COMPTROL 36 User manual

MODEL 36, TYPE B & C
SINGLE RANGE TENSIONCELLS
INSTRUCTION MANUAL A-279
1
Copyright 2023 - Revised Comptrol All Rights Reserved
PART I - DESCRIPTION
I-A GENERAL INFORMATION
Comptrol Series 36 Type “B”and “C”Tensioncells are
force transducers especially designed to measure and
control web tension on continuous strip processing lines.
They are normally installed in matched pairs at each end
of a measuring roll. (See Figure 1 & 2)
A Tensioncell consists of a unique combination of two
integral systems (one mechanical, the other electrical)
for converting the mechanical force of strip tension into
an electrical signal which is directly proportional to the
strip tension.
Type “B”
Type "B" Tensioncells are designed for use in NON-
ROTATING shaft installations. A self-aligning shaft clamp
assures proper alignment of the measuring roll when the
Tensioncells are bolted to the frame of the machine. Type
"B"cells aresuppliedin matched pairs,onetobemounted at
each end of the measuring roll. Note that the cell marked
"W2" is a mirror image of "W1". "W2" allows for thermal
expansionofthe shaft. (See Figure1)
Type “C”
Type "C" Tensioncells are intended for ROTATING shaft
installations. They are supplied with self-aligning ball
bearings to assure positive alignment of the measuring
roll. Type "C" Tensioncells are supplied in matched
pairs, one to be mounted at each end of the tension
measuring roll. Note that the cell marked 'W2" is a mirror
image of "W1". The "W2" cell allows for thermal
expansion of the rotating shaft. (See Figure 2)
I-B THE MECHANICAL SYSTEM
The mechanical system consists of a Patented "C-
Flexure Pivot Assembly" which incorporates a mounting
Base Block, frictionless elastic pivot (or hinge), and Load
Plate. (See Figure 3.) When a mechanical force is
applied to the Load Plate the pivot permits its deflection
toward or away from the Base Block. ·
(Continued on next page)
Table of Contents
General Information……………………….... 1
Installation and Operation-……………........… 4
Adjustments…………………………........ 6
Troubleshooting…………………......…….7
Dimension Drawing................................... 8
How To Order.................................................... 10
Application Review.................................11

MODEL 36, TYPE B & C
SINGLE RANGE TENSIONCELLS
INSTRUCTION MANUAL A-279
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Copyright 2023 - Revised Comptrol All Rights Reserved
For our discussion here, deflection of the Load Plate
toward the Base Block is defined as the "Compression
Mode", while the opposite is defined as the "Tension Mode".
Tensioncells are designed to operate equally well ineither
mode.
The Base Block contains an integral Mechanical Stop to limit
the amount of deflection in either direction, and a Viscous
Damper to allow control of the Tensioncell response to rapid
changesinapparent tension loads. (SeePage1, Figure 3)
I-C THE ELECTRICAL SYSTEM
The electrical system consists of a Linear Variable Differential
Transformer (LVDT) which converts the mechanical deflection
of the Load Plate into a useful electrical output signal. (See
Figure 4) The movable core of the LVDT is mechanically
coupled to the Load Plate by means of the Core Adjust
Assembly. (See Figure 4.) This adjustment is factory set and is
not accessible.
I-D TYPE “K” DC LVDT
As illustrated in Figure 4, a DC LVDT consists of the
following components:
•An oscillator network, which converts the DC
input voltage into a high frequency alternating
current for exciting the Primary Coil (P1).
•A Primary Coil (P1).
•A movable, permeable metallic core.
•Two Secondary Coils (S1and S2).
•A demodulator and summing network to rectify
and integrate the currents from the Secondary
coils.
With Comptrol LVDTs, the input and output circuits are
electrically isolated from each other and from the
mechanical structure of the Tensioncells. Thus, they
may be used in “floating ground”or “ground return”
systems. This eliminates the need for extra circuit
boards which are required for most strain gage loadcells.
Tensioncells are factory adjusted to provide an offset
voltage with no load applied (no deflection). Using an
input of 24 volts DC, the LVDT is set to provide an
output of 3.5 volts into a resistive load of not less than
100,000 ohms. The voltage resulting from the maximum
rated deflection then adds to or subtracts from the 3.5
volt offset. This results in an output voltage of 3.5 to 6.5
volts in the Compression Mode and 3.5 to 0.5 volts in the
Tension Mode. (See Figure 5)
While acceptable performance may be obtained over an
input voltage range of 6.0 to 30.0 volts DC, the output
voltage will vary in direct proportion to the input voltage.
Because of this, the use of a “well regulated” constant
voltage power supply is essential for accurate and
repeatable tension measurement.
In standard applications, where two Tensioncells are
used, the inputs may be connected in parallel allowing
the Tensioncells to be excited from the same power
supply. The LVDT outputs are then summed to obtain a
signal representing the strip tension and tare loads
distributed across the roll
Comptrol Tensioncell Indicators supply 24volt DC and
integrate the output signals in a summing amplifier. This
permits incorporation of additional circuitry for offset and
tare adjustments, as well as adjustments for balance and
gain.

MODEL 36, TYPE B & C
SINGLE RANGE TENSIONCELLS
INSTRUCTION MANUAL A-279
3
Copyright 2023 - Revised Comptrol All Rights Reserved
I-E DESCRIPTION OF OPERATION
The total resultant load per cell (JT) is calculated by
resolving web force vectors acting upon the
Tensioncells, with respect to the Loading Line (OX). (JT)
is the resultant of both TENSION and TARE loads, PER
CELL! (See Figure 6)
The intrinsic design of Comptrol Tensioncells allows the
location of the Resultant Load of Web Tension (H) on
any angle with respect to the Load Line (OX). Note,
however, that the Total Force vector (JT) must always
be calculated on the line (OX).
Any force vector falling on the line (OR) (through the
pivot point of the C-Flexure) will produce no deflection,
and thus no change in electrical output.
Rotating the Tensioncell on its mounting bolt changes
the force vectors on the cell. This feature makes it
possible to minimize the tare component and maximize
the load signal output.
The resultant tare is minimized by mounting the
Tensioncell so that (N) is 149° (See Figure 7A and 7B)
or so that (N) is 329° (See Figure 8A and 8B).

MODEL 36, TYPE B & C
SINGLE RANGE TENSIONCELLS
INSTRUCTION MANUAL A-279
4
Copyright 2023 - Revised Comptrol All Rights Reserved
PART II - INSTALLATION AND OPERATION
II-A INSPECTION UPON DELIVERY
Comptrol Tensioncells are carefully packaged in sturdy
reinforced cartons or wooden boxes and are securely
blocked or bolted in place.
1. Upon receipt, examine the exterior of the
container for obvious damage or tampering.
2. Check the contents against the packing list.
3. Promptly report any damage or shortage to both
the carrier and Comptrol.
II-B HANDLING
Tensioncells can be handled manually.
II-C LONG TERM STORAGE
While Comptrol loadcells are plated, exposure to
weather, dirt, or moisture should be avoided when they
are stored.
II-D MECHANICAL INSTALLATION
NOTE: Refer to the Dimension Drawing Page 9 of this
manual for detailed identification of all parts.
Tensioncells are designated as ‘W1”and “W2”, one
being the mirror image of the other to provide for
mounting between two fixed walls. (See Figure 9.)
Comptrol Wall Mounted Tensioncells are mounted to a
base assembly by a 5/8-11 UNC bolt which is in line with
the centerline of the measuring roll shaft. This allows the
Tensioncell to be rotated around the centers of the
measuring roll and mounting bolt to achieve the proper
mounting angle. (Description of Operation on Page 3)
A locating tab prevents the Tensioncell from rotating and
secures it in a permanent location. It also provides a
means of repeating rotatory position when the
Tensioncell needs replacement. (See Figure 9)
To Install Tensioncells:
1. Check that mounting surfaces to which the
Tensioncells are to be mounted are flat to within
.002-inch T.I.R.
2. Refer to Figure 10 for the size, location and
orientation of the Tensioncell Base Assembly
mounting holes to be drilled and tapped in the
stands or base structures.
3. Drill and tap the holes in the stand or base
mounting structure to accept the Tensioncell Base
Assembly.
4. Mount the Tensioncell Base Assembly to the stand
or base mounting structure.
5. Fasten the Tensioncell to the Base Assembly with a
5/8- 11 x1-1/4 Hex Head Cap Screw.
6. Rotate the Tensioncell to the proper mounting
angle and tighten the mounting bolt. (Refer to N on
on thecalibration sheet for the proper mounting
angle)

MODEL 36, TYPE B & C
SINGLE RANGE TENSIONCELLS
INSTRUCTION MANUAL A-279
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Copyright 2023 - Revised Comptrol All Rights Reserved
7. Drill a #6 (.204) hole concentric withthe 1/4" hole in the
locating tab.
8. Remove the Tensioncell and tap the hole for a 1/4 -20
thread.
9. Repeat steps 1 through 8 for the Tensioncell to be mounted
at the other end ofthe measuring roll.
10. Assemble the Tensioncell onto the end of the measuring
roll shaft.
11. Position the rollwith the Tensioncells on the machine and
fasten with the mounting bolt.
12. Rotate the Tensioncell to the proper mounting angle and
tighten the mounting bolts.
13. Lock the locating pad foreach Tensioncell against the
machine frame using the 1/4-20 X 1/2” socket head cap
screw.
14. Tighten the shaft in the mounting block on the “W1”unit.
(The shaft end at “W2”is left free to allow it to move as the
shaft expands with the temperature change).
II-E MECHANICAL ALIGNMENT
Align the sectional measuring roll to avoid any
mechanical binding or friction. The measuring roll must
be level and perpendicular to the path of the strip
material for accurate measurement.
The Mechanical Stops are fixed for the required travel of
the Load Table.
II-F ELECTRICAL INSTALLATION
(Read the entire electrical wiring procedure before
proceeding.)
1. Turn off all electrical power to the loadcell.
2. Usetwistedtwo conductor signal cable, Belden 9402
or equivalent,in conduit fromtheLVDTstothecontrol
panel.
3. Observing correct polarity, connect the positive (+)
input lead to Pin A and the negative (-) input lead to
Pin B. (See Figure 4)
(Continued on page 6)

MODEL 36, TYPE B & C
SINGLE RANGE TENSIONCELLS
INSTRUCTION MANUAL A-279
6
Copyright 2023 - Revised Comptrol All Rights Reserved
4. Connect the positive (+) output lead to Pin D and the
negative (-) output lead to Pin C. (See Figure 4)
5. Repeat Steps 1 through 4 of the electrical wiring
procedure for the Tensioncells mounted on the other
end of the measuring roll.
II-G ELECTRICAL ZERO ADJUSTMENT
(Read the complete Electrical Zero Adjustment
procedure before proceeding with the adjustment.)
1. Disengage strip from the measuring roll so that no
tension force is applied to the loadcell.
2. Connect a voltmeter to Pins C and D (See Figure
4)
3. Apply 24-volt DC electrical power to the loadcell
observing the correct polarity. [Plus (+) to Pin D
and minus (-) to Pin C]. Do not exceed the
maximum rated input voltage.
NOTE: Allow 20 minutes for the loadcell to warmup
before taking first readings to insure accurate readings.
4. Measure the output voltage of the LVDT between
the Green and Blue leads for each Tensioncell with
a voltmeter with a sensitivity of at least 100,000
ohms per volt. The output voltage should be
between 0.5 and 6.5 volts.
5. Since Comptrol Tensioncells cannot be
mechanically zeroed, refer to the Control Manual
for zeroing out the tare weight voltage.
II-H FULL LOAD ADJUSTMENT
After the loadcell has been zeroed, a pull test can be
made to check the output voltage of the loadcell at full
load. (See calibration sheet for voltage output)
1. Run a non-stretchable rope over the center of the
tension roll simulating the web path. (NOTE: the rolls
should be free to turn)
2. With one end of the rope secured, hang a known
weight, equally over the roll so that the total tension is
equal to the maximum strip tension specified on the
calibration sheet, at the other end. (See Figure 6)

MODEL 36, TYPE B & C
SINGLE RANGE TENSIONCELLS
INSTRUCTION MANUAL A-279
7
Copyright 2023 - Revised Comptrol All Rights Reserved
3. With a voltmeter connected to Pins C and D of the
connector, an output voltage will be observed.
4. Repeat Step 3 for the Tensioncell mounted on the
opposite end of the measuring roll.
Comptrol loadcells instrumentation provides the required
signal conditioning and a reliable high level output signal
for use as feedback control of a tension drive system.
The feedback signal is directly proportional to the strip
tension applied. If a Comptrol control is used, refer to the
control manual for further calibration.
Although the electrical output of Comptrol Tensioncells
are sufficient to drive most electrical indicators,
substantial signal conditioning is normally required for
effective tension instrumentation system control. Refer to
the documentation available from the instrumentation
supplier for more information.
PART Ill –TROUBLE SHOOTING
When properly installed in accordance with the original
design specifications, Comptrol Tensioncells should
require little or no regular maintenance or service.
Certain conditions, however, can impair their inherently
accurate and reliable performance. Therefore, if trouble
should arise, the following conditions should be checked.
III-A MECHANICAL
1. Has the tension measuring system been changed?
a. An increase or decrease in web tension. (Refer to A
on the calibration sheet for specified web tension)
b. An increase or decrease in the wrap angle. (Refer to
B on the calibration sheet for the specified wrap angle)
If the above parameters have been changed enough to
prevent the unit from operating within the limits of the
fixed Mechanical Stops, replacement of the Flexure will
be required. For this modification, the Tensioncell should
be returned to the factory with complete specifications.
2. Are the loadcells mounted securely?
3. Is tension measuring roll in proper alignment and does
it turn freely?
4. Are bearings and seals free of all binding and
stickiness? Are they worn?
III-B ELECTRICAL
1. Are LVDTs receiving correct input voltage?
Check line voltage, fuses or circuit breakers, and power
switches. Check power supply output and voltage to
LVDTs.
2. Are all connections secure?
Check for continuity. Retighten all connections. Recheck
operation.
3. Are LVDTs open or shorted.
To check, turn off power and disconnect the input and
output leads. Check coil continuity and resistance.
(Refer to Figure 4)
a. Pin A to Pin B (Primary Coil) should be in excess of 2
megohms.
b. Pin A or Pin B to LVDT shell should be in excess of 5
megohms.
c. Pin C to Pin D (Secondary Coil) should be
approximately 20,000 ohms.
d. Pin C or Pin D to LVDT shell should be in excess of 5
megohms.
If LVDT circuits are open or shorted, replace LVDT.
Contact Comptrol with Tensioncell model number and
serial number.

MODEL 36, TYPE B & C
SINGLE RANGE TENSIONCELLS
INSTRUCTION MANUAL A-279
8
Copyright 2023 - Revised Comptrol All Rights Reserved

MODEL 36, TYPE B & C
SINGLE RANGE TENSIONCELLS
INSTRUCTION MANUAL A-279
9
Copyright 2023 - Revised Comptrol All Rights Reserved

MODEL 36, TYPE B & C
SINGLE RANGE TENSIONCELLS
INSTRUCTION MANUAL A-279
10
Copyright 2023 - Revised Comptrol All Rights Reserved

MODEL 36, TYPE B & C
SINGLE RANGE TENSIONCELLS
INSTRUCTION MANUAL A-279
11
Copyright 2023 - Revised Comptrol All Rights Reserved

MODEL 36, TYPE B & C
SINGLE RANGE TENSIONCELLS
INSTRUCTION MANUAL A-279
12
Copyright 2023 - Revised Comptrol All Rights Reserved
37400 Lakeland Blvd.
Eastlake, OH 44095
Phone: [phone]
Email: [e-mail]
www.comptrolinc.com
The information contained in this document is subject to change without notice. Comptrol has made effort to ensure
the accuracy and completeness of the descriptions and procedures discussed in this document. Failure to comply with
these procedures may result in personal injury, or damage to the Comptrol product or the equipment used in
conjunction with it.
Comptrol assumes no liability for incidental or consequential personal or equipment damages arising from the use of
this document, the software and hardware described, or failure to comply with the procedures contained in this
document.
Note that protective covers or guarding may not be shown in some illustrations to provide a clearer view of specific
components or assemblies. All protective covers and guarding must be installed before operating the unit.
Reproduction, copying, or the disclosure to any third party for any unauthorized purpose of the contents or software
contained or described in this document is prohibited with written authorization form Comptrol. Violators will be
prosecuted.