November 2016 Better Web Control Newsletter

In this issue:
End of the Year Planning
Troubleshooting Tip

Gear up for 2017
End of the Year Tension Control Upgrades to Start off 2017 Right

With fiscal planning underway for 2017, manufacturers look to maximize their 2016 budgets. An end of the year tension control upgrade is the perfect opportunity to add productivity and profitability to your machines.

Its the perfect time to start the budgetary quoting process to capitalize on any remaining 2016 budget at the end of the year while starting off 2017 right!

A tension control upgrade is an extremely cost effective method for adding increased capabilities and productivity to your machine. Whether it’s just a few key component upgrades or a larger tension control retrofit, Montalvo gives you the performance enhancements you require for years to come.

• Reduced scrap
• Increased line speed
• Higher quality end product
• Easier operation
• Reduced maintenance

These are just a few of the possible benefits you can achieve through a Montalvo tension control upgrade.
Talk to a Montalvo Applications Specialist today to receive a quote.

Troubleshooting Tip: Is Your Tension Climbing of Becoming Unstable Near the Core?
BWC Blog

If you are experiencing problems at your unwind, particularly as the roll approaches the core, in the form of tension climbing and/or the web tension becoming unstable, it is often caused by an I-P or E-P converter in the need of re-calibration.

The I/P or E/P converter is the device that takes the regulated output control signal from the controller (either open-loop or closed-loop) and adjusts the air pressure to the brake in order to maintain proper tension control.

These devices tend to be subject to the variability of the input air supply and/or suffer degradation over time due to poor air quality (water and/or oil in the supply) or simple wear and tear. Utilizing a high quality air filer (ex: MAF3) will improve air quality and assist system performance. In any event, the overall system performance will benefit from regular, routine calibration of the converter.

The good news is that it is a very simple procedure; it only takes a few minutes, and can be typically performed during roll changes or during a very short down time.

Read the full post here

Here For You!
Need technical assistance, have a question about your application, adding components to a new machine, or want to explore an upgrade or retrofit, we are here to help you any way we can.

Contact a Montalvo Applications Specialist

Check out Coast Controls latest shifting unwind stand featuring Montalvo Tension Control components.

Troubleshooting Tip: No Response from the Amplifier on Your Controller
BWC Blog

1. Always check to make sure the proper power is being supplied to the amplifier. For example our A4 Amplifier requires 24 VDC input whereas a M3200 utilizes 120/240 VAC. If the wrong voltage is supplied to the amplifier, the amplifier will not work and could potentially permanently damage the amplifier.

2. Ensure the output signal wires of the amplifier are connected properly. Please check your amplifier manual for proper signal wire connections. Your controller or PLC will expect either a +4-20mA or +0-10VDC, and thus the proper signal connection must be made. Make sure you connect EITHER the +4-20mA or the +0-10VDC (or both) depending on the requirements of your control method.

3. If you have correctly checked the first two items, the next step is to ensure proper installation of your load cells, which will vary depending on the type of load cell you are utilizing.

If you are still experiencing issues, or need any other additional assistance, please contact a Montalvo Applications Specialist.

Read this entry on Montalvo.com

Coast Control At LabelExpo 2016
Featuring Live Montalvo Tension Control Products

LabelExpo 2016
Hall C
Booth 3622

Coast Controls, manufacturers of All-Air Web Guiding systems, will be featuring a live demonstration unit running clear plastic film through various web guiding systems including a cantilevered unwind, displacement and steering guides with center guiding, splice table, auto centering and finally a new cantilevered rewind system, featuring Montalvo Tension Control components throughout.

Coast will also be discussing their custom turnkey unwind and rewind systems featuring Montalvo tension controls! Let Coast design an Unwind or Rewind guiding system that meets the needs of your application!

Check out the latest in web guiding and tension control technology live at the Coast Controls Booth 3622 in Hall C at LabelExpo 2016, September 13-15.

See More

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In this issue:
Key Considerations: Load Cell Installation
Range Expansion Demonstration
Tension Control Packages: 2 Weeks or Less

Dead Shaft Idler Load Cell Installation Considerations

ES Dead Shaft/Idler Load Cells

When installing your ES Series Dead Shaft-Idler load cells there are a few key considerations to ensure proper installation. Follow the provided installation instructions with your components, but if you are experiencing some issues, check the following:

Idler Roll Support
The load cells should be supporting the roll as if the roll were attached directly to the machine frame. If the idler roll is not completely supported by the load cell you will run into issues. This is typically caused by either the idler roll dead-shaft being too short, or the shaft diameter is not the same size as the load cell coupling. If you have a shaft size diameter that is not the same size as the load cell coupling Montalvo does supply bushings to ensure the shaft properly fits into the load cell. Contact us for more information.

Heavy Idler Roll
When selecting the correct load rating for your load cells, the weight of the idler roll must be accounted for. The load on the load cells is determined by the web tension, the wrap angle (how much of the idler roll is contacted by the material as it passes over the roller), the direction of force due to web tension, and the weight of the idler roll. If you are utilizing a pair of 50 lb (22kg) rated load cells (meaning their maximum is 50 lbs each) and your idler roll weighs 50 lbs, you effectively only have half of the load cells capacity left to account for the three other factors contributing to the total load. When sizing a load cell it is always recommended that you discuss your process with a Montalvo Applications Specialists to ensure the load cells are properly sized based on all of your process variables.

Uniform Mounting
A critical step in installation is to ensure that both load cells are mounted the same way in respect to the direction of force. Montalvo ES load cells are labeled with a “force arrow” indicating how the load cell should be mounted. The arrow should be aimed in the direction of force due to web tension. If one load cell is aiming in one direction and the other load cells is aiming in another direction then you may receive signal errors, and the load cells could be operating at less than optimum efficiency.
Read this post at Montalvo.com

Range Expansion: It’s Like Getting a Brand New Machine
Check out the Video

In today’s environment, manufacturers are required to do more with less. Manufacturers cannot always afford new machines, and current machines may now need to perform functions they were not originally intended for. The automatic range expander gives you that ability.

Range expansion increases the capabilities of existing machines, allowing them to be more effective at:
running multiple types of materials with differing tension levels
gain greater control at lower torque ranges
run high mass rolls at lighter tensions (i.e. films & foils)
run low torque and tension applications that require high torque to stop (i.e. sheeters)
reduce friction pad wear

Check out the video here to see exactly how our Range Expander works and expands the capabilities of your machine.

Delivered in 2 Weeks or Less
Industry Leading Tension Control Component Packages

Get the process improvements you require through our industry leading tension control products faster than ever. We are proud to offer some of the shortest lead times in the industry on controllers, load cells, safety chucks, amplifiers and more.

Available products in 2 weeks or less include:

• S4 Tension Controllers
• U4 Open Loop Tension Controllers
• M3200 Amplifiers
• A4 Amplifiers
• M4 Meters
• ES Dead Shaft-Idler Load Cells
• CD Tension Brakes
• DPS 45 Dancer Position Sensors
• US4 (100mm to 1m) Ultrasonic Sensors
• MPC4 IP Converters and PDA Valves

Additional Montalvo products are still available within 3 or 4 weeks, including Z4 Controllers, V, HP and Standard Brakes, Guardian Safety Chucks (standard), U Series Load Cells and much more. Half the time of other manufacturers.

Quality, performance, and productivity delivered quickly to you!
See More

Here For You!
Need technical assistance, have a question about your application, adding components to a new machine, or want to explore an upgrade or retrofit, we are here to help you any way we can.

Contact a Montalvo Applications Specialist

In this issue:
Achieve More: Tension Control Upgrades
Troubleshooting: Setpoint and Air Pressure
Tension Control Packages: 2 Weeks or Less

Expanded Capabilities, Increased Productivity, Greater Consistency, Easier Operation – Achieve More with a Tension Control Upgrade

Montalvo delivers the key upgrades your machine requires to expand its capabilities and effectively compete with today’s newer machines. Whether upgrading components or building in new tension control systems, we give you a quick return on investment and help you Achieve More!

Experience
With soon to be 70 years of experience in the tension control industry, you know you are getting the best in knowledge and experience to make your application more productive.

Drop In Replacements
Whether you’re upgrading our components or other manufacturers, a majority of our upgrades easily integrate into your current application.

Cost Effective
We specialize in cost effective upgrades that deliver a quick return on investment and increase your productivity for years to come.

Support
We pride ourselves on our ongoing after sales service and support for all of our customers. We are here for you!

Increases Your Capabilities
A few key, simple changes will make your machine run as practically new, enhancing the capability, productivity, and profitability of your application.

Learn More and See Specific Upgrade Examples

What to do When Your Tension Reading is Not Steady

Depending on where your controller is in its service life, and if a controller has been moved from a different machine, or is simply running a different process, certain process parameters might have been changed that need to be changed within the controller.

1.  If you find your cannot get the controllers setpoint above a certain level, switch to the “supervisory messages” and check the value programmed into “meter scale”. Whatever this level is set to, will be the highest your setpoint will go to. Simply change it according to your needs.
2. If the air pressure to your brake is not going above a certain PSI and you suspect it should be, check the “Out Limit” and “Out Scale” values. Both of these should be set to the factory default of 75 PSI.

Especially in older controllers, if you feel something is out of sorts, check the “Factory Settings” for your controller, your technical manual, or contact a Montalvo Applications Specialist for assistance.

Read this blog on Montalvo.com

Delivered in 2 Weeks or Less
Industry Leading Tension Control Component Packages

Get the process improvements you require through our industry leading tension control products faster than ever. We are proud to offer some of the shortest lead times in the industry on controllers, load cells, safety chucks, amplifiers and more.

Available products in 2 weeks or less include:

• S4 Tension Controllers
• U4 Open Loop Tension Controllers
• M3200 Amplifiers
• A4 Amplifiers
• M4 Meters
• ES Dead Shaft-Idler Load Cells
• CD Tension Brakes
• DPS 45 Dancer Position Sensors
• US4 (100mm to 1m) Ultrasonic Sensors
• MPC4 IP Converters and PDA Valves

Additional Montalvo products are still available within 3 or 4 weeks, including Z4 Controllers, V, HP and Standard Brakes, Guardian Safety Chucks (standard), U Series Load Cells and much more. Half the time of other manufacturers.

Quality, performance, and productivity delivered quickly to you!

See More

Here For You!
Need technical assistance, have a question about your application, adding components to a new machine, or want to explore an upgrade or retrofit, we are here to help you any way we can.

Contact a Montalvo Applications Specialist

In this issue:
BWC Blog: What is Progressive Gain and Why
BWC Blog: When Tension Reading isn’t Steady
BLUE Lifetime Assurance

What is Progressive Gain? Why is it Important?

Most people that are tasked with the tuning of controllers are familiar with three terms; Progressive Gain, Integral Gain, and Derivative Gain, better known as PID. These adjustments are often referred to as “Controller Gain” as they determine the controller’s responsiveness to disturbances. However, in many cases, the dynamic behavior of the actual process may require further action. This would be to prevent the controller from becoming unstable at certain points in the process. This is commonly known as “process gain or progressive gain”.

In unwinding applications, where there are large build-downs, as roll diameter decreases, the system gain must decrease proportionally to ensure a smooth, consistent, quality process. Progressive gain must be implemented. Without this proportional decrease you run the risk of either lack of response at large diameters and/or instability at the core. Depending on the advancements and capabilities of your controller, traditionally, in order to proportionally decrease the gain, your tension controller will need to know what the diameter of the roll is, typically through the use of an ultrasonic sensor, laser sensor, or proximity sensors. If utilizing a PLC for control it can be very time consuming to create the gain calculation, and can mean additional I/O modules.

However, Montalvo tension controllers already include the Progressive Gain software, and I/O’s for any of the diameter sensing options to deliver the precise adjustments you require right out of the box. Taking this one step further, our latest controller technology has allowed us to utilize progressive gain without a diameter measurement. Simply utilizing tension and output can be precise enough for progressive gain.

Progressive Gain is a critical feature in maximizing your productivity and end product quality when dealing with large build-downs, and is just one of the many standard features we have incorporated into our tension controllers.
View this blog post on Montalvo.com

What to do When Your Tension Reading is Not Steady

When your tension reading is not steady, we often recommend switching the controller into manual mode to help diagnose the problem. If in manual mode and the tension reading is steady, contact a Montalvo Applications Specialist. It may just be simply that the controller is not tuned properly and there just needs to be a minor adjustment. If in manual mode and the tension is still not reading steady this indicates either a mechanical issue with the machine, or a problem with the load cells.

1. The tension is actually stable (no variations at all) but the load cells are indicating that there is a variation.

a. This would usually indicate that either the load cell is not mounted securely to the machine frame, that the clamps holding the shaft are not tight, that the bearing in the roller is bad, or that there is a faulty electrical connection in the cable. First check your load cell installation for any of these issues.

2. If it is evident that the web tension is indeed fluctuating, then the load cells are operating correctly. This can only mean there is some sort of a mechanical issue with the machine or even the material itself. These can be (some noted below):

a. Roll of material not perfectly concentric. This can usually be seen if you watch the roll very closely. Another way to tell is, with no air on the brake; rotate the roll manually stopping it frequently. If you stop the roll and it continues to rotate by itself, then it is not concentric. A perfectly concentric roll should be able to be stopped anywhere.

b. If the shaft holding the roll is held by safety chucks – If you once again rotate the roll and you feel it bump every ¼ or half a turn, this indicates that the chuck or the shaft end is worn. This is very common.

c. Make sure that the brake modules are centered between the brake discs. If one of them is dragging on the disc when no air pressure is applied, readjust it.

d. If the material is very stretchable, the variation can be caused by this. If there is a number of rollers that the material passes over, and if they are all not turning freely or if the material is slipping or not turning a roller, this could also be an issue.
If you have any questions or require further assistance contact a Montalvo Applications Specialist.

Read this blog on Montalvo.com

BLUE Lifetime Assurance
We Are Here for You!

Our commitment to provide you our very best in every way.

BACK to BETTER WEB CONTROL
Things happen. And when they do, our first priority is to get you back up and running as quickly as possible. We want your machine running.

LOCAL ACCESS
In person, phone, e-mail, or online. With four worldwide offices (USA, Germany, Denmark, China) and an authorized licensee & representative network throughout five continents, we give you the local dependability you rely on.

UNCOMPROMISING SERVICE & SUPPORT
Whether you have a single question, need a tension control consultation, or require technical support or service, we are committed to you for the entire life of your Montalvo products and beyond. We are here for you!

EXPERTISE
Since 1947, Montalvo has differentiated itself by offering more than just high quality and high performance tension control products. We are your resource for the tension control expertise required to expand the capabilities of your machinery and production line.
Learn more about Montalvo BLUE Lifetime Assurance

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Doug Brockelbank
Montalvo Applications Specialist

Read the full article

Montalvo pioneered dancer tension control when we introduced the only controller on the market to capitalize on the benefits of both load cells and dancers within one highquality tension controller.

Unwind Zone, Dancer and Load Cell Feedback

The Z4-UI represents the next advancement in dancer tension control technology. Designed for unwind tension zones utilizing dancer arm feedback for control and load cell feedback for tension indication giving you the best of both worlds and maximize your capability and productivity.

The Z4-UI features the only dancer controller with a 7″ HD interactive display screen, and 5 day trend storage. Additional features include:

• Compatible with Pneumatic and Electric Brakes
• Compatible with Drives
• Muli-Lingual HMI
• Upgradeable Communications
• User Defined Units and Scale
• Multiple Installation Options

The Z4-UI also offers a wide range of high performance functions while still being easy to set-up and operate:

• Soft-Start
• Anti-CoastSplice
• Web Break Detection
• Remote Setpoint
• Progressive Gain
• Programmable Diameter Alarm
• Range Expansion
• Remotely Turn Tension On/Off

Learn more about the Z4-UI

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ES Dead Shaft-Idler Load Cells (ES-I)

Higher Quality, Higher Performance – Faster Delivery.

Montalvo ES Series Dead Shaft-Idler Load Cells are built from 100% stainless steel with a semiconductor strain gauge for superior signal sensitivity and service life. Add in Mechanical Variance Compensation and 360° Overload Protection and it’s no wonder why more people prefer the Montalvo ES.

ES Dead Shaft/Idler Load Cells

Additional features include:

• Industry Leading Resolution
• Standard, Flange, and Split Pillow Block Mounting Options
• M12 Connector
• Multiple Sizes and Load Ratings

Standard styled ES-I Load Cells ship out in less than 1 week, delivering superior quality and performance fast!

Standard ES-I Load Cells have a 6 o’clock connector position and feature one of the following load ratings: Size 0-50lbs, Size 0-150lbs, Size 2-150lbs, Size 2-500lbs

Check out the ES-I Dead Shaft Idler Load Cells for more information.

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In this issue:
TSC Demo Video
Tension Control Q&A
End of the Year Planning

Torque Sensing Control System Demonstration Video

For the first time ever in an open loop control system, you get a precise, reliable tension reference that operators can use to ensure consistent, high quality production runs. The TSC™ is a total tension control solution that delivers performance, convenience, and productivity. Simple, compact and easy to install and operate, the TSC is the latest innovation in open loop tension control. Patent pending technology allows easy integration into existing machines as well as new machine builds.

Check out the video to see just how this latest technology works, the components involved, and the benefits it can provide your process.

• Easy Installation, Set Up & Operation
• Reduces Machine Build Cost
• Easily Upgrade Existing Machines
• Smooth, Precise, Repeatable Tension Control from Full Roll to Core
• Compact, Space Saving Tension Control Package
• Performance Driven, High Quality Components

Watch the Video

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Tension Control Q & A

How many brakes does my unwind need when utilizing core chucks?

Many machines that use core chucks (shaftless unwinds) utilize two brakes. This insures that equal torque will be applied to both ends of the rolls. By not using dual brakes, depending on the type of core chucks (pneumatic, mechanical, or just the cone shaped devices) you could run the risk of slipping on the core.

However, some OEM machines are actually designed to utilize only one brake with the core chucks. If your machine was originally designed in this capacity and you have the original core chucks, one brake should be sufficient.

As always, your best option is to have a detailed discussion with your Montalvo Applications Specialists to review all the variables of your application for the best recommendations.

Contact a Montalvo Applications Specialist

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Gear up for 2017

End of the Year Tension Control Upgrades to Start off 2017 Right

With fiscal planning underway for 2017, manufacturers look to maximize their 2016 budgets. An end of the year tension control upgrade is the perfect opportunity to add productivity and profitability to your machines.

Its the perfect time to start the budgetary quoting process to capitalize on any remaining 2016 budget at the end of the year while starting off 2017 right!

A tension control upgrade is an extremely cost effective method for adding increased capabilities and productivity to your machine. Whether it’s just a few key component upgrades or a larger tension control retrofit, Montalvo gives you the performance enhancements you require for years to come.

• Reduced scrap
• Increased line speed
• Higher quality end product
• Easier operation
• Reduced maintenance

These are just a few of the possible benefits you can achieve through a Montalvo tension control upgrade.

Talk to a Montalvo Applications Specialist today to receive a quote.

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In this issue:
Faster Deliveries
Narrow Web Upgrades
BWC Blog: When Tension is Not Known
All Air Web Guides

Tension Control Components Delivered in 2 Weeks or Less

Get the process improvements you require through our industry leading tension control products faster than ever. We are proud to offer some of the shortest lead times in the industry on controllers, load cells, safety chucks, amplifiers and more.

Available products in 2 weeks or less include:

• S4 Tension Controllers
• U4 Open Loop Tension Controllers
• M3200 Amplifiers
• A4 Amplifiers
• M4 Meters
• ES Dead Shaft-Idler Load Cells
• CD Tension Brakes
• DPS 45 Dancer Position Sensors
• US4 100mm to 1m Ultrasonic Sensors
• MPC4 IP Converters and PDA Valves

Additional Montalvo products are still available within 3 or 4 weeks, including Z4 Controllers, V, HP and Standard Brakes, Guardian Safety Chucks (standard), U Series Load Cells and much more. Half the time of other manufacturers.

Quality, performance, and productivity delivered quickly to you!

Narrow Web Tension Control Upgrades for Increased Productivity

Narrow web, laminating, and label manufacturing is constantly evolving. Whether it is changes in material weight, colors, two sided processing, RFID chips and more, narrow web manufacturers are constantly challenged with having to meet these changing demands with their existing equipment.

High quality tension control plays a vital role in expanding the capabilities of narrow web and label machines while at the same time adding increased productivity, reduced waste, and increased end product quality.

We have worked on a wide variety of narrow web and label applications (Mark Andy, Comco, Nilpeter, Prophiteer, Webtron, Rotopress, and many more), easily integrating high performance and high quality tension control components into new and existing machines.

See an example of one of our Narrow Web Press Upgrades or Contact a Montalvo Applications Specialist to discuss your application.

Paper/Paperboard: What to do When a Tension Value is Not Known

Sometimes when first starting out with new paper or paperboard material you might not know what the best tension setpoint to run is. In this scenario we can utilize TAPPI guidelines as a quality starting point. TAPPI is a 100 year old organization that was formed to serve the pulp, paper, and packaging industries and has created reference numbers based on Basis Weight/Thickness to determine tension.

Based on our 70 year experience we have slightly adjusted their numbers to create a Common Unwind Tension Values for Converting Applications chart that will serve as a good starting point for your initial tension.

You can download our Tension Values Chart on the Tools page of our website.

If you are still unsure, contact a Montalvo Applications Specialists who can work you to find the precise tension level required to maximize the quality of your end product.

All Air Web Guides

All-Air web guiding systems operating exclusively on low pressure air without the use of electricity, electronics, or hydraulics combined with an unparalleled 10-year warranty so you can achieve more with less!

Montalvo and Coast Controls have partnered to offer complete tension control and web guiding equipment packages. Coast Controls All Air Web Guiding Systems are simple to install, simple to operate, are highly cost effective and have a longer service life.

In select regions Coast Controls Web Guides are available for direct sales, service, and support through Montalvo and Montalvo Representatives.

Learn More

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