ABB PFEA112-20 3BSE050091R20 Tension Control amplifier

ABB PFEA112-20 3BSE050091R20 Tension Control amplifier

Product core positioning

ABB PFEA112-20 3BSE050091R20 is a high-precision industrial grade tension control amplifier designed specifically for coil production scenarios such as film, paper, metal foil, textile fabrics, etc. Its core function is to receive analog signals from tension sensors (such as tension detectors and load sensors), and after precise calculation and amplification, output control instructions to the executing mechanism (such as frequency converters, servo motors, magnetic powder brakes) to adjust the tension of the coil in real-time during transportation, winding, and unwinding, avoiding problems such as stretching, wrinkling, and breakage of the coil. As a key component of ABB's tension control system, it can operate independently or be integrated into DCS/PLC systems, and is widely suitable for industries such as printing, packaging, metallurgy, and textiles that require strict tension accuracy.

Key technical parameters

1. Signal input and output characteristics

Input signal type:

Tension sensor input: Supports 4-20mA analog current signal (compatible with ABB tension sensors such as PFTL series or third-party standard sensors), input impedance ≤ 250 Ω;

Reference tension setting: Supports 0-10V analog voltage signals (manually set or remotely set by the upper system), or receives the set value through a digital interface (RS-485);

Speed compensation input: Supports 0-5V analog voltage signals (used to compensate for the impact of changes in coil speed on tension).

Output control signal:

Analog output: 2 independent 4-20mA current signals (control actuator, load capacity ≤ 500 Ω), output accuracy ± 0.1% FS

Digital output: 2-channel relay output (used for tension over limit alarm, system fault prompt, contact capacity 250V AC/3A);

Communication interface: 1 RS-485 interface (supporting Modbus RTU protocol), used for communication with upper computers (such as PLC, HMI) to achieve parameter configuration and data monitoring.

2. Tension control performance

Control accuracy: Tension control error ≤ ± 0.5% (within the rated tension range, under stable operating conditions);

Response speed: The step response time is ≤ 100ms (from the occurrence of tension deviation to the completion of output command adjustment), which can quickly suppress tension fluctuations;

Tension range: Supports 0-50kN tension control (adapts to tension sensors of different ranges through parameter settings, and can be expanded up to 100kN);

Control mode: Supports three modes: constant tension control, taper tension control (gradually reducing tension with increasing coil diameter during winding process), and segmented tension control (setting different tension values at different production stages), to meet diverse production needs.

3. Environmental and electrical parameters

Working temperature range

-10 ℃ to+55 ℃

Adapt to industrial workshop environment, avoid direct sunlight or proximity to high-temperature equipment

Protection level

IP30 (module body)

It needs to be installed inside the control cabinet to prevent a large amount of dust from entering

Power requirements

24V DC (± 15% voltage fluctuation)

Maximum power consumption ≤ 12W, with overvoltage and overcurrent protection functions

Anti-interference ability

Compliant with EN 61000-6-2 (Industrial Environment Immunity) standard

Can resist electrostatic discharge (± 6kV contact discharge, ± 8kV air discharge) and electrical fast transient pulse group (2kV/5kHz) interference, ensuring stable control signals

Physical dimensions

100mm x 75mm x 150mm (length x width x height)

Adopting DIN rail installation (compatible with 35mm standard rail), compact design saves control cabinet space

4. Security and authentication

Through CE certification and UL certification, it meets the electrical safety standards of the European Union and North America;

Equipped with tension over limit protection function (can set upper and lower limit thresholds), when the tension exceeds the range, it automatically outputs an alarm signal and cuts off the control output (optional) to prevent equipment damage or coil scrap.

Core performance advantages

High precision and high stability: A 24 bit high-precision AD converter is used to collect tension signals, combined with ABB's self-developed PID+feedforward control algorithm, which can effectively eliminate static errors and dynamic lag. Even in the case of changes in coil speed (such as acceleration, deceleration, start stop) or uneven material, tension stability can still be maintained; Built in temperature compensation circuit can offset the impact of environmental temperature changes on electronic components, ensuring long-term accuracy without drift.

Flexible adaptation and ease of use: Supports the integration of multiple types of tension sensors and actuators without the need for additional signal conversion modules, reducing system integration costs; Equipped with a 4.3-inch monochrome LCD display screen and 4 operation buttons, the module can directly set tension values, modify control parameters (such as PID parameters, alarm thresholds), and display real-time information such as current tension, output current, and operating status without relying on the upper computer, simplifying debugging and operation processes.

Intelligence and fault diagnosis: Built in self diagnostic function can monitor sensor disconnection, power supply abnormality, actuator failure and other issues in real time, and display fault codes on the display screen (such as "E01" representing sensor open circuit, "E03" representing power overvoltage), while triggering relay alarms to help operation and maintenance personnel quickly locate faults; Support parameter backup and recovery (through RS-485 interface or local button operation) to avoid parameter loss caused by module replacement and shorten downtime.

Scalability and compatibility: Multi module networking can be achieved through RS-485 interface (supporting up to 32 modules communicating simultaneously), adapting to the multi station tension control requirements of large production lines (such as synchronous control of unwinding, printing, and rewinding in printing machines); Compatible with ABB AC500 PLC and 800xA DCS systems, it can also communicate with third-party PLCs such as Siemens S7-1200/1500 and Schneider M340, and can be integrated into existing control systems without modifying hardware.