May 2016 Better Web Control Newsletter

In this issue:
BWC Blog: Using the Z4 Data Logger
Dancer Position Sensor
Coast Shifting Roll Stands

Troubleshooting Your Application with the Z4 Data Logger 

Montalvo’s new line of Z4 Tension Controllers, designed for Unwind, Intermediate/Nip, and Rewind applications utilizing load cells, a dancer, or both has a built in data logger for monitoring, analyzing, and troubleshooting application run data.BWC-web

Recently a customer with a Dancer based application was running into difficulty, and presumed the problem to be the controller. In order to troubleshoot the situation Montalvo’s Applications Specialists assisted the customer with tuning, wiring verification, input verification, and switching from diameter based control to output based control on the tension controller. Despite the adjustments, the change only made minor improvements in the process. With only minor improvements in the process we asked for a copy of the file from the controller’s data logger. The customer plugged in a USB and downloaded the data logging file.

The Z4’s data logger is an every 5 second sample with a 5 day “sliding window” that records the following:
Controller run mode (Auto, Hold, Manual, etc.)
Dancer Position
Output to the brake
Roll Diameter
Time Hack
From this we can see what happens when the controller senses that the machine has started and the controller is in AUTO mode.

In this particular situation the brake output was climbing, but the dancer position was not immediately changing. Once the brake output reached a value that would overcome stiction, the dancer began to respond. When this happens, chances are the dancer will over shoot, and the dancer will be very unstable. This told us that the brake needed to overcome the force required to make the dancer cylinder move closer to the zero position from maximum negative. This information led us and the customer to look more closely at the design of the dancer system vs. the controller as the errors were more mechanical or with the air cylinder.

Montalvo’s Z4 Data Logger can give you valuable insight into how your machine is running, whether it is to troubleshoot an issue, determine where improvements can be made, or just to see how long a machine is or isn’t running.

Learn more about the Z4 Series of Tension Controllers.

DPS Dancer Position Sensor – No Wear Parts. Zero Maintenance

Say goodbye to complicated, time consuming dancer/rider arm potentiometers with the DPS. Utilizing the latest in sensor technology the DPS is a micro-electric, no wear part system that responds quickly and accurately to any changes in the dancer’s position.

DPS Installed on Dancer

DPS Installed on Dancer


Easy Installation
Compact housing & two mounting holes allows for versatile and easy mounting.

Extended Service Life
Non-contact housing, no wear parts, and IP-68 Rated (water & dust proof)

High Accuracy
Immediate response time with extreme accuracy of +/- 0.5° (99.98%)

Flexible Access Mounting
Dual Axis Measuring ability for X or Y mounting.

High Repeatability
0.002 of measuring range/scale, and 0.001 after a half hour of operation.

Rapid Response Time
0.05 to 0.1 second response for full swing

Short Circuit Proof

Learn more about the DPS Dancer Position Sensor

Coast Controls Shifting Roll Stands Featuring Montalvo Tension Controls
Coast Controls, Inc, exclusive manufacturers of all air web guide systems, is announcing the launch of its latest Unwind Shifting Roll Stand (SRS), the SRS4-R15-U. The SRS4-R15-U is designed as a simply supported Shifting Roll Stand on quad raceway assemblies with a sturdy A-frame construction to accurately unwind various mid to large range web widths with rolls weighing up to 2,500 lbs. (1133.9).  With the incorporation of a complete Montalvo Unwind Tension Control System, the SRS4-R15-U provides precise, automatic, total control of the web’s tension and alignment as it enters the converting/printing process. Coast Controls manufacturers a wide range of Shifting Roll Stands (SRS), customizable to the precise needs of any manufacturer.

Additional Features and Functions Include:

  • Heavy-Duty 2×2 welded steel tube construction.
  • Primed and Painted to the customer’s specification.
  • Auto-Centering for new roll loading.
  • Precision Aluminum idlers engineered for each application.
  • Completely assembled, calibrated, tested and ready for production.
  • Engineered to quickly adapt to each customer’s application reducing lead time.
Montalvo system components include:
  • S4 Tension Controller
  • V307 Series Unwind Tension Brakes with LoPro Cover
  • Guardian Safety Chucks
  • ES Idler Load Cells
  • I/P Converter with Gauge Kit and Filtration system