Montalvo U4 User manual

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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

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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

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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

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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.

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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

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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
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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
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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
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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

Montalvo US4 Ultrasonic Sensor
3
3
9
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3.4 Set-up
Basics
The following parameters can only be entered or modied if the SETUP ENABLE switch is in
the correct position. Ensure that both the AUTO LED and TENSION LED are illuminated. If the
TENSION LED is not illuminated, press the key. If the AUTO LED is not illuminated, press the
key.
The Set-up mode is activated by pressing the keys together for 2 seconds. If the
SETUP ENABLE switch is in the DISABLE position or the AUTO LED and TENSION LED are not
illuminated, pressing the keys together for 2 seconds will have no effect. When The
Set-up mode is activated you will see this: The Red digit indicates the parameter number and
the green digits indicate the value of the parameter.
Diameter Alarms
It is possible to enter two different diameter values. When these diameters are reached, 24 VDC
will be applied to a particular terminal on the U4 board. This 24 VDC can be used to activate a
24 VDC relay that can be wired to a light or a bell or buzzer to alert the operator. This output can
also be wired into a PLC or Drive to slow down and/or stop the machine at selected diameters.
If this feature will not be used, simply us the key to scroll to parameter number 5.
Parameters 1 and 2 are the only parameters that need to be set in order to run the
machine and display accurate diameter values. By pressing the key other optional
features may be used to optimize you particular application. These features are explained
below. To start running now, simply press and hold the key for 4 seconds to exit set-up.
Display Description
8.8.8.8.8.8.8. 1.4.0. 0.0.
Press the or keys to set this value to the maximum full roll
diameter. Press the key when done.
8.8.8.8.8.8.8.2.8.6. 0.0.
Press the or keys to set this value to the minimum core
diameter.
Display Description
8.8.8.8.8.8.8.3.8.0. 0.0.
Press the or keys to set the diameter value that will apply 24
VDC to terminal 18.
8.8.8.8.8.8.8.4.8.0. 0.0.
Press the or keys to set the diameter value that will apply 24
VDC to terminal 20.

Montalvo US4 Ultrasonic Sensor
3
3
10
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Press and hold the key for 2 seconds to exit the Set-up mode, ready to run the machine.
Stop / Hold / Start
The following 5 parameters only need to be set if large rolls are being accelerated or decelerated
very quickly. By connecting a dry contact between terminals 11 and 12 that opens when the
machine is started and closes when the machine starts to decelerate and remains closed until
the machine is restarted, the controller can be programmed to prevent the roll from coasting as
well as providing a soft start function.
3.4 Setup - continued
Display Parameter Description
8.8.8.8.8.8.8.5.8. 1.0.0.
Anticoast % Percent the output will instantly increase when the
contact closes.
8.8.8.8.8.8.8.6.8. 1. 0.1.
Stop Time
Typically set to how long it takes for the machine
to stop once the stop button is pushed. Output will
ramp to Hold value.
8.8.8.8.8.8.8.7.8. 1. 0.1.
Hold %
Percent of increase or decrease of running
output that will be maintained while the machine is
stopped.
8.8.8.8.8.8.8.8.8. 1. 0.1.
Start Reduction Percent of decrease in running output when the
contact opens.
8.8.8.8.8.8.8.9.8. 1. 2.1.
Start Time Ramp time from start reduction to running output.

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Proximity Switches
4
4
1All Proximity switches must be PNP type.
2Prox switch for Roll Pulse must pulse 1 to 4 times per revolution.
3Prox switch for Web Pulse must be mounted on a roller that is rotating at Line Speed. The
recommended web length per pulse is between 10 and 250 mm/pulse (0.5 to 10 inches). The
shorter the distance between web pulses, the higher the resolution/accuracy of the calculation.
Pneumatic Brake or Clutch
INPUT Z
INPUT Z
I/P Converter
Y Web Direction Z
Unwind or Rewind
Proximity
Switches
Web Pulse
ROLL Pulse
Y Regulated Air
Y Air Supply
Y OUTPUT
U4
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
4.1 Mounting

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Proximity Switches
4
4
4.2 Wiring
WEB ROLL
Start/Stop Contact
shown in Run Mode
Dry Contact Only
Proximity
Switches
Power Connections
model options include
VAC or VDC controllers
3
°
4
1
+
2
-
Montalvo MPC-4
I/P Converter
GND 24 VDC (output) Web Pulse (Digital input) GND 24 VDC (output) Roll Pulse (Digital input) 4-20mA (regulated output to I/P) GND GND Start / Stop 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
GND 0 VDC +24VDC
G
24 VDC
-+
GND Neutral 100-240 VAC

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Proximity Switches
4
4
Basic
The following parameters can only be entered or modied if the SETUP ENABLE switch is in
the correct position. Insure that both the AUTO LED and TENSION LED are illuminated. If the
Tension LED is not illuminated, press the key. If the Auto LED is not illuminated, press the
key.
The Set-up mode is activated by pressing the keys together for 2 seconds. If the SETUP
ENABLE switch is in the DISABLE position or the AUTO LED and TENSION LED are not
illuminated, pressing the keys together for 2 seconds will have no effect. When the Set-up
mode is activated you will see this: The Red digit indicates the parameter number and the green
digits indicate the value of the parameter.
Display Description
8.8.8.8.8.8.8. 1.4.0. 0.0.
Use the / keys to set this value to the maximum full roll
diameter. Press the key when done.
8.8.8.8.8.8.8.2.8.6. 0.0.
Use the / keys to set this value to the to the minimum core
diameter.
Display Description
8.8.8.8.8.8.8.3.8.0. 0.0.
Use the / keys to set this value to the diameter value that will
apply 24 VDC to terminal 18.
8.8.8.8.8.8.8.4.8.0. 0.0.
Use the / keys to set this value to the diameter value that will
apply 24 VDC to terminal 20.
Diameter Alarms
It is possible to enter two different diameter values. When these diameters are reached, 24 VDC
will be applied to a particular terminal on the U4 board. This 24 VDC can be used to activate a
24 VDC relay that can be wired to a light or a bell or buzzer to alert the operator. This output can
also be wired into a PLC or Drive to slow down and/or stop the machine at selected diameters.
If this feature will not be used, simply us the key to scroll to parameter number 5.
4.3 Set-up

14
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Proximity Switches
4
4
4.3 Set-up - continued
Stop / Hold / Start
The following 5 parameters only need to be set if large rolls are being accelerated or decelerated
very quickly.
By connecting a dry contact between terminals 11 and 12 that opens when the machine is
started and closes when the machine starts to decelerate and remains closed until the machine
is restarted, the controller can be programmed to prevent the roll from coasting as well as
providing a soft start function. See Section 6.5 for more information.
Display Parameter Description
8.8.8.8.8.8.8.5.8. 1.0.0.
Anticoast % Percent the output will instantly increase when the
contact closes.
8.8.8.8.8.8.8.6.8. 1. 0.1.
Stop Time
Typically set to how long it takes for the machine
to stop once the stop button is pushed. Output will
ramp to Hold Value.
8.8.8.8.8.8.8.7.8. 1. 0.1.
Hold %
Percent of increase or decrease of running
output that will be maintained while the machine is
stopped.
8.8.8.8.8.8.8.8.8. 1. 0.1.
Start Reduction Percent of decrease in running output when the
contact opens.
8.8.8.8.8.8.8.9.8. 1. 2.1.
Start Time Ramp time from start reduction to running output.
Display Parameter Description
8.8.8.8.8.8.1.o.8. 1. 3.2.
mm/pulse or
inches/pulse
Distance web travels per pulse. Depends on
setting of DIP switch #2.
8.8.8.8.8.8.1.1.8. 1. 4.2.
Pulses per
Revolution Pulses per revolution of unwind or rewind roll.
8.8.8.8.8.8.1.2.3.0. 0.0.
New Roll
Diameter
Diameter that U4 will default to when tension is
turned off, then on.
Proximity Switch Parameters

Montalvo TS Torque Sensor
5
5
15
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5.1 Mounting
Existing brake installation
1A Remove brake
1B Remove all Anti-Rotations studs
New brake installation
1C Locate, drill and tap hole for ONE sensor
All installations
2 Mount sensor and attach sensor cable
3 Install/reinstall brake (see brake installation
instructions)
Make sure retaining ring is installed on TS
4 Calibrate sensor
Sensor
• Must be mounted so that connector
points directly towards or away from
direction of rotation (perpendicular to shaft).
• Can be located anywhere on bolt circle.
Note: It is highly recommended to located
as shown in the 3 (or 9) o’clock position
to enable accurate and simple calibration.
Align and Lock
• Hand tighten nut against sensor body
• Screw sensor into tapped hole in mounting
suface until nut just touches
• Loosen sensor just enough to obtain
proper alignment
• Tignten nut against mounting surface to
lock sensor in position
Brake Model
Bolt Circle
Radius
in (mm)
TS
Model
TS Sensor
Hole Tap Size*
in (mm)
Anti-Rotation Stud
Hole Tap Size
in (mm)
CS100 3.0 (76) TS1 1/2-13 or M12x1.75 1/2-13 or M12x1.75
CS130 3.25 (83) TS1 1/2-13 or M12x1.75 1/2-13 or M12x1.75
V250 3.75 (95) TS1 1/2-13 or M12x1.75 1/2-13 or M12x1.75
V300 5.31 (135) TS1 1/2-13 or M12x1.75 1/2-13 or M12x1.75
**V400 6.38 (162) TS2 **3/4-10 or M20x2.5 **1/2-13 or M12x1.75
*TheTS Torque Sensor is available in either inch or metric thread - verify thread size if replacing an existing
Anti-Rotation Stud.
** Standard V400 Anti-Rotation Studs are 1/2-13 (M12x1.75 option). Some non-standard installations may use a
single 3/4-10 (M20x2.5 option) stud. An existing mounting hole (or a new hole) may need to be drilled and tapped
at 3/4-10 or M20x2.5 to accept the TS2. Check thread size carefully!
Cable
Connects to U4
B
r
a
k
e
R
o
t
a
t
i
o
n
+ Excitation (pin 1) BK
Signal (pin 2) WH
No connection (pin 3)
- Excitation (pin 4) BN or RD
Avoid excessive force on sensor pin!
Never impact sensor!
Mount sensor in
either direction
Bolt Circle Radius
See dimensions
Mounting Location
Recommended
3 o’clock (shown)
or 9 o’clock
Nut
Locks sensor in
aligned position
If signal displays negative,
do one of the following:
1- Reverse Exictation at U4
on terminals 13 and 15 or
2- Rotate TS 180°

Montalvo TS Torque Sensor
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5.2 Wiring
Montalvo TS
Torque Sensor
Power Connections
model options include
VAC or VDC controllers
+ Excitation (output to TS Torque Sensor) Torque Input -
Excitation (output to TS Torque Sensor)
0
-
10 VDC (output to tension meter)
GND 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
GND 0 VDC +24VDC
G
24 VDC
-+
GND Neutral 100-240 VAC
0
10
20
30 40 50 60 70
80
90
100
www.montalvo.com
www.montalvo
M4
Meter
Montalvo M4
Tension Meter
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
TS

Montalvo TS Torque Sensor
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[email protected] / www.montalvo.com / Technical details subject to change without notice. U4-technical manual-us © Montalvo
5.3 Calibration When Using an Ultrasonic Sensor
1Check that the torque sensor is mounted and oriented properly (see mounting instructions).
Be sure that the DIP switch SW 5 is enabled, and that DIP switch SW1 is set to ultrasonic.The
ultrasonic sensor must also be installed and calibrated prior to calibration of the torque sensor
with this method. If Proximity sensors are used instead, refer to the calibration procedure for
that style.
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. If no analog meter is being used, you will simply be calibrating the
0-10VDC tension output on terminal 16.
3 Apply power to the controller and let it warm up for at least 10 minutes.
4 Enter setup mode by holding keys together for 2 seconds (both Tension and Auto
lights need to be illuminated to enter setup). and to 13.
5 With roll removed and no torque applied to the sensor, use a voltmeter to measure the
value / between terminal 14 and 19 use / keys to 13 to match volt meter value.
Hold to exit menu. to tension and verify that display reads close to 0.
6 Install a shaft with a roll of material onto the machine. It is permissible to use any diameter
from an empty core up to a full roll. It is recommended to use a small to medium roll to simplify
later steps of the procedure.
7 Set brake air pressure to 75 psi / 100%. The simplest way to do this is to bypass the I/P
converter and put 75 psi of regulated air straight to the brake. Note: Prior to this step the
brake must be fully installed and secured, airlines must be connected. At this point the brake
should be engaged and movement of the roll of material restricted.
8 Wrap a rope or at strap around the unwind roll. Rope can be tied to itself after the rst wrap
and then wrapped at least 2-3 full turns to provide a xed support. Then thread the remainder
of the strap around the rst roller, or if there is sufcient room, it can be left hanging down
provided it will not touch the ground with a weight applied. Note: Verify that the tension
direction on the strap mimics the torque direction transmitted through the roll during normal
operation.
9 Attach a weight of known value to the free end of the rope. For best results, the weight should
be at least 25% of the TS torque sensor's full-scale value.
10 Enter setup mode by holding keys together for 2 seconds and to 15. Determine the
scale you will use for tension (100% by default). Change the value to reect this and record it
for later use.
11 To determine the value of 14, rst compute the value of the following formula:
Voltage 14 = 10*(weight hung / meter scale value 15)
12 Scroll around to 14. Place the voltmeter across terminals 16 and 17. Use the / keys to
make the voltmeter reading match the value computed in step.
13 Remove weight and check that tension display returns to zero. If not, repeat steps 4 to 7.
Otherwise enable the I/P converter. You have successfully calibrated the torque sensor.

Montalvo TS Torque Sensor
5
5
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[email protected] / www.montalvo.com / Technical details subject to change without notice. U4-technical manual-us © Montalvo
1Check that the torque sensor is mounted and oriented properly (see mounting instructions).
Be sure that the DIP switch SW5 is enabled, and that DIP switch SW1 is set to proximity
sensor. The proximity sensor must also be installed and settings congured prior to
calibration of the torque sensor with this method. If an ultrasonic sensor is used instead,
refer to the calibration procedure for that style.
2Before 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. If no analog meter is being used, you will simply be calibrating the
0-10VDC tension output on terminal 16.
3Apply power to the controller and let it warm up for at least 10 minutes.
4Enter setup mode by holding keys together for 2 seconds (both tension and Auto
lights need to be illuminated to enter setup) and to 13.
5With roll removed and no torque applied to the sensor, use a voltmeter to measure the value
between terminal 14 and 19 use / keys to 13 to match volt meter value. Hold to
exit menu. to tension and verify that display reads close to 0.
6Determine what size roll of material will be used for calibration. Measure the diameter of the
roll. to 12 in the setup mode and input this diameter.
7Install a shaft with the selected roll of material. It is permissible to use any diameter from an
empty core up to a full roll. It is recommended to use a small to medium roll to simplify later
steps of the procedure.
8Set brake air pressure to 75 psi / 100%. The simplest way to do this is to bypass the I/P
converter and put 75 psi of regulated air straight to the brake. Note: Prior to this step the
brake must be fully installed and secured, airlines must be connected. At this point the brake
should be engaged and movement of the roll of material restricted.
9Wrap a rope or at strap around the unwind roll. Rope can be tied to itself after the rst wrap
and then wrapped at least 2-3 full turns to provide a xed support. Then thread the
remainder of the strap around the rst roller, or if there is sufcient room, it can be left
hanging down provided it will not touch the ground with a weight applied. Note: Verify that
the tension direction on the strap mimics the torque direction transmitted through the roll
during normal operation.
10 Attach a weight of known value to the free end of the rope. For best results, the weight
should be at least 25% of the TS torque sensor's full-scale value.
11 Enter setup mode by holding keys together for 2 seconds and to 15. Determine
the scale you will use for tension (100% by default). Change the value to reect this and
record it for later use.
12 To determine the value of 14, rst compute the value of the following formula:
Voltage (14) = 10*(weight hung / meter scale value (15)
13 Scroll around to 14. Place the voltmeter across terminals 16 and 17. Use the / keys to
make the voltmeter reading match the value computed in step 12.
14 Remove weight and check that tension display returns to zero. If not, repeat steps 4 to 7.
Otherwise enable the I/P converter. You have successfully calibrated the torque sensor.
5.4 Calibration When Using Proximity Switches