COMPTROL CTI-1200-1 Use and care manual

MODEL CTI-1200-1
TENSION INDICATOR
INSTRUCTION MANUAL A-342
1
Copyright 2023 - Revised, Comptrol All Rights Reserved
MODEL CTl-1200-1 TENSION INDICATOR
INSTALLATION AND CALIBRATION MANUAL
A-342
37400 Lakeland Blvd.
Eastlake, OH 44095
Phone: [phone]
Fax: [phone]
Email: [e-mail]
www.comptrolinc.com

MODEL CTI-1200-1
TENSION INDICATOR
INSTRUCTION MANUAL A-342
2
Copyright 2023 - Revised, Comptrol All Rights Reserved
TABLE OF CONTENTS
PART I
General Information............................................................................................................................1
PART II
Inspection Upon Delivery...................................................................................................................1
PART Ill
Installation...........................................................................................................................................1
Power Connection ..............................................................................................................................1
Loadcell Connection...........................................................................................................................2
Output Connection..............................................................................................................................2
Display Decimal Point.........................................................................................................................2
PART IV
Calibration...........................................................................................................................................3
Notes on Calibration...........................................................................................................................3
Initial Calibration.................................................................................................................................3
Periodic Calibration ............................................................................................................................4
PARTV
Troubleshooting ..................................................................................................................................4
Power Switch Does Not Illuminate with Power Applied...................................................................4
Power Switch Goes Dark After A Few Minutes................................................................................5
Voltage Swings the Wrong Way Under Load.....................................................................................5
No Output from One Cell...................................................................................................................5
Incorrect Voltage at TP1 or TP2........................................................................................................5
Incorrect Voltage/Current at Output..................................................................................................5
Connection Diagram....................................................................................................................................6
Block Diagram..............................................................................................................................................7
Dimension Drawing...................................................................................................................................... 8
Specifications ............................................................................................................................................... 8
Declaration of Conformity............................................................................................................................ 9
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 from Comptrol. Violators will be
prosecuted.

MODEL CTI-1200-1
TENSION INDICATOR
INSTRUCTION MANUAL A-342
3
Copyright 2023 - Revised, Comptrol All Rights Reserved
PART I -GENERAL INFORMATION
The CTl-1200 Tension Indicator is designed for applications utilizing one or two Comptrol loadcells to monitor
web tension on continuous processing lines. It interfaces with Comptrol Monocells, Tensioncells, and
Superloadcells. It provides DC power to the cells, as well as signal conditioning. An analog meter version
is available as the CTl-1000. Both carry the CE label.
The cover of this manual shows the front panel of the CTl-1200. Unless otherwise specified at the time of
order, the meter will be set to indicate 100.0 percent tension at full scale. However, the decimal can be set
for 1.99, 19.99, 199.9, or 1999. (See Display Decimal Point on Page 2 and 3) The display full scale is also
adjustable from 200-1999.
The CTl-1200 has an isolated output which signals composite tension. It is configurable for 0-10 volts or 4-
20 mA with staple jumpers. Loop power is provided in the 4-20mA mode.
PART II - INSPECTION UPON DELIVERY
Upon receipt:
1. 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 to Comptrol.
PART Ill - INSTALLATION
The CTl-1200 is housed in a stainless-steel enclosure with mounting flanges. Refer to the back cover for
dimensions. There are four pre-punched holes for conduit. Two-hole seals are provided to cover unused
holes. Loadcell and output cables may share a conduit, but the power wiring must be separate fromboth. For
best interference rejection, mount the box to a grounded metal structure, or ground it with braid.
The enclosure may be mounted in any orientation. No ventilation is required, provided that the ambient
temperature limitation is observed.
NOTE: A static strap is provided for use while installing or making internal adjustments to the CTl-1200.
One end of the strap is clipped to the enclosure and the other is attached to the wrist.
POWER CONNECTION
The CTl-1200 accepts single phase AC power at 50 or 60 Hertz. Voltage may be 110-125 or 220-240 with
one side neutral. If both lines are hot with respect to ground, external fusing must be provided in both
lines. Power and safety ground should be connected to J1 as labeled on the board. A ferrite choke
(provided) should be clipped over all three wires within one inch of their entrance to the enclosure.
Configure the CTl-1200 for the power provided by setting SW2 to the proper voltage, and by installing the
correct fuse in holder F1. It uses 5mm slow-blow fuses rated at 250VAC. A 0.2A fuse with UL/CSA
approval is shipped inthe holder for 115V power. A 0.1A fuse with SEMKO approval is provided for 230V
power.
Switch SW1, located at the top of the board, interrupts power to the board when changing the fuse. During
operation, it must be in the I position.
NOTE: The input power selector switch SW2 and fuse must correspond to the voltage of the input power
source.

MODEL CTI-1200-1
TENSION INDICATOR
INSTRUCTION MANUAL A-342
4
Copyright 2023 - Revised, Comptrol All Rights Reserved
LOADCELL CONNECTION
A Comptrol loadcell is equipped with either a 4-pin type MS connector, a terminal strip, or a pigtail.
The following table shows typical wiring to each type. Cell #1 connects to J4, and Cell #2 connects to
J5.
J4/J5
CABLE
CONN. TERM. PIGTAIL
Connections to the loadcell depend on the geometry of the application. If the Resultant Load Force
squeezes the load plate toward the base plate, the loadcell is operating in the compression mode. If
the Resultant Load Force pulls the load plate away from the base plate, the unit is operating in the
tension mode.
If a Tensioncell is operating in compression, or a Superloadcell or Monocell is operating in tension,
the connections to “In H”and “In L”in the above table must be-reversed. The J Value on the Calibration
Data Sheet provided with the loadcells will specify tension or compression.
Optimum cable for the loadcells contains two shielded twisted pairs, such as Belden 8723 or
equivalent. Two single-pair cables are also acceptable. For best interference rejection, strip the cable
shield back to within a few inches of where the cable enters the box. Connect the drain wire from the
cable shield to the stud right next to the hole where it enters the box, not to the SHLD terminal on J4
or J5. The wire should be just long enough to reach from the hole to the stud to make the connection.
Leave the loadcell end of the cable shield unconnected. Tape it.
If you are using a single loadcell, connect it to J4. Install a jumper between In H on J4 and J5. Install
another jumper between “In L”on J4 and J5.
OUTPUT CONNECTION
J6 provides the connection for the isolated output signal. This signal may be either 0-10V DC or 4-
20mA DC depending on the setting of the V-I jumpers.
0-10V Minimum load impedance is 5Kohm. Output impedance is 500 ohms.
4-20mA Maximum load impedance is 1Kohm. The 80-166 provides loop power.
+24
RET
1st pair
1st pair
A
B
1
2
Red
Black
In H
2nd pair
C
3
Green
In L
2
nd
pair
D
4
White

MODEL CTI-1200-1
TENSION INDICATOR
INSTRUCTION MANUAL A-342
5
Copyright 2023 - Revised, Comptrol All Rights Reserved
In either case, the output signal is available on J6 between terminals 'Out+' and 'Out-". A terminal marked 'Shld'
is also provided for a shield connection for this cable.
Cable containing a shielded twisted pair will minimize noise pickup. For best interference rejection, strip the
cable shield back to within a few inches of where the cable enters the enclosures. Connect the drain wire from
the cable shield to the stud right next to the hole where it enters the box, not to the J6 “Shld”terminal. Do not
connect the other end of the shield. Tape it.
If the isolated output is being used, the downstream equipment should be connected while performing the initial
calibration procedure.
DISPLAY DECIMAL POINT
Comptrol sets the digital panel meter decimal point per customer order when it ships. Changing it requires a pencil
soldering iron with grounded tip, rosin-core solder, and solder wick. Switch off the main disconnect SW1 while working on
the circuitry
On the back of the digital panel meter is a printed circuit board, with several split pads. The three pads labeled (SG1,
SG2, and SG3) on the bottom right corner are used to set the decimal point placement as follows:
SG1 = 1.999 SG2 = 19.99 SG3 = 199.9
If all of the gaps are open, there will be no decimal point display (1999). To enable a specific decimal point, it is
necessary to close the gap in the respective pad with solder. When re-assigning decimal places, remember to open
previously closed solder gap using solder wick to remove the solder.
NOTE: Turn off power to the board and meter at SW1, before working on the circuitry.
PART IV- CALIBRATION
NOTES ON CALIBRATION
To calibrate the CTl-1200 a calibrated load must be applied on the measuring roll. In the case of tension
measurement, the easiest and most accurate way is referred to as a "pull test". One or more cables ropes, or straps
are threaded through the web path, and weights are hung from one end to produce the required load. Make sure that
THEY ARE CAPABLE OF SAFELY SUPPORTING THE LOAD.
The cable should follow the web path at least over the preceding roll, over the measuring roll, and over the
succeeding roll. It doesn't matter which end gets tied off and which gets the weights, except that there should be
no driven rolls between the measuring roll and the weights.
When using a single cable, position it at the center of the web, and apply a weight equal to the maximum web
tension. Note that this applies a point load to the weakest part of the roll. If the full-scale load has the potential to
deform the roll, use multiple cables & weights distributed symmetrically about the center of the measuring roll.
When using multiple cables, it is impossible to apply the weights to all cables simultaneously, so they will need to slip
to equalize tension. Place something soft between the cables and the rolls. This also protects the surface of the
roll.
INITIAL CALIBRATION
A static strap is provided for use while making internal adjustments to the CTl-1200. One end of the strap is clipped to the
enclosure and the other is attached to the wrist.

MODEL CTI-1200-1
TENSION INDICATOR
INSTRUCTION MANUAL A-342
6
Copyright 2023 - Revised, Comptrol All Rights Reserved
The following procedures assume the loadcells have been properly installed. Refer to the appropriate Loadcell
documentation for detailed information for installing the loadcell before proceeding.
NOTE: Maximum accuracy is obtained when the pull test simulates full scale tension. If this is not practical, a
portion of full scale may be used. When the calibration procedure calls for setting a meter or voltage
to full scale, use the same proportion.
If the isolated output is being used, the downstream equipment should be connected while performing the initial calibration
procedure.
Apply power and turn on the power switch. If the switch does not illuminate, skip to the troubleshooting section. For
maximum accuracy, the loadcells should be allowed to stabilize for twenty minutes after any power interruption before
calibrating.
Remove all load except tare weight from the measuring roll.
NOTE: Clip one end of the static strap to the enclosure and the other to your wrist before making internal
adjustments to the CTl-1200.
Attach the negative lead from a digital voltmeter to TP7.
Adjust ZERO & FINE ZERO in the CH1 group for zero volts at TP1.
Adjust ZERO & FINE ZERO in the CH2 group for zero volts at TP2.
Using a nonmetallic screwdriver, adjust the screw on the panel meter face for a reading of zero.
If the isolated output is not being used, skip this section.
If using 0-10V output, measure voltage across Out+ and Out- on J6.
If using 4-20mA output, measure current going out of Out+ on J6.
Adjust ZERO in the OUTPUT group for a reading of zero volts or 4mA.
Apply full scale load to the measuring roll.
Attach the negative lead from a digital voltmeter to TP7.
Adjust SPAN & FINE SPAN in the CH1 group for 10 volts at TP1.
Adjust SPAN & FINE SPAN in the CH2 group for 10 volts at TP2.
Adjust SUM in the METER SPANS group for full scale on the panel meter (between 200-1999).
Hold the panel switch at #1 CELL, and adjust CH1 in METER SPANS for full scale on the panel meter.
Hold the panel switch at #2 CELL, and adjust CH2 in METER SPANS for full scale on the panel meter.
If the isolated output is not being used, skip this section.
If using 0-10V output, measure voltage across Out+ and Out- on J6.
If using 4-20mA output, measure current going out of Out+ on J6.
Adjust SPAN in the OUTPUT group for 10 volts or 20 mA.
The panel meter is normally damped with a time constant of 0.5 seconds. Turning SUM DAMP
counterclockwise extends the time constant up to 2.5 seconds ONLY when displaying total tension.
After placing the system in operation, adjust the SUM DAMP to attain the desired time constant.

MODEL CTI-1200-1
TENSION INDICATOR
INSTRUCTION MANUAL A-342
7
Copyright 2023 - Revised, Comptrol All Rights Reserved
PERIODIC CALIBRATION
The following procedure may be used to check and trim calibration during scheduled shutdowns. The switch and
meter referred to are on the front panel. The loadcells should be allowed to stabilize for 20 minutes after any power
interruption before calibrating.
• Remove all load except tare weight from the measuring rolls.
• Hold the switch at #1 CELL and adjust ZEROs in the CH1 group for zero on the meter.
• Hold the switch at #2 CELL and adjust ZEROs in the CH2 group for zero on the meter.
• Apply full scale load to the measuring roll.
• Hold the switch at #1 CELL and adjust SPANs in the CH1 group for full scale on the meter.
• Hold the switch at #2 CELL and adjust SPANs in the CH2 group for full scale on the meter.
• The meter face and front panel may be cleaned with a household glass cleaner.
PART V - TROUBLESHOOTING
Each procedure starts with a major symptom. Execute each test in turn until one reaches a conclusion. If the problem
persists, contact Comptrol.
NOTE: Clip one end of the static strap to the enclosure and the other to your wrist before making internal adjustments to
the CTl-1200.
POWER SWITCH DOES NOT ILLUMINATE WITH POWER APPLIED
SW1 on the PC Board is a main disconnect. Make sure it is the I POSITION.
Unplug J4 and J5. If this turns the light on, there is a short between +24 and RET on one of the loadcell cables, or
loadcells.
Turn off SW1 and inspect the fuse. Unless the 0.1A fuse was used with 115 volts, a blown fuse probably
signifies damage on the 80-166 main board. Only try replacing it once. Don't forget to turn SW1 back on.
Replacement should be 5 mm slow blow, rated for 250V. 115VAC = 0.2Amps. 230VAC = 0.1Amps.
The light is an LED so it is probably not burned out. Do not replace it with a regular filament bulb. If
24VDC is present between X1 and X2, the LED is defective and needs to be replaced.
POWER SWITCH GOES DARK AFTER A FEW MINUTES
The LED bulb in the power switch runs off the 24-volt power to the loadcells, and is protected by a thermal
switch. If a loadcell is drawing excessive current (more than 50mA) or the LED bulb was improperly replaced with
a filament bulb, the supply will shut off in a few minutes.
INCORRECT OUTPUT POLARITY UNDER LOAD
The connections to “In H”and “In L”have been reversed, or the loadcell mounting angle is wrong. Review the
loadcell connection section, and the Calibration Data Sheet which came with the cell. Don't just switch the
wires. ·

MODEL CTI-1200-1
TENSION INDICATOR
INSTRUCTION MANUAL A-342
8
Copyright 2023 - Revised, Comptrol All Rights Reserved
NO OUTPUT FROM ONE CELL
Swap J4 and J5. If the problem stays with one channel of the CTl-1200, the board has a defective input. Replace the
board. Don't forget to switch J4 and J5 back again.
If the voltage between “In H” and “In L” is zero with the power off, and not zero with it on, but doesn't change under
load, the loadcell is defective or its mounting is incorrect.
The problem is with the loadcell or its cable. The following facts will help in checking the wiring:
The board is providing 24VDC between +24 and Ret. A good cell will draw 18-45 mA
The output section of the cell is completely isolated. It should read 15-25Kohms with no power on.
All four cell connections should be completely isolated from the cell housing.
INCORRECT VOLTAGE AT TP1 or TP2
Attach meter negative lead to TP7 and check TP8 (-15V) and TP9 (+15V). They should not deviate by more than
0.8 volts. If more, replace the board.
Measure the voltage between “In H”and “In L”. The board should be able to achieve zero at the test points with a
tare voltage between +/-6.4 volts. it should be able to produce full scale for any input change of at least 0.6 volts.
If the cell voltage is out of range, check the geometry of the installation against the Calibration Data Sheet which
came with the loadcell. If the cell inputs are within these ranges, the board is defective.
INCORRECT VOLTAGE/CURRENT AT OUTPUT
Attach the voltmeter negative lead to TP10 and check TP11 (-15V) and TP12 (+15V). They should not
deviate by more than 0.8 volts. If more, replace the board.
If the board is configured for voltage output, remove the cable from J6 and recheck. If it works now,
check the load being provided by the downstream equipment. It must be at least 5Kohms.
If the board is configured for current output, remove the cable J6 and attach the meter across Out+ and
Out-. If it works now, check the load provided by the downstream equipment. It must be less than 1000
ohms and not have any voltage sources. The CTl-1200 provides loop voltage.

MODEL CTI-1200-1
TENSION INDICATOR
INSTRUCTION MANUAL A-342
9
Copyright 2023 - Revised, Comptrol All Rights Reserved

MODEL CTI-1200-1
TENSION INDICATOR
INSTRUCTION MANUAL A-342
10
Copyright 2023 - Revised, Comptrol All Rights Reserved

MODEL CTI-1200-1
TENSION INDICATOR
INSTRUCTION MANUAL A-342
11
Copyright 2023 - Revised, Comptrol All Rights Reserved
SPECIFICATIONS
Power In................................................................120/240 VAC, 1 Phase, 50-60 HZ, <1.0 Amp
Output (Proportional to Tension) ........................................................0-10 VDC or 4-20 mA DC
Transducer Supply..........................................................................................................24 VDC
Ambient Temperature ....................................................................................................0-104oF
Meter Scales .............................................................................Customer Specific (No Charge)
Standard ................................................................................................Percent (0-100)
Approximate Weight ........................................................................................................12 lbs.
Enclosure Dimensions ............................................................................11.50” X 8.96” X 4.40”
Specification and dimensions subject to change without notice.

MODEL CTI-1200-1
TENSION INDICATOR
INSTRUCTION MANUAL A-342
12
Copyright 2023 - Revised, Comptrol All Rights Reserved
DECLARATION OF CONFORMITY
Manufacturer's Name....................Comptrol
Manufacturer'sAddress.................34700 Lakeland Blvd
Eastlake, OH 44095 Model
Number: .......................................... CTI-1200-1
Description ....................................Tension Indicator
Type of Equipment ........................Industrial Control
Application of Council Directives...73/23/EEC(LVD), 89/336/EEC(EMC)
Standards: .....................................EN61010-1, EN50081-2, EN50082-2
Compliance iscontingent uponinstallation asdetailed in Part Ill ofthe
manual.
37400 Lakeland Blvd.
Eastlake, OH 44095
Phone: [phone]
Fax: [phone]
Email: [e-mail]
www.comptrolinc.com