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ABB PFEA111-65 (3BSE028140R0065) Electronic Tension Controller 

1. Key Parameters

• Product Model: PFEA111-65
• Order Code (ABB Part Number): 3BSE028140R0065
• Product Series: ABB Industrial Web Tension Controllers
• Core Function: Regulates material tension in web/strip processing; monitors tension via load cells or dancer arms; controls brakes/clutches or drives (e.g., ABB ACS880) to maintain set tension; supports closed-loop tension feedback
• Tension Control Specifications:
  • Tension Range: 0.1N ~ 50kN (adjustable; compatible with low-tension films and high-tension metal strips)
  • Control Accuracy: ±0.5% of full-scale (ensures consistent tension for high-precision applications like thin film coating)
  • Control Modes:
    • Closed-Loop Mode: Uses load cell (4~20mA) or dancer position sensor (0~10V/4~20mA) feedback for real-time adjustment
    • Open-Loop Mode: Pre-set torque/current control for simple unwinding applications (e.g., low-speed paper feeding)
    • Dancer Control Mode: Compensates for material length variations via dancer arm position feedback
  • Response Time: ≤10ms (fast adjustment for sudden speed changes or material thickness variations)
• Input/Output Interfaces:
  • Analog Inputs:
    • 2× Tension Feedback Inputs (4~20mA; for load cells or dancer sensors)
    • 1× Speed Reference Input (0~10V/4~20mA; from line speed encoder or PLC)
    • 1× Tension Setpoint Input (0~10V/4~20mA; from HMI or PLC)
  • Analog Outputs:
    • 2× Control Outputs (4~20mA; for brake/clutch actuators or drive torque references)
    • 1× Tension Monitor Output (4~20mA; for HMI display of actual tension)
  • Digital Inputs: 4× Discrete Inputs (24V DC; for start/stop, mode selection, or fault reset)
  • Digital Outputs: 4× Discrete Outputs (24V DC; for status indication, fault alarms, or interlock signals)
• Communication Interfaces:
  • Built-in Protocols: Modbus RTU (RS485), Profibus DP (optional), Ethernet/IP (optional)
  • Communication Speed: Up to 115.2kbps (Modbus RTU); up to 12Mbps (Profibus DP)
  • Remote Control: Supports tension setpoint adjustment and status monitoring via PLC/HMI (e.g., ABB CP600 HMI)
• Mechanical Specifications:
  • Housing Type: Flame-retardant plastic (UL94 V-0; DIN rail-mountable)
  • Dimensions (W×H×D): 45mm × 144mm × 105mm (fits standard 35mm DIN rails in control cabinets)
  • Mounting: DIN rail-mounted (35mm; no additional brackets required)
  • Weight: Approximately 300g
  • Display: 4-digit 7-segment LED display (shows actual tension, setpoint, or fault codes)
  • Keypad: 4 tactile buttons (for local setpoint adjustment, mode selection, and menu navigation)
  • LED Indicators: Power (PWR, green), Run (RUN, green), Fault (FLT, red), Alarm (ALM, amber)
• Environmental Ratings:
  • Operating Temperature Range: 0℃~+55℃ (32℉~131℉; suitable for control cabinet installation)
  • Storage Temperature Range: -20℃~+70℃ (-4℉~158℉; no component degradation)
  • Humidity Tolerance: ≤90% RH (non-condensing, 40℃; compatible with factory environments)
  • Vibration Resistance: 10~500Hz, 1g acceleration (IEC 60068-2-6; no display or keypad damage)
  • Shock Resistance: 15g acceleration (11ms duration, IEC 60068-2-27; maintains electrical integrity)
• Compliance Standards: IEC 61010-1 (safety of electrical measuring equipment), EN 61326-1 (EMC for industrial control), UL 508 (industrial safety), CE, RoHS

2. Key Features

• High-Precision Tension Regulation: ±0.5% full-scale accuracy and ≤10ms response time ensure consistent tension for sensitive materials (e.g., thin plastic films, aluminum foil) and high-speed lines (up to 1000m/min)—minimizes material stretching, tearing, or wrinkling.
• Dual Control Modes: Closed-loop (sensor feedback) and open-loop (pre-set) modes adapt to diverse applications: closed-loop for high-precision coating lines, open-loop for simple unwinding of non-sensitive materials (e.g., cardboard).
• Seamless Drive Integration: Optimized for ABB AC drives (e.g., ACS880, ACS580) via analog outputs or communication protocols—enables direct torque reference control for winding/unwinding drives, eliminating the need for intermediate controllers.
• Flexible Communication: Built-in Modbus RTU and optional Profibus DP/Ethernet/IP support integration with factory automation systems (e.g., ABB AC500 PLC, Siemens S7-1200)—allows remote tension adjustment and real-time status monitoring.
• User-Friendly Operation: 4-digit LED display and tactile keypad enable local setpoint adjustment and fault diagnosis; no specialized software is required for basic configuration (advanced settings via ABB Tension Controller Software).
• Rugged DIN Rail Design: Compact, flame-retardant housing (UL94 V-0) and DIN rail mounting simplify installation in control cabinets—saves space and ensures compatibility with standard industrial enclosures.
• Comprehensive Fault Protection: Detects overloads, sensor faults, and communication errors; triggers alarms (digital output + LED) and stores fault codes for troubleshooting—reduces downtime by enabling quick root-cause identification.

3. Application Fields

• Web Processing Industries: Primary application—tension control for continuous material lines:
  • Paper & Printing: Regulates tension in newspaper/magazine printing lines; ensures uniform ink application and prevents paper breakage during high-speed (800m/min) printing.
  • Plastic Film Manufacturing: Controls tension in stretch film or packaging film extrusion lines; maintains consistent film thickness and avoids stretching during winding.
  • Metal Foil Processing: Regulates tension for aluminum foil or copper strip lines; prevents foil wrinkling during slitting or coating (critical for battery electrode foil production).
• Textile & Nonwoven Production: Ensures quality in fiber processing:
  • Textile Weaving: Controls yarn tension in weaving machines; maintains uniform fabric density and reduces yarn breakage (essential for high-quality cotton or polyester fabrics).
  • Nonwoven Manufacturing: Regulates tension in nonwoven fabric lines (e.g., hygiene products); ensures consistent material strength and avoids tearing during bonding.
• Industrial Coating & Laminating: Supports precision coating processes:
  • Electronics Coating: Controls tension in PCB substrate coating lines; ensures uniform application of conductive inks or adhesives (critical for flexible electronics).
  • Laminating Lines: Regulates tension in film/foil laminating (e.g., food packaging); prevents delamination and ensures consistent bond strength.
• Packaging Machinery: Optimizes packaging line performance:
  • Vertical Form-Fill-Seal (VFFS) Machines: Controls film tension to ensure proper bag formation and sealing; reduces packaging waste from misaligned seals.
  • Labeling Machines: Regulates label web tension; ensures accurate label placement on bottles or packages (critical for pharmaceutical or beverage packaging).

4. Precautions

• Load Cell Compatibility: Use only ABB-approved load cells (or load cells with 4~20mA output) for closed-loop control. Mismatched sensors (e.g., 0~5V output) will cause inaccurate tension readings and control errors.
• Wiring Guidelines:
  • Separate analog signal wires (tension feedback, control outputs) from power cables (24V DC, AC drives) by at least 15cm—prevents electrical noise interference (common in drive-rich environments) and ensures stable tension control.
  • Use shielded twisted-pair cables for analog inputs/outputs; ground the cable shield at the controller end (single-point grounding) to eliminate ground loops.
• Tension Range Setting: Configure the controller’s full-scale tension range to match the application (e.g., 0~1kN for film, 0~50kN for metal strips). Setting an overly wide range reduces control accuracy (e.g., 0.1N tension cannot be resolved in a 0~50kN range).
• Environmental Limitations:
  • Install in a control cabinet with ambient temperature ≤55℃. Avoid placing near heat sources (e.g., AC drives, heaters)—high temperatures reduce control accuracy and shorten component life.
  • Do not expose the controller to dust or moisture (IP rating is for indoor cabinet use only); use a cabinet with IP54 or higher protection in dusty environments (e.g., paper mills).
• Calibration Requirements:
  • Calibrate the controller with a known tension reference (e.g., calibration weights) after installation. Uncalibrated systems will have ±5%~±10% accuracy errors—critical for high-precision applications like battery foil processing.
  • Re-calibrate annually (or after sensor replacement) to maintain ±0.5% accuracy; use ABB Tension Controller Software for automated calibration.
• Fault Handling:
  • If the Fault (FLT) LED illuminates, check the 7-segment display for fault codes (e.g., "E01" = load cell fault, "E02" = over-tension). Refer to the user manual to resolve the issue (e.g., check load cell wiring for E01).
  • Do not reset faults without identifying the root cause (e.g., over-tension may indicate a material jam)—repeated fault resets can damage the controller or material.
• Communication Setup:
  • When using Modbus RTU or Profibus DP, ensure the controller’s baud rate, parity, and address match the PLC/HMI settings. Mismatched parameters cause communication timeouts and remote control failures.
  • For Ethernet/IP (optional), use a dedicated network for industrial control (not a corporate IT network)—avoids network congestion and ensures real-time tension adjustments

The structure and details of the product：

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