ABB PFEA113 Tension Controller Troubleshooting Guide

Flash or EEPROM errors: These types of hardware level faults are usually not repairable on site and can only be resolved by replacing the controller.

Symptom 2: During the operation of the strip, there is a significant fluctuation or zero drift in the displayed tension value

Checking for interference sources: Parallel routing of power cables and signal cables is a typical error. The two must maintain a distance of at least 0.3 meters and intersect at a right angle.

Check the wiring terminals: Solid wires should not be used for wires, and suitable pin terminals must be crimped. If there are loose copper wires overlapping adjacent terminals, it will cause small leakage current interference.

Checking polarity: This is the easiest thing to overlook. Apply a simulated tension force to the sensor with both hands and observe if the displayed value is positive. If connected in reverse, the signals from sensors A and B will cancel each other out when summing up, resulting in 'no signal even when loaded'.

Symptom 3: Profibus communication interruption

Check the physical connection: Is the bus terminal resistor set to the correct position? Is the shielding layer of the network cable damaged?

Verify if the Profibus address (0-125) of PFEA113 matches the PLC configuration exactly? Does the GSD file match?

Special strategy: Single side measurement downgrading operation (life-saving straw)

If a tension sensor (such as side A) suddenly breaks during peak production and cannot be replaced in a short period of time, PFEA113 provides a very practical emergency solution.

Disconnect the damaged sensor A.

Short circuit excitation circuit: Connect a short wire between X2:1 and X2:2 (if C is damaged, short circuit X2:5 and X2:6).

Modify parameters: Enter the menu and change the "Object Type" from "StandardRoll" to "SingleSideA".

At this point, the controller will automatically multiply the tension value measured on the B side by 2, in order to maintain the degraded operation of the production line in the event of a sensor failure on one side, avoiding the entire production line from shutting down.

Accurate setting of Wrap Gain

In order to display the actual strip tension on the display screen, it is necessary to determine the ratio between the strip tension and the pressure measured on the sensor (wrap angle gain). PFEA113 provides two methods:

Hang Weight method: the simplest and most direct. Hang a weight of known weight along the path of the strip with a rope. The system will automatically measure the force and calculate the package angle gain. Attention: All rollers must be freely turning idler rollers, and only the closest roller can be used to define the strip path to reduce friction losses.

EnterWrapGain input method: If it is not possible to hang weights, they can be calculated using a formula. The range of angular gain is 0.5-20. If it exceeds the range, the screen will prompt "WrapGainTooLow" or "WrapGainTooHigh".

During debugging, the Zero Set must be performed in a state where there is no tension in the strip on the measuring roller. If the zero adjustment is accidentally triggered when the strip is tightened, the controller will mistakenly record the current tension as "tare weight" as zero, resulting in significantly lower subsequent measurement values.