S3100/S3110SW Version 20 Pub. date: 02/28/03 v1

Digital Controller

INSTALLATION AND OPERATION INSTRUCTIONS

2/28/03 3

S3100/S3110: Table of Contents Quick Set-Up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5

1 General Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7

2 Technical Data - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 92.1 Mechanical Specifications - - - - - - - - - - - - - - - - - - - -9

2.2 Electrical Specifications - - - - - - - - - - - - - - - - - - - - - -9

3 Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 103.1 Controller Mounting - - - - - - - - - - - - - - - - - - - - - 10

3.2 Electrical Installation - - - - - - - - - - - - - - - - - - - - - - - 11

3.3 Terminal Block Descriptions - - - - - - - - - - - - - - - - - - 12

4 Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 154.1 Description of Adjustments - - - - - - - - - - - - - - - - - - 15

4.2 Description of PCB Status LEDs - - - - - - - - - - - - - - 16

4.3 Description of Front Panel and Keyboard - - - - - - - - 16

4.4 Tension Calibration - - - - - - - - - - - - - - - - - - - - - - - - 18

4.5 Programming - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19

4.6 Tuning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27

5 Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 285.1 Manual Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28

5.2 Auto Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28

5.3 Auto / Manual Switching - - - - - - - - - - - - - - - - - - - - 28

5.4 Taper Tension (rewind only)- - - - - - - - - - - - - - - - - - 28

5.5 New Roll - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29

5.6 Help- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29

5.7 Operator’s Message Table - - - - - - - - - - - - - - - - - - - 29

6 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30

7 Appendix - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 32

Quick Set-Up

Quick Set-UpThe Quick Set-Up Guide is intended to help get the system up and running in a very short period of time. Please read the entire manual in order to maximize system performance.

When the S-3100 or S-3110 is ordered as part of a complete system (including load cells, an I/P converter and brake), all jumpers and most of the programming messages are factory set.

This installation manual describes both the S-3110 panel mount and the S-3100 enclosure versions of the controller. Be sure to refer to the diagrams and descriptions specific to the model you are installing.

Standard settings for the US markets are:

• 230 VAC Input

• 4 to 20 mA output to the I/P converter

• Output displayed in pounds per square inch (p) and scaled to a maximum of 75 PSI

• Total tension displayed in pounds (#)

Mechanical Installation

• Install the S-3100 enclosure according to the instructions provided in Section 3.1, or

• Install the S-3110 panel according to the instructions provided in Section 3.1 and the appendix.

Pneumatic Installation

• Connect the input and output air supply to the brake as described on the I/P converter data sheet.

• Please note the recommendations for filtration, as failure to provide clean, dry air will reduce the service life of the I/P converter.

Electrical Installation

• Refer to the electrical installation instructions in Section 3.2, "Electrical Installation‚" p. 11.

• Make all of the basic connections listed under Section 3.3, "Terminal Block Descriptions‚" p. 12.

• Insure optimum performance by connecting the Optional Start contact to Terminals 27 and 28. Refer to Section 3.3.3, "Load Cell Connections‚" p. 13. Wiring in this contact will take full advantage of the controller’s “set it and forget” capability. This contact will automatically turn the tension controller on when the line is started, first in Soft Start, then cycling into Automatic and regulating to Setpoint. When the line is stopped, the controller will go into Anticoast (if needed), then switch to Soft Startuntil the line is restarted. Refer to Section 4.5.3, "Description of

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Quick Set-Up

Features for Standard Unwind Applications‚" p. 21, for a complete description.

Calibration

• Double check all electrical connections.

• Make sure the voltage selector switch on the power supply card matches the AC input supply.

• Follow the Tension Calibration procedure in Section 4.4.

Programming

• Refer to Section 4.5.4, "Programming Features for Standard Unwind Applications‚" p. 22.

• Most applications do not require Anticoast. For a full description of these features, refer to Section 4.5.3, "Description of Features for Standard Unwind Applications‚" p. 21.

Start-Up

You should now be ready to start the machine.

Refer to Section 4.6, "Tuning‚" p. 27. As suggested, start the machine with the controller in the Manual mode, then switch to Auto and change the tuning number if necessary. The default Auto Tune number, 47, works for most applications. Tuning the controller to the machine dynamics may improve performance.

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1 General Description

1 General DescriptionThe Montalvo S-3100 and S-3110 digital controllers provide precise automatic control of web tension.

The microprocessor can be programmed for all wide variety of options which are selected by menus.· The progressive regulator automatically compensates for roll diameter.

The S-3100/S-3110 is used in a closed loop, of which the load cell roll and brake (or other torque-producing devices) are a part.

In order to properly set up and operate the controller, and to take advantage of all of the available features, it is important to have a general understanding of the controller and how it fits into the tensioning system.

Please refer to the diagram of a typical pneumatic system below. The same principles apply to most closed loop control systems. Control outputs of 4 to 20 mA or 0 to 10 volts DC enable the S-3100/S3110 to interface with a wide variety of output devices to control web tensioning brakes, clutches, and motors.

INPUT (electrical signal)

Regulated Air

Electrical Supply

OUTPUT (electrical signal)

Air Supply

Pneumatic Brakeor Clutch

I/P Converter

Load Cell

S-3100ce

Web

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1 General Description

Load Cell Function

Two load cells (also called transducers) are normally used. The signals from the load cells are summed together to give the total web tension across the entire web. Each load cell contains 2 strain gauges connected in series. The two load cells are connected so that the 4 strain gauges form a Wheatstone bridge configuration supplied with 5VDC. The web tension transfers a force to the load cell roll, causing the resistance values in the bridge to change. The resulting voltage change is amplified and calibrated at the regulator card.

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. Other converters may be used depending on the application.

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 using the keypad and digital display. The feedback from the load cells is calibrated to display the actual web tension on both the digital display and 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 feed-back 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 using 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.

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2 Technical Data

2 Technical Data

2.1 Mechanical Specifications

2.2 Electrical Specifications

S-3100 S-3110

Dimensions: W x H x D13" (330mm) x 10"(260) x 6.4"(163)Weight: 10 lbs. (4.55 kg)

Dimensions: W x H x D7.81" (198mm) x 9.25" (235) x 3.35" (85)Weight: 3.45 lbs. (1.57 kg)

AC Input 115 or 230 VAC ±10%50 or 60 Hz

Fuse Size 115 V - 160 mA T (slow-blowing type) 230 V - 80 mA T

Load Cell Supply ±2.5 VDC (semiconductor strain gauges)±5 VDC (foil strain gauges)

Load Cell Input ±250 mVDC (semiconductor strain gauges)±20 mVDC (foil strain gauges)

Zero Range (tare) 50% of combined load cell rating

Calibration Range Gain - 1 to 1000

Temperature Range 32o to 122o F (0 to 50o C)

Enclosure Degree of Protection S-3100 - IP 54

Regulator Outputs0 to 10 VDCMaximum load - 5 Ma4 to 20 mARL = 0 to 500 ohms

Meter Output0 to 100 µARO = 50 K ohms0 to 10 VDCMaximum load - 5 mA

Analog Input Voltage 0 to 10 VDCRI = 100 K ohms

Digital Input Voltage Contact closure or current sink5 mA maximum

Standards Designed to meet UL 508 and EN60204

Type: S-3100ce-UW SN: XXXXSupply voltage: 115/230V 60/50HzSupply current:

SOFTSTART

ANTI-COAST

TENSIONAUTO

0

20

40 60

80

100

w w w. m o n t a l v o . c o m

<0.5A

7.16 (182)

9.25(235)

4.39(111)

4.27(108)

7.81 (198)

Type: S-3110-ceSN: XXXX U: 115/230VI: <0.5A F: 50/60Hz

SOFTSTART

ANTI-COAST

TENSIONAUTO

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3 Installation

3 Installation3.1 Controller Mounting

3.1.1 S-3100 Optional Enclosure Panel Mount

• The S-3100 should be mounted in a dry place, away from any source of heat.

• The mounting surface should be free of any excessive vibration.

• If possible, the controller should be mounted at eye level and in a location that is accessible to the operator.

• If an I/P converter is used, it should be mounted close to the brake.

1. Drill 2 holes in the mounting surface 8.70” (220mm) apart.

2. Secure large bracket to the mounting surface using appropriate pan head or flat head fasteners.

3. Place small bracket in the bottom slot on the back of controller. Place controller on large bracket on the mounting surface. Slide the small bracket to the center of controller and mark the mounting surface through the hole in the bracket.

4. Slide the small bracket to one side. Drill a mounting hole for the small bracket as marked in step 3. Slide the small bracket back into place and secure with an appropriate pan head or flat head fastener.

IL041.epsIL038.eps

IL039.eps IL040.eps

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Thumb screws (2)

M8 x 1 SHCS (2)Panel bracket mount (2)

2

1

3

Customer control Panel surface

S3100 Controller

Cutout dimensions323 mm x 253 mm12.72” x 9.96”

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3.2 Electrical Installation

3.1.2 S-3110 Panel Mounting

3.2 Electrical InstallationWarning: electrical installation must be performed by skilled personnel. Damage from improper wiring is not covered by warranty.

• Wiring must meet all applicable codes and standards

• Refer to the appropriate wiring and terminal descriptions for external connections.

• Be sure the voltage selector on the PCB is in the correct position for the voltage supplied.

• The PCB fuse size must be selected according to the input voltage selected. The maximum recommended external fuse on the input is 10 A.

Note: Double check accuracy of all wiring connections before applying power to the controller.

EMC Requirements

• The protective ground wire must be connected to the terminal marked PE. Ground wires should be as short as possible.

• Shielded cable must be used for all external connections and the shield terminated at the controller end only for analog signals and at both ends for digital signals.

• For the S-3100, the shield may be connected to the cabinet at the point where the cable enters, either to the buss bar or to the connector housing.

• For the S-3110, connect the shield directly to the buss bar.

• The S-3110 should be mounted in a dry place, away from any source of heat.

• The mounting surface should be free of any excessive vibration.

• If possible, the controller should be mounted at eye level and in a location that is accessible to the operator.

1. A template for the cutout and mounting holes is provided with the controller.

2. Be sure to debur cutout and mounting holes.

3. Carefully slide the circuit board into the cutout, taking care not to damage the ribbon cable at the top of the circuit board.

4. Mount the panel with the sup-plied hardware.

Cutout dimensions 175 mm x 215mm (6.89” x 8.46”)

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3 Installation

• Keep the shield as short as possible (not to exceed 10 mm or 0.4 inches). For best results, secure the shield directly to the buss bar as shown below.

• Keep signal cables away from supply cables or any wires that conduct high current.

• For best noise immunity, run signal cables close to the machine frame, mounting plates or other grounded structures.

3.3 Terminal Block Descriptions

3.3.1 Basic Connections Required For All Applications

115/230 VAC Supply: Terminal Block J101

The controller must be supplied with the voltage indicated on the voltage selector switch on the printed circuit board.

1 PE Ground: for protective conductor

3 L Supply Voltage

4 N Supply Voltage

PE L N

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3.3 Terminal Block Descriptions

3.3.2 Regulated Outputs: Terminal Block J107

3.3.3 Load Cell Connections

17 Regulated Voltage 0 to 10 V output corresponding to 0 to maximum output from the regulator. May be used to control variable speed drives operating in the torque mode.

16 Regulated Current 4 to 20 mA current signal to I/P or other converter.

15 GND Regulated voltage or current signal common.

1 2 3 4 5 67 8 9 10

11 12 13 14

15 16 17 18 19 2021 22 23 24

25 26 27 28

GND

0-100uA

0-10V

GND

WEB BREAK

SHIELD

-VLC

LOADCELL-

+VLC

GND4-20mA

0-10V

GND

RMSP

+10V

SHIELD

-VLC

LOADCELL+

+VLC

GND

GND

GND

GNDT1

SPLC

INPT

STRT

NC

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S3100

J107

7 Shield Connects to load cell cable shield (S3100 circuit card version only).

8 Negative Excitation Supply Connects to pin 3 on load cell 1 or N-series load cell (red).

9 -Load Cell Input Negative-going load cell input. Connects to pin 1 on load cell 1 or N-series load cell (white).

10 Positive Excitation Supply Connects to pin 2 on load cell 1or N-series load cell (black).

21 Shield Connects to load cell cable shield (S3110 circuit card version only).

22 Negative Excitation Supply Connects to pin 2 on load cell 2 (black).

23 + Load Cell InputPositive: going load cell input. Connects to pin 1 on load cell 2 (white) or pin 4 on N-series load cell(green).

24 Positive Excitation Supply Connects to pin 3 on load cell 2 (red).

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3 Installation

3.3.4 Optional Connections

1

2

3

4 5

6

7 8

9

10

11 1

2 1

3 1

4

15 1

6 1

7 18

19

20

21 2

2 23

24

25

26 2

7 28

GND

4-20mA0-10V

GND

RMSP

+10V

SHIELD

-VLCLOADCELL+

+VLC

GND

GND

INPT

STRT

GND

0-100uA

0-10V

GND

WEB BREAK

GND

-VLC

LOADCELL-+VLC

GND

GND

T1

SPLC

NC

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S3110

J107

1 GND (ground) Common for tension signal outputs

2 Meter - 100 µA 0 to 100 µA tension signal proportional to full scale tension. Connected to tension meter on cabinet.

3 Meter 10V 0 to 10V DC proportional to full scale tension. May be used for a remote meter (with proper scaling).

4 GND (ground) Common for Web Break signal output.

5 Web Break

24 V DC output that is provided whenever tension drops below a preset level. It can be used as an alarm or can be connected to stop the machine upon detection of a web break. For a complete description, refer to Section 4.5.7, "Programming Optional Features - All Applications‚" p. 24.

11 GND (ground) Common for T1 (if used).

12 T1 Used for special applications only. If used, connection information supplied in the appendix.

13 GND (ground) Common for SPLICE.

14 Splice

When activated by an N.C. contact opening to Terminal 13, the controller output switches to a value equal the output at the time splice is initiated multiplied by the splice factor programmed during setup. It can also be programmed to go to a fixed value. Refer to the options programming section for complete explanation.

18 GND (ground) Common for Remote Setpoint Input.

19 Remote Setpoint

For adjustment of desired web tension (setpoint) by external signal instead of keypad. Can be used with a remote potentiometer or to set tension with a PLC. Input must be between 0 and 10 V DC. To use with a 4 to 20 mA signal, terminate with a resistor (100 to 500 ohms). Software calibration sets the zero and span. If used, refer to the remote setpoint programming instructions in Section 4.5.7 for a complete explanation.

20 Remote Setpoint 10 V Supply

Reference that can be used for external remote setpoint potentiometer. Maximum load - 5 mA.

25 GND (Ground) Common for INPUT (if used).

26 Input Used for special applications only. If used, connection information supplied in the appendix.

27 GND (Ground) Common for START (if used).

28 Start

Although not required, the preferred method for start/stop sequencing of the S-3100/S3110 is activation by an external, isolated N.C. (normally closed) contact. When the start function is activated by the contact to Terminals 27 and 28 opening, the controller switches the tension on and sequences through the correct start function (depending on the options selected when the controller is programmed). After the start function, the controller switches into the auto mode. Refer to the options programming section for a complete explanation. The same contact activates the programmed stop functions when the external contact is closed.

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4 Calibration

4 Calibration4.1 Description of Adjustments

Supervisor Switch - Flip the toggle to the unlock position to access setup menus and turn on optional features. After programming, moving the toggle to the lock position locks out the setup mode and provides the operator with a minimum number of messages for ease of operation.

Contrast - Adjusts the alphanumeric display for optimum viewing in the controller mounting position. Note: single-turn potentiometer.

Output Zero R2 - Adjusts the minimum regulated output when the microprocessor regulator output is zero. Factory set for 0 volts on terminal 17 and 4 milliampere on terminal 16. Note: 25-turn potentiometer.

Remote Setpoint Zero R1 - Optional feature. Coarse zero adjustment for the remote input value that represents a setpoint of zero. Final zero adjustment is done through the software. Adjustment required only if using the remote setpoint feature. If used, follow adjustment instructions in the Appendix. Note: 25-turn potentiometer.

TensZero - Coarse zero (tare) adjustment of the load cell input. Necessary to prevent much of the calibration range from being used up by a heavy load cell roller. The final zero adjustment is done through software. Note: 25-turn potentiometer.

S-3100 S-3110

0R2

0R1

0

Use the supplied Montalvo screwdriver to make adjustments and to move the toggle on the supervisor switch. Use caution and avoid inserting the screwdriver too far, as damage to the PCB could result.

0R1

0R2

Type : STC 2-2 Voltage : 115 / 230 V ACCurrent : < 200 mAS.nr. : 101

12345

0

Output Zero

Contrast Remote Setpoint Zero

TensZero Adjust

Supervisor ModeOperator Mode

Web Break

Input Splice

T1

Start

0R1

0R2

Type : S3110P-ce Voltage : 115 / 230 V ACCurrent : < 200 mAS.nr. : 101

54321

0

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4 Calibration

4.2 Description of PCB Status LEDs

1. Web Break. If the web break option has been turned on, LED 1 is illuminated and there is 24 VDC on terminal 5. For additional information, refer to Section 4.5.6, "Programming Features for Standard Rewind Applications‚" p. 23.

2. T1. Illuminated to show that T1 is high. If this function is used, LED 2 will go out when this input is connected to ground.

3. Input. Illuminated to show that Input is high. If this function is used, LED 3 will go out when this input is connected to ground.

4. Splice. Illuminated to show that Splice Input is high and controller is in splice mode (if Splice is used).

5. Start. Illuminated to show that controller has received a machine start or run signal. LED 5 goes out when controller receives stop signal.

4.3 Description of Front Panel and Keyboard

Analog Meter (S3100 only)

Displays the actual web tension.

Alphanumeric Display

Displays messages for operation, calibration and programming. The messages displayed depend on choices made during the programming of the controller. For simplicity, the message lists are broken up into several different levels. Two of these levels are for factory use to program specific options based on the application. Most of the following pages describe the supervisor’s level where the calibration and setup is done. Once programmed, changing the position of a board-mounted toggle switch locks out all of the setup menus, so only a short operator’s menu of messages is displayed.

Status LEDs (display current operating mode)

• AUTO - On for automatic, blinking for taper on, off for manual and splice modes.

12345

54321

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S-3100 S-3110

SOFTSTART

ANTI-COAST

TENSIONAUTO

0

20

40 60

80

100

w w w . m o n t a l v o . c o m

Analog meter

Digital displayStatus LEDs

Help key

Keypad

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4.3 Description of Front Panel and Keyboard

• TENSION* - On when controller output is enabled, blinking when the controller is in the jog mode.

• ANTICOAST* - On during anticoast or inertia compensation stop time if these features are selected.

• SOFT START* - On when in the soft start or inertia compensation start mode, blinking during soft start or inertia compensation start time. (*Refer to Section 4.5, "Programming‚" p. 19)

Help Key(Refer to keypad diagram) 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.

Key Function Description

Scroll Pressing these keys displays other messages as you move back through the menu.

SetpointThis is a shortcut key that returns you to the setpoint (desired web tension) message from anywhere in the menu. Pressing the key again will toggle back to the last message displayed.

Auto/Manual

This key functions only when tension is on (TENSION LED is illuminated). Pressing the key will toggle the operating mode from automatic to manual. When in auto, the AUTO LED is either illuminated or blinking.

Plus

A number underscored by the cursor can be edited. Pressing the”+” or "-" key changes the number.

Minus

Cursor

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 is showing, 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.

Enter

For numeric values which can be entered, pressing the enter key when the cursor is displayed stores the value in permanent memory. For text messages with options other than the one displayed, pressing enter repeatedly toggles through all available options before coming back to the first option displayed.

Tension On/Off

Pressing this key toggles the output of the regulator circuit ON or OFF. Tension is on when the TENSION LED is either illuminated or blinking.

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4 Calibration /

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4.4 Tension Calibration

Note: Bold text indicates the messages as they will appear on the alphanumeric display. TEXT IN ALL CAPITALS INDICATES KEYS.

1. Verify that the load cells are mounted and oriented properly. Refer to the load cell installation instructions.

2. Before applying power, verify that the analog tension meter is mechanically zeroed. If not, adjust the small screw below the meter scale until the meter reads zero.

3. Apply power to the controller and let it warm up for at least 10 minutes. When power is applied, the front panel LEDs will flash in a sequential test pattern and the display will read Initializing... . A Montalvo copyright message will then scroll across the screen. When that message is finished, the display will scroll to the next message, depending on programming options selected. If necessary, adjust the contrast potentiometer so the display can easily be read at the angle the controller is mounted.

4. Insure that the supervisor switch is in the unlocked position. (Refer to illustration in Section 4.1, "Description of Adjustments‚" p. 15)

5. SCROLL down approximately 4 times (the exact number depends on preset software options) to the TensZero xxxxx message. With the web removed and no tension applied to the sensing roll, adjust the TensZero potentiometer until the display reads zero.

Note: TensZero is a 25-turn potentiometer, so many rotations may be required. Also note that in some applications, it may not be.possible to reach zero. In this case, adjust the TensZero as close to zero as possible. The controller can easily compensate for a reading of ± 300 without affecting accuracy or linearity. Scroll down once.

6. TensCalibrate.... is now displayed. Press ENTER. C>RemoveWeb is displayed. Be sure the web is removed and press ENTER. After C>PleaseWait counts down, you will be prompted to press ENTER. C> PlaceCalWgt is displayed. Do not press again until you have completed steps 7 and 8.

7. Thread a rope over the center of the tension sensing roll following the exact path of the web. Be sure the rope extends at least one roll before and one roll after the sensing roll. Make sure the rope does not pass over any dead bars or non-freewheeling rolls. Fasten one end of the rope securely.

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.

9. Press ENTER and C>CalWgt is displayed. Set the digits to the weight you are using by placing the cursor under the number you want to change, and use the + or - key to change the value. Press ENTER and C>PleaseWait is displayed.

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4.5 Programming

10. After countdown, C>Calibrated will be displayed and the analog meter will indicate the calibration weight. If you see a message C>CellsReversed, exchange the load cell signal wires on terminals 9 and 23. If you see a message C>Wgt TooSmall!, check to make sure that load cells are mounted correctly. If so, increase the weight used for calibrating. The S-3100/S3110 can also be configured for higher load cell signal amplification. Contact Montalvo Applications Specialists for more information.

4.5 Programming

4.5.1 Features Common to All Applications

The following features must be set up for every application. They are factory set whenever possible, so for most applications, no changes are required.

Unwind / Rewind Selection

Scroll to the WebLine message. Press ENTER to select Unwind for brake applications or Rewind for clutch or winder drive applications.

Unwind/Rewind selects different sub-menus specific to the application, so be sure you have selected the correct type before moving on to specific unwind or rewind programming instructions.

Meter Scale

SCROLL to Meter Scale. This should be set to the full scale value on the analog meter. If it is not, change the appropriate digits and press ENTER to store the scale in memory.

Output Scaling

SCROLL to OutScale. If not already set, change the digits to the maximum calibrated output of the converter (i.e. 75 PSI, 6 bar, 100%, etc.). If changed, press ENTER to store the data.

Calibration Quick ReferenceDisplayed Message Action Required

TensZero Remove web.

TensZero Adjust TensZero Pot for 0 on display.

TensCalibrate.... Press ENTER.

C>Remove Web Confirm web is removed. Press ENTER.

C>Press ENTER Press ENTER.

C>Place CalWgt Thread rope following web path, hang known weight, press ENTER.

C>CalWgt Set digits to weight used, press ENTER.

C>Press ENTER Press ENTER.

C>Calibrated! None: calibration complete.

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4 Calibration //

Output Limit

SCROLL to OutLimit. This is normally set to the same value as OutScale, but in some applications may require reducing the value.

4.5.2 Features Common To All Applications, Optional Settings

As mentioned above, most features are factory set. In some cases, it may be desirable to change the following parameters. These are located in a hidden menu that is accessible by keypad.

Access to Menu

SCROLL to the Montalvo SC2 z.xx message. Press the ENTER key and the message S>SetupEnabled appears briefly. Press the CURSOR key and the message S>Setup Data On appears briefly. Now when you SCROLL through the message list, numerous additional messages appear. The ones listed below are the only ones that are typically changed to suit an application. DO NOT change any other messages unless instructed by a factory representative or by additional information provided in the appendix.

Meter Damping

SCROLL down to DampMeter? No/Yes. This feature selects the filtering of the analog meter output (auto mode only). Meter damping is useful when tension is fluctuating due to mechanical factors. If damping is turned off, it is easier to see if the tension is fluctuating due to instability or improper tuning. Normally, damping is left off. (DampMeter? No).

Tension Display: Total or PLI

SCROLL to TensShow. This may be set to have the display show Total tension or PLI (tension per unit width - PLI or gm/cm). Normally set to Total. For more information, refer to Section 4.5.7, "Programming Optional Features - All Applications‚" p. 24.

Set Units

The controller is normally preset with units customary for the application and the country where it is shipped. Units will be set to English for the USA and Canada, and metric for other markets. To change the settings, at the SetUnits? No, press the ENTER key to display SetUnits? Yes. SCROLL down and Unitforce xx is displayed. Pressing ENTER toggles through lb, oz, kg, gm and N. When the desired unit is displayed, scroll to UnitOut xx. Press ENTER to select psi, bars, volts or percent. SCROLL to UnitLength and select in., cm. or mm. When finished, scroll back to SetUnits? Yes and press ENTER to change to Set Units? No. The choices are saved and the units menu closes.

Web Break

Used to detect a tension drop below a preset percentage of full scale. It can be used to stop the machine or sound an alarm. To make the Web Break feature available, SCROLL to WebBrkPkg? No and Press ENTER to select WebBrkPkg? Yes. For

20 2/28/03

4.5 Programming

ld.

web break programming instructions, refer to Section 4.5.7, "Programming Optional Features - All Applications‚" p. 24.

4.5.3 Description of Features for Standard Unwind Applications

Soft Start / Anticoast

The Soft Start function is used to prevent starting up with maximum tension when the web is slack. The preferred method of implementing Soft Start is by an external contact connected to terminals 27 and 28. The contact must be closed when the machine is stopped and open when the machine is running. If Anticoast is being used, the contact should close at the time the machine decelerates prior to stopping. If Anticoast is not used the contact can close either when the line is stopped or when it decelerates. The contact should not open when the line is being jogged.

Opening the contact turns tension on (if it is not already on) and sets the output to a level equal to the NRollOut (New Roll Out) value multiplied by the SoftFrac percentage. It is at this level for an adjustable period set by SoftTime. During this time, the soft start LED will blink. After SoftTime, the controller switches into automatic (the soft start LED goes out and the auto LED comes on). After the machine has run for approximately 2 seconds, the controller begins to store the regulator output in memory. When the start / stop contact closes, the anticoast timer is initiated. If Anticoast has not been selected, the controller stays in automatic.

After AntiTime, the output switches to a hold level equal to the output prior to stoppingmultiplied by the Hold Frac percentage.

The Anticoast function is used to prevent the drop in tension that normally occurs during rapid deceleration. It is normally only required for high inertia rolls or short deceleration times. If Anticoast is being used, when the start/stop contact closes, the output immediately switches to a level equal to the output prior to stopping multiplied by the AntiFrac percentage. This level starts to decrease decreases exponentiallyto the stored level, reaching it at the end of AntiRamp time. The controller switches back into auto and regulates until AntiTime expires. The controller then switches to Ho

2/28/03 21

line

o low, top).

Auto Soft Start

This feature can be used for simple processes in which the machine does not stop and start frequently and in which an external contact is not available. [Consult factory applications specialists to see if this function would work in your application.]

4.5.4 Programming Features for Standard Unwind Applications

Soft Start and Anticoast by Contact

1. SCROLL to SoftSt? No. Press ENTER to select SoftSt? Contact.

2. SCROLL to NRollOut. Set a value consistent with the output required for a full (new) roll diameter. This value is used to compute the jog and soft start outputs when the operator tells the controller that a new roll has been installed. When TENSION is turned off, the message NewRoll? Yes automatically appears. If the operator does not press ENTER to select NewRoll? No, the value entered for NRollOut is used. If NewRoll? No is selected, the controller will use the output value stored in memory prior to turning TENSION OFF. Change the value for NRollOut as required and press ENTER.

3. SoftFrac is displayed. Set the desired percentage of running output to be used at start up. The default value is 50% and will work for almost all applications. If changed, press ENTER to save the value.

4. SCROLL to SoftTime. A time of 2 seconds will work for most applications.

5. SCROLL to AntiCoast? No. Press ENTER to select AntiCoast?Yes if anticoast will be used. If AntiCoast? Yes is selected, SCROLL to AntiFrac . Set to 150%as a starting value. Scroll to AntiRamp and set for 2-3 seconds. Run at maximumspeed, largest diameter roll. Stop the machine and observe the tension meter. If the tension goes too high, decrease the AntiFrac and/or AntiRamp. If it goes toincrease AntiFrac and/or AntiRamp . SCROLL to AntiTime, which appears even ifAntiCoast?No was selected. Set for 2 seconds longer than the machine stop timeat maximum speed. SCROLL to Hold Frac and set for 100% (or desired value at S

4.5.5 Description of Features for Standard Rewind Applications

Note: The rewind features are used only for applications that have separate winder motors and that can develop standing tension. The rewind torque can be controlled through a clutch with an AC motor driving its input, or directly by a DC drive operated in the torque mode.

If the rewind clutch is driven off of the main drive of the machine, the controller must be programmed to unwind so that the soft start function can be used.

Inertia Compensation

This feature is used to overcome the friction and inertia of the rewind at start up. The start/stop contact must be wired in and must open when the machine starts. On a

22 2/28/03

4.5 Programming

separately driven rewind, standing tension is created by the operator pushing the TENSION ON/OFF and then AUTO/MANUAL keys. The output of the controller increases until the tension setpoint is reached. When the machine is started, the controller output must immediately rise to a higher level to overcome the friction and inertia of the roll. When the contact opens, the output immediately switches to a level equal to the output prior to starting multiplied by the ICStrtFrac (Inertia Compensation Start) percentage. It is at this level for an adjustable time set by ICStrtTime. During this time, the soft start LED will blink. After ICStrtTime, the controller switches back into automatic.

Alternately, the contact can be used to turn tension on without the operator needing to push any keys. When the start button for the machine is pushed, the start/stop contact opens and turns tension on. The output is set to a level equal to the ICStrtOut value multiplied by the ICStrtFrac percentage. It remains at this level for ICStrtTime, then switches into automatic. Using this method eliminates having the operator press any keys to start the tension controller, but the starting torque is dependent on the accuracy of the ICStrtOut value.

Also available is the inertia comp stop function, which rapidly decreases the torque during fast stops to help prevent the tension from going too high due to the roll inertia. This feature is rarely used with a clutch, but may be beneficial when used with a regenerative drive. The drive could provide braking torque to the roll to help maintain the proper tension during fast stops. When the start/stop contact closes, the output immediately switches to a level equal to the output prior to stopping multiplied by the ICStopFrac. It remains at this level for the ICStopTime.

Taper Tension

This function is used to reduce the web tension as the roll diameter increases. Taper is used to prevent roll starring and telescoping, especially when winding slippery webs. Knowledge of the roll diameter is necessary for any controller to perform the taper function. The S-3100 calculates the roll diameter by monitoring the controller output and comparing it with the tension. No additional sensors, tachometers or rider roll inputs are necessary. With selection of Taper? Yes, the taper function is initialized a few seconds after the line is started. The amount of taper is set by the Taper message. When taper is on, the auto LED blinks to remind the operator. Taper function diameter calculation is reset by a splice function or by NewRoll? Yes when TENSION is turned off.

4.5.6 Programming Features for Standard Rewind Applications

Inertia Comp Start, Stop by Contact

1. SCROLL to ICmpSt? No. Press enter to change displayed message to ICmpSt? Contact.

2. SCROLL to ICStrtOut. Set a value consistent with the output required for standing tension at core (new roll) diameter. This value will be used to compute the inertia comp start and stop outputs when the operator tells the controller that a new core has been installed. When the tension is turned off, the message NewRoll? No automatically appears. If the operator does not press ENTER to select NewRoll? Yes, the controller uses the output prior to turning tension off multiplied by the ICStrtFrac. If the operator presses ENTER to select NewRoll? Yes, the value entered for ICStrtOut is used. Change the value as required and press ENTER.

2/28/03 23

4 Calibration

3. ICStrtFrac is displayed. Set the percentage increase of the output required for standing tension that will be applied at start up. This increased output overcomes the mechanical inertia and friction of the rewind. Set only high enough to overcome the inertia. Too high a value may cause tension to drop again after ICSrtTime. Set the desired value and press to save the value.

4. ICSrtTime is displayed. A time of 2 seconds will work for most applications.

5. SCROLL to ICmpStop? No. If controlling a clutch, leave at No for most applications. If controlling a regenerative drive when inertia is high, press ENTER to select Yes.

6. SCROLL to ICStopFrac. Sets the percentage decrease of the output required for the drive to apply additional braking torque to the roll. Change the value and press ENTER to store it.

7. ICStopTime is displayed. A time of 1 or 2 seconds will work for most applications.

NOTE: TaperOn? Yes is selected and the taper percentage is not set to zero, the Auto LED will blink to remind the operator that taper is on. If taper is turned off at any point while winding, the tension remains at the taper-reduced setpoint for the rest of the roll. When TENSION is turned off, the message NewRoll? No appears automatically. Each time a new roll is started, the operator must press ENTER to select NewRoll? Yes and reset the taper calculation.

Taper Tension

1. SCROLL to Taper? No. Press ENTER to change to Taper? Yes. This causes the message TaperOn? No to appear in the operator’s menu.

2. If taper is required, the operator presses ENTER while this message is displayed to select TaperOn? Yes. Taper% then appears in the operator’s messages and can be seen by scrolling up.

3. The operator sets the desired percentage of taper and presses ENTER to save the value.

4.5.7 Programming Optional Features - All Applications

Splice

Used during a flying splice to immediately switch the output from that required at the expiring roll to the value required for a new roll. Splice may also be used any time it is desirable to take the control out of closed loop control and go to a fixed or proportional output.

1. SCROLL to the Splice? No message. Press ENTER to select either Splice? Timed or again to select Splice? Contact. Either is initiated by a normally closed contact which opens at the time of the splice. Timed allows the contact to be momentary. Contact keeps the controller at the splice level for as long as the contact is open.

2. SCROLL to SplcType? Press ENTER to select Fixed or Pct (percent).

3. If Fixed is selected, the next message is SplcOut. Set for the desired output during splice. In addition to a splice function, this mode can also be used for fast or emergency stop.

4. If SplcType? Pct was selected, the next message will be SplcFctr. Set the desired percentage of the expiring roll output to be applied to the new roll or core. The next message is SplcMinOut, which is the minimum allowable output

24 2/28/03

4.5 Programming

that can be multiplied by the splice factor. This is intended to avoid the problem with unwind splices where the output may be zero near core, so the resulting splice output is zero.

5. If Splice? Timed was selected, the next message is SplcTime. If a momentary splice contact is used, such as on a knife limit switch, Splice?Timed determines length of output at splice level.

Web Break

Web break provides a 24 VDC output on terminal 5 whenever WebBr?Yes is selected. When tension is turned on, the controller immediately starts comparing the actual tension with the level set in WebBrkFrac. If the tension is below this level for 10 seconds (start up delay) plus the time set in WebBrTime, the 24 volt output turns off for 2 seconds. Typically, this output energizes a relay from which a normally open contact is wired in series with the main drive run circuit. When the 24 volts turns off in response to a web break, the auxiliary relay stops the machine. A second delay, WebBrWait, determines how long the controller waits after the Web Break before it turns tension off. Note that the web break operates whether the controller is in AUTO or MANUAL mode, but for unwind, tension will be turned off after WebBrWait in the Auto Mode only.

1. SCROLL to WebBr? No message and press ENTER to select WebBr?Yes.

2. SCROLL to WebBrFrac. Set the value below which the controller will assume a web break has occurred. This value can be set between 1 and 20% of the meter scale.

3. SCROLL to WebBrTime. Set the time between 1 and 10 seconds in which tension must be below the WebBrFrac level before the web break output goes low for 2 seconds.

4. SCROLL to WebBrWait and set a time between 1 and 60 seconds that the controller will delay after a web break detection before turning tension off.

Tension Show Per Unit of Width

For most applications, the alphanumeric display of tension and setpoint refer to the total web tension. The TensShw message allows the supervisor to select the option of displaying tension per unit of width (PLI, gm/cm). SCROLL to the TensShw Total message. Press ENTER to select PLI. This causes a new message to appear in the operator’s list. Web Width is displayed and must be set to match the material before the machine is started. The SetPoint message changes to SetPt/UW. The analog tension meter still displays total tension, which is equal to the SetPt/UW multiplied by the Web Width.

Saving and Recalling Materials

The S-3100/S-3110 can save and recall up to 14 different groups of programming and tension settings. Most parameters can be stored as a material number, eliminating the need to change individual parameters when a wide range of materials is run.

1. SCROLL to the MatlSave message. Enter a number between 1 and 14 and press ENTER to save all parameters.

1 2 3 4 5 67 8 9 10

11 12 13 14

15 16 17 18 19 2021 22 23 24

25 26 27 28

GND

0-100uA

0-10V

GND

WEB BREAK

SHIELD

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LOADCELL-

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GND4-20mA

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GND

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SHIELD

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GND

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SPLC

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J107

1

2

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6

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9

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19

20

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24

25

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SHIELD

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GND

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0-100uA

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WEB BREAK

GND

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GND

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SPLC

NC

WD048.eps

S3110

J107

2/28/03 25

4 Calibration

2. The material settings can then be recalled from the operator’s messages by scrolling to Material and entering the correct digits. Press ENTER and all previously saved settings will be restored. Typically, the material message is used to simplify changes in setpoint, soft start/inertia values, taper percentages, and also to save different meter scales for wide tension ranges.

3. The material settings can be erased by scrolling to MatlClear. Change the digits to the material to be cleared and press enter. (Please Confirm) is displayed. Press enter again to clear.

4. Even if multiple materials are not run on the machine, it is advisable to save the parameters using MatlSave. In the event any parameters are changed, the material message will allow all parameters to be restored in one step.

Remote Setpoint Calibration

Connect the source for the remote setpoint to Terminals 18 (GND) and 19 (positive input, 10 volts maximum). If using 4 to 20 mA, terminate the current leads with a resistor of 500 ohms or less. The exact voltage developed is not critical. If using a potentiometer for the input, the 10 volt reference on Terminal 20 can be used as a source (5 mA max. load).

Once the basic controller setup has been completed, you can then calibrate the remote setpoint input. In the supervisor’s message list, SCROLL to RemoteSetpt No and press ENTER to select RemoteSetptYes. The next message displayed is RemSetZero. Apply the input that corresponds to a set point of 0. Adjust the Remote Setpoint Zero potentiometer R1 until the display reads 0. Scroll down to the next message, RemSetptCal.... Press ENTER and the message C>RemSetptMin appears. Press ENTER and C>RemSetptMax appears. Apply the input that corresponds to the maximum setpoint (full scale on the analog meter). Press ENTER again to complete the setup.

Once the Remote Setpoint Option has been selected in the Supervisor’s message list, RemoteSetpt Yes/No will appear in the operator’s list as well. This allows the operator the option of changing the setpoint either from the keypad or from the remote source.

Other Options

The controller has many features not covered in the basic manual. A few of the features available are: normal/reverse controller action, bipolar output, and multiple calibration. Some options require additional hardware and/or programming. If supplied, specific information will be included in the Appendix. If additional special features are required to suit the application, contact Montalvo. The function may already be available in the standard software and can be enabled via the keypad.

1

2

3

4 5

6

7 8

9

10

11 1

2 1

3 1

4

15 1

6 1

7 18

19

20

21 2

2 23

24

25

26 2

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SHIELD

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26 2/28/03

4.6 Tuning

4.6 Tuning

The S3100/S-3110 provides a single adjustment, semi-automatic tuning feature. Individual values of minimum gain, maximum gain, integration, and error limit values have been grouped into logical combinations and assigned AutoTune numbers. These numbers range from 1 to 64, with 1 being very stable and 64 being very responsive. The tuning procedure is described below:

1. SCROLL to the AutoTune message. If necessary, set to the default value of 47.

2. SCROLL to ManOutSet. Enter an output value consistent with the operation of the machine. The value should be approximately equal to the output that will give the desired tension at the current roll diameter. It is better to start with a low value. Press ENTER.

3. Turn tension on by pressing TENSION ON/OFF key. The value entered in step 2 should be applied to the converter. Start the machine and run slowly, adjusting the ManOut value if necessary. The tension meter should be fairly stable because the output is fixed and the control loop is open. If the meter is fluctuating, the problem may be due to out of round rolls, bad bearings, a surging drive or some other mechanical factor. Please note that the controller cannot compensate for mechanical problems.

NOTE: When the AutoTune message is displayed, the analog meter displays the output of the regulator circuit instead of web tension.

4. SCROLL to the Tension xxx message and note the tension value that corresponds to the ManOut value entered above. Press the SETPOINT key and enter a value equal to the value you are running in manual. Press ENTER.

5. Scroll to the AutoTune message.

6. Press the AUTO/MANUAL key to put the controller in automatic. Accelerate the machine to approximately 50% of maximum speed. Position the cursor under the least significant digit. If the output displayed on the analog meter is stable, increase the AutoTune number one at a time. Changing the AutoTune immediately affects the output response. It is not necessary to press ENTER each time the number is changed. Continue increasing the number until the output becomes unstable, then reduce it until it is stable again. If the output was unstable with an AutoTune number of 47, reduce the number until the output becomes stable. Press ENTER to store the AutoTune number in permanent memory.

7. SCROLL to MatlSave. Enter a number between 1 and 14 and press ENTER.

2/28/03 27

5 Operation

5 Operation 5.1 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.

• Using the CURSOR key, 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.

5.2 Auto Mode

If the start/stop contact has been wired in and Soft Start or Inertia Comp Start has been selected, the S-3100 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 Soft Start or Jog until the line is restarted. For rewind applications, it will remain in auto. If the start/stop contact is not used, the controller can be switched 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.

5.3 Auto / Manual Switching

When going 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.

5.4 Taper Tension

If taper tension has been programmed, the message TaperOn? No will appear in the message list. To activate the taper function, scroll to this message and press ENTER. The message changes to TaperOn? Yes, and the Taper% message appears next. Change the appropriate digits and press to save the new value.

28 2/28/03

5.5 New Roll

5.5 New RollIf 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.

5.6 HelpFor 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. Refer to the Section 5.7, "Operator’s Message Table‚" p. 29 below.

5.7 Operator’s Message Table

Note: This message is displayed only if Soft Start, Inertia Compensation or Taper Tension options are selected during programming. Turning tension off automatically brings up the NewRoll? Message because the controller must be reset when the roll is changed.

Displayed Message

Tension Off (no LEDs on)

Manual (tensionLED on)

Auto (tension & Auto or Soft Start LEDs on)

ManOutSetOutput when tension is turned on (can be changed)

Not displayed Not displayed

ManOut Not displayed Output in manual (can be changed) Not displayed

OutputDisplays 0.0 because output is off Not displayed Output in automatic

SetPoint Desired operating tension while in Auto mode (can be changed)

Tension Display of the total web tension

OPTIONAL MESSAGES (depending on programming choices)

Material Displays current material selection (can be changed)

Meter Scale Displays current analog meter full scale value (cannot be changed)

Web WidthTension Per Unit Width Mode onlyCurrent web width (can be changed)

Web width(cannot be changed)

SetPt/UWTension Per Unit Width Mode onlyDesired operating tension while in Auto mode (can be changed)

Tens/UW Tension Per Unit Width Mode only - Display of tension per unit width

TaperOn?Taper Mode only - Press ENTER to toggle between Yes & No(Auto LED blinks when Taper is on)

Taper%Rewind Taper Mode only - Message appears only if TaperOn? Yes is selectedCurrent Taper percentage (can be changed)

New Roll? Yes/No See Note 1 below Not displayed

2/28/03 29

30 2/28/03

6 Troubleshooting

6 Troubleshooting

If the use of the S-3100/S3110 is no longer required, dispose of it according to the regulations in force at the time. For service, please contact:

Symptom Cause Check For

Web tension unstable both in MANUAL and AUTO modes...

Mechanical problemBad roll, bad bearings, bent shafts, worn gears, missing teeth, loose chains or belts, line speed variations, brake, clutch or drive problem.

Pneumatic problem Fluctuating air input, air leaks, water or oil in air lines.

Web tension and output stable in MANUAL but unstable in AUTO...

Tuning problem Check regulator tuning. Refer to Section 4.6.

Regulator problem Check analog inputs and outputs - if faulty, consult factory or replace circuit board.

Converter problem If signal voltage OK, check converter calibration or replace converter.

Web tension stable in MANUAL, but analog tension meter reading unstable...

Load cell problem Loose cables, plugs or load cell mounting, unbalanced roll.

Tension meter Defective meter, loose connections. Check excitation supply, tension output.

Regulator problem Replace controller board if defective.Tension meter does not read zero when web is slack...

Load cell problem Faulty or improperly installed load cell. Refer to load cell installation instructions.

Adjustment problem Refer to tension calibration, Section 4.4.

Web tension too low in both AUTO and MANUAL modes...

Pneumatic problem Check input air pressure for air leaks. I/P converter may be defective.

Regulator problem Check programming. Check analog inputs and outputs - if faulty, consult factory or replace circuit board.

Brake, clutch or drive problem

Brake/clutch too small, not enough pads activated, motor too small, drive current limit set too low.

UNWIND - Web tension increases at small roll diameters in both AUTO and MANUAL modes...

Mechanical problem Bearings on unwind defective, too much friction.Pneumatics I/P converter may be defective.

Regulator problem Check programming. Check analog inputs and outputs - if faulty, consult factory or replace circuit board.

Brake problem Brake too large, too many pads activated.Controller loses calibration or programming...

Power supply Low AC input voltage, power surges.

EMC problem Drives or other EMI sources nearby, input and output wiring routed too close to supply cables or motor wiring.

The Montalvo Corporation50 Hutcherson Drive Gorham, ME 04038 USATel: (207) 856-2501 Fax: (207) 856-2509

E-mail: info@montalvo.comWeb Site: www.montalvo.com

Danarota Technic A/SGI. Skartved 5, DK-6091Bjert, DenmarkTel: +45 75 57 27 11 Fax: +45 75 57 29 97

7 Appendix

2/28/03 31

7 Appendix

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am -

Pneu

mat

ic U

nwin

d/R

ewin

dW

D116

.dsf

10K

OH

M P

OT

EN

TIO

ME

TE

R

+

RE

MO

TE

0-1

00 µ

A M

ET

ER

(O

PTIO

NA

L)

100K

OH

M

CC

W

SET

POIN

T(O

PTIO

NA

L)

CW

WIP

ER

-

RE

MO

TE

7 Appendix

(SCROLL). To move horizontally, press

(ENTER).

MontalvoSC2 z.20

WebLine Unwind

MeterScale xxxx

OutScale xxp

OutLimit xxp

TensZero xxx

TensCalibrate... C>Remove Web PleaseWait 5s..4s..3s..2s..1s.. C>Press ENTER

C>Place Cal Wgt C>CalWgt xx.x# PleaseWait 5s..4s..3s..2s..1s.. C>Press ENTER

C>CellsReversed! C>Calibrated!

C>WgtTooSmall!

SoftSt? No Contact

NRollOut xx.xp

SoftFrac xx %

xx %

SoftTime xx s

AntiTime xx s

xx %

AntiCoast?

No AntiCoast?

Yes

AntiFrac

AntiTime

xx s

Splice? No Timed Contact

SplcType Pct SplcType Fixed

SplcFctr xxx % SplcOut xx.xp

SplcMinOut xx.xp

SplcTime x s

AutoTune xx

Unwind Message Map To move down through message map, press

HoldFrac?

xx sAntiRamp

2/28/03 33

7 Appendix

AutoTune xx

ManOutSet x.x p

Output x.xp

SetPoint xx.x#

Tension xx.x#

MatlClear x

MatlSave x

Material x

MontalvoSC2 z.20

System Setup Menu

At the Montalvo version message, press (ENTER), then (CURSOR), to access the menu.

MontalvoSC2 z.20

NRollDef Yes NRollDef No

SetUnits? No SetUnits? Yes

UnitForce lb oz kg gm N

UnitOut psi bar volts percent

DampMeter? Yes DampMeter? No

CntlActn Normal CntlActn Reverse

MultiCal? No MultiCal? Yes

MtrScaleDef xxx (should match full-scale analog meter)

RemSetPkg? No RemSetPkg? Yes

TnsShow Total TnsShow PLI

JogPkg? Yes JogPkg? No

ASoftS? No ASoftS? Yes

MontalvoSC2z.20 S>Setup Disabled

34 2/28/03

7 Appendix

WebLine Rewind

MeterScale xxxx

OutScale xxp

OutLimit xxp

TensZero xxx

TensCalibrate... C>Remove Web PleaseWait 5s..4s..3s..2s..1s.. C>Press ENTER

C>Place Cal Wgt C>CalWgt xx.x# PleaseWait 5s..4s..3s..2s..1s.. C>Press ENTER

C>CellsReversed! C>Calibrated!

C>WgtTooSmall!

ICmpSt? No Contact

ICStrtOut xx.xp

ICStrtFrac xxx%

ICStrtTime xx s

ICmpStop? No ICmpStop? Yes

ICStopFrac xx%

ICStopTime xs

Splice? No Timed Contact

SplcType Pct SplcType Fixed

SplcFctr xxx% SplcOut xx.xp

SplcMinOut xxx%

SplcTime x s

Taper? No Taper? Yes

AutoTune xx

ManOutSet x.xp

Output x.xp

SetPoint xx.x#

Rewind Message Map

(SCROLL). To move horizontally, press (ENTER).To move down through message map, press

2/28/03 35

36 2/28/03

7 Appendix

SetPoint xx.x#

Tension xx.x#

TaperOn? No TaperOn? Yes

Taper %

MatlClear x

MatlSave x

Material x

Montalvo SC2 z.20

System Setup MenuAt the Montalvo version message, press (ENTER), then (CURSOR), to access the menu.

MontalvoSC2 z.18

NRollDef Yes NRollDef No

SetUnits? No SetUnits? Yes

UnitForce lb oz kg gm N

UnitOut psi bar volts percent

DampMeter? Yes DampMeter? No

CntlActn Normal CntlActn Reverse

MultiCal? No MultiCal? Yes

MtrScaleDef xxx (should match analog meter full scale)

RemSetPkg? No RemSetPkg? Yes

TnsShow Total TnsShow PLI

AnalogOut Zero AnalogOut Out AnalogOut Rate

MontalvoSC2z.20 S>Setup Disabled

7 Appendix

2/28/03 37

Parameter SettingsParameterMaterial 1 2 3 4 5 6 7 8 9

MeterScale

OutScale

OutLimit

SoftSt

RollOut

SoftFrac

SoftTime

HoldFrac

AntiCoast

AntiFrac

AntiTime

AntiRamp

Splice

SplcType

SplcFctr

SplcMinOut

SplcTime

AutoTune

SetPoint

ManOutSet

The Montalvo Corporation • 50 Hutcherson Drive, Gorham, Maine 04038 USA • E-mail: info@montalvo.com / www.montalvo.comTel: (207) 856-2501 Fax: (207) 856-2509 Toll Free Tel: 1-800-226-8710 Toll Free Fax: 1-800-644-5097

Technical details subject to change without notice. Printed in U.S.A. S-3100/3110CE © 2002 MONTALVO