I. Basic Information

Product Introduction: An ABB Pressductor series radial magnetostrictive tension load cell designed for shaft-through mounting. It acts as a core component for real-time radial tension detection on web processing production lines, working in conjunction with PFEA111/PFEA113 tension transmitters and AC800M DCS for 24/7 continuous on-line tension monitoring in papermaking, plastic film and lithium-ion electrode coating production lines. All PFRL101 variants (Type A/B/C/D) share identical mounting bore and overall dimensions, enabling direct in-situ replacement with 0.5kN or 2kN range sensors from the same rack manufactured by ABB Group.

• Brand: ABB Measurement & Analytics | Country of Origin: Finland
• Category: Shaft-penetrated Radial Magnetostrictive Tension Load Cell
• Compatibility: Shaft bearing seats of coaters, paper machines, plastic film extruders and textile slitting machines; matched with ABB PFEA-series signal amplifiers as well as Symphony / AC800 control systems.
• Mounting: Flange fixation with the roller shaft passing through the sensor center; Dimensions: Outer Diameter φ108mm, Inner Bore φ52mm, Thickness 35mm; Net Weight: approx. 0.21kg; One-piece forged 316 stainless steel housing with fully encapsulated internal filling; IP67 ingress protection, resistant to oil contamination, cooling water splash and dust.
• Onboard Configuration: Side-mounted 5-pin M12 circular connector outlet, built-in magnetostrictive core plus high-precision sensing element, fully shielded internal wiring.

II. Technical Specifications

(1) Mechanical & Electrical Parameters

• Rated Load: 1.0kN (≈102kgf); Safe Overload: 150% FS; Ultimate Breaking Load: 500% FS (ABB Group)
• Accuracy: Total comprehensive error ≤±0.2% FS, repeatability error ＜±0.1% FS; Full-scale deformation only 0.01mm for ultra-high rigidity (ABB Group)
• Sensing Principle: Proprietary ABB Pressductor magnetostrictive technology; free of creep drift seen in strain-gauge sensors and superior to conventional load cells in shock resistance (ABB Group)
• Raw Output: mV/V low-level signal; converted into standard 4~20mA analog output via PFEA113 transmitter for direct connection to DCS AI modules.
• Cabling: Standard 5-core shielded cable with industrial M12 anti-pull waterproof connector.

(2) Environmental Parameters

• Operating Temperature: -20℃～+80℃ for long-term continuous operation; Storage Temperature: -40℃～+85℃
• Humidity: 5%~98% RH non-condensing; Compliant with IEC61000 EMC immunity against high-frequency harmonic interference from variable frequency drives; CE industrial metrology certification approved.

III. Key Features

1. Exclusive Design for Radial Shaft Load MeasurementThe roller spindle runs directly through the sensor inner bore, and all radial tension from the roller is fully borne by the sensor. Perfectly suited for dancer roller tension structures and eliminates measuring deviation induced by lateral component force.
2. Long-term Drift-free Magnetostrictive PerformanceUnlike conventional strain-gauge transducers, the magnetostrictive core features negligible temperature drift and creep, requiring no periodic field calibration even under humid papermaking conditions or solvent-corrosive coating environments for years of operation.
3. Fully Sealed IP67 Industrial Grade ProtectionSealed stainless steel construction with internal potting allows direct installation in workshops with cooling water spraying and oil mist, delivering reliable protection against water, dust and chemical corrosion.
4. Modular Interchangeability Across Load Ranges with Uniform DimensionAll PFRL101C sensors adopt unified housing dimensions; three rated capacities (0.5kN/1.0kN/2.0kN) share identical outline, so only the sensor needs replacement without altering rack mounting dimensions during equipment retrofits.
5. Standardized System CompatibilityRaw millivolt signals are amplified and conditioned by PFEA111/PFEA113 transmitters; the resulting 4~20mA signal can be directly wired to ABB AC800M, S800 I/O or analog modules of third-party PLC brands.

IV. Working Principle

V. Application Fields

1. Tension control for dryer and rewinder sections on base paper & specialty paper production lines in paper mills;
2. Dancer roller tension sampling for BOPET/CPP plastic film extrusion, slitting and coating lines;
3. On-line closed-loop tension control for lithium electrode & aluminum foil coating and slitting equipment;
4. Replacement spare parts for tension system upgrade on nonwoven fabric, textile printing & dyeing and adhesive tape production lines.

Range & Version Classification

• PFRL101C-1.0kN (3BSE023316R1002): Standard in-stock version with 1kN rating, widely used for medium & low tension applications in film and papermaking industries;
• PFRL101C-0.5kN (3BSE023315R×××): For small-tension measurement of ultra-thin substrate materials;
• PFRL101C-2.0kN (3BSE002964R002): Designed for heavy-duty high-tension scenarios of thick paper and heavy-gauge plastic films.