The PFEA112-20 3BSE050091R20 is a fully functional and reliably performing tension control unit belonging to the ABB Web Tension Systems series. Built on the patented Pressductor sensing technology, it adds PROFIBUS-DP fieldbus communication functionality to the basis of the PFEA111. It can accurately collect dual load cell signals and convert them into stable analog outputs and digital communication signals. Widely applicable to web tension measurement and control scenarios in industries such as papermaking, plastics, and textiles, it provides high-precision tension monitoring and closed-loop control support for continuous web processing in industrial production. It has obtained multiple international certifications including UL, CSA, and CE, and fully complies with compliance requirements such as RoHS, EMC, and low-voltage directives.

Data Sheet Download:

PFEA112-20 3BSE050091R20.pdf

I. Core Functions and Technical Advantages

Precise Tension Measurement and Signal Processing

Adopt ABB's patented Pressductor® electromagnetic induction technology. It detects tension changes without physical deformation, ensuring high measurement accuracy and stability. Specific performance indicators include linear deviation < ±0.5%, hysteresis deviation < ±0.3%, and repeatability error < ±0.1%, which guarantee reliable web tension data.Support dual load cell input, capable of real-time output of sum, single-channel, and differential signals. It adapts to two measurement modes: standard roller (dual load cells) and single-side (single load cell). For single-side measurement, the signal is automatically doubled to meet different installation requirements.Offer flexible parameter configuration. Users can set measurement units (8 types including N, kN, kg, lbs), web width, and decimal places (0-5 digits). Zero calibration and tare compensation functions eliminate installation errors.

Diverse Output and Communication Capabilities

Equipped with standard analog output interfaces. The voltage output range is -5V~+11V (default 0~10V) and the current output range is 0~21mA (default 4~20mA). Support customizing output values corresponding to high/low tension and output limits, with configurable 6-level filtering (15ms~1500ms) to adapt to different response speed requirements.Built-in PROFIBUS-DP slave communication interface with RS-485 physical layer. It has a maximum transmission rate of 12Mbit/s and an address range of 0-125, supporting Class 1/2 acyclic parameter transmission. Can be quickly integrated into PLC systems via GSD files, enabling remote reading of tension data and issuance of zero calibration control commands.Realize synchronous transmission of dual-channel tension measurement values, matching the response characteristics of voltage and current outputs respectively. Support both default scaling and user-defined scaling modes to adapt to data acquisition needs of different control systems.

Flexible Installation and Environmental Adaptability

Provide two protection versions: IP20 (DIN rail mounting) and IP65 (NEMA 4 sealed enclosure). The IP20 version has dimensions of 86×136×58mm, fitting standard industrial control cabinets. The IP65 version adopts a wall-mounted design with 6 cable glands, complying with EN 60529 for protection, and can be directly installed in harsh on-site conditions.The load cell excitation circuit supports a maximum cable resistance of 5Ω, adapting to wiring distances up to 50m. Cable shielding with single-end grounding and anti-interference wiring specifications ensure signal stability in strong industrial electromagnetic environments.Cover wide operating temperature ranges: 0°C~60°C (IP20) and -10°C~80°C (IP65), with humidity tolerance of 5%~95% (non-condensing). Vibration and shock resistance meet industrial application requirements.

Convenient Debugging and Maintenance Features

Equipped with a 2×16-character multi-language display and operation buttons, supporting language switching (including Chinese and English). Parameter configuration, zero calibration, and tension calibration can be quickly completed via the panel without additional tools.Support two quick debugging modes: hanging weight calibration (automatically calculating wrap gain) and manual input of wrap gain (adjustable range 0.5-20), adapting to installation scenarios with different web wrap angles.Built-in comprehensive self-diagnostic functions. It detects faults such as flash memory errors, EEPROM errors, power failures, and abnormal load cell excitation. Status indicators and on-screen alarm messages enable quick fault location, with support for PROFIBUS communication fault early warning.

II. Key Technical Parameters

1. Power Supply and Load Cell Parameters

• Power supply: IP20 version uses 18-36V DC; IP65 version supports 85-264V AC (45-65Hz) or 18-36V DC. Power consumption is 8W (when powered by 24V).
• Load cell excitation: 330Hz sine wave with 0.5A rms constant current output. Compatible with the full range of ABB load cells including PFCL 201/301E, PFTL 101/201/301E, and PFRL 101.
• Input impedance: 10kΩ. Supports differential signal input from dual load cells, with signal polarity adjustable via wiring.

2. Output and Communication Parameters

• Analog output: Maximum load for voltage output is 5mA; maximum load for current output is 550Ω. Step response time is 15ms, and bandwidth is 35Hz.
• PROFIBUS-DP communication: Supports Sync/Freeze mode. Input/output buffers are each 6 bytes, including 2 channels of 16-bit tension data, 5 status bits, and 1 control bit. Supports cyclic and acyclic data transmission.

3. Environmental and Physical Parameters

• Protection class: IP20 (non-sealed) / IP65 (sealed). Cable glands of the IP65 version are compatible with cables of Φ6-12mm and Φ4-8mm.
• Weight: Approximately 0.3kg for the IP20 version; approximately 1.9kg for the IP65 version.
• Electromagnetic compatibility: Complies with EN 61326-1 standard. Features strong anti-electromagnetic interference capability, suitable for complex industrial electromagnetic environments.

Application Scenarios

It is suitable for various continuous web processing equipment, including paper machines, film production lines, textile machines, printing machines, coating machines, etc. It can perform full-process tension monitoring and closed-loop control on webs such as paper, plastic films, textiles, and metal foils. This ensures uniform tension of the web during transportation and processing, avoids problems such as stretching, wrinkling, or breaking, and improves the processing accuracy and qualification rate of products.

Maintenance and Troubleshooting

1. Preventive Maintenance

• Regularly check the tightness of the fixing screws of the load cell. Clean the dust and debris in the gap between the load cell and the adapter plate to prevent corrosive substances from contacting the load cell.
• Inspect that the cables are free of damage and the terminal screws are tight. For the IP65 version, confirm that the housing is well-sealed and the cable glands are not loose.
• Periodically calibrate the zero point and tension calibration data to ensure long-term stable measurement accuracy. After replacing the load cell, re-perform zero calibration and maximum load reset.

2. Common Troubleshooting

• For communication failures: Check the PROFIBUS address configuration, bus terminating resistors, cable connections, and shield grounding to ensure the bus topology complies with the EN 50170 standard.
• For no tension signal output: Verify the wiring polarity of the load cell, cable resistance (should be <25Ω), and whether the load cell excitation circuit is normal.

• For excessive signal fluctuation: Adjust the filtering parameters, check if the wiring crosses and interferes with power cables, or confirm the flatness of the load cell mounting surface and the dynamic balance of the roller.

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