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ABB PFEA111-65 (3BSE028140R0065) Tension Control Module 

1. Key Parameters

• Product Model: PFEA111-65
• Order Code: 3BSE028140R0065
• Product Series: ABB AC800M Process Control Modules (Web/Strand Tension Regulation)
• Core Function: Acquires analog tension signals from transducers; executes closed-loop tension control (PID); outputs control signals to actuators (e.g., drives, brakes); monitors tension deviations and triggers alarms; synchronizes with AC800M for centralized control
• Electrical Specifications:

  Parameter	Details	Performance Metrics
  Input Channels	- Tension Sensor Inputs: 2× analog channels (4~20mA DC; 0~10V DC, configurable) - Reference Inputs: 1× analog (4~20mA/0~10V) + 1× digital (PROFIBUS DP setpoint) - Feedback Inputs: 1× encoder input (A/B phase, up to 100kHz) for speed-compensated tension	Supports dual-sensor redundancy; Enables speed-adaptive tension control
  Output Channels	- Control Outputs: 2× analog (4~20mA DC; 0~10V DC) for drives/brakes - Alarm Outputs: 2× digital relay outputs (2A AC 250V / 2A DC 24V) for fault signaling	Drives unwinder/winder actuators; Triggers emergency stops for tension anomalies
  Tension Control Performance	- Control Accuracy: ±0.5% of full scale (FS) - PID Response Time: ≤10ms (settling time for 10% FS step change) - Tension Range: 0~100kN (configurable via software)	Ensures uniform web tension (e.g., ±0.5N for 100N film tension)
  Communication Protocol	PROFIBUS DP V1 (slave mode); Baud rate: 9.6kbps~12Mbps (auto-negotiation) - Cycle time: ≤1ms (for tension data sync with AC800M)	Real-time tension data exchange with AC800M; Enables remote setpoint adjustment
  Power Supply	24V DC ±10% (single input); Current consumption: ≤60mA (no load); ≤120mA (full load)	Compatible with standard industrial 24V DC power systems
  Isolation Level	- Input-to-output: 2kVrms (1min dielectric test) - Signal-to-bus/power: 1kVrms (1min dielectric test)	Prevents ground loops and EMI interference between tension sensors and drives
  Protection Features	- Over-tension Protection: Configurable threshold (e.g., 120% FS) triggers alarm/output cutoff - Under-tension Protection: Configurable threshold (e.g., 80% FS) triggers warning - Sensor Fault Detection: Open/short circuit detection for tension inputs	Prevents web breakage (over-tension) or slack (under-tension); Identifies faulty sensors

• Mechanical Specifications:
  • Housing Material: Flame-retardant thermoplastic (UL94 V-0); Impact resistance: IK04
  • Dimensions (W×H×D): 22mm × 100mm × 160mm (DIN rail-mountable; fits AC800M I/O racks)
  • Mounting: 35mm standard DIN rail (TS 35/7.5); Snap-on installation (no tools required)
  • Weight: Approximately 150g
  • Terminals: 2× 24-pin spring-cage terminals (for inputs/outputs); 1× 9-pin D-sub connector (PROFIBUS DP)
  • LED Indicators:
    • Power (PWR): Green (24V DC active); Red (power fault)
    • Bus (BUS): Green (PROFIBUS DP normal); Flashing green (data transmission); Red (bus fault)
    • Tension Status (TNS): Green (normal); Yellow (under-tension warning); Red (over-tension alarm)
    • Sensor (SNS1/SNS2): Green (sensor normal); Red (sensor fault)
• Environmental Ratings:
  • Operating Temperature Range: -25℃~+60℃ (-13℉~140℉)
  • Storage Temperature Range: -40℃~+85℃ (-40℉~185℉)
  • Humidity Tolerance: ≤95% RH (non-condensing, 40℃; suitable for paper/film plant environments)
  • Vibration Resistance: 10~500Hz, 1g acceleration (IEC 60068-2-6; No tension control deviation)
  • Shock Resistance: 15g acceleration (11ms duration, IEC 60068-2-27; Maintains PID stability)
  • EMC Immunity: Complies with IEC 61000-4-2 (ESD: ±8kV contact); IEC 61000-4-4 (EFT: ±2kV); IEC 61000-4-6 (RS: 10V/m) | Resists noise from drive systems |
• Compliance Standards: IEC 61131-2 (industrial control equipment), EN 61000-6-2 (EMC immunity), UL 508 (industrial safety), CE, RoHS, IEC 61508 (SIL 1 capable for tension safety loops)

2. Key Features

• High-Precision Tension Regulation: ±0.5% FS control accuracy and ≤10ms PID response time ensure consistent web tension—critical for high-quality products (e.g., uniform paper thickness, no film stretching) and reduces material waste (e.g., web breakage) by 40% compared to basic tension controls.
• Dual-Sensor Redundancy & Fault Detection: 2 independent tension sensor inputs with open/short circuit detection enable sensor redundancy—if one sensor fails, the module switches to the backup (≤5ms switchover), avoiding unplanned downtime in 24/7 processes (e.g., paper mills).
• Speed-Compensated Tension Control: Integrated encoder input (up to 100kHz) adjusts tension setpoints based on web speed (e.g., lower tension at high unwinder speeds, higher tension at low speeds)—eliminates speed-induced tension fluctuations (e.g., film slack at startup) common in fixed-setpoint systems.
• AC800M PROFIBUS DP Seamless Integration: Automatically recognized by ABB AC800M via PROFIBUS DP; Control Builder M software provides pre-configured tension control function blocks (e.g., PID tuning, setpoint ramping)—reduces setup time by 60% compared to custom-programmed tension systems.
• Configurable Over/Under-Tension Protection: User-defined tension thresholds trigger alarms or emergency output cutoff—prevents catastrophic failures (e.g., web breakage from over-tension, product defects from under-tension) and protects expensive equipment (e.g., rollers, drives).
• Compact 22mm Form Factor: Fits densely packed AC800M I/O racks—eliminates the need for bulky standalone tension controllers, reducing control cabinet space by 30% and simplifying wiring (shared power/bus with other AC800M modules).
• SIL 1 Safety Compliance: Meets IEC 61508 SIL 1 requirements for tension safety loops—suitable for low-risk web processes (e.g., non-critical film production), ensuring basic fault mitigation aligned with industrial safety standards (e.g., ISO 13849-1).

3. Application Fields

• Web Processing Industries: Primary application—tension control for continuous web materials:
  • Paper & Pulp Mills: Regulates tension of paper webs in printing/papermaking lines; uses dual PFTL101A tension transducers to monitor web tension between rollers; speed-compensated control adjusts for varying press speeds, ensuring uniform paper thickness and preventing web breaks.
  • Plastic Film Production: Controls tension of polyethylene/polyester films in extrusion lines; over-tension protection (120% FS) triggers drive cutoff to avoid film stretching, while under-tension warning (80% FS) alerts operators to slack, maintaining consistent film width.
• Metal Processing Lines: Tension regulation for metal strips/foils:
  • Steel Strip Coating Lines: Maintains tension of steel strips during galvanizing/painting; encoder input synchronizes tension with strip speed (up to 50m/min), preventing strip wrinkling or tearing; PROFIBUS DP sync with AC800M enables centralized tension monitoring across multiple coating stations.
  • Aluminum Foil Rolling Mills: Controls tension of thin aluminum foil (0.01mm~0.1mm) during cold rolling; ±0.5% FS accuracy ensures uniform foil thickness, while sensor fault detection avoids unplanned stops from faulty tension transducers.
• Textile & Nonwoven Production: Tension control for textile strands/nonwoven webs:
  • Textile Dyeing Lines: Regulates tension of yarn strands during dyeing/weaving; under-tension protection prevents yarn tangling, while over-tension protection avoids yarn breakage—reducing textile waste by 30% compared to manual tension adjustment.
  • Nonwoven Fabric Lines: Maintains tension of nonwoven webs (e.g., hygiene product materials) during bonding/rewinding; speed-adaptive control adjusts for web thickness variations, ensuring consistent fabric density and bond strength.
• Printing & Packaging Industries: Tension control for print media/packaging materials:
  • Flexographic Printing Presses: Controls tension of plastic films/label stock during printing; precise PID regulation ensures alignment of print layers (e.g., multi-color labels), while alarm outputs trigger press stops for tension anomalies—reducing misprinted material waste by 25%.
  • Packaging Rewinding Machines: Maintains tension of packaging films (e.g., stretch film) during rewinding onto rolls; over-tension protection prevents roll deformation, while AC800M integration enables remote setpoint adjustment for different roll sizes.

4. Precautions

• System Compatibility (Critical): Use exclusively with ABB tension transducers (e.g., PFTL101A, PFTL201A) and AC800M PLCs—non-ABB sensors may have incompatible signal ranges (e.g., 0~5V vs. 0~10V), causing tension measurement errors (e.g., 50% under-read). Verify sensor compatibility with ABB technical specifications.
• Installation & Calibration:
  • Sensor Wiring: Use shielded twisted-pair cables (24AWG~20AWG) for tension sensor inputs—unshielded cables pick up EMI from drives, causing tension signal noise (e.g., ±2% FS fluctuation). Ground shields at the module end (single-point grounding).
  • Tension Calibration: Calibrate the module with a precision tension calibrator (e.g., ABB CPC200) after installation—incorrect calibration (e.g., 100N sensor mapped to 200N FS) leads to over/under-tension control, damaging web materials. Follow ABB calibration procedures in the user manual.
• PID Tuning & Setpoint Configuration:
  • PID Parameter Matching: Tune PID gains (proportional/integral/derivative) to match web material properties (e.g., high integral gain for flexible films, low derivative gain for rigid metal strips)—poor tuning causes tension oscillations (e.g., web "hunting" between over/under-tension), degrading product quality.
  • Setpoint Ramping: Enable setpoint ramping (via Control Builder M) for startup/shutdown—abrupt setpoint changes (e.g., 0→100N in 1ms) cause web shock loads, leading to breakage. Set ramp time to 1~5s based on material flexibility.
• Electrical Safety & Protection:
  • Power Disconnection: Disconnect 24V DC power and PROFIBUS DP bus before wiring/removing the module—exposed terminals carry live voltage and control signals; accidental contact can damage the module or trigger unintended drive actuation (e.g., brake release).
  • Over-Tension Threshold Setting: Set over-tension threshold to 110%~120% of normal operating tension—too high (e.g., 150% FS) risks web breakage, while too low (e.g., 105% FS) causes false alarms, disrupting production. Validate with material strength data.
• Environmental Limitations:
  • Temperature & Humidity: Do not operate above +60℃ or in condensing humidity—high temperatures degrade PID circuit stability, while condensation causes terminal corrosion, leading to intermittent sensor signals (e.g., random tension spikes). Install in air-conditioned control cabinets for paper/film plants with high humidity.
  • Vibration & Shock: Avoid mounting near high-vibration equipment (e.g., web rollers, drives)—vibration >1g causes encoder signal loss, leading to speed-compensation errors. Use vibration-damping DIN rail mounts if needed.
• Maintenance & Monitoring:
  • Quarterly Sensor Checks: Inspect tension sensors for alignment (e.g., no misalignment with web path) and cable integrity—misaligned sensors measure incorrect tension (e.g., 10% low), while damaged cables cause sensor faults. Clean sensor surfaces (e.g., load cells) to remove web debris.
  • PID Performance Monitoring: Track tension deviation via AC800M DCS—consistent deviations (>1% FS) indicate sensor drift or PID gain degradation; recalibrate sensors or retune PID parameters promptly to avoid product defects.
  • Firmware Updates: Update module firmware only with ABB-approved versions (via PROFIBUS DP)—unauthorized firmware may disable safety features (e.g., over-tension protection), increasing equipment damage risk

The structure and details of the product：

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