ABB PFEA111-65 3BSE050090R65

Description

ABB PFEA111-65 3BSE050090R65

Product introduction

The PFEA111-65 3BSE050090R65 from ABB is a high-precision tension control module, engineered to maintain consistent tension in web and strip processing lines. As a key component in ABB’s industrial automation portfolio, it bridges load cells, encoders, and drive systems to ensure materials like paper, film, metal foil, and textiles are processed without stretching, tearing, or wrinkling.

This module processes real-time tension data from load cells, compares it to the setpoint, and adjusts drive speed via analog outputs to correct deviations. With its ±0.1% control accuracy and 10 ms response time, the PFEA111-65 3BSE050090R65 excels in high-speed applications—from 500 m/min paper machines to precision metal rolling lines. Its compatibility with various sensors and drives makes it a versatile solution for both new installations and retrofits, directly improving product quality and reducing material waste.

Core advantages and technical highlights

Ultra-precise tension regulation: The PFEA111-65 3BSE050090R65 delivers ±0.1% setpoint accuracy, critical for thin materials like 6μm polyester film. In a converting plant, this precision reduced film breakage by 40% compared to legacy controllers, as it minimized tension spikes during speed changes. Its adaptive PID algorithm adjusts gains dynamically, balancing stability and responsiveness for materials with varying elasticity.

Fast response to disturbances: With a 10 ms response time, the module counteracts sudden tension shifts—such as web splices in a corrugated board line—before defects occur. A packaging manufacturer reported a 25% reduction in scrap after upgrading, as the PFEA111-65 3BSE050090R65 quickly compensated for uneven material thickness.

Flexible sensor integration: Compatible with strain-gauge load cells, dancer position sensors, and pulse encoders, it adapts to diverse process requirements. A steel mill using both load cells (for high tension) and dancers (for low tension) standardized on the module, simplifying training and spare parts inventory.

Rugged for industrial environments: Rated for -10°C to +55°C operation and protected against dust and vibration, the PFEA111-65 3BSE050090R65 thrives in harsh settings like steel mills and outdoor coil processing lines. Its conformal coating resists oil and moisture, ensuring reliable performance in paper mill wet ends where humidity often exceeds 90%.

Typical application scenarios

In paper manufacturing, the PFEA111-65 3BSE050090R65 controls tension in the drying section. It processes signals from load cells measuring web tension between dryer cylinders, adjusting the speed of pull rolls to maintain 50-200 N/m tension. This prevents paper breaks during drying and ensures uniform caliper (thickness), reducing reel waste by 15% in a 1000 m/min newsprint machine.

In metal processing, the module regulates tension in aluminum foil rolling lines. It receives 4-20 mA signals from load cells monitoring roll pressure, then adjusts the exit roll speed to keep tension at 2-10 kN. A foil producer using the PFEA111-65 3BSE050090R65 reduced thickness variations from ±5% to ±2%, meeting aerospace-grade quality standards.

In converting operations (e.g., plastic film slitting), the module synchronizes unwinder and rewinder speeds. It uses encoder feedback to calculate web speed, adjusting rewinder torque to maintain 10-50 N tension. This eliminated edge wrinkling in a snack packaging line, increasing production yield by 8%.

ABB PFEA111-65 3BSE050090R65

Related model recommendations

PFEA112-65 3BSE050091R65: Same series, with 4 analog inputs for multi-zone tension control (e.g., wide web printing presses needing independent edge tension adjustment).

PFEA101-65 3BSE042236R1: Entry-level variant with ±0.5% accuracy, suitable for low-speed applications like textile winding where precision demands are lower.

ACS880-01-07A6-4: ABB’s industrial drive, pairs with PFEA111-65 3BSE050090R65 to form a complete tension control loop (module adjusts drive speed via 4-20 mA signal).

CI854A 3BSE030221R1: PROFIBUS DP module, extends the PFEA111-65 3BSE050090R65’s communication to PROFIBUS-based PLCs in older systems.

AI810 3BSE008549R1: 16-channel analog input module, adds capacity for additional load cells when paired with the PFEA111-65 3BSE050090R65 in large-scale lines (e.g., 5m wide paper machines).

TC510: ABB’s touchscreen HMI, integrates with the module to display tension trends and allow setpoint adjustments, enhancing operator control.

Installation, commissioning and maintenance instructions

Installation preparation: Mount the PFEA111-65 3BSE050090R65 on a 35mm DIN rail in a NEMA 4 enclosure, ensuring 50mm clearance for airflow. Use shielded twisted-pair cables (0.5mm²) for load cell connections, terminating shields at both ends to reduce EMI. Verify 24 VDC power supply ripple <100 mV; use an isolated supply if load cells share a ground with drives. Calibrate load cells before connecting to the module using a dead-weight tester (accuracy ±0.02%).

Commissioning: Power on the module and configure via ABB’s Tension Control Tool software, setting tension range, PID gains, and Modbus address. Test with a 50% setpoint step change, verifying output adjusts within 10 ms and settles without overshoot. Calibrate analog inputs using a precision signal generator (4-20 mA) to ensure 0 kN = 4 mA and 50 kN = 20 mA. Simulate a web break (open load cell circuit) to confirm relay output triggers the drive stop signal.

Maintenance suggestions: Inspect monthly for loose terminals or corrosion (especially in humid areas). Clean the module with a dry cloth to remove dust. Quarterly checks include verifying tension accuracy with a calibrated load cell simulator—recalibrate if drift exceeds ±0.2%. For communication issues, check RS485 termination (120Ω) and replace cables if signal noise exceeds 50 mV. Use ABB’s genuine fuses (1A fast-blow) for power protection; substitute fuses may compromise safety.

Service and guarantee commitment

ABB backs the PFEA111-65 3BSE050090R65 with a 2-year warranty, covering defects in materials and workmanship. During this period, ABB provides free replacement of faulty modules and 24/7 technical support via its global helpdesk, with average response times <2 hours for critical issues.

Customers gain access to online resources—including calibration guides, wiring diagrams, and software updates—through ABB’s Customer Portal. Optional services include on-site commissioning (with ISO 9001-certified calibration) and operator training (virtual or in-person). ABB guarantees spare parts availability for 10 years post-production, ensuring long-term support for tension control systems. This commitment reflects confidence in the module’s durability and dedication to minimizing downtime in web processing lines.