ABB PFEA111-65 3BSE050090R65

Description

The ABB PFEA111-65 3BSE050090R65 is a specialized pillow block load cell designed for ABB’s PFEA111 series tension measurement systems, providing precise web tension sensing in continuous strip processing applications. This high-accuracy force transducer converts mechanical tension forces into proportional electrical signals for closed-loop tension control in paper, metal, film, and textile industries. The ABB PFEA111-65 3BSE050090R65 represents ABB’s latest generation of strain gauge-based tension measurement technology, delivering laboratory-grade accuracy in harsh industrial environments.

Product Overview and Description

The ABB PFEA111-65 3BSE050090R65 functions as a complete force measurement system packaged within a rugged pillow block housing, integrating precision strain gauge sensors, temperature compensation circuitry, and signal conditioning electronics. This self-contained transducer mounts directly into existing machine framing, replacing standard bearing support blocks without requiring extensive mechanical modifications. The ABB PFEA111-65 3BSE050090R65 incorporates dual independent strain gauge bridges for redundancy and enhanced accuracy, providing two separate 4-20 mA output signals for control and monitoring applications. Designed for continuous operation in demanding process environments, the transducer features stainless steel construction, hermetic sealing (IP67), and integral overload protection to 500% rated capacity. The “-65” suffix denotes specific 6500 N (approximately 660 kg / 1460 lb) force rating, calibrated for medium to heavy web tension applications.

Key Parameters and Specifications

• Force Rating: 6500 N (650 kg / 1433 lb) nominal capacity.
• Output Signal: 2x independent 4-20 mA, 2-wire loop powered.
• Excitation: 12-30 VDC, <1 W power consumption.
• Accuracy: ±0.1% of rated output typical, ±0.2% including non-linearity, hysteresis, and repeatability.
• Temperature Effect: ±0.02%/°C on zero, ±0.01%/°C on span.
• Overload Rating: 500% of rated capacity without damage, 1000% ultimate.
• Bridge Resistance: 350 Ω nominal, each bridge.
• Frequency Response: DC to 100 Hz typical, limited by mechanical installation.
• Environmental Rating: IP67, NEMA 6; suitable for washdown and outdoor installation.
• Material: Stainless steel, epoxy-coated aluminum enclosure option.
• Operating Temperature: -20°C to +80°C standard, -40°C to +100°C optional.
• Mounting: 4x M12 bolts, industry-standard pillow block footprint.
• Cable: 5m integral shielded cable, 6-conductor, PVC jacket.
• Certifications: CE, UL, CSA, ATEX Zone 2/22 hazardous area versions available.

Advantages and Functional Benefits

The ABB PFEA111-65 3BSE050090R65 delivers distinct advantages for web tension measurement:

1. Direct Replacement Design: Identical mounting footprint to standard pillow block bearings enables retrofit without machine modification; typically installable during scheduled maintenance within 2 hours.
2. Dual Bridge Redundancy: Two independent measurement bridges provide both control and monitoring signals; failure of one bridge does not affect second bridge output, eliminating single point of failure.
3. High Overload Capacity: 500% overload rating withstands web breaks and machine jam events without sensor damage, eliminating costly transducer replacement and production delays.
4. Temperature Stability: Active temperature compensation maintains ±0.1% accuracy across 100°C temperature range; suitable for installations near drying ovens and heated rolls.
5. Hazardous Area Certification: ATEX Zone 2/22 certified variants enable installation in potentially explosive atmospheres without supplementary protection measures.

Application Fields and Use Cases

The ABB PFEA111-65 3BSE050090R65 is extensively deployed in continuous web processing applications:

• Paper Manufacturing: Dry end tension control, winder/unwind stands, coating section tension measurement.
• Metal Processing: Annealing furnace tension control, pickling line bridle tension, slitting line rewind tension.
• Film & Foil: Cast film extrusion winding, metallizing line tension control, laminating station tension measurement.
• Textiles: Dye range tension control, sanforizing machine feed tension, carpet coating line tension.
• Rubber & Tire: Calender feed tension, bias cutter tension control, tread extrusion take-up tension.

Competitor Comparison

When evaluated against alternative web tension measurement solutions, the ABB PFEA111-65 3BSE050090R65 demonstrates distinctive leadership. Dover Flexo Electronics’ W30 series tension transducers offer comparable accuracy but require separate signal conditioning electronics, increasing installed cost and panel space requirements. Montalvo D-300 series provides similar dual bridge configuration but exhibits reduced overload capacity (300% versus ABB PFEA111-65 3BSE050090R65‘s 500%). Erhardt+Leimer DTR 200 series utilizes magnetostrictive technology with lower temperature stability (±0.05%/°C versus ABB PFEA111-65 3BSE050090R65‘s ±0.01%/°C). The ABB PFEA111-65 3BSE050090R65 maintains distinct advantage through integrated signal conditioning eliminating external amplifiers, superior temperature compensation, and ABB’s global application engineering support network. While competing products require annual recalibration, the ABB PFEA111-65 3BSE050090R65 demonstrates 5-year calibration stability under normal operating conditions.

Selection Recommendations and Precautions

• Capacity Selection: The ABB PFEA111-65 3BSE050090R65 (6500 N) is suitable for total web tension of 1300-5200 N when installed as pair (typical configuration). Select capacity such that normal operating tension is 30-70% of rated capacity for optimal accuracy and overload margin. Consult ABB tension calculator tool for application-specific sizing.
• Mounting Orientation: The ABB PFEA111-65 3BSE050090R65 measures force perpendicular to mounting base; verify load direction arrow orientation before installation. Incorrect orientation measures zero force or causes negative output, resulting in uncontrolled tension.
• Mechanical Alignment: Transducer mounting surfaces must be flat within 0.05 mm and parallel within 0.1 mm; misalignment introduces measurement errors and reduces overload margin. Shim as required during installation.
• Cable Routing: Integral 5m cable requires protection from mechanical damage and flexing; use flexible conduit for moving machine applications. Cable extension beyond 100m requires 4-20 mA repeaters; do not extend millivolt signal leads.
• Bridge Selection: Use primary bridge for closed-loop control, secondary bridge for monitoring or backup; the ABB PFEA111-65 3BSE050090R65 bridges are electrically isolated and may be powered from separate supplies.
• Grounding: Connect cable shield at controller end only; the ABB PFEA111-65 3BSE050090R65 transducer body must be electrically isolated from machine frame to prevent ground loops. Use isolated mounting hardware as required.
• Environmental Verification: Standard IP67 rating permits washdown; verify connector/cable entry orientation prevents water pooling. ATEX certified ABB PFEA111-65 3BSE050090R65 variants require certified cable glands for hazardous area compliance.
• Spare Parts Strategy: The ABB PFEA111-65 3BSE050090R65 remains in active production; maintain minimum 25% spares inventory for critical continuous process lines. Current manufacturing lead times extend to 12-16 weeks; emergency exchange service available for qualifying facilities.
• Calibration Interval: Factory calibration stability typically 0.1% over 5 years; however, formal recalibration every 24 months is recommended for ISO 9001 registered facilities and custody transfer applications. ABB maintains global service centers for certified calibration with 5-day typical turnaround.
• Zero Adjustment: The ABB PFEA111-65 3BSE050090R65 provides ±10% zero adjustment range via potentiometers accessible through sealed cover. Zero after installation with web threaded and minimal tension; never adjust zero under load.

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