Description

ABB PFTL101A-0.5kN 3BSE004160R1

I. Overview

ABB PFTL101A-0.5kN 3BSE004160R1 is a tension sensor, with its core positioning as a tension detection unit for light-load scenarios. It is specially designed for precise tension control in industries such as textile, printing, papermaking and film production. The "0.5kN" in the model indicates a rated measurement range of 0–500N. Based on the strain gauge sensing principle, it can collect tension signals of coils, wires and filaments in real time, convert physical tension into standard electrical signals for output, and provide accurate data support for automatic control systems. It is a key component to ensure uniform material tension and avoid tensile deformation during the production process.

This sensor features high measurement accuracy, excellent anti-interference capability and stable long-term operation performance. Encapsulated in a fully sealed metal housing, it is suitable for industrial sites with heavy dust and humidity fluctuations. Supporting standard signal output and multiple installation methods, it can be seamlessly integrated into ABB DCS systems such as 800xA and AC 800M as well as third-party control systems. Widely used in closed-loop tension control of equipment like spinning frames, printing machines and film slitting machines, it balances detection accuracy with the convenience of installation and operation.

II. Core Features

High-precision Tension Detection: Adopting imported high-precision strain gauges, it achieves a measurement accuracy of ±0.1%FS with a linear error of less than 0.05%FS and high resolution. It can accurately capture tiny tension changes within the range of 0–500N, meeting the precise control requirements of light-load scenarios and preventing material damage or uneven stretching caused by tension fluctuations.
Standard Signal & Flexible Adaptation: Outputs 4–20mA analog signal by default, with zero and full-scale adjustment via built-in potentiometers, compatible with various control systems such as PLC and DCS. It supports bidirectional tension detection, capable of measuring both tension and pressure, featuring strong adaptability.
Industrial-grade Stable Protection: Encapsulated in a stainless steel housing with IP65 protection rating, it has good dustproof, waterproof and corrosion-resistant performance. Built-in overload protection circuit with 150%FS overload capacity can effectively withstand instantaneous impact tension, avoiding sensor damage and extending service life.
Easy Installation & Calibration: Supports multiple installation methods including flange and bracket mounting. With compact structure and small size, it can be flexibly integrated into the limited space of equipment. The calibration process is simple, supporting on-site zero and full-scale calibration without professional complex equipment, reducing operation and maintenance difficulty.
Strong Anti-interference Capability: Adopts shielded cables and anti-electromagnetic interference design, complying with industrial EMC standards. It can effectively resist electromagnetic radiation interference from on-site equipment such as frequency converters and motors, ensuring stable signal transmission and preventing clutter from affecting measurement accuracy.

III. Technical Parameters

Parameter Name	Specification
Product Model	ABB PFTL101A-0.5kN 3BSE004160R1
Product Type	Industrial strain gauge type tension sensor
Rated Measurement Range	0–0.5kN (0–500N)
Measurement Accuracy	±0.1%FS, linear error ≤0.05%FS
Output Signal	4–20mA DC analog signal, load resistance 0–500Ω
Power Supply Parameters	24V DC±10%, power consumption ≤2W
Protection Performance	IP65 protection rating, stainless steel housing, 150%FS overload capacity
Installation Method	Flange mounting, bracket mounting, supporting horizontal/vertical installation
Dimensions	Φ80mm × 55mm (main body), mounting hole spacing 60mm
Product Weight	Net weight approx. 0.8kg
Operating Environment	Temperature -20℃~+60℃, relative humidity 5%~95% (non-condensing)

IV. Working Principle

The ABB PFTL101A-0.5kN 3BSE004160R1 sensor is based on the strain gauge working principle, with its core being a closed-loop detection process of tension force bearing – strain conversion – electrical signal output. It realizes real-time tension monitoring by accurately capturing material tension changes and converting them into recognizable electrical signals. The specific working process is divided into three core stages:

Stage 1: Tension Force TransmissionWhen tension is generated in measured objects such as coils and wires, the tension is transmitted to the internal elastic body through the force-bearing end of the sensor. The elastic body undergoes tiny elastic deformation under tension (deformation range at micron level, invisible to the naked eye), and the deformation degree has a linear correspondence with the applied tension.

Stage 2: Strain Signal ConversionThe high-precision strain gauges attached to the surface of the elastic body expand and contract synchronously with the deformation of the elastic body, resulting in changes in the resistance value of the strain gauges (following Ohm's Law). The sensor's built-in Wheatstone bridge circuit converts resistance changes into weak voltage signals, and the signal amplification circuit amplifies the weak signals to a processable range while filtering out clutter interference.

Stage 3: Standard Signal OutputThe amplified voltage signal is converted into a 4–20mA standard analog signal through analog-to-digital conversion and calibration processing (0N corresponds to 4mA, 500N corresponds to 20mA), and transmitted to control systems such as PLC and DCS via shielded cables. The control system adjusts the actuator according to the received signal to achieve closed-loop tension control. Meanwhile, the sensor's built-in overload protection circuit automatically limits the output when the tension exceeds 150%FS, protecting the core components.

V. Common Fault Troubleshooting

1. Abnormal Output Signal, Inaccurate Measurement

Phenomenon: The output signal deviates from the 4–20mA range, or the signal remains unchanged/fluctuates violently. The tension value displayed by the control system is inconsistent with the actual value, affecting production accuracy.

Causes: Sensor zero drift without timely calibration; offset installation of the force-bearing end, causing tension not to be transmitted vertically to the elastic body; unstable power supply voltage beyond the range of 24V DC±10%; on-site electromagnetic interference affecting signal transmission.

Solutions: 1. Perform on-site zero calibration: disconnect the force-bearing end and adjust the built-in zero potentiometer to stabilize the output signal at 4mA; perform full-scale calibration if the deviation is excessive. 2. Check the installation position, adjust the sensor angle to ensure tension acts vertically on the force-bearing end, and tighten the mounting bolts to avoid loosening. 3. Detect the power supply voltage and install a voltage stabilizer to ensure voltage stability; replace with shielded cables and keep away from frequency converters and high-voltage lines to reduce electromagnetic interference.

2. No Output Signal, No Feedback from Control System

Phenomenon: No 4–20mA signal output after the sensor is powered on, no tension data displayed by the control system, and no response from the sensor indicator light (if equipped).

Causes: Open circuit, short circuit or wiring error of the power supply line; damage to the internal circuit of the sensor (e.g., broken strain gauges, amplifier circuit failure); damaged output cable, causing signal transmission interruption.

Solutions: 1. Check the wiring of the power supply line, confirm correct connection of positive and negative poles, tighten the wiring terminals, repair open/short circuits, and ensure stable 24V DC power supply. 2. Test the sensor output terminal with a multimeter; if there is no signal and the power supply is normal, it is determined that the internal circuit is damaged. Contact authorized personnel for maintenance or sensor replacement. 3. Check the output shielded cable and replace the damaged cable to ensure smooth signal transmission.

3. Sensor Damage Due to Overload, Failure to Work Normally

Phenomenon: After the tension exceeds 500N, the sensor output signal is distorted or unchanged, failing to restore normal measurement accuracy subsequently, and even housing deformation may occur.

Causes: Instantaneous tension impact during production exceeds the 150%FS overload limit; no tension buffer device installed, causing sudden tension peaks to act directly on the sensor; application of over-range tension due to misoperation.

Solutions: 1. Check the sensor appearance and output signal; if the housing is deformed or the signal is permanently distorted, replace the sensor immediately and do not continue to use it. 2. Install a tension buffer at the force-bearing end of the sensor to absorb instantaneous tension peaks and avoid over-range impact. 3. Optimize the production process and set tension warning values to prevent sudden over-range tension; standardize the operation of operators to eliminate overload caused by misoperation.