First make sure you are using the latest firmware:

http://download.yamaha.com/search/product/?site=usa.yamaha.com&language=en&category_id1=16244&category_id2=16381&category_id3=&product_id=2166246

The current version is 1.51

When updated you will get the option for [UTILITY] “Settings” Advanced” and choose “SINGLE”
Then the Montage will act like a normal controller.

The firmware version that was on the units was 1.20.4 and there was a SINGLE setting in [UTILITY] Advanced that we had set the units to when we had the issue. Have updated the units to the current 1.51 firmware but since I don't currently have access to MainStage 3, unfortunately I can't test to see if this rectifies the problem. Even though 1.20.4 had the SINGLE setting, do you know if the latest firmware update resolves the program change when playing on the keyboard issue?

Maybe Mainstage 3 isn't setup properly. Because next patch/previous patch you can assign to a physical key on the keyboard - maybe that was setup in their Mainstage setup for a different keyboard and now using Montage they are running into that key as they play.

I take it the client brought Mainstage with them - along with all the settings. Were they using the same size keyboard with mainstage? Also a Montage? etc. etc. I think if you inherit someone else's software you also possibly inherit their incorrect settings. So possibly the only way to rectify this as a possibility is to manage the software + hardware combination yourself and either purchase Mainstage and set it up for use with your Montage(s) or next time go through with a fine-tooth comb the client's software settings to ensure everything is OK with your hardware.

As a worst-case their Mainstage setup was previously setup for a 25-key synth without buttons to change "patches" - so they setup two of the lower keys on the 25-key keyboard to switch to the previous or next patch. And such a small keyboard would place the patch change keys right in the playing field of an 88-key Montage.

You have to use the Master Zones probably.

Their setup with MainStage 3 worked with stock Yamaha Motifs. My main question is then, how is the Montage basic MIDI controller setup different from the Motif?

There's a hidden (to me sometimes anyway!) setting in MainStage that reads, "Route unassigned Midi Messages to Channel Strips."
It sounds to me like that could be an issue with last week's snafu.
Just a thought.

I do not how different the MIDI routing is in MainStage from logic pro x but I was able to control the DAWS faders and rotary knobs in Logic pro x with Montage Faders when I enable the Master zones and set each performance part to their own MIDI channel 1-16 per part.

This was also the case with Studio one 3 pro.

Ted wrote:

Their setup with MainStage 3 worked with stock Yamaha Motifs. My main question is then, how is the Montage basic MIDI controller setup different from the Motif?

It's going to be difficult to completely answer this kind of question given experienced keyboard techs had an issue getting Montage to cooperate - all that can be done is some nudging to try to help the OP arrive at an answer.

The overall issue here was more with the compressed amount of time allowed for working this out. MIDI setup, routing, programming is something that takes a while given the flexibility of MIDI and variety of implementation nuances between keyboards and host controllers including software. Given that the problematic setup has left the building - it's not going to go very far until the OP captures the same setup either through purchasing the missing pieces or having another client come in with the same software demand (and supplies this).

I just manage to assign and map the Rotary knobs and Faders within Mainstage 3 layout page. Montage You have to zone and assign the Performance parts to the zones/MIDI Channels make sure MIDI send is on within the edit-part-common, also within the edit-part-common/MIDI Pgm Num you can change the Patch list within MainStage 3 Perform mode

Quick setup = MIDI rec DAW

Once you have Performance parts setup via zone for each part your faders and rotary knobs will control that specific Performance part that is selected on the Montage.