ABB PFRL 101C‑0.5kN (Order No.: 3BSE023316R0502) is a high‑precision radial force measurement sensor from the ABB Pressductor series, specially designed for industrial web tension and radial load monitoring. It utilizes ABB patented Pressductor magnetoelastic technology, mainly for precise online tension measurement and closed‑loop control in web processing equipment such as paper, film, textile and metal foil lines, ensuring stable material tension and consistent product quality during continuous production.
This model has a nominal measuring range of 0.5 kN (approximately 51 kg load) and features 0.1% F.S. high accuracy, strong anti‑interference capability, high overload resistance, excellent long‑term stability and no mechanical wear. It is suitable for harsh industrial environments and can be seamlessly integrated with ABB tension controllers such as PFEA112 and PFEA113 to enable precise force control and data acquisition in industrial automation systems. It is a standard tension measurement component in web processing, printing, packaging and related industries.
Technical Specifications
- Model & Order No.: PFRL 101C‑0.5kN; 3BSE023316R0502
- Measuring Principle: ABB patented magnetoelastic (Pressductor) effect
- Nominal Range: 0.5 kN (500 N), equivalent to approx. 51 kg (g = 9.8 m/s²)
- Extended Load: 0.75 kN (750 N)
- Ultimate Overload: 2.5 kN in measuring direction; 1.25 kN lateral; 2.5 kN axial
- Accuracy Class: ±0.1% F.S. (full scale)
- Spring Constant: 50 kN/mm
- Deflection: ≤ 0.01 mm at nominal load
- Output Signal: High-power, low-impedance AC signal (for Pressductor controllers)
- Protection Class: IP67 (all-stainless steel sealed, waterproof and dustproof)
- Housing Material: All stainless steel (316L)
- Operating Temperature: -20℃ ~ +85℃
- Mounting: Sleeve-type radial mounting (for guide roll / dancer roll bearing housings)
- Cable Connector: Standard industrial waterproof connector (custom cable lengths available)
Features & Benefits
- Patented Pressductor TechnologyNon-contact magnetoelastic measurement, no strain gauges, no mechanical wear, service life far exceeding conventional sensors. Resistant to vibration, shock and fatigue.
- High Accuracy & Stability0.1% full-scale accuracy, long-term zero drift < 0.05% F.S./year, ideal for high-precision tension control applications.
- High Overload & Anti-Interference Performance5x nominal overload protection, high-power low-impedance output, excellent immunity to electromagnetic interference (EMI/RFI), suitable for complex industrial electrical environments.
- Compact & Robust DesignDisc-type compact structure, all-stainless steel IP67 sealing, resistant to oil, moisture and chemical corrosion, ideal for harsh conditions in metallurgy, papermaking, printing and other industries.
- Easy Integration & StandardizationCompatible with ABB PFEA112 / PFEA113 tension controllers, supports Profibus, Modbus and other industrial buses, enabling quick connection to DCS / PLC systems.
Applications
- Paper Industry: Tension control for paper machines, rewinders, and slitters.
- Printing Industry: Precise web tension control for rotogravure presses, flexographic presses, and offset presses.
- Plastic Film Industry: Film tension monitoring in film blowing lines, cast film lines, and slitting machines.
- Textile Industry: Yarn and fabric tension control for weaving machines, dyeing and finishing machines, and non-woven fabric equipment.
- Metal Processing Industry: Tension control for aluminum foil, copper foil, and steel strip rolling and slitting processes.
- Packaging Industry: Tension control of packaging materials in flexible packaging machines, bag making machines, and laminating machines.
- Wire & Cable Industry: Wire tension monitoring during extrusion and wrapping of electric wires and cables.
Frequently Asked Questions (FAQ)
Q1: What to do if the sensor signal is unstable and fluctuates severely?
A1: ① Check installation: insufficient base rigidity, loose bolts, or misalignment can cause fluctuations. Retighten fasteners and align level and concentricity.② Eliminate interference: cables routed with power lines, poor shielding, or incorrect grounding. Rewire cables and apply single-point shield grounding.③ Remove contaminants: iron filings or oil on contact surfaces. Clean mounting surfaces and roller shafts.④ Adjust controller settings: optimize filter parameters (15–75 ms) on the PFEA controller to suppress high-frequency noise.
Q2: How to resolve large measurement errors and substandard accuracy?
A2: ① Recalibrate: perform zero reset under no-load condition and full-scale calibration to correct zero and span drift.② Check for overload: prolonged operation above 0.5 kN may cause magnetic circuit shift; switch to a higher-range ABB model.③ Inspect mechanical damage: sensor impact or deformation requires factory inspection or replacement.④ Mitigate temperature effects: if operating outside -20℃~+85℃, install thermal insulation or cooling measures.
Q3: What causes no output signal from the sensor?
A3: ① Power fault: check controller power supply, broken cables, or loose connectors.② Wiring error: reversed power, signal, or shield wires. Reconnect according to the terminal diagram.③ Sensor failure: internal magnetic circuit fault or water ingress due to failed sealing. Contact ABB service for repair.
Q4: Can PFRL 101C-0.5kN replace other range models?
A4: Random replacement is not allowed. Mismatched range will reduce accuracy or cause overload damage.The 0.5 kN model is designed for low-tension applications and will activate overload protection under excessive load.Using a larger range (e.g., 1.0 kN) for light tension will lower resolution and increase error.Select the exact model based on the equipment’s actual tension range.
Q5: What is the service life and how to extend it?
A5: Under normal conditions (no overload, no corrosion, proper installation), service life is ≥10 years.To extend lifespan:① Do not exceed the rated range or temperature limits.② Clean regularly, inspect sealing, and avoid mechanical damage.③ Install properly to prevent eccentric or lateral loads.④ Calibrate periodically to correct drift in a timely manner.
Q6: Is it compatible with non-ABB tension controllers?
A6: Compatibility is theoretically possible via signal conversion modules, but pairing with ABB PFEA112/PFEA113 is strongly recommended.The Pressductor uses a dedicated AC signal; third-party controllers may suffer from poor signal matching, accuracy loss, and weak anti-interference performance, affecting control stability.
Q7: How to quickly handle sensor zero drift?
A7: ① Short-term solution: perform one-touch zero reset on the controller to eliminate temporary drift.② Long-term solution: if drift exceeds 0.05% F.S. per month, check mounting stress, temperature influence, or sensor aging, then reinstall or calibrate regularly.
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