Description

The ABB PFTL101A 0.5 kN(internal part number 3BSE004160R1)is a high-accuracy,compact S-beam tension load cell engineered for precise force measurement in continuous web processing applications.Designed for integration into ABB’s automation ecosystems—including AC 800M controllers and System 800xA—it delivers reliable real-time tension feedback for materials such as paper,plastic film,textiles,and metal foil.

This rugged transducer combines strain gauge technology with built-in signal conditioning to provide a stable analog output,enabling closed-loop tension control that minimizes web breaks,improves product quality,and maximizes line speed.

Application Scenarios

At a European flexible packaging plant,frequent film breaks during high-speed lamination were causing 15%production loss and inconsistent adhesive coating thickness.Engineers installed ABB PFTL101A 0.5 kN load cells on the unwind and rewind stations to monitor web tension in real time.Integrated with an AC 800M controller running PID-based tension regulation,the system maintained tension within±0.5 N across speeds from 50 to 400 m/min.Within weeks,web breaks dropped by 90%,coating uniformity improved by 30%,and annual waste costs fell by over€220,000.This transformation highlights how the PFTL101A 0.5 kN turns mechanical force into actionable intelligence—making it indispensable in precision converting operations.

Parameter

Main Parameters Value/Description

Product Model PFTL101A 0.5 kN

Internal Part Number 3BSE004160R1

Manufacturer ABB Ltd.

Product Category Tension Load Cell/Force Transducer

Nominal Capacity 0.5 kN(50 kgf/112 lbf)

Output Signal 0–10 V or 4–20 mA(configurable via internal jumper)

Accuracy±0.1%of full scale(including nonlinearity,hysteresis,and repeatability)

Protection Rating IP67(dust-tight and protected against temporary immersion)

Operating Temperature–10°C to+70°C(compensated range:0°C to+60°C)

Material Stainless steel(AISI 304),corrosion-resistant

Electrical Connection M12 5-pin industrial connector(standard)

Mounting Style Dual M6 threaded holes(tension-only application)

Compliance CE,RoHS,EMC Directive 2014/30/EU

Technical Principles and Innovative Values

Innovation Point 1:Integrated Signal Conditioning–Unlike raw strain gauge bridges,the PFTL101A 0.5 kN includes onboard amplification and filtering,delivering a clean,noise-immune analog signal directly compatible with PLCs and DCS I/O cards—eliminating external transmitters.

Innovation Point 2:Temperature-Compensated Strain Gauges–Proprietary foil gauge layout and thermal compensation algorithms minimize drift across ambient swings,ensuring consistent accuracy in unconditioned factory environments.

Innovation Point 3:Optimized for Dynamic Web Loads–The S-beam geometry provides high stiffness and natural frequency(>1 kHz),enabling accurate response to rapid tension changes during acceleration,deceleration,or splicing.

Innovation Point 4:Seamless ABB Ecosystem Integration–Pre-characterized scaling parameters allow direct use in Control Builder M and 800xA graphics,reducing engineering time and configuration errors during system commissioning.

Application Cases and Industry Value

In a North American label printing facility,inconsistent die-cut registration was traced to tension fluctuations during roll changes.After retrofitting all dancer roller arms with ABB PFTL101A 0.5 kN sensors,the closed-loop dancer control system achieved±1%tension stability.Registration errors fell by 75%,and press uptime increased by 12%.Similarly,a lithium battery electrode coater in Asia replaced legacy load cells with PFTL101A 0.5 kN units to meet tighter coating weight tolerances.The result:±0.8µm coating thickness variation(down from±2.5µm),directly improving cell energy density and cycle life—proving the sensor’s value in high-tech manufacturing.

Related Product Combination Solutions

ABB AC 800M PM864:Controller for implementing advanced tension control logic using PFTL101A 0.5 kN feedback

ABB AI810 Analog Input Module(3BSE008516R1):16-channel 4–20 mA card for interfacing multiple PFTL101A sensors

ABB PFTL101A 1.0 kN/2.0 kN:Higher-capacity variants for heavy-duty converting or steel strip lines

ABB DCS880 Drive:Integrates tension reference from PFTL101A for coordinated master/follower speed control

ABB System 800xA:Visualizes real-time tension trends,alarms,and historical analysis for predictive maintenance

ABB TB840 Terminal Block:Provides secure,shielded connection between PFTL101A and I/O modules

ABB PCM600:Engineering tool for calibrating and validating PFTL101A signal integrity during commissioning

ABB 3BSE004161R1(PFTL101A 0.25 kN):Lower-range option for ultra-light films or lab-scale pilot lines

Installation,Maintenance,and Full-Cycle Support

Installing the ABB PFTL101A 0.5 kN requires proper mechanical alignment to ensure pure tensile loading—avoid bending moments or side loads.Mounting surfaces must be parallel and clean;torque specifications for M6 bolts should be strictly followed(typically 6 Nm).The M12 connector enables quick field wiring with standard industrial cables,and shielded twisted-pair is recommended for analog signals to reject EMI from nearby drives.

Routine maintenance is minimal due to the solid-state design and IP67 sealing,but periodic verification(e.g.,annually or after mechanical impact)using a calibrated deadweight tester is advised.Zero-point drift can be corrected via software offset in the controller—no physical recalibration needed.All units we supply are factory-tested for linearity,hysteresis,and temperature performance across the full 0.5 kN range.

We offer end-to-end support:from mechanical mounting consultation and signal validation to integration with your existing ABB or third-party control system.Every PFTL101A 0.5 kN comes with a calibration certificate,test report,and 12-month warranty.

Contact us for a customized solution—whether you’re upgrading a legacy tension system,troubleshooting web instability,or designing a new high-speed converting line,our expertise ensures your ABB PFTL101A 0.5 kN delivers micron-level process control,maximum yield,and long-term reliability.

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