ABB PFRL101C

ABB PFRL101C

Product Brief:​ The PFRL101C is a member of ABB’s Pressductor® PillowBlock (PFRL)​ family — a robust, hermetically sealed tension/force transducer based on the magnetostrictive (Pressductor®) principle or high-precision strain-gauge bridge (depending on series — PFRL1xx is typically the Pressductor magnetostrictive type for high accuracy & overload capability). It measures the running web tension​ in paper, foil, plastic film, metal strip, or wire lines by detecting the small force exerted on a measuring roll supported by two PillowBlocks. The “C” suffix often denotes a specific cable exit orientation, mounting variant, or calibrated range option. The sensor outputs a low-level mV/V signal (Pressductor versions output a conditioned current/voltage via separate amplifier; strain-gauge versions are 4-wire bridge 2 mV/V typical).

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Category: SKU: ABB PFRL101C

Description

ABB PFRL101C

  • Technical Specifications
    • Measuring Principle: Pressductor® magnetostrictive (some PFRL1xx also offered as strain-gauge SG version — verify by nameplate)
    • Rated Load (Fn): Selected per frame size — common sizes: 1 kN, 2 kN, 5 kN, 10 kN, 20 kN, 50 kN, 100 kN, 200 kN, 500 kN (for strip mills)
    • Overload Capability: 150 % of rated load (static), 300 % (shock) — Pressductor excels here vs. strain-gauge
    • Output Signal:
      • Pressductor version: Requires PFSA / PFTL amplifier → standard 0–10 V / 4–20 mA proportional to tension
      • Strain-gauge version: 2 mV/V (nominal), 350 Ω bridge; exc. 10 V DC recommended
    • Accuracy / Nonlinearity: ≤±0.5 % FS (Pressductor); ≤±0.1 % FS (SG calibrated)
    • Repeatability: ≤±0.1 % FS
    • Hysteresis: ≤±0.1 % FS
    • Temperature Effect on Zero / Span: ≤±0.005 % FS/°C (Pressductor — very low)
    • Operating Temp. (Sensor): –20 °C to +70 °C (–40 °C storage)
    • Ingress Protection: IP67 (hermetically sealed stainless steel housing; laser-welded)
    • Material: Stainless steel measuring element & housing (AISI 316L / 17-4 PH); nickel-plated alloy steel bolts (high tensile)
    • Cable: Polyurethane or PVC-jacketed, armored option; typical length 5 m / 10 m; shielded 4-wire (SG) or 2×twisted-pair + shield (Pressductor with amp)
    • Mounting: Horizontal (web over roll) or vertical (roll hangs between two PillowBlocks) — PFRL designed for both; use appropriate adapter plates / bearing blocks per ABB mounting kit
  • Functional Features:
    • High overload withstand without damage or zero shift — ideal for rolling mill shock loads
    • Immune to temperature drift (Pressductor) — no frequent re-zeroing needed in varying ambient
    • No moving parts — wear-free; very long MTBF
    • Measures both total tension and (with dual-PillowBlock + math) can infer off-center loading
    • Compatible with ABB tension electronics (PFSA140, PFTL301E, PFVI401, etc.)
  • Application Scenarios:
    • Paper / board machine — couch roll, size press, calendar stack tension measurement
    • Metal strip rolling mill — entry/exit strip tension (PFRL in vertical mount between backup chocks & load cell seat)
    • Plastic film / foil converting — unwind / rewind tension control
    • Wire & cable drawing lines — capstan tension
    • Printing press — nip load inference via measuring roll on PFRL PillowBlocks
  • Material & Structure:
    • One-piece forged stainless steel body with integral measuring zone (Pressductor plate or SG bridge inside)
    • Top & bottom machined flats with locating dowel holes for adapter plates
    • Cable gland: M12 or PG7 stainless steel; cable strain-relieved
    • Alignment pins / mounting holes per ABB PillowBlock dimensional drawing (ISO 8513compatible envelope for many sizes)
  • Working Principle:
    • Pressductor®:​ An alternating magnetic field is established in a ferromagnetic plate (Pressductor element) by an excitation coil. When mechanical stress is applied, the magnetostrictive effect changes the permeability anisotropically → secondary pick-up coils detect a stress-proportional voltage. This voltage is linear with the applied normal force (tension reaction on the roll bearing). The external amplifier (PFSA140) demodulates, scales, and outputs standard analog signals.
    • Strain-Gauge version:​ Four resistive strain gauges form a Wheatstone bridge on the elastic element. Applied force causes micro-strain → bridge imbalance → output voltage proportional to load (2 mV/V typical). Conditioned by a strain-gauge transmitter (PFTL301E etc.).
  • Installation Requirements:
    • Mount PillowBlocks on a rigid, flat machined seat — parallelism between upper & lower mounting surfaces ≤0.05 mm
    • Use ABB-specified high-tensile mounting bolts; tighten to specified torque (typically 0.7 × bolt yield strength) in cross pattern
    • Align measuring roll’s bearing housings with PillowBlock bores; ensure roll axial float is taken up by one side (fixed) and the other side (floating) allows thermal expansion — do NOT restrain both sides axially​ or thermal growth will appear as false tension
    • Route signal cable separate from VFD / power cables; ground shield at amplifier / transmitter end only; do NOT ground at sensor end (to avoid ground loops — some local codes require shield drain wire connected at sensor end via 1 MΩ to earth — follow ABB wiring diagram)
    • After installation perform mechanical zero (roll installed, web off, no tension) → zero the amplifier
  • Precautions:
    • Never apply side thrust / moment to PillowBlock​ beyond manufacturer’s allowable — it is designed for pure vertical/horizontal compressive load only
    • Do NOT exceed rated overload repeatedly — though Pressductor tolerates shocks, repeated over-range shortens life
    • Protect cable from hot metal splash (mills) or cutting oils — use armored conduit / steel spring guard if needed
    • For Pressductor version: always use with specified ABB amplifier (PFSA140 / PFTL301E with Pressductor option) — mismatch causes incorrect scaling or no signal
    • Periodically verify zero with web off (no tension) — drift >spec indicates possible mechanical binding or cable fault

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