
b) Push (d not hold) Analog button
ANALOG
Teach Accepted
Power LED: ON
Output LED: ON
Teach Not Accepted
Power LED: OFF
Output LED: Flashing