This device integrates signal acquisition, processing, output and communication functions, and supports the connection of multiple types of load cells. It has a comprehensive debugging, operation and maintenance, and fault diagnosis system, which can adapt to web tension monitoring scenarios of different complexity in industrial production. Meanwhile, it meets a number of international safety and electromagnetic compatibility certification standards including CE, UL, and CSA. It is suitable for tension closed-loop control or condition monitoring in web processing industries such as papermaking, printing, textiles, and film processing.

The PFEA113 Tension Measurement System is mainly composed of the PFEA113 tension electronic unit, the PFCL 301E/PFTL 301E/PFRL 101/PFTL 101/PFCL 201/PFTL 201 series of load cells, and the PFXC 141 junction box.

related documents

PFEA113-20 3BSE028144R0020.pdf

Technical Parameters

1. Power Supply Parameters

Different device versions correspond to different power supply specifications. The IP20 (unsealed DIN rail version) adopts DC power supply with an operating voltage range of 18-36V DC (nominal 24V DC), is equipped with a built-in auto-reset fuse, and has a power consumption of 15W (excluding digital outputs). The IP65 (NEMA 4 wall-mounted version) supports dual AC/DC power supply: the AC supply voltage range is 85-264V AC (100V-15% to 240V+10%) with a frequency of 47-63Hz, and the DC supply voltage range is 18-36V DC (nominal 24V DC); it is equipped with an external slow-blow fuse (2A/250V), and the current is 0.1-0.2A when powered by AC.

2. Sensor Excitation Parameters

The excitation current is 0.5A rms at 330Hz (stable constant current output). The maximum load capacity can drive 4 compatible Pressductor sensors (such as PFCL 301E, PFTL 301E and other models), and allows a maximum cable resistance of 10Ω and capacitance of 1μF between the sensor and the device.

3. Input and Output Parameters

It covers multiple aspects of functions:

• Sensor Input: It has 4 input channels (corresponding to sensors A/B/C/D) with an input impedance of 10kΩ.
• Analog Output (AO1-AO6): The output type can be configured as voltage (0-10V, maximum load current 5mA) or current (4-20mA, maximum load resistance 550Ω). It supports multiple filtering levels: 5ms (35Hz), 15ms (15Hz), 30ms (5Hz), 75ms (1.5Hz), 250ms (0.5Hz), 750ms (0.25Hz), and 1500ms. The range limits are -5V to +11V for voltage output and 0mA to 21mA for current output.
• Analog Input (AI1-AI2): It adopts 0-10V differential input, which is mainly used for tension signal aggregation when multiple PFEA113 devices are cascaded.
• Digital Input and Output: The digital input (DI) is differential input, with a passive state voltage range of -36V to +5V and an activated state voltage >16V (maximum +36V), supporting zero setting and gain scheduling functions. The digital outputs (DO1-DO4) are group-isolated current-driven outputs, with a maximum current of 0.1A per channel, which can be configured for level detection, system status indication and other functions.

4. Communication Parameters

The communication interface is a Profibus DP slave station (RS485 physical layer), supporting a maximum transmission rate of 12Mbit/s, with an address range of 0-125 configurable via the local menu. Data interaction supports transmission of 6 tension measurement values, issuance of commands such as zero setting/gain scheduling, and reporting of device fault status.

5. Environmental and Mechanical Parameters

The specific indicators are as follows:

• Operating Temperature: -10℃ to +80℃ for sensors; +5℃ to +55℃ for electronic units.
• Storage Temperature: -40℃ to +90℃.
• Protection Level: IP20 (DIN rail version); IP65 (NEMA 4 wall-mounted version).
• Dimensions: 124×136×110mm for the IP20 version; 300×200×159mm for the IP65 version.
• Weight: 0.8kg for the IP20 version; 5.2kg for the IP65 version.

Functions and Features

1. Measurement Principle

Based on ABB  patented Pressductor electromagnetic induction technology, two orthogonal coils inside the sensor change their magnetic field coupling state when subjected to force, generating electrical signals proportional to tension without mechanical deformation. It features overload resistance, vibration resistance, and strong long-term stability, and the measurement accuracy is not affected by mechanical wear of the sensor.

2. Tension Measurement Modes for Multi-Scenario Adaptation

• It supports three load sensor combination modes: single-roll (dual sensors/single sensor on one side), dual-roll, and segmented roll. The segmented roll mode can cascade up to 3 devices via the AI interface and connect 12 sensors, meeting the tension monitoring needs of wide-width webs (e.g., large rewinding machines).
• It provides a gain scheduling function, which can switch tension gain parameters for two different web paths via digital input or Profibus, adapting to the production of multiple-specification webs at the same station.

3. Flexible Debugging and Configuration

• Two debugging processes are supported: Fast Setup and Complete Setup. Fast Setup can complete basic configuration by hanging weights or directly inputting gain values; Complete Setup allows customization of all parameters such as language, unit, sensor nominal load, analog range, and digital logic.
• A built-in zero calibration function compensates for sensor zero drift and roll tare weight, with a calibration range of ±2 times the sensor’s nominal load.

4. Comprehensive Fault Diagnosis

The device can real-time monitor faults such as flash memory/EEPROM failure, power supply abnormality, sensor excitation failure, Profibus communication failure, and synchronization failure. Fault status is reported via local indicators, display screen, and Profibus. Meanwhile, it supports switching to single-side measurement mode when a single sensor fails, ensuring production continuity.

5. Data Recording and Simulation Functions

• It can record historical maximum load data of each sensor, with support for manual reset.
• A built-in sensor signal simulation function can generate input signals simulating -100% to +200% of the nominal load, which is used for device self-test and control system joint debugging.

Applications and System Composition

A complete PFEA113-20 tension system typically consists of the following components: the PFEA113-20 electronic unit, Pressductor load cells (such as PFCL 201, PFTL 301E, etc.), a junction box (PFXC 141, optional), as well as a matching insulation amplifier (PXUB 201) or relay board (PXKB 201, optional). Its typical applications include:

• Tension monitoring for the wire section, press section, and winding section of paper machines in the papermaking industry;
• Closed-loop tension control for laminating and slitting processes in the printing and packaging industry;
• Stable tension control for web forming and winding in the film and textile industries.

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