Strip Tension Systems
Pressductor® PillowBlock Load Cells
Strip tension measurement for process lines
including furnace sections
PillowBlock
– quality tension measurement for quality tension control
Keeping the tension
constant in strip
processes is
essential for high
product quality and
productivity
The PillowBlock load cells are designed for reliable and long-term stable strip tension measurement in process lines like pickling, annealing and
galvanizing lines.
The Pressductor® based load cells have for more
than 50 years proven their superior performance in
a large number of demanding applications.
The performance of the PillowBlock load cells
is well-proven for applications characterized by
heavy rolls, high speeds and severe conditions.
The key reason is the operating principle.
ABB PillowBlock load cells produce signals as a
result of magnetic change, which frees them from
the limitations and design compromises of measurement technologies relying on some form of
physical movement.
The result is a load cell that combines strong,
low-impedance signal output with an exceedingly
stiff and rugged construction. A reliable, highperformance load cell with exceptional resistance
to vibration, overloads, extreme temperatures
and otherwise harsh environments.
A complete PillowBlock measuring
system consists of appropriately sized load
cells and a tension electronics. A junction
box is sometimes used to simplify the
cabling and reduce cabling costs.
2
ABB offers two different types of PillowBlock
load cells: one design intended for conventional
vertical force measurement, and a second, unique
design that measures only the horizontal force
component resulting from strip tension on a roll.
Several models and nominal loads are available
in standard stainless steel constructions as well as
in acid-resistant and mill-duty versions.
The user-friendly digital signal-processing
electronics provides a high level of functionality to
cover a wide range of applications.
T h e a s s u r a n c e o f P r e s s d u c t o r ® Te c h n o l o g y
• Consistent measurement
• Exceptional stiffness
• Durable construction
• Long service life
• Recalibration-free
The Pressductor® difference
Like ABB’s other load cells based on Pressductor®
Technology, PillowBlock load cells rely on electromagnetic changes in the transducer, not on physical
movement, to sense fluctuations in strip tension.
The Pressductor® Technology operating principle
provides improvements in load cell performance
characteristics, including reliability (notably
absence of drift), durability, repeatability, and wider
measurement range.
Machined from a solid block of steel, the
load cells are rugged and stiff, affording high
overload protection as well as an extended measurement range above the nominal capacity. And
they won’t contribute to machine vibration, even
at high speeds.
Since the transducer action – the magnetic
flux – takes place inside a steel core, environmental factors like dirt or fluids can’t degrade performance and reliability.
Furthermore, low transducer impedance – less
then a couple of ohms – helps eliminate susceptibility to radio-frequency and electromagnetic
interference.
There is a ABB PillowBlock load cell suitable for most strip processing lines.
The PillowBlock load cells are designed for reliable and long-term stable strip tension
measurement in process lines like pickling, annealing and galvanizing lines.
The Pressductor® based load cells have for more than 50 years proven their superior performance in a large number of demanding applications.
3
How the measurement signal is generated
Two commonly used transducer types – the strain
gauge and the LVDT transducer – rely on physical movement in the
transducer to produce a
measurement signal (see
Strain gauge: Stretching alters drawings). Stretching,
resistance of electrical circuits. compression or bending
motions are prerequisites for signal generation.
ABB’s exclusive Pressductor Transducer produces
a signal as a result of changes in an electromagnetic
field. This operating principle has its
origin in a metallurgical phenomenon
according to which
LVDT: Movement of piston causes
mechanical forces
alter the capacity of signal change in output coils.
some steels to convey magnetic flux.
Two perpendicular windings of copper wire around a
steel core combine to provide the transducers measurement signal. A magnetic
field is created in one of
the windings, sized so
there is no magnetic coupling between them.
When the transducer
is subjected to a force,
Pressductor® Technology:
the magnetic field patMechanical force alters mag- tern changes. A portion
netic field.
of the field couples with
the second winding and induces an AC voltage. This
voltage – a comparatively strong transducer signal that
is proportional to the force – is converted by the load
cell system’s electronics into the system output.
Selecting and sizing
– for best measurement accuracy
Extended-range
operation
An extended range
of measurement
beyond the nominal load allows the
PillowBlocks to be
sized for normal, as
opposed to maximum,
tension levels. As a
result, they permit
greater application
flexibility in the strip
processing line.
Designers appreciate...
✔ Remarkably high spring constant
✔ Wide measurement range
✔ High reliability
Operators value a load cell with...
✔ No drift
✔ No recalibration
✔ No failures
✔ High reliability
Measurement essentials
Keeping the tension constant in strip processes is
essential for high product quality and productivity. Continuously measuring the tension is an
obvious prerequisite for accurate tension control.
Drives and operator instruments need quick and
accurate input to regulate tension levels and monitor line ­performance.
Most strip processing lines put a premium on
long-term reliability, in addition to accuracy and
overall performance. The measurement system,
after all, is the front line of line control, exposed
to all the rigors of the operating environment.
The costs associated with downtime and poor
product bring out the true value of its components.
Quality measurement technology for superior
tension control that will keep your processing
lines productive and producing top-notch output... that’s what you can expect from us. We’re
entirely devoted to providing process measurement systems and services, and we have 50 years
of experience in the field. We have an extensive
knowledge and experience in web and strip tension as well as force measurement for most purposes and applications.
4
Selecting and sizing load cells
Two types of ABB PillowBlock load cells are
designed for either conventional vertical force
measurement or to sense the horizontal force
component that may arise as the processed strip
partially wraps around a measurement roll.
Using the “horizontal” load cells can be quite
advantageous. By design, they can be made exceptionally sturdy, rugged, and stiff. So, requirements
for recalibration, other maintenance, or replacement are negligible, and they won’t contribute to
machine vibration. Since they don’t measure the
tare weight, but just the horizontal force component of the strip tension, they can be sized smaller
than otherwise possible, measuring tension with
greater accuracy.
Application requirements may dictate the
selection of a “vertical” load cell. But whenever an
adequate horizontal force component is ­present
(or can be developed), the horizontal cell should
be considered.
The size, or nominal load, of a load cell is
contingent on the anticipated force it will measure.
When a “vertical” load cell is mounted horizontally (the most common arrangement), the measurement force (FR) is a function of the tension in the
strip (T), the deflection angles (α and β), and the
tare weight of the roll and bearings (Tare).
The “horizontal” load cell senses the strip
tension’s (T) horizontal component (FR); not the
vertical force (FV).
In this scenario, the measurement force (FR) is
a function of only the tension in the strip (T) and
the strip angles (α and β). Since the tare force –
the weight of the deflector roll and bearings – will
not be measured, it can be very large compared to
the strip tension without affecting the accuracy of
the tension measurement.
Specifying the load cell
Since load cells are typically used at both ends of
a roll, rating the individual cell is usually based
on half of the resultant force. The ideal load cell
size is usually the smallest nominal capacity rating accommodating that force level, so long as
the force exceeds 10 percent of the nominal load.
Before choosing a larger size, however, consider
using the “extended range” feature of ABB load
cells. And always verify that overload specifications will not be exceeded in either direction.
Vertical measuring load cells
Application hint
Two “10 percent” application guidelines are useful
in selecting load cell
sizes:
The proportion
of strip tension
that is actually sensed
by the load cell should
be at least 10 percent of
total strip tension. For
operational conditions
producing values below
10 percent, consult ABB.
During normal operation, the sensed
force should not be less
than 10 percent of the load
cell’s capacity.
1.
2.
FRtot=FR+Tare=T(sinα+sinβ)+Tare
FVtot=FV=T(cosβ-cosα)
Horizontal measuring load cells
FRtot=FR=T(cosβ-cosα)
FVtot=FV+Tare=T(sinβ+sinα)+Tare
FR= Force component of Tension in the measuring direction
FRtot= Total force in the measuring direction
FV= Force component of Tension transverse to the measuring direction
FVtot= Total force in the transverse direction
T=
Tension in strip
Tare= Weight of roll and bearings
α,β=Deflection angles
5
Vertical force
Horizontal
force
Furnace section
– design solutions
Conventional design
ABB PillowBlock load cells,
type PFTL 201C-20kN,
installed in a CAL furnace
section, with 90 degree
wrap angle.
Installations in furnace sections
Furnace sections in galvanizing and annealing
lines are very demanding and it is crucial to control strip tension in a correct and accurate way.
The strip tension range is often large; the
temperature in the furnace can reach 1000°C and
at the load cell position it can be as high as 90°C.
The elongation of the deflector rolls, from furnace
start to process temperature, can be as large as 50
mm. In order to accommodate the large elongation, with a minimum of influence on measurement performance, the deflector roll installation
has to be designed with care.
In order to keep up with the competition
many mills are continuously working on improvements of the strip quality towards the end-users.
To guarantee a high constant strip quality as well
as eliminating the risk of strip breaks the mills
want accurate control of strip tension in furnace
sections. A prerequisite is then reliable strip tension measurement, independent of furnace temperature changes.
Linear bearing design
ABB PillowBlock load cells,
type PFCL 201C-20kN,
installed in a CAPL furnace section, with 180
degree wrap angle.
6
ABB offers following design solutions:
Conventional design
– with ABB standard load cells
This solution is recommended when there are low
axial expansion forces. The ABB standard load cell
have proven outstanding dependability in a number of furnace sections in galvanizing and annealing lines around the world.
Linear bearing design
– with ABB standard load cells
This solution is recommended when high axial
forces can occur. In order to eliminate these axial
forces ABB has a proven solution with a linear
bearing unit on the free side of the roll.
Following benefits can potentially be achieved
when using the ABB solution with linear bearing
in furnace installations:
• The combination ABB Large PillowBlock load
cells + Linear Bearing is proven to be very reliable with long-term stable measurement
• The Linear Bearing solution is insensitive to
and unaffected by temperature variations
• The ABB load cells are virtually maintenacefree and the Linear Bearings require a minimum of service
ABB recommends considering the following issues
in order to achieve best possible measurement performance in the furnace sections:
• Protection bellows around deflector roll shafts
between furnace and bearing housings must be
flexible to avoid axial forces caused by thermal
expansions
• In order to reduce the load cell temperature
variations, heat radiation shields may be fitted
between load cells and furnace
• Deflector roll elongation must be accommodated by the free side bearing. The measurement influence can be minimized in two ways.
1) Clearance between roll bearings and bearing housings on the free side bearing, as well
as lubrication must be designed for actual
operating conditions.
2) ABB's proven solution with linear bearing
on the free side of the roll can be utilized to
accommodate the roll elongation.
ABB is working very close with the customer and
together we always find the best solution. Thanks
to the fact that standard load cells are used, the
same type of load cells can be fitted both in
the hot and cold sections of galvanizing and/
or annealing lines. Another advantage is that the
standard pedestal bearing houses can be used.
Consult ABB for advice how to design an optimal load cell installation in your furnace section.
In order to drastically reduce the expansion
friction on the free side, the standard ABB
Large PillowBlock load cell and bearing housing
are fitted on a linear bearing unit. The axial
expansion friction coefficient drops from typically
0.2 inside a bearing housing in good condition,
to <0.01 in a linear bearing unit.
7
ABB's proven solution
with linear bearing on
the free side of the
roll can be utilized to
accommodate the roll
elongation.
Pressductor® PillowBlock Load Cells
– horizontal force measurement 10 - 100 kN
ABB’s “horizontal”
Pressductor® load
cells are specifically
designed for horizontal
force measurement.
Key advantages:
• Smaller load cell
sizes can be specified since the tare
weight won’t be a
factor
• Inherently sturdier
designs are virtually maintenancefree.
• No contribution to
machine vibration.
PFTL 201C
�����������
��������
�����������
��
������
��
���
������
������
��������������������
�����������
�� ��
������
������
��������
���
������
��
������
����������������������
��
������
��������������������
��
������
�����������
PFTL 201D
����
������
������
�����������
��������
��
������
��
������
��������
��
������
���
������
�����������
mm (inch)
���
������
8
In many strip processes, the strip tension inherently produces a horizontal force component on a
roll... or, by design, it can be made to do so.
Using this horizontal force component to
measure strip tension can be highly advantageous.
The load cell can be sized to measure just the strip
tension, excluding the tare weight of the roll. The
result is optimized measurement accuracy.
Another advantage is that ABB’s unique horizontal load cell – specifically designed to measure
this force component – provides ­stiffness levels
and overload tolerances in all force directions that
are significantly greater than what can be achieved
with vertical load‑cells.
Four different models, with force measurement capacities ranging from 0.5 kN (112 lbs.) to
100 kN (22,500 lbs.), make up the family of hori­
zontal load cells (PFTL 201 and PFTL 101).
Two versions of the PFTL 201 are available:
• The standard version PFTL 201C/D equipped
with Cannon connector for the connection cable.
• The mill-duty version PFTL 201CE/DE with
fixed connection cable in protective hose, best
suited for positions with severe environments.
PFTL 201C/CE
Properties
Nominal load
(rated capacity)
Extended load1)
Permitted load
Transverse direction
(vertical) h=300 mm
Overload capacity2)
Measurement direction
(horizontal)
Transverse direction
(vertical) h=300 mm
Deflection3)
Spring constant
PFTL 201D/DE
kN
Lbs.
kN
Lbs.
10.0
2250
15.0
3375
20.0
4500
30.0
6750
50.0
11250
75.0
16875
50.0
11250
75.0
16875
100.0
22500
150.0
33750
kN
Lbs.
100.0
22500
200.0
45000
250.0
56250
500.0
112500
500.0
112500
kN
Lbs.
100.0
22500
200.0
45000
500.0
112500
500.0
112500
1000.0
225000
kN
Lbs.
mm
1/1000 in.
kN/mm
1000 Ibs/in.
100.0
22500
0.010
0.4
1000
5720
200.0
45000
0.020
0.8
1000
5720
250.0
56250
0.050
2.0
1000
5720
500.0
112500
0.025
1.0
2000
11440
500.0
112500
0.050
2.0
2000
11440
All load cells
1)
Operating principle
Electromagnetic
Pressductor® Technology
4)
Accuracy class %
±0.5
Repeatability error
%
<±0.05
Operating range
30:1
Stainless steel
SIS 23875)
DIN X4CrNiMo165
Working temp. range
Zero point drift6)
%/°C
%/°F
Sensitivity drift6)
%/°C
%/°F
-10 to +90°C
14 to 194°F
<±0.005
<±0.003
<±0.010
<±0.006
Values indicate the total capacity of the load cells when
taking into account their permissible “extended capacity”. In
the extended range, above the nominal load, some decline
in measurement accuracy may be experienced.
2)
Maximum permitted loads without affecting load cell calibration.
3)
At nominal load.
4)
Accuracy class is defined as the maximum deviation, and
is expressed as a percentage of the sensitivity at nominal
load. This includes linearity deviation, hysteresis and repeatability error.
5)
Corrosion resistance properties similar to AISI 304
6)
Applies for
+20 – 80°C
68 – 176°F
9
Height (h) from load cell’s
bottom surface to roll center line.
Pressductor® PillowBlock Load Cells
– horizontal force measurement 0.5 - 20 kN
Application hint
Horizontally measuring load cells
are ideal in applications
with high tare loads and
relatively small tensions,
such as paper machines.
In applications
where high overloads can occur in any
direction, the high overload tolerance in all directions of ABB’s horizontal
PillowBlock load cell
adds reliability.
✓
✓
If no horizontal
resultant force is
present, mounting the
load cell on a slant will
give rise to one.
✓
In process lines where the tension levels are relatively low, there are smaller sizes of horizontal
PillowBlock load cells to choose from. These
stainless steel load cells comes in two standard
sizes, PFTL 101A and PFTL 101B, and are made
for measurement forces between 0.5 and 20 kN.
They are machined from a solid block of stainless
steel to the shape of two steel plates linked by four
or six vertical membranes. This makes them insensitive to transverse load, but on the other hand
they can measure in both horizontal directions.
PillowBlock type PFTL 101 comes in three
versions:
• PFTL 101A/B with standard Cannon cable
conection.
• PFTL 101AE/BE with 20 meter fixed cable
and a degree of protection of IP 661).
• PFTL 101AER/BER made in acid-resistant
stainless steel and with 20 meter fixed cable.
All load cells are delivered standard calibrated.
1)
PFTL 101A
78
(3.07)
18
(0.71)
19
(0.75)
84 (3.31)
70
(2.76)
78
(3.07)
170 (6.69)
230 (9.06)
260 (10.24)
360 (14.17)
260 (10.24)
360 (14.17)
125 (4.92)
18
(0.71)
16.5
(0.65)
19
(0.75)
230 (9.06)
84 (3.31)
70
(2.76)
98
(3.86)
16.5
(0.65)
17.5
(10.69)
170 (6.69)
125 (4.92)
18 101B
PFTL
(0.71)
125 (4.92)
18
(0.71)
50
(1.97)
17.5
(10.69)
125 (4.92)
50
(1.97)
20
(0.79)
104 (4.09)
98
(3.86)
104 (4.09)
mm (inch)
10
20
(0.79)
According to IEC 529, EN 60-529
PFTL 101A/AE/AER
Properties
Nominal load
(rated capacity)
kN
Lbs.
Permitted load
(in transverse direction) kN
Lbs.
1)
Overload capacity
Measurement direction
(horizontal)
kN
Lbs.
2)
Deflection
mm
1/1000 in.
Spring constant
kN/mm
1000 Ibs/in.
PFTL 101B/BE/BER
0.5
112
1.0
225
2.0
450
2.0
450
5.0
1125
10.0
2250
20.0
4500
5.0
1125
10.0
2250
10.0
2250
30.0
6740
30.0
6740
30.0
6740
40.0
9000
2.5
562
0.015
0.6
32
183
5.0
1125
0.015
0.6
65
371
10.0
2250
0.015
0.6
130
743
10.0
2250
0.015
0.6
130
743
25.0
5625
0.015
0.6
325
1857
50.0
11250
0.015
0.6
650
3715
80.0
18000
0.015
0.6
1300
7430
All load cells
Operating principle
Electromagnetic
Pressductor® Technology
3)
Accuracy class %
±0.5
Repeatability error
%
<±0.05
Operating range
30:1
Standard/mill-duty version
Stainless steel
SIS 23834)
DIN 17440X12CrMoS17
Degree of protection IP 655) (standard version)
IP 665) (mill-duty version)
Acid resistant version
Stainless steel
SIS 23486)
DIN 17440X2CrNiMo17 13 2
Degree of protection IP 66/675) (>NEMA 4)
Working temp. range
-10 to +105°C
14 to 221°F
Zero point drift7)
%/°C <±0.003
%/°F <±0.002
Sensitivity drift7)
%/°C <±0.015
%/°F <±0.007
1)
Maximum permitted loads without affecting load cell
calibration.
2)
At nominal load.
3)
Accuracy class is defined as the maximum deviation, and
is expressed as a percentage of the sensitivity at nominal
load. This includes linearity deviation, hysteresis and repeatability error.
4)
Corrosion resistance properties similar to AISI 430F
5)
According to IEC 529, EN 60-529
6)
Corrosion resistance properties similar to AISI 316L
7)
Applies for
11
+20 – 80°C
68 – 176°F
Pressductor® PillowBlock Load Cells
– vertical force measurement 5.0 - 50.0 kN
For applications that
demand vertical force
measurement, the
standard and mill-duty
versions of ABB’s “vertical” PillowBlock load
cell provide the best
in measurement range
and durability.
Extended-range
operation
An extended range
of measurement
beyond the nominal
load allows ABB’s
PillowBlock load cells
to be sized for normal,
as opposed to maximum, tension levels.
As a result, they permit greater application
flexibility in the strip
processing line.
These units are designed for strip tension measurement in applications where it is essential or
advantageous to determine the vertical force component.
Machined from a single block of stainless
steel, they have exceptionally high tolerance for
overloads, shock and impact, in addition to high
immunity to dust and corrosion.
The standard construction is of highly resistant stainless steel with potted internal components. Mill-duty versions are available for exceptionally hostile environments in e.g. rolling mills,
galvanizing lines and pickling lines.
The family of “vertical” load cells comprises
units in four operating ranges offering measurement capacities from 5 kN (1,125 lbs.) to more
than 50 kN (11,250 lbs.).
ABB’s vertical load cells, like their counterparts for horizontal measurement, feature an
extended operating load range. Up to 50 percent
more measurement capacity is available in this
range with fully retained performance characteristics, except some decline in measurement accuracy. As a result, in most applications, the load
cells can safely be specified for the strip’s normal
tension range, but still will accommodate substantial peak loads.
12
In fact, both types of ABB PillowBlock load
cells feature an exceptionally wide measurement
range. With the capacity to measure strip tension ranges of up to 30:1, they provide valuable
machine versatility in processing a variety of
applications.
Three versions are available:
• The standard version PFCL 201C equipped
with Cannon connector for the connection
cable.
• PFCL 201CD equipped with a tight cable
gland and 20 m Teflon® insulated connection
cable.
• The mill-duty version PFCL 201CE with 20
meter fixed connection cable in protective
hose, best suited for applications in extremely
severe environments.
All load cells
PFCL 201C/CD/CE
Properties
Nominal load
(rated capacity)
Extended load1)
Permitted load
Transverse direction
(horizontal) h=300 mm
Overload capacity2)
Measurement direction
(vertical)
Transverse direction
(horizontal) h=300 mm
Deflection3)
Spring constant
kN
Lbs.
kN
Lbs.
5.0
1125
7.5
1690
10.0
2250
15.0
3370
20.0
4500
30.0
6740
50.0
11250
75.0
16900
kN
Lbs.
2.5
563
5.0
1125
10.0
2250
25.0
5625
kN
Lbs.
50.0
11250
100.0
22500
200.0
45000
500.0
112500
kN
Lbs.
mm
1/1000 in.
kN/mm
1000 Ibs/in.
2.5
562
0.02
0.8
250
1430
5.0
1125
0.02
0.8
500
2860
10.0
2250
0.02
0.8
1000
5720
25.0
5620
0.02
0.8
2500
14300
Operating principle
Electromagnetic
Pressductor® Technology
Accuracy class4)
%
±0.5
Repeatability error
%
<±0.05
Operating range
30:1
Stainless steel
SIS 23875)
DIN X4CrNiMo165
Working temp. range
Zero point drift6)
%/°C
%/°F
Sensitivity drift6)
%/°C
%/°F
-10 to +90°C
14 to 194°F
<±0.005
<±0.003
<±0.010
<±0.006
1)
Values indicate the total capacity of the load cells when
taking into account their permissible “extended capacity”. In
the extended range, above the nominal load, some decline in
measurement accuracy may be experienced.
2)
PFCL 201C/CD
��
������
��
������
������������
����������
����������
��
������
mm (inch)
��
������
������������
��
������
PFCL 201CE
���
������
���
������
13
At nominal load.
4)
Accuracy class is defined as the maximum deviation, and is
expressed as a percentage of the sensitivity at nominal load.
This includes linearity deviation, hysteresis and repeatability
error.
6)
Corrosion resistance properties similar to AISI 304
Applies for
+20 – 80°C
68 – 176°F
����
������
�����������
���
������
�����������
3)
5)
�����������
�����������
��
������
Maximum permitted loads without affecting load cell calibration.
Height (h) from load cell’s
bottom surface to roll center line.
Tension Electronics
– bringing something new to strip tension
The basic function of the
tension electronics is to
provide a 330 Hz excitation to the tension load
cells and to process the
measurement signals. It
also provide outputs for
control and/or indication
of the measured tension.
The signal processing
function of the tension
electronics amplifies, rectifies, and filters the measurement signals from the
load cells and provides
an accurate and reliable
output signal.
Covering a wide range of applications the Tension
Electronics comes in three versions, with different levels of performance and functionality. All
three versions have multi-language digital display
and configuration keys. The configuration keys
being used for setting different parameters and to
check the status of the tension system. The 2 x 16
character display can present sum, difference or
individual load cell signals. All three versions are
available in both DIN-rail version and enclosed
IP651) version for mounting in more severe environments.
PFEA 111
A cost-effective, compact and user-friendly tension
electronics providing an accurate and reliable fast
analog SUM signal from two load cells for control
and/or monitoring. The display can show the SUM
individual A & B and difference signal. The small
size and DIN-rail mount make this unit very easy to
integrate into many types of electrical cabinets.
PFEA 112
This unit provides the same functionality and userfriendliness as the PFEA 111 with the addition of
fieldbus communication via Profibus-DP.
PFEA 113
This advanced tension electronics can supply up
to four load cells and has six configurable analog
outputs for control and/or monitoring of strip
tension. The output signals are also available on
Profibus-DP.
Another useful feature is the possibility to, via
the digital input or Profibus, switch the gain for
two different web paths. Alternatively, the digital
input could be used for remote gain scheduling
or zero set. This unit also includes a self-diagnostic
function and four configurable digital outputs for
alarms and level detection. Status of self-diagnostic
functions are also available on Profibus-DP.
The high level of functionality and userfriendliness make the PFEA 113 one of the most
complete tension electronics on the market.
1)
14
According to IEC 529, EN 60-529
Features and benefits
• Interactive menu
The tension electronics has a unique interactive menu which guides the
commissioning step by step, eliminating the potential for making mistakes
and significantly reducing start-up time. – An extremely helpful tool.
• Built-in self-diagnostics
The electronics continuously supervise a
number of important parameters and provides
error messages if something goes wrong.
• Fieldbus communication
Versions PFEA 112 and PFEA 113 have fieldbus communication via Profibus-DP as standard. In contradiction to many other tension
systems the PFEA 112 and PFEA 113 provide
a scaled and zeroed tension output ready for
use in control or monitoring.
• Filter function
All units come with
a selectable filter
function for removal of roll unbalance,
machine vibrations
and other disturbances.
• Multi-language
display
The multi-language
display is a great
feature that helps to
eliminate mistakes,
during start-up
and/or operation of
the tension system.
• Load memory
The resetable load memory stores max. load
values. A useful tool for maintenance.
• Analog outputs
Individual scaling and filtering of all analog
outputs.
• Commissioning without calibration weights
All Pressductor load cells are standard calibrated to the same sensitivity before delivery
from ABB factory. This means that the fastest
and most accurate way to commission a tension system is to use a calculated value instead
of using calibration weights.
Mounting
To provide flexibility of mounting, all three versions of the Tension Electronics are available in
two mounting alternatives. For mounting on a
standard DIN-rail the IP 20 and for wall mounting the IP 65.
Floor cubicle
Floor cubicle type MNS
Select is available for
housing of up to 24 pcs.
of PFEA 111/112 or 12
pcs. of PFEA 113 when
mounted on 19” plates.
Exact numbers depend
on the combination of
different tension electronics and the number
of optional units used.
15
110 (
SD821 2.5 A
SD822 5 A
SD823 10 A
PFEA 111 PFEA 112 PFEA 113
6
6
3*
12
12
6*
24
24
12*
* Supply of digital outputs are not included
110 (4.34)
162 (6.37)
58 (2.30)
D-sub
connector
only
PFEA 112
PFEA 113 IP 20 version (unsealed)
58 (2.30)
16
136 (5.35)
D-sub
connector
only
PFEA 112
Power supply unit
When using the DIN-rail IP 20 version of the
electronics and 24 V main supply is not available,
ABB offer optional power supply units.
The compact units transform main supply from
110 - 120 V/207 - 240 V AC to 24 V DC for supply of the PFEA 111, 112 and 113.
Three power supply units with different power
ratings are available. The table below indicates
max. number of electronics per power supply unit.
136 (5.35)
86 (3.38)
+24 V DC
18 mA
6 A at 250 V
6 A at 250 V
PFEA 111
IP 65 version
Supply voltage Power consumption
Contact data AC
DC
PFEA 112
IP 65 version
Relay board PXKB 201
PXKB 201 is DIN-rail mounted and can be
mounted in the IP 65 versions of the Tension
Electronics together with the insulation amplifier.
PFEA 113-65 can hold up to four PXKB 201.
136 (5.35)
86 (3.38)
+24 V (20 - 253 V AC/DC)
10 mA + external load
Output
0 - ±10 V
0 - ±20 mA
4 - +20 mA
600 V (basic)
PFEA 111/112 IP 20 version (unsealed)
Supply voltage Current consumption
Signal range Input
0 - ±10 V
0 - ±10 V
0 - 10 V
Rated insulation voltage
PFEA 113
IP 65 version
Insulation amplifier
PXUB 201
The insulation amplifier can be used when galvanic
insulation is required for analog output signals.
The insulation amplifier can be connected to all
versions and PFEA 113 - IP 65 can hold up to four
PXUB 201.
Dimension drawings
mm (inch)
Options
To meet certain special application requirements
the following options are available:
Dimension drawings
162 (6.37)
136 (5.35)
Data
Power supply
IP 20
Voltage
Power requirement
IP 65
Main voltage
Frequency
Number of load cells
Load cell excitation
Current
Max. load
PFEA 111
PFEA 112
PFEA 113
DC 24 V (18 - 36 V)
7.5 W
7.5 W
12 W
DC 24 V (18 - 36 V) 100 (-15%) - 240 (+10%) V AC
45 - 65 Hz
2
2
4
0.5 A rms, 330 Hz
2 load cells
Plus 5 Ω cable resistance
0.5 A rms, 330 Hz
2 load cells
Plus 5 Ω cable resistance
0.5 A rms, 330 Hz
4 load cells
Plus 10 Ω cable resistance
Inputs
Digital inputs (remote zero or gain scheduling)
1
Analog inputs (connection of multiple PFEA 113 units)
2
Outputs
Analog outputs (voltage or current)
6
-5 - +11 V (max.load 5 mA)
1
1
0 - 21 mA (max. load 550 Ω)
1
1
Selectable filter
Step response (0 - 90%) can be set for each output 15, 30, 75, 250, 750, 1500 ms 15, 30, 75, 250, 750, 1500 ms 5, 15, 30, 75, 250, 750, 1500 ms
Scaling function of analog outputs
Yes
Yes
Yes
Digital outputs (Status OK and/or Level detectors)
4
Self-diagnostics, Status OK
LED (green/red)
Yes
Yes
Yes
Alarm on Digital output
Yes
Alarm via Profibus
Yes
Yes
Multi-language interactive display1)
Yes
Yes
Yes
Selectable tension units on the display
N, kN, kg and Ibs, N/m, kN/m, kg/m, pli
Maximum load memory
Yes
Yes
Yes
Zero offset memory
Yes
Yes
Yes
Communication
ProfiBus DP, baud rate up to 12 Mbit
Yes
Yes
GSD-file
ABB_0716.GSD
ABB_0717.GSD
Environmental tolerance
Electrical environment
Electrical interference environment
As per EMC Directive 89/336/EEC
Elecrtical safety
As per Low Voltage Directive 73/23/EEC
As per UL508 Industrial control equipment2)
Ambient temperature
+5 - +55°C
Degree of protection
IEC 529 Protection class IP 20 or IP 65
1)
2)
English, German, Italian, French, Japanese, Portugese
Not PFEA 112-65
17
Ordering guide
Product
Load cells
Nominal load kN (Ibs)
0.5 (112)
0.5 (112)
0.5 (112)
1.0 (225)
1.0 (225)
1.0 (225)
2.0 (450)
2.0 (450)
2.0 (450)
2.0 (450)
2.0 (450)
2.0 (450)
5.0 (1125)
5.0 (1125)
5.0 (1125)
10.0 (2250)
10.0 (2250)
10.0 (2250)
20.0 (4500)
20.0 (4500)
20.0 (4500)
Cables
Model designation
Ordering number
PFTL 101A-0.5
PFTL 101AE-0.5
PFTL 101AER-0.5
PFTL 101A-1.0
PFTL 101AE-1.0
PFTL 101AER-1.0
PFTL 101A-2.0
PFTL 101AE-2.0
PFTL 101AER-2.0
PFTL 101B-2.0
PFTL 101BE-2.0
PFTL 101BER-2.0
PFTL 101B-5.0
PFTL 101BE-5.0
PFTL 101BER-5.0
PFTL 101B-10.0
PFTL 101BE-10.0
PFTL 101BER-10.0
PFTL 101B-20.0
PFTL 101BE-20.0
PFTL 101BER-20.0
3BSE004160R1
3BSE004211R1
3BSE023010R1
3BSE004166R1
3BSE004212R1
3BSE023011R1
3BSE004172R1
3BSE004213R1
3BSE023012R1
3BSE004185R1
3BSE004214R1
3BSE023158R1
3BSE004191R1
3BSE004215R1
3BSE023159R1
3BSE004197R1
3BSE004216R1
3BSE023160R1
3BSE004203R1
3BSE004217R1
3BSE023161R1
Cable with male plug connector
Cable with male plug connector
Cable with male plug connector
Cable with male angled plug connector
Cable with male angled plug connector
Cable with male angled plug connector
Male plug connector without cable
Male angled plug connector without cable
Product
Model designation
Ordering number
Nominal load kN (Ibs)
10.0 (2250)
10.0 (2250)
20.0 (4500)
20.0 (4500)
50.0 (11250)
50.0 (11250)
50.0 (11250)
50.0 (11250)
100.0 (22500)
100.0 (22500)
PFTL 201C-10.0
PFTL 201CE-10.0
PFTL 201C-20.0
PFTL 201CE-20.0
PFTL 201C-50.0
PFTL 201CE-50.0
PFTL 201D-50.0
PFTL 201DE-50.0
PFTL 201D-100.0
PFTL 201DE-100.0
3BSE007913R10
3BSE007913R11
3BSE007913R20
3BSE007913R21
3BSE007913R50
3BSE007913R51
3BSE008922R50
3BSE008922R51
3BSE008922R100
3BSE008922R101
5.0 (1125)
5.0 (1125)
5.0 (1125)
10.0 (2250)
10.0 (2250)
10.0 (2250)
20.0 (4500)
20.0 (4500)
20.0 (4500)
50.0 (11250)
50.0 (11250)
50.0 (11250)
PFCL 201C-5.0
PFCL 201CD-5.0
PFCL 201CE-5.0
PFCL 201C-10.0
PFCL 201CD-10.0
PFCL 201CE-10.0
PFCL 201C-20.0
PFCL 201CD-20.0
PFCL 201CE-20.0
PFCL 201C-50.0
PFCL 201CD-50.0
PFCL 201CE-50.0
3BSE027070R5
3BSE029774R5
3BSE027062R5
3BSE027070R10
3BSE029774R10
3BSE027062R10
3BSE027070R20
3BSE029774R20
3BSE027062R20
3BSE027070R50
3BSE029774R50
3BSE027062R50
Junction box
Tension Electronics PFEA 111, IP 20
PFEA 112, IP 20
PFEA 113, IP 20
PFEA 111, IP 65
PFEA 112, IP 65
PFEA 113, IP 65
PFEA 113, IP 65, incl. 1 insulation amplifier PXUB 201 - Voltage output (connected to AO1)
PFEA 113, IP 65, incl. 2 insulation amplifier PXUB 201 - Voltage output (connected to AO1,2)
PFEA 113, IP 65, incl. 3 insulation amplifier PXUB 201 - Voltage output (connected to AO1,2,3)
PFEA 113, IP 65, incl. 4 insulation amplifier PXUB 201 - Voltage output (connected to AO1,2,3,4)
PFEA 113, IP 65, incl. 1 insulation amplifier PXUB 201 - Current output (connected to AO1)
PFEA 113, IP 65, incl. 2 insulation amplifier PXUB 201 - Current output (connected to AO1,2)
PFEA 113, IP 65, incl. 3 insulation amplifier PXUB 201 - Current output (connected to AO1,2,3)
PFEA 113, IP 65, incl. 4 insulation amplifier PXUB 201 - Current output (connected to AO1,2,3,4)
Options
Insulation amplifier PXUB 201
Relay board PXKB 201
Power supply unit SD821 (2,5 A)
Power supply unit SD822 (5 A)
Power supply unit SD823 (10 A)
Floor cubicle MNS Select, ventilated IP 21 including 24 V power supplies
Floor cubicle MNS Select, sealed IP 54 including 24 V power supplies
Adapter plates for load cells PFTL 201 and PFCL 201 are available on request.
Linear bearing solution – ask ABB for advise
18
3BSE018741R15
3BSE018741R30
3BSE018741R50
3BSE018741R115
3BSE018741R130
3BSE018741R150
YM 321 002-D
3BSC860249R1
15 m (49 ft)
30 m (98 ft)
50 m (164 ft)
15 m (49 ft)
30 m (98 ft)
50 m (164 ft)
PFXC 141
PFTC 101X
3BSE029997R1
3BSE009852R1
PFEA 111-20
PFEA 112-20
PFEA 113-20
PFEA 111-65
PFEA 112-65
PFEA 113-65
PFEA 113-65.1PXV
PFEA 113-65.2PXV
PFEA 113-65.3PXV
PFEA 113-65.4PXV
PFEA 113-65.1PXC
PFEA 113-65.2PXC
PFEA 113-65.3PXC
PFEA 113-65.4PXC
3BSE050090R20
3BSE050091R20
3BSE050092R20
3BSE050090R65
3BSE050091R65
3BSE050092R65
3BSE050092R165
3BSE050092R265
3BSE050092R365
3BSE050092R465
3BSE050092R1165
3BSE050092R1265
3BSE050092R1365
3BSE050092R1465
PXUB 201
PXKB 201
SD821
SD822
SD823
3BSC630149R1
3BSC810039R1
3BSC610037R1
3BSC610038R1
3BSC610039R1
3BSE030582R21
3BSE030582R54
Yo u r a p p l i c a t i o n
We can quickly assist you in determining the ideal specifications of one or several PillowBlock Tensiometer
Systems. Simply fill in the details of your application on copies of this page and fax them to us.
Strip path
On the template at right,
sketch the strip path of
your application
Examples
Indicate the load cell
position and close estimates of angles α, β
and, if applicable γ, to
the horizontal dashed
lines, as appropriate.
Machine attributes
Please indicate the pertinent machine attributes below.
Roll specifications
Strip tension
Width
____________mm (in.)
Normal ____________kN or kN/mm (lbs. or pli)
Min. ___________mm (in.)
Weight
____________kg (lbs.)
Max.
____________kN or kN/mm (lbs. or pli)
Max. ___________mm (in.)
Shaft dia. ____________mm (in.)
Min.
____________kN or kN/mm (lbs. or pli)
Speed
Specify... Strip width
____________rpm
Please fill in your address information below
Please fax to:
+46 21 34 00 05
Name
Title
or mail to:
Company
ABB AB
Force Measurement
S-721 59 Västerås
Sweden
Address
City
Country
Tel
Tel: +46 21 32 50 00
Fax: +46 21 34 00 05
Internet: www.abb.com/pressductor
Fax
E-mail
19
Print: Edita Västra Aros, Västerås 2009-06
3BSE036625R0401
ABB (www.abb.com) is a leader in power and automation technologies that
enable utility and industry customers to improve performance while lowering
environmental impact. The ABB Group of companies operates in around 100
countries and employs more than 110,000 people.
The main focus of ABB Process Automation is to provide customers
with integrated solutions for control, plant optimization, and industryspecific application knowledge. Key customer benefits include improved asset
productivity and energy savings.
ABB Force Measurement is a unit within ABB Process Automation. We
provides equipment for accurate, reliable measurement and control in a broad
range of applications in the metal, paper and marine industries.
ABB AB
Force Measurement
S-721 59 Västerås, Sweden
Phone: +46 21 32 50 00
Fax:
+46 21 34 00 05
Internet:www.abb.com/pressductor