Web Tension Systems

Web Tension Systems

Web Tension
measurement
with Tension Electronics PFEA111/112
User Manual
3BSE029380R0001 Rev B
Pressductor® Technology
Use of DANGER, WARNING, CAUTION, and NOTE
This publication includes, DANGER, WARNING, CAUTION and NOTE information where appropriate to point out safety
related or other important information.
DANGER Hazards which could result in severe personal injury or death
WARNING Hazards which could result in personal injury
CAUTION Hazards which could result in equipment or property damage
NOTE Alerts user to pertinent facts and conditions
Although DANGER and WARNING hazards are related to personal injury, and CAUTION hazards are associated with
equipment or property damage, it should be understood that operation of damaged equipment could, under certain operational
conditions, result in degraded process performance leading to personal injury or death. Therefore, comply fully with all
DANGER, WARNING, and CAUTION notices.
TRADEMARKS
®
Pressductor is a registered trademark of ABB Automation Technologies AB.
NOTICE
The information in this document is subject to change without notice and should not be construed as a commitment by ABB
Automation Technologies AB. ABB Automation Technologies AB assumes no responsibility for any errors that may appear in
this document.
In no event shall ABB Automation Technologies AB be liable for direct, indirect, special, incidental or consequential damages
of any nature or kind arising from the use of this document, nor shall ABB Automation Technologies AB be liable for incidental
or consequential damages arising from use of any software or hardware described in this document.
This document and parts thereof must not be reproduced or copied without ABB Automation Technologies AB’s written
permission, and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose.
The software described in this document is furnished under a license and may be used, copied, or disclosed only in accordance
with the terms of such license.
CE-MARKING
The Tension Electronics PFEA111/112 fulfills the requirements as stated in the EMC Directive 89/336/EEC and the Low
Voltage Directive 73/23/EEC, provided that the installation is carried out in accordance with the installation instructions given
in Chapter 2 Installation, included in this User Manual.
The Tension Electronics PFEA111-20, PFEA111-65 and PFEA112-20 fulfill the requirements of safety approval for USA and
Canada according to the standard UL61010C-1 for Process Control Equipment and CSA C22.2 No. 1010-1 Safety
Requirements for Measurement, Control and Laboratory Use, Part 1: General Requirements Certificate No. 170304-E240621
and No. 240504-E240621, provided that the installation is carried out in accordance with the installation instructions given in
Chapter 2 Installation, included in this User Manual.
3BSE001264/B
Copyright  ABB Automation Technologies AB, 2004.

Template: 3BSE001286/D
3BSE029380R0001 Rev B
Tension Electronics PFEA111/112, User Manual
Table of Contents
TABLE OF CONTENTS
Chapter 1 - Introduction
1.1 About this Manual ................................................................................................... 1-1
1.2 How to Use this Manual .......................................................................................... 1-1
1.2.1 Getting Started ........................................................................................ 1-1
1.2.2 Saving Actual Data and Settings at Commissioning .............................. 1-1
1.3 About this System.................................................................................................... 1-2
1.4 Safety Instructions ................................................................................................... 1-3
1.4.1 Personnel Safety ..................................................................................... 1-3
1.4.2 Equipment Safety.................................................................................... 1-3
1.5 The Measuring Technique Based on Pressductor‚ Technology............................... 1-4
Chapter 2 - Installation
2.1 About this Chapter ................................................................................................... 2-1
2.3 Mounting the Load Cells ......................................................................................... 2-1
2.4 Installing the Electronic Unit................................................................................... 2-2
2.4.1 Selecting and Routing the Cabling ......................................................... 2-2
2.4.1.1 Recommended Cabling .................................................... 2-2
2.4.1.2 Interference ...................................................................... 2-4
2.4.1.3 Synchronization ............................................................... 2-4
2.4.2 Mounting the Tension Electronics PFEA111/112................................... 2-5
2.4.2.1 IP 65-version (NEMA 4).................................................. 2-5
2.4.2.2 IP 20-version (Unsealed) ................................................. 2-7
2.4.3 Earthing................................................................................................... 2-8
2.5 Connecting the Load Cells....................................................................................... 2-9
2.6 Connecting Optional Units .................................................................................... 2-10
2.6.1 Insulation Amplifier PXUB 201 (only for the IP 20-version) .............. 2-10
2.6.2 Power Supply Unit................................................................................ 2-10
Chapter 3 - Commissioning
3.3 Necessary Equipment and Documentation .............................................................. 3-1
3.4 Using the Panel Buttons........................................................................................... 3-2
3.4.1 Navigating and Confirming .................................................................... 3-2
3.4.2 Changing Numerical Values and Parameters.......................................... 3-2
3.5 Menu Overview ....................................................................................................... 3-3
3.6 Step-by-step Commissioning Guide ........................................................................ 3-4
3.7 Performing Basic Settings ....................................................................................... 3-5
3BSE029380R0001 Rev B i
Table of Contents
CONTENTS (continued)
3.8 Performing a Fast Setup ........................................................................................... 3-5
3.8.1 Performing Fast Setup using Hanging Weights ...................................... 3-6
3.8.2 Performing Fast Setup using Wrap Gain ................................................ 3-8
3.9 Checking Load Cell Signal Polarity......................................................................... 3-9
3.10 Checking Load Cell Function ................................................................................ 3-10
3.11 Performing a Complete Setup ................................................................................ 3-11
3.11.1 Overview ............................................................................................... 3-11
3.12 Complete Setup Sequence...................................................................................... 3-12
3.12.1 Presentation Menu................................................................................. 3-12
3.12.1.1 Set Language .................................................................. 3-12
3.12.1.2 Set Unit........................................................................... 3-12
3.12.2 Set Object .............................................................................................. 3-13
3.12.3 Nominal Load........................................................................................ 3-14
3.12.4 Zero Set ................................................................................................. 3-15
3.12.5 Set Wrap Gain ....................................................................................... 3-16
3.12.6 Voltage Output ...................................................................................... 3-18
3.12.7 Current Output ...................................................................................... 3-20
3.12.8 Miscellaneous Menu ............................................................................. 3-22
3.12.8.1 Profibus .......................................................................... 3-22
3.12.8.2 Set Factory Default......................................................... 3-22
3.12.9 Service Menu ........................................................................................ 3-23
3.12.9.1 Maximum Load / Present Offset .................................... 3-24
3.12.9.2 Reset A/B ....................................................................... 3-24
3.13 Profibus DP Communication with PFEA112......................................................... 3-25
3.13.1 General Data about Profibus DP ........................................................... 3-25
3.13.2 Master-slave Communication ............................................................... 3-25
3.13.3 Commands through Profibus................................................................. 3-26
3.13.4 Handling of Measurement Data through Profibus ................................ 3-26
3.13.4.1 Scaling of Profibus Measurement Values....................... 3-26
3.13.4.2 Filtering of Profibus Measuring Values.......................... 3-26
3.13.4.3 Input Buffer, Communication Block from
PFEA112 to PLC ............................................................ 3-27
3.13.4.4 Output Buffer, Communication Block from
PLC to PFEA112 ............................................................ 3-27
3.14 Commissioning of Optional Units ......................................................................... 3-28
3.14.1 Insulation Amplifier PXUB 201 ........................................................... 3-28
ii 3BSE029380R0001 Rev B
Table of Contents
Chapter 4 - Operation
4.3 Operating Devices.................................................................................................... 4-1
4.4 Start-up and shut-down ............................................................................................ 4-2
4.4.1 Start-up.................................................................................................... 4-2
4.4.2 Shut-down............................................................................................... 4-2
4.5 Normal Run.............................................................................................................. 4-2
4.6 Operator Menus ....................................................................................................... 4-3
4.6.1 Web Tension............................................................................................ 4-3
4.6.1.1 Standard Roll (two load cells).......................................... 4-3
4.6.1.2 Single Side Measurement (one load cell) ........................ 4-3
4.6.2 Error and Warning Messages .................................................................. 4-4
Chapter 5 - Maintenance
5.2 Preventive Maintenance........................................................................................... 5-1
Chapter 6 - Fault-tracing
6.3 Interchangeability .................................................................................................... 6-2
6.4 Necessary Equipment and Documentation .............................................................. 6-2
6.5 Fault-tracing Procedure............................................................................................ 6-3
6.6 Error and Warning Messages in PFEA111/112 ....................................................... 6-4
6.6.1 Error Messages ....................................................................................... 6-4
6.6.2 Warning Messages .................................................................................. 6-4
6.7 Fault Symptoms and Measures ................................................................................ 6-5
6.8 Warnings and Errors Detected by the Tension Electronics...................................... 6-7
6.8.1 Errors ...................................................................................................... 6-7
6.8.1.1 Flash Memory Error......................................................... 6-7
6.8.1.2 EEPROM Memory Error ................................................. 6-7
6.8.1.3 Supply Error ..................................................................... 6-7
6.8.1.4 Load Cell Excitation Error ............................................... 6-8
6.8.2 Warnings ................................................................................................. 6-8
6.8.2.1 Profibus Communication Problem................................... 6-8
6.8.2.2 Synchronization Problem ................................................. 6-8
6.8.3 Changing to Single Side Measurement If One Load Cell Is Faulty ....... 6-9
6.9 Changing Load Cells ............................................................................................. 6-10
3BSE029380R0001 Rev B iii

Table of Contents
Appendix A - Technical Data for Tension Electronics PFEA111/112
A.1 About this Appendix ............................................................................................... A-1
A.2 Definitions used in the Web Tension Systems ........................................................ A-2
A.2.1 Coordinate System ................................................................................. A-3
A.3 Technical Data......................................................................................................... A-4
A.4 Factory Default Settings.......................................................................................... A-7
A.5 Optional Units ......................................................................................................... A-8
A.5.1 Insulation Amplifier PXUB 201 ............................................................ A-8
A.5.2 Power Supply Unit ................................................................................. A-9
A.5.3 Junction Box PFXC 141......................................................................... A-9
A.6 Profibus DP - GSD File for PFEA112 .................................................................. A-10
Appendix B - PFCL 301E - Designing the Load Cell Installation

B.1 About This Appendix.............................................................................................. B-1
B.2 Basic Application Considerations ........................................................................... B-1
B.3 Step-by-Step Guide for Designing the Load Cell Installation ................................ B-2
B.4 Installation Requirements........................................................................................ B-3
B.5 Mounting Alternatives, Calculating Force and Calculating Wrap Gain ................. B-4
B.5.1 Horizontal Mounting.............................................................................. B-4
B.5.2 Inclined Mounting.................................................................................. B-5
B.6 Force Calculation for Measurement with a Single Load Cell................................. B-6
B.6.1 The Most Common and Simple Solution............................................... B-6
B.6.2 Force Calculation when the Web is not Centered on the Roll ............... B-7
B.7 Mounting the Load Cells......................................................................................... B-8
B.7.1 Routing the Load Cell Cable.................................................................. B-8
B.7.2 Connecting the Load Cell Extension Cable ........................................... B-8
B.8 Technical Data......................................................................................................... B-9
B.9 Cable Diagram 3BSE028140D0065, page 2/5, Rev. B..........................................B-11
B.10 Mounting Instruction, Cable Connector, 3BSE019064, Rev. A ........................... B-12
B.11 Dimension Drawing, 3BSE015955D0094, Rev. C ............................................... B-13
B.12 Assembly Drawing, 3BSE015955D0096, Rev. B................................................. B-14
iv 3BSE029380R0001 Rev B
Table of Contents
Appendix C - PFTL 301E - Designing the Load Cell Installation
C.1 About This Appendix...............................................................................................C-1
C.2 Basic Application Considerations............................................................................C-1
C.3 Step-by-Step Guide for Designing the Load Cell Installation .................................C-2
C.4 Installation Requirements ........................................................................................C-3
C.5 Mounting Alternatives, Calculating Force and Calculating Wrap Gain..................C-4
C.5.1 Horizontal Mounting...............................................................................C-4
C.5.2 Inclined Mounting...................................................................................C-5
C.6 Force Calculation for Measurement with a Single Load Cell .................................C-6
C.6.1 The Most Common and Simple Solution ...............................................C-6
C.6.2 Force Calculation when the Web is not Centered on the Roll ................C-7
C.7 Mounting the Load Cells .........................................................................................C-8
C.7.1 Routing the Load Cell Cable ..................................................................C-8
C.7.2 Connecting the Load Cell Extension Cable............................................C-8
C.8 Technical Data .........................................................................................................C-9
C.9 Cable Diagram 3BSE028140D0065, Page 1/5, Rev. B .........................................C-11
C.10 Mounting Instruction, Cable Connector, 3BSE019064, Rev. A ............................C-12
C.11 Dimension Drawing, 3BSE019040D0094, Rev. B................................................C-13
C.12 Assembly Drawing, 3BSE019040D0096, Rev. B .................................................C-14
Appendix D - PFRL 101 - Designing the Load Cell Installation

D.1 About This Appendix...............................................................................................D-1
D.2 Basic Application Considerations............................................................................D-1
D.3 Step-by-Step Guide for Designing the Load Cell Installation .................................D-2
D.4 Installation Requirements ........................................................................................D-3
D.5 Load Cell Orientation Depending on Measurement Direction................................D-4
D.6 Mounting Alternatives, Calculating Force and Calculating Wrap Gain..................D-5
D.6.1 Horizontal Mounting...............................................................................D-5
D.6.2 Inclined Mounting...................................................................................D-6
D.7 Force Calculation for Measurement with a Single Load Cell .................................D-7
D.7.1 The Most Common and Simple Solution ...............................................D-7
D.7.2 Force Calculation when the Web is not Centered on the Roll ................D-8
D.8 Mounting the Load Cells .........................................................................................D-9
D.8.1 Mounting with Brackets........................................................................D-11
D.8.2 Mounting Screws for the Load Cells ....................................................D-12
D.8.3 Routing the Load Cell Cable ................................................................D-12
D.9 Technical Data .......................................................................................................D-13
D.10 Cable Diagram, 3BSE028140D0065, Page 3/5, Rev. B ........................................D-15
D.11 Cable Diagram, 3BSE028140D0065, Page 4/5, Rev. B ........................................D-16
D.12 Dimension Drawing 3BSE004042D0003, page 1/2, Rev. N .................................D-17
D.13 Dimension Drawing, 3BSE004042D0003, page 2/2, Rev. N ................................D-18
D.14 Dimension Drawing, 3BSE004042D0065, Rev. - .................................................D-19
D.15 Dimension Drawing, 3BSE010457, Rev. A ..........................................................D-20
3BSE029380R0001 Rev B v
Table of Contents
Appendix E - PFTL 101 - Designing the Load Cell Installation
E.1 About This Appendix...............................................................................................E-1
E.2 Basic Application Considerations ............................................................................E-1
E.3 Step-by-Step Guide for Designing the Load Cell Installation .................................E-2
E.4 Installation Requirements.........................................................................................E-3
E.5 Mounting Alternatives, Calculating Force and Calculating Wrap Gain ..................E-4
E.5.1 Horizontal Mounting...............................................................................E-4
E.5.2 Inclined Mounting...................................................................................E-5
E.6 Force Calculation for Measurement with a Single Load Cell..................................E-6
E.6.1 The Most Common and Simple Solution................................................E-6
E.6.2 Force Calculation when the Web is not Centered on the Roll ................E-7
E.7 Mounting the Load Cells..........................................................................................E-8
E.7.1 Routing the Load Cell Cable...................................................................E-9
E.8 Technical Data........................................................................................................E-10
E.9 Cable Diagram 3BSE028140D0065, Page 3/5, Rev. B .........................................E-12
E.12 Dimension Drawing, 3BSE004171, Rev. B ...........................................................E-15
E.13 Dimension Drawing, 3BSE004995, Rev. C ...........................................................E-16
E.14 Dimension Drawing, 3BSE023301D0064, Rev. B ................................................E-17
E.17 Dimension Drawing, 3BSE023223D0064, Rev. B ................................................E-20
Appendix F - Actual Data and Settings at Commissioning

F.1 Document the Commissioning in this Form ............................................................F-1
vi 3BSE029380R0001 Rev B
Section 1.1 About this Manual
Chapter 1 Introduction
1.1 About this Manual

This User Manual describes your new MeasureIT Web Tension System. When you have read the
manual, you will have the necessary knowledge for mechanical and electrical installation,
commissioning, operation, preventive maintenance and basic fault tracing of your measurement
system.
To get the best reliability and precision out of your measurement system, study this User
Manual first.
1.2 How to Use this Manual

This user manual comprises two main parts.
1. Information about the Tension Electronics:
- System and safety information (Chapter 1)
- Installation, commissioning, maintenance, operation and fault tracing (Chapters 2-6)
- Technical data (Appendix A)
2. Information about Designing the Load Cell Installation:
- Vertical-force sensing load cell PFCL 301E (Appendix B)
- Horizontal-force sensing load cell PFTL 301E (Appendix C)
- Radial-force Tensiometer PFRL 101 (Appendix D)
- Horizontal-force sensing load cell PFTL 101 (Appendix E)
Each appendix contains detailed information about one of the above load cell types when
used in web tension systems with Tension Electronics PFEA111/112.
1.2.1 Getting Started

You can use the Fast Setup sequence to set up your system for basic measurement.
The Fast Setup guides you through a minimum number of steps to set up the tension electronics.
Perform the actions in the following sections:
• Section 3.6 Step-by-step Commissioning Guide
• Section 3.7 Performing Basic Settings
• Section 3.8 Performing a Fast Setup
For extended functionality, use “Performing a Complete Setup”.
See Section 3.11 Performing a Complete Setup.
1.2.2 Saving Actual Data and Settings at Commissioning

When commissioning is completed you can use the form in Appendix F, where actual
commissioning data and settings can be filled in and saved for future use.
3BSE029380R0001 Rev B 1-1

1.3 About this System

Your system for tension measurement consists of:
• Tension Electronics PFEA111 or PFEA112
– PFEA111 is a cost effective compact and user friendly tension electronics providing
an accurate and reliable fast analog SUM signal from two load cells for control
and/or monitoring. The display can show the SUM, individual A & B and difference
signal. The small size and DIN-rail mount make this unit very easy to integrate into
many types of electrical cabinets
– PFEA112 provides the same functionality and user friendliness as the PFEA111 with
the addition of fieldbus communication via Profibus-DP.
Covering a wide range of applications the Tension Electronics comes in three versions
(The PFEA 113 is described in a separate manual), with different levels of performance
and functionality. All three versions have multi-language digital display and configuration
keys. The configuration keys being used for setting different parameters and to check the
status of the tension system. The 2 x 16 character display can present sum, difference or
individual load cell signals. All three versions are available in both DIN-rail version (IP
20-version, unsealed) and enclosed IP 65-version (NEMA 4) for mounting in more severe
environments.
• Load cells of type PFCL 301E, PFTL 301E, PFRL 101 and PFTL 101.
The equipment is intended for use in a wide range of manufacturing processes where a web of
any kind of material, e.g. paper, plastic or textile, is transported in a machine. The only
requirement is that the web is wrapped over a roll. The force on the roll is proportional to the
web tension. The resulting force is transferred through the bearing housings into the load cells.
The load cells create a signal that is proportional to the force acting in the measuring direction
of the load cells. This signal is processed and amplified in the tension electronics and can be
used as an input signal for process control, presentation on a display or for registration.
Web
Measuring roll
Tension Electronics
Bearing housing
Load cell
Profibus (PFEA112 only)
Instrument output
Control output
Power supply 24 V DC
Figure 1-1. Typical Tension Measurement System with Tension Electronics PFEA111/112 (IP 20-version)
1-2 3BSE029380R0001 Rev B

Section 1.4 Safety Instructions
1.4 Safety Instructions

Read and follow the safety instructions given in this section before starting any work. However,
local statutory regulations, if stricter, are to take precedence.
The tension measurement system contains no moving parts. However, the load cells are
mounted close to a rotating roll over which a web is running.
1.4.1 Personnel Safety

WARNING
Never work with the load cells, or nearby, when the production line is in service.
Before starting any work, switch off and lock the operating switch of the drive
section for the measuring roll.
DANGER
Switch off and lock the mains operating switch to the tension electronics before
performing any work on the tension electronics. When the work is completed,
check that there are no loose wires, and that all units are properly secured.
NOTE
All personnel working with the installation must know the location of the main
power supply switch to the measurement system and how it is operated.
1.4.2 Equipment Safety

CAUTION
Always switch off the mains supply voltage to the measurement system before
replacing a unit.
CAUTION
Handle the electronic unit carefully to reduce the risk of damage from
Electric Static Discharge (ESD). Note the warning label on the circuit boards.
3BSE029380R0001 Rev B 1-3

1.5 The Measuring Technique Based on Pressductor Technology

The operating principle of a force transducer has a great effect on how well it will perform. It
also affects how stiff and vibration-free the entire load cell will be, as well its robustness and
tolerance to overload. All of these factors impact on the design, operation, and maintenance of
the web processing machinery.
ABB’s Pressductor® transducer technology produces a signal as a result of changes in an
electromagnetic field when the load cell is subjected to mechanical force. It is an operating
principle that has its origin in a metallurgical phenomenon according to which mechanical
forces alter the ability of some steels to convey a magnetic field. Unlike other types of load cell
technologies, physical movement such as compression, bending or stretching is not required for
signal generation.
A Pressductor® transducer (the sensor inside the load cell) is a simple and elegant design.
Essentially, two perpendicular windings of copper wire around a steel core combine to provide a
measurement signal.
An electromagnetic field is created by continuously feeding an alternating current to one of the
windings. The field is positioned in such a way that, since the windings are at right angles to
each other, there is no magnetic coupling between them when the load cell is unstressed.
However, when the transducer is subjected to a force, as shown in the figure, the magnetic field
pattern changes. A portion of the field couples with the second winding and induces an AC
voltage that reflects the tension exerted by the web on the measurement roll. This voltage - a
comparatively strong transducer signal - is converted by the load cell system’s tension
electronics into a system output.
Figure 1-2. The Sensor Based on Pressductor® Technology
1-4 3BSE029380R0001 Rev B

Section 2.1 About this Chapter
Chapter 2 Installation
2.1 About this Chapter

The way you install your system has more influence on its functionality, accuracy and reliability
than you might think. The more accurate the installation, the better the measurement system. By
following the instructions in this chapter, you will fulfill the most important requirements for
proper mechanical and electrical installation.
The equipment is a precision instrument which, although intended for severe operating
conditions, must be handled with care.

Read and follow the safety instructions given in Chapter 1 Introduction, before starting any
installation work. However, local statutory regulations, if stricter, are to take precedence.
2.3 Mounting the Load Cells

Installation requirements and mounting instructions are given in:
• Appendix B PFCL 301E - Designing the Load Cell Installation
• Appendix C PFTL 301E - Designing the Load Cell Installation
• Appendix D PFRL 101 - Designing the Load Cell Installation
• Appendix E PFTL 101 - Designing the Load Cell Installation
3BSE029380R0001 Rev B 2-1

2.4 Installing the Electronic Unit
2.4.1 Selecting and Routing the Cabling
2.4.1.1 Recommended Cabling

The cabling between the load cells and the electronic unit and electrical connections must be
carefully carried out in accordance with connection diagram 3BSE028140D0065 (See the
appendix for your type of load cell) or according to order-specific documentation.
External indicating
PFEA111/112
instrument
(not included in
Cable screens should be connected: the ABB delivery)
- to an earth bar close to the
IP 20-version (unsealed)
- to the earth bar fitted inside the
enclosure of the IP 65-version
(NEMA 4)
Mains supply n × 0.5 mm2

3 × 1.5 mm2 IP 65-version + screen
(NEMA 4)
To control system
Profibus-DP
(PFEA112 only)
Junction Box
Load cell signals

2 × 2 × 0.5 mm2 + screen
4 × 1.0 mm2 + screen Load cell excitation

max. 50 m 2 × 2.5 mm2
Load cell A Load cell B
Figure 2-1. Recommended Cabling
2-2 3BSE029380R0001 Rev B

Section 2.4.1 Selecting and Routing the Cabling
• The maximum permitted cable resistance in the excitation circuit is shown in Table 2-1.
Before commissioning, check cable resistance in the load cell excitation circuit.
Table 2-1. Maximum Permitted Cable Resistance
Load cell Max. permitted cable resistance

PFCL 301E 5Ω
PFTL 301E 5Ω
PFRL 101 5Ω
PFTL 101 5Ω
• Solid conductors should not be connected to terminals. Pins should not be crimped to
stranded cores.
• The cable from the load cell must be a robust four core cable, see Figure 2-2.
Diagonal pairs must be used for the signal circuits and excitation circuits.
Signal Load cell excitation
D
B
Figure 2-2. Core Arrangement in Load Cell Cable
• Between the junction box and the tension electronics, signal and excitation must be routed
in separate cables. For example: a 2 × 2.5 mm2 cable for the excitation and a shielded
2 × 2 × 0.5 mm2 cable with twisted pair cores for the load cell signals.
• Cable for synchronization of two of more tension electronics must be screened or a twisted
pair.
• The signal cable between the tension electronics and instruments, or process equipment,
must be a screened 0.5 mm2 cable.
• Cable screens must be connected to the copper earth bar. The screen connection maximum
length is 50 mm.
• The protective earth conductor of the incoming mains supply must be connected to the
copper earth bar in the cubicle.
3BSE029380R0001 Rev B 2-3

2.4.1.2 Interference
For immunity to interference, the load cell cables should be separated as far as possible from
noisy power supply cables. A minimum distance of 0.3 m (12 inches) is recommended. Where
the measuring system cables meet noisy cables, they must cross at right angles.
2.4.1.3 Synchronization
Synchronization is not required for the wall mounted IP 65-version (NEMA 4) of the tension
electronics.
If two or more IP 20-version (unsealed) tension electronics are mounted in the same cabinet
they must be synchronized.
Synchronization is done by interconnecting the "SYNC" terminals, screw terminal X1:14, of all
the units and interconnecting screw terminal X:15 of all units. A twisted pair cable or a screened
cable must be used.
If one unit is turned off or removed the remaining units are still synchronized.
PFEA111/112 PFEA111/112 PFEA111/112 PFEA111/112

1 2 3 n
X1:15 14 X1:15 14 X1:15 14 X1:15 14
Figure 2-3. Connection for Synchronization
2-4 3BSE029380R0001 Rev B

Section 2.4.2 Mounting the Tension Electronics PFEA111/112
2.4.2 Mounting the Tension Electronics PFEA111/112
2.4.2.1 IP 65-version (NEMA 4)

The electronic unit is delivered in an enclosure intended for wall mounting.
When choosing a place for installation, check that there will be space to open the enclosure lid
fully. Also check that there is enough working space in front of the enclosure.
The enclosure is fitted with cable glands (PFEA 111 five and PFEA 112 six cable glands).
Note.To fulfill UL-requirements, the cable

gland for mains supply cable must be
replaced with an UL-listed metal fitting.
1 x for cable ∅ 6-12 [0.24”-0.47”]

Enclosure threaded for NPT-1/2”
Cable glands
2 x for cable ∅ 6-12 [0.24”-0.47”] PFEA 111
2 x for cable ∅ 4-8 [0.16”-0.31”]
Figure 2-4. Installation Dimensions for PFEA 111/112
3BSE029380R0001 Rev B 2-5

Figure 2-5. Cable Glands PFEA 112
Connect the cables to terminals according cable diagrams in Appendix (B, C, D, or E)

depending on installed load cell type.
NOTE
Do not connect solid conductors to terminals. Do not crimp pins to stranded
cores.
NOTE
The incoming mains voltage must be provided with fuses and a means of
disconnection outside the tension electronics.
2-6 3BSE029380R0001 Rev B

Section 2.4.2 Mounting the Tension Electronics PFEA111/112
2.4.2.2 IP 20-version (Unsealed)
mm (inches)
(EN 50022-35x7,5
or equivalent)
Figure 2-6. Installation Dimensions
Connect the cables to terminals according cable diagrams in Appendix (B, C, D, or E)

depending on installed load cell type.
NOTE
Do not connect solid conductors to terminals. Do not crimp pins to stranded
cores.
Grounding
The metal bottom of PFEA111-20 and PFEA112-20 connects to the metallic DIN-rail which
serves as the Tension Electronics ground connector.
This is to ensure a good ground connection both for internal logic and for the EMI immunity
and RF emission of the electronics.
The DIN-rail must have a good connection to the PE (Protective Earth) of the cabinet.
To achieve the best possible corrosion resistance, DIN-rails should be chromium plated, for
instance, yellow chromium treated. Use star washers with each screw used to fasten the
DIN-rail to the mounting plate.
To fasten the DIN-rail onto the mounting plate, the minimum screw diameter is 5 mm and
the maximum distance between screws is 100 mm.
3BSE029380R0001 Rev B 2-7

2.4.3 Earthing
For trouble free operation, the earthing must be carried out carefully. Note the following:
• If the free (unscreened) length exceeds 0.1 m (4 in.) the individual pairs of power
and signal conductors must be twisted separately
• The external protective earth (PE) cable must be attached to one of the earthbar screw
clamps.
• All the cable screens have to be connected to the earth bar and the length of the screen
connection must be less than 50 mm (2 in.).
NOTE
The cable screens must be earthed at one end only.
• Since the signal earth of the measurement system is connected to the chassis earth of the
tension electronics, the input of a superior system connected to the control system must not
be earthed. The best ways of interconnecting the measurement system and a superior
system to achieve optimal function are shown in Figure 2-7 and Figure 2-8.
PFEA111/112
+
0V -
0V
Figure 2-7. Connection to a superior system with an insulated or differential input
PFEA111/112
+ +
0V -
0V
Figure 2-8. Connection to a superior system through a separate insulation amplifier
2-8 3BSE029380R0001 Rev B

Section 2.5 Connecting the Load Cells
2.5 Connecting the Load Cells

Information for connecting the load cells is given in the appendix for each load cell type, see
table below.
Type of load cell Cable diagrams in Appendix

PFCL 301E B
PFTL 301E C
PFRL 101 D
PFTL 101 E
3BSE029380R0001 Rev B 2-9

2.6 Connecting Optional Units
2.6.1 Insulation Amplifier PXUB 201 (only for the IP 20-version)

Insulation amplifier PXUB 201 is used when galvanic insulation between input and output, or
between power supply and input/output, is required. See Section A.5.1 Insulation Amplifier
PXUB 201.
Insulation amplifier PXUB 201 is intended to be installed on a DIN-rail. The PXUB 201 is
connected by screw terminals.
PXUB 201 is normally supplied from the same +24 V DC supply that supplies the tension
electronics.
If PXUB 201 is mounted close to the terminal group, it is not necessary for the cable between
the tension electronics and PXUB 201 to be screened.
PFEA111/112 PXUB 201

X1
A+B Voltage 11 3
Output +
4 – 5
0 V 12 +
6
–
+24 V X1:1 7
+
X1:2 8 –
0V
Figure 2-9. Typical Connection of Insulation Amplifier PXUB 201
2.6.2 Power Supply Unit

If no 24 V is available, the power supply units SD 821, SD 822 and SD 823 can be used as
power supply for the IP 20-versions.
The main supply voltage for all the three power supply units are:
• 115 V AC (85 - 132 V), 100 V -15% to 120 V + 10%
(Mains voltage selection switch in position 115)
• 230 V AC (176 - 264 V), 207 V -15% to 240 V + 10%
(Mains voltage selection switch in position 230)
Table 2-2. Number of PFEA111/112 that can be supplied
Power Supply Unit PFEA111 PFEA112

SD 821 (2.5 A) 6 6
SD 822 (5 A) 12 12
SD 823 (10 A) 24 24
2-10 3BSE029380R0001 Rev B

Chapter 3 Commissioning

This chapter contains necessary information for commissioning your Web Tension System.
It is assumed that the Web Tension System has been installed according to the instructions given
in Chapter 2 Installation and Appendix (B, C, D or E) depending on installed load cell type.
You must know the following data before starting commissioning:
1. Load cell type and nominal load, see Appendix for installed load cell type
2. Object type, see Section 3.12.2
– Standard roll (two load cells)
– Single side measurement (one load cell)
3. Maximum web tension
4. Desired output data at given web tension
5. Communication data, see Section 3.13

Read and follow the safety instructions stated in Chapter 1 Introduction, before starting any
commissioning work. However, local statutory regulations, if stricter, are to take precedence.
3.3 Necessary Equipment and Documentation

The following items are required:
• Cable diagram
• Service tools
3BSE029380R0001 Rev B 3-1

3.4 Using the Panel Buttons
3.4.1 Navigating and Confirming
Display Button How to use it

Steps back to previous menu.
Sometimes you must press this button
Power Status
two or more times to get back to the
desired menu.
Set language
Steps up in a list.
[English]
Steps down in a list.

Steps to next main menu.
OK (acknowledgment) button. Confirms
a selection or a parameter setting.
3.4.2 Changing Numerical Values and Parameters
SetTensionAt10V NominalLoad
XXXXXX N ZZ kN ZZ lbs
• X indicates a numerical value.

• Z indicates that a parameter can be chosen from a list.
SetTensionAt10V NominalLoad
[XXXXXX] N [ZZ kN ZZ lbs]
To change a numerical value, X, or parameter, Z, press . The numerical value or parameter is

then placed within brackets [XXXXXX] or [ZZ] to show that it can be changed.
If it is a “Z” parameter, use and to go up or down in the list. When the desired value is
shown on the display press . When is pressed the new parameter value is saved and the
brackets around the value disappear.
If you have pressed so that the parameter is placed within brackets, you can cancel the
entering mode by pressing . The selections you have done with and will not be
stored. If is pressed the old value is displayed without brackets.
To change a numerical value, press so that the value is placed within brackets. Then the first
digit can be changed with and . When the first digit has the desired value press , then
the second digit can be changed with and . When pressing after the last digit has
been set, the new value is saved and displayed without brackets.
Using when entering a numerical value means returning to the previous digit. By pressing
a sufficient number of times you will leave the entering mode and the old value will be
displayed without brackets.
3-2 3BSE029380R0001 Rev B

Section 3.5 Menu Overview
3.5 Menu Overview

Operator Menus 1) Configuration and Service Menus
3)
WebTension >5s FastSetUp SetWrapGain
0N See 3.8 [ZZ]
Tension A PresentationMenu SetLanguage SetLanguage

0N See 3.12.1 ZZ [ZZ]
Tension B SetUnit SetUnit

0N ZZ [ZZ]
TensionDiff A-B SetObject

0N See 3.12.2
Error and 2) NominalLoad NominalLoad

warning messages ZZ kN ZZ lbs [ZZ kN ZZ lbs]
ZeroSet
See 3.12.4 4)
SetWrapGain HangWeight HangWeight

1) Operator menus are described See 3.12.5 XXXXXX.X N [XXXXXX.X] N
in Section 4.6.
2) Error and warning messages are EnterWrapGain EnterWrapGain
described in Section 6.6. XX.XX [XX.XX]
3) Press for 5 seconds to go to VoltageOutput

the first of the Configuration and See 3.12.6
Service menus.
CurrentOutput
4) Note! Some sub menus asking See 3.12.7
confirmation questions are not
shown in this overview. In these MiscellaneousMenu Profibus On/Off Profibus On/Off
menus you have to confirm that See 3.12.8 ZZ [ZZ]
your settings should be
performed. ProfibusAddress ProfibusAddress
XXX [XXX]
SetFactory
4)
ServiceMenu PFEA112
See 3.12.9 Version 1.0
MaximumLoad A
XXXXXX.X N
PresentOffset A
XX.XX N
Reset A
4)
Repeat procedure for load cell B

3BSE029380R0001 Rev B 3-3
3.6 Step-by-step Commissioning Guide
Step Measurement See section

1 Check that the mains supply voltage is switched off.
2 Check all cabling according to the cable diagrams. Appendix
B, C, D or E
3 Check the supply voltage 3.7
DIN-rail mounted IP20-unit (unsealed)
Nominal 24 V DC, Working range 18 - 36 V DC, X1:1-2
Wall mounted IP65-unit (NEMA 4)
85 - 264 V AC (100 V - 15% to 240 V + 10%), 45-65 Hz, X9:1-2
Nominal 24 V DC, Working range 18 - 36 V DC, X1:1-2
4 Perform basic settings (if necessary) 3.7
5 Perform setup:
Fast setup 3.8
Complete setup 3.11
6 Check load cell signal polarity 3.9
7 Check load cell function 3.10
3-4 3BSE029380R0001 Rev B

Section 3.7 Performing Basic Settings
3.7 Performing Basic Settings

When the tension electronics has been powered on for the first time after delivery, you are asked
to SetLanguage and then to SetUnit. These two settings must be performed to be able to
proceed with the rest of the setup. Language and unit can be changed later on if desired.
1 SetLanguage Select desired language from the list with and

[English] . English is set as default.
Confirm with .
2 SetUnit Select desired presentation unit from the list with
[N] and . N (Newton) is set as default.
Confirm with .
3 FastSetUp Press to start the fast setup sequence.
See Section 3.8.
If you want to make a complete setup, go to the
separate setup menus by pressing .
See Section 3.11.
3.8 Performing a Fast Setup

The fast setup guides you through a minimum number of steps to set up the tension electronics.
You are asked to answer some questions and to enter desired values. These selections and
parameter settings must be made to get the tension electronics ready for measurement.
Only a limited number of selections and parameter settings are set in the fast setup. All other
parameters are set as factory default values. See Appendix A.4 Factory Default Settings.
The fast setup can be made in two ways, depending on how the wrap gain is set.
The wrap gain can be set by selecting “HangWeight” or “EnterWrapGain”.
• Using Hanging Weights, see Section 3.8.1.
• Using Wrap Gain, see Section 3.8.2.
Hanging Weights and Wrap Gain are explained in Section 3.12.5.
3BSE029380R0001 Rev B 3-5

3.8.1 Performing Fast Setup using Hanging Weights

The simplest method to set the wrap gain in this tension system is to use a known weight that
loads the center of the roll with a rope that follows the web path exactly.
All rolls must be

free turning idlers.
To keep friction
losses low, only
use the closest
rolls to define web Load cell Rope
supported roll
path.
Weight
Figure 3-1. Setting Wrap Gain with Hanging Weights (example of installation)
Follow the steps below to run a fast setup using hanging weights.
1 WebTension Press for 5 seconds to go to the FastSetUp menu.

>5
seconds
3 SetWrapGain Select HangingWeights from the list with and .

[HangingWeights]
Confirm with .
4 CellsOnRoll Select the number of load cells that support the roll (1 or 2)
[2] from the list with or . Confirm with .
5 NominalLoad Check the nominal load on the load cell name plate.
[1 kN 225 lbs]
Select nominal load from the list with or .
Confirm with .
6 WithNoTension 1. Check that no load is applied on the roll.
PressOkToZeroSet
2. Press to zero set. “ActionDone” is shown on the
display for one second to confirm the zero setting action.
7 HangWeight 1. Apply a known weight on the roll (see Figure 3-1).
[XXXXXX] N
2. Enter the value of the known weight. Confirm with .
3-6 3BSE029380R0001 Rev B

Section 3.8.1 Performing Fast Setup using Hanging Weights
8
VoltageOut? Select Yes and press to set up the voltage output.
[Yes]
No Yes
9 SetTensionAt10V Enter the tension value corresponding to 10 V.

[XXXXXX] N
Confirm with .
10 StepResponseTime Select the step response time (15, 75, 250 or 750 ms) from
[15] the list with or . Confirm with .
11 CurrentOut? Select Yes and press to set up the current output.

[Yes]
Confirm with .
No Yes
12 SetTensionAt20mA Enter the tension value corresponding to 20 mA.

[XXXXXX] N Confirm with .
[15]
the list with or . Confirm with .
To
WebTension
14 Finished Press to finish the fast setup and go to the operator
PressOk menu.
3BSE029380R0001 Rev B 3-7

3.8.2 Performing Fast Setup using Wrap Gain

1 WebTension Press for 5 seconds to go to the fast setup menu.
>5
seconds
3 SetWrapGain Select WrapGain from the list with or .

[WrapGain]
Confirm with .
4 CellsOnRoll Select the number of load cells that support the roll (1 or 2)
[2] from the list with or . Confirm with .
5 NominalLoad Check the nominal load on the load cell name plate.
[1 kN 225 lbs]
Select nominal load from the list with or .
Confirm with .
6 WithNoTension 1. Check that no load is applied on the roll.
PressOkToZeroSet
2. Press to zero set. “ActionDone” is shown on the
display for one second to confirm the zero setting action.
7 EnterWrapGain Enter the calculated wrap gain. For calculating wrap gain,
[XX.XX]SeeManual see Appendix (B, C, D or E) for installed load cell type.
Confirm with .
8 VoltageOut? Select Yes and press to set up the voltage output.
[Yes]
No Yes
9 SetTensionAt10V Enter the tension value corresponding to 10 V.

[XXXXXX] N
Confirm with .
10 StepResponseTime Set the step response time (15, 75, 250 or 750 ms) from the
[15] list with or . Confirm with .
11 CurrentOut? Select Yes and press to set up the current output.

[Yes]
No Yes
12 SetTensionAt20mA Enter the tension value corresponding to 20 mA.

[XXXXXX] N Confirm with .
[15] the list with or . Confirm with .
To
WebTension
14 Finished Press to finish the fast setup and go to the operator
PressOk menu.
3-8 3BSE029380R0001 Rev B
Section 3.9 Checking Load Cell Signal Polarity
3.9 Checking Load Cell Signal Polarity

This is a simple method to check that the load cells are connected to give a positive output
signal change from the tension electronics for increased web tension.
1. Push with your hand to apply a force corresponding to increased web tension on one load
cell at a time (as close to the load cell as possible) and check if the display reading is
positive. If the display reading is negative, invert the load cell signal connection to the
tension electronics.
NOTE
If you don’t know in which direction the force is acting,
connect load cell A and B with the same force direction.
To change the polarity of load cell A, invert X1:5 and 6 (In A+ and In A-).
To change the polarity of load cell B, invert X1:9 and 10 (In B+ and In B-).
2. After changing load cell polarity, check that the display reading is positive for increased
web tension.
3BSE029380R0001 Rev B 3-9

3.10 Checking Load Cell Function

The “Hanging Weight” procedure can also be used as a function test on load cells,
see Section 3.8.1.
The rope should then be placed in the web path but as close as possible to one of the load cells.
The output signal should be noted, and the rope moved close to the other load cell. Check that
the difference in output signal is small.
Figure 3-2. Load Cell Function Test
3-10 3BSE029380R0001 Rev B

Section 3.11 Performing a Complete Setup
3.11 Performing a Complete Setup
3.11.1 Overview
The complete setup is built up by a number of main and sub menus. The table below shows the
main menus in order of appearance when stepping through the complete setup. The table also
gives an overview of the selections and parameter settings you can do below in each main menu.
The complete setup sequence is described in Section 3.12.
See details
Main menus Selections and parameter settings
in section...
PresentationMenu Set language 3.12.1
Set unit
SetObject Set object type 3.12.2

- Standard roll (load cells A and B) or
- Single side measurement (load cell A)
NominalLoad Set nominal load 3.12.3
1000 N 225 lbs
ZeroSet Zero set load cells 3.12.4
SetWrapGain Set hanging weights (actual force) or 3.12.5

Set wrap gain (calculated value)
VoltageOutput Set step response time 3.12.6

Set high tension value and high output
voltage
Set low tension value and low output voltage
Set high and low output voltage limit
CurrentOutput Set step response time 3.12.7
Set high tension value and high output
current
Set low tension value and low output current
Set high and low output current limit
Miscellaneous Set Profibus address 3.12.8
Menu
Reset all values to factory default
ServiceMenu Read service information 3.12.9

Reset maximum load for load cell A
Reset maximum load for load cell B
3BSE029380R0001 Rev B 3-11

3.12 Complete Setup Sequence

This section gives a step-by-step description with detailed information of all available setup
menus with related parameters, data and settings.
3.12.1 Presentation Menu
WebTension
From FastSetUp
>5s
FastSetUp PresentationMenu SetLanguage SetLanguage
ZZ [ZZ]
Presentation-
Menu
SetUnit SetUnit
SetObject To SetObject ZZ [ZZ]
NominalLoad
Figure 3-3. Main and Sub Menus of the Presentation Menu
ZeroSet
SetWrapGain Use up and down keys to select language [ZZ] and unit [ZZ] from list.
VoltageOutput
CurrentOutput
Miscellaneous
Menu
ServiceMenu
3.12.1.1 Set Language

The following languages are available:
• English
• German
• Italian
• French
• Portuguese
• Japanese
3.12.1.2 Set Unit

The following units can be set:
• N (Newton)
• kN (kiloNewton)
• kg (kilogram)
• lbs (US pounds)
3-12 3BSE029380R0001 Rev B

Section 3.12.2 Set Object
3.12.2 Set Object

WebTension
From PresentationMenu
>5s
FastSetUp SetObject AreYouSure SetObject
ZZ [ZZ]
Presentation-
Menu
SetObject To NominalLoad
NominalLoad Figure 3-4. Set Object Menus

Use up and down keys to select type of object [ZZ] from list.
ZeroSet
SetWrapGain There are two object types that can be selected.

VoltageOutput • Standard roll (if both load cell A and B are connected to the roll)
CurrentOutput
Standard roll
Miscellaneous Two load cells with separate signals
Menu PFEA111/112
ServiceMenu
B A Signal input
A
B
Figure 3-5. Object Type Standard Roll
• Single side measurement (if only load cell A is connected to the roll)
Single side measurement

One load cell signal PFEA111/112
A Signal input
A
Figure 3-6. Object Type Single Side Measurement

When single side measurement is selected the measured signal is multiplied by two and
presented as web tension on display and analog output.
3BSE029380R0001 Rev B 3-13

3.12.3 Nominal Load

From SetObject
WebTension
NominalLoad NominalLoad
>5s ZZ kN ZZ lbs [ZZ kN ZZ lbs]
FastSetUp
Presentation-
Menu To ZeroSet
SetObject
Figure 3-7. Nominal Load Menus
NominalLoad The nominal load is selected from the list below and must be the same as the nominal load on
the load cell name plate. The load cell nominal load is displayed in kN and lbs on the same row.
ZeroSet
The following nominal loads can be selected:
SetWrapGain Table 3-1. Nominal Loads
VoltageOutput
[kN] [lbs]
CurrentOutput 0.1 22
Miscellaneous 0.2 45
Menu
0.5 112
ServiceMenu
1.0 225
2.0 450
5.0 1125
10 2250
20 4500
50 11250
100 22500
200 45000
3-14 3BSE029380R0001 Rev B

Section 3.12.4 Zero Set
3.12.4 Zero Set

Zero set is used to compensate for load cell zero signal and tare weight.
WebTension
The zero setting range is ±2 x Fnom (load cell nominal load).
>5s
FastSetUp
Presentation- From NominalLoad

Menu
SetObject
ZeroSet AreYouSure ActionDone
(shown for 1 s.)
NominalLoad
ZeroSet
To SetWrapGain
SetWrapGain
Figure 3-8. Zero Set Menus
VoltageOutput
NOTE
CurrentOutput Zero set must be done with no tension applied to the roll.
Miscellaneous
Menu
ServiceMenu
3BSE029380R0001 Rev B 3-15

3.12.5 Set Wrap Gain

To be able to present actual web tension on the display, the ratio between web tension and
measured force on the load cell must be determined.
This ratio is a scaling factor called Wrap Gain.
The Wrap Gain depends on the web's wrap angle on the measuring roll and the orientation of the
load cells. Therefore, Wrap Gain depends on the actual installation.
This gives:
T (tension) = Wrap Gain × FR (force of web tension in load cell measuring direction)
WebTension
>5s From ZeroSet

Fast SetUp
Presentation- SetWrapGain HangWeight HangWeight

Menu XXXXXX.X N [XXXXXX.X] N
SetObject
EnterWrapGain EnterWrapGain
XX.XX [XX.XX]
NominalLoad To
VoltageOutput
ZeroSet
Figure 3-9. Wrap Gain Menus
SetWrapGain
Voltage Output There are two ways to find out the ratio between web tension and measured force on the load
cells, by Hanging weights or by Calculation.
Current Output • With hanging weights (Menu HangWeight)
Miscellaneous
String a rope that follows the web path exactly and apply a known weight.
Menu The applied known weight simulates the actual web tension and the electronics measures
ServiceMenu the resulting force on the load cells caused by the applied weight.
When both web tension (T) and the corresponding measured force (FR) are known the
tension electronics calculates the ratio T / FR and stores the value as Wrap Gain.
When web tension is applied to the roll the tension electronics calculates web tension by
multiplying the measured force on the load cells with the Wrap Gain.
After the hanging weight procedure the wrap gain calculated by the tension electronics can
be found in the EnterWrapGain menu.
All rolls must be

free turning idlers.
To keep friction
losses low, only
use the closest
Load cell Rope rolls to define web
supported roll
path.
Weight
Figure 3-10. Setting Wrap Gain with Hanging Weights (example of installation)
3-16 3BSE029380R0001 Rev B
Section 3.12.5 Set Wrap Gain
• By calculation (Menu EnterWrapGain)

Wrap Gain is a scaling factor which corresponds to the ratio between Web Tension (T) and
the force component (FR) from web tension that is acting in the load cell measuring
direction.
The Wrap Gain range is 0.5 - 10. If you try to set the wrap gain outside this range, the
message “OutOfRange” will be shown on the display. The wrap gain can be set with a
resolution of 0.01.
Examples describing the principle of calculating Wrap Gain:
Wrap angle
Wrap angle
T
T T
FR
T T T FR Installations where FR
is lower than T
FR
FR = 2T FR = T FR < T
Wrap gain = FT Wrap gain = FT Wrap gain = FT

R R R
T
Wrap gain = 2T = 0.50 Wrap gain = T = 1.00
T
Wrap gain = 0.50 Wrap gain = 1.00 Wrap gain = > 1
(Min. value of Wrap Gain) (Max. permitted value
of Wrap Gain is 10)
See calculation of Wrap Gain in Appendix (B, C, D or E) for installed load cell type.
3BSE029380R0001 Rev B 3-17

3.12.6 Voltage Output

WebTension
From SetWrapGain
>5s
FastSetUp VoltageOutput StepResponseTime StepResponseTime
ZZ [ZZ]
Presentation-
Menu HighTension HighTension
SetObject XXXXXX.X N [XXXXXX.X] N
To
CurrentOutput
NominalLoad HighOutput HighOutput
XX.XX V [XX.XX] V
ZeroSet
LowTension LowTension
SetWrapGain XXXXXX.X N [XXXXXX.X] N
VoltageOutput LowOutput LowOutput

XX.XX V [XX.XX] V
CurrentOutput
HighLimit HighLimit
Miscellaneous XX.XX V [XX.XX] V
Menu
ServiceMenu LowLimit LowLimit
XX.XX V [XX.XX] V
Figure 3-11. Voltage Output Menus
3-18 3BSE029380R0001 Rev B

Section 3.12.6 Voltage Output
The following parameters can be set:

• Step response time (filtering)
See Table 3-2.
• High Tension (N, kN, kg, lbs), (factory default = 2000 N)
• High Output, (factory default = +10 V)
• Low Tension (N, kN, kg, lbs), (factory default = 0 N)
• Low Output, (factory default = 0 V)
• High Limit, (factory default = +11 V)
• Low Limit, (factory default = -5 V)
Voltage Output [V]
High Limit
High Output
Low Output
Low Limit
Web Tension
Low Tension High Tension N, kN, kg, lbs
Figure 3-12. Parameter Definitions
Filtering may be used if the voltage output signal is too fast or to compensate roll imbalance.
The filters are of type linear phase, maximum flat, 20 dB/decade.
Table 3-2. Filtering
Step response time 0 - 90% Cut-off frequency –3dB

15 ms 35 Hz
75 ms 5 Hz
250 ms 1.5 Hz
750 ms 0.5 Hz
3BSE029380R0001 Rev B 3-19

3.12.7 Current Output

WebTension
From VoltageOutput
>5s
FastSetUp
CurrentOutput StepResponseTime StepResponseTime
ZZ [ZZ]
Presentation-
Menu
HighTension HighTension
SetObject XXXXXX.X N [XXXXXX.X] N
To
Miscellaneous
NominalLoad Menu HighOutput HighOutput
XX.XX mA [XX.XX] mA
ZeroSet
LowTension LowTension
SetWrapGain XXXXXX.X N [XXXXXX.X] N
VoltageOutput
LowOutput LowOutput
XX.XX mA [XX.XX] mA
CurrentOutput
HighLimit HighLimit
Miscellaneous XX.XX mA [XX.XX] mA
Menu
ServiceMenu
LowLimit LowLimit
XX.XX mA [XX.XX] mA
Figure 3-13. Current Output Menus
3-20 3BSE029380R0001 Rev B

Section 3.12.7 Current Output
The following parameters can be set:

• Step response time (filtering)
See Table 3-3.
• High Tension (N, kN, kg, lbs), (factory default = 2000 N)
• High Output, (factory default = 20 mA)
• Low Tension (N, kN, kg, lbs), (factory default = 0 N)
• Low Output, (factory default = 4 mA)
• High Limit, (factory default = 21 mA)
• Low Limit, (factory default = 0 mA)
Current Output [mA]
High Limit
High Output
Low Output
Low Limit
Web Tension
Low Tension High Tension N, kN, kg, lbs
Figure 3-14. Parameter Definitions
Filtering may be used if the current output signal is too fast or to compensate roll imbalance.
The filters are of type linear phase, maximum flat, 20 dB/decade.
Table 3-3. Filtering
Step response time 0 - 90% Cut-off frequency –3dB

15 ms 35 Hz
75 ms 5 Hz
250 ms 1.5 Hz
750 ms 0.5 Hz
3BSE029380R0001 Rev B 3-21

3.12.8 Miscellaneous Menu

WebTension
> 5 s From CurrentOutput

FastSetUp
Miscellaneous Profibus On/Off Profibus On/Off

Presentation- Menu ZZ [ZZ]
Menu
SetObject
ProfibusAddress ProfibusAddress
ZZ [ZZ]
To
NominalLoad
ServiceMenu
SetFactory AreYouSure ActionDone
ZeroSet Default (shown for 1 s.)
SetWrapGain
VoltageOutput
CurrentOutput Figure 3-15. Miscellaneous Menus

Miscellaneous
Menu
ServiceMenu
3.12.8.1 Profibus
• Profibus On/Off
The Profibus can be enabled or disabled.
• Profibus address
If the Profibus is enabled, the Profibus address must be set in the range 000 - 125.
Read more about the Profibus in Section 3.13.
3.12.8.2 Set Factory Default

• Set factory default
The parameters are set as on delivery except Maximum load A and Maximum load B.
Read more in Appendix A.4 Factory Default Settings.
3-22 3BSE029380R0001 Rev B

Section 3.12.9 Service Menu
3.12.9 Service Menu

WebTension
From MiscellaneousMenu
>5s
FastSetUp ServiceMenu PFEA112
Version X.X
Presentation-
Menu
MaximumLoad A
SetObject [XXXXXX.X] N
NominalLoad PresentOffset A
XX.XX N
ZeroSet
Reset A AreYouSure ActionDone
SetWrapGain (shown for 1 s.)
VoltageOutput MaximumLoad B
[XXXXXX.X] N
CurrentOutput
PresentOffset B
Miscellaneous XX.XX N
Menu
ServiceMenu Reset B AreYouSure ActionDone
(shown for 1 s.)
Figure 3-16. Service Menus

The service menu has parameters that can be viewed only and parameters that can be set. If
single side measurement is selected in menu SetObject input B is not connected.
• Parameters that can be viewed only:
– Software version number
– Maximum load A
Displays maximum load since last reset
– Present offset A
Displays zero offset at last zero set
– Maximum load B
Displays maximum load since last reset
– Present offset B
Displays zero offset at last zero set
• Parameters that can be set:
– Reset A
This action sets “Maximum load A” to zero.
– Reset B
This action sets “Maximum load B” to zero.
3BSE029380R0001 Rev B 3-23

3.12.9.1 Maximum Load / Present Offset

For each load cell connected to the web tension electronics PFEA111/112, a maximum load
memory, with the range ±6.5 x Fnom, will store the highest load that is applied to the load cell.
The maximum load consists of:
• Load cell zero signal (with no load on the load cell)
• FRT, applied force component of tare in the measuring direction of the load cell
and
• FR, measured force (force component of tension in the measuring direction of
the load cell).
The maximum load memory can be reset if a load cell is replaced.
3.12.9.2 Reset A/B

Reset A sets “MaximumLoad A” to zero.
Reset B sets “MaximumLoad B” to zero.
3-24 3BSE029380R0001 Rev B

Section 3.13 Profibus DP Communication with PFEA112
3.13 Profibus DP Communication with PFEA112
3.13.1 General Data about Profibus DP

The purpose of the Profibus DP communication in PFEA112 is to provide a high speed
communication link between superior systems and the PFEA112.
Profibus DP is a multidrop communication protocol intended to connect PLCs to sensors (DP
means “Distributed Peripherals”).
The physical interface is RS 485 (two wire cable).
The maximum transfer rate is 12 Mbit/s.
The protocol is based on a master-slave principle. The PFEA112 is a slave. A Profibus master
polls the slaves all the time, that means the polling is going on with a fixed time interval even
when no new data is available from the PFEA112.
Each slave has an address in the range 0 to 125.
Profibus requires that the message format, communication parameters and error codes
of slaves are made available in a so called type file, also known as GSD file (See Appendix A.6
Profibus DP - GSD File for PFEA112). This file is then stored in the Profibus Master.
At start-up the Profibus Master verifies that the Slave with the given type file is indeed available
on the bus.
3.13.2 Master-slave Communication

The Master and the slave communicate via an output buffer and an input buffer.
The master reads the input buffer and writes to the output buffer once every scan cycle for
Profibus.
The slave polls the output buffer and updates values in the input buffer.
Slave – MC400
Slave-PFEA112
Output buffer
Output buffer MC400
PFEA112
Master - PLC measuring
measuring
Master-PLC
process
process
Input buffer
Input buffer
3BSE029380R0001 Rev B 3-25

3.13.3 Commands through Profibus

Profibus DP is available in PFEA112 (not in PFEA111).
“Zero set” is the only command that can be performed through Profibus in PFEA112.
3.13.4 Handling of Measurement Data through Profibus

Two web tension measurement values are transferred through Profibus:
• Value 1 has the same step response time as "voltage output"
• Value 2 has the same step response time as "current output".
The scaling of "voltage output" and "current output" does not affect the measurement values
transferred through Profibus.
If zero set has been performed, the zero set values are transferred through Profibus.
For scaling of Profibus measurement values, see Section 3.13.4.1.
Each measurement value has 16 bit, 2-complement representation (Integer 16).
3.13.4.1 Scaling of Profibus Measurement Values

Depending on the load cell nominal load the least significant bit of the measurement value is as
specified in Table 3-4.
Table 3-4. Scaling of Profibus Measurement Values
Number of load cells connected to the

Value of least significant bit
analog output channel
1 or 2 load cells 0.001 × 2 × Fnom (1)
(1) Fnom = load cell nominal load (see load cell nameplate)
Example for one or two 0.5 kN (500 N) load cells:

The value of the least significant bit is 0.001 x 2 x Fnom = 0.001 x 2 x 500 = 1 N
3.13.4.2 Filtering of Profibus Measuring Values

“Value 1” has the same filtering as the voltage output.
“Value 2” has the same filtering as the current output.
3-26 3BSE029380R0001 Rev B

Section 3.13.4 Handling of Measurement Data through Profibus
3.13.4.3 Input Buffer, Communication Block from PFEA112 to PLC

This section specifies measurement values and Boolean values in the input buffer
communication block.
Bit No.
Data Byte No.
7 6 5 4 3 2 1 0
01 MSB
Value 1
02 LSB
03 MSB
Value 2
04 LSB
Boolean in 05 No. 7 No. 6 No. 5 No. 4 No. 3 No. 2 No. 1 No. 0
06 Spare for future use
Data:
Value 1, Web tension
Step response time (filtering) equal to the setting for voltage output, 16-bit, 2-complement
representation (Integer 16)
Value 2, Web tension
Step response time (filtering) equal to the setting for current output, 16-bit, 2-complement
representation (Integer 16)
Boolean in:
The error or warning is active when the corresponding bit is set to “1”.
Bit No. 0: Flash memory error
Bit No. 1: EEPROM error
Bit No. 2: Supply error
Bit No. 3: Load cell excitation error
Bit No. 4: Synchronization problem
3.13.4.4 Output Buffer, Communication Block from PLC to PFEA112

This section specifies Boolean values in the output buffer communication block.
Bit No.
Data Byte No.
7 6 5 4 3 2 1 0
Boolean out 01 No. 7 No. 6 No. 5 No. 4 No. 3 No. 2 No. 1 No. 0
02 Spare for future use
Bit No. 0: Zero set. Zero set is performed when the bit is changed from “0” to “1”.
3BSE029380R0001 Rev B 3-27

3.14 Commissioning of Optional Units
3.14.1 Insulation Amplifier PXUB 201

The insulation amplifier is connected to the tension electronics voltage output.
S1 is normally set for voltage 1:1 ratio.
The output is selected to generate a voltage or current output by means of switch S1 and S2.
Slower response is selected by means of switch S2, position 3.
The switches are located inside the unit.
Pull out the top lid,

after you released
the snap-locks.
Top lid
S2
ON
1 2 3
Snap-lock Snap-lock
S1
ON
1 2 3
To release Spring lock

Figure 3-17. Insulation Amplifier PXUB 201
You must open the insulation amplifier to be able to set the switches S1 and S2.
1. Demount the insulation amplifier from the DIN rail.
Use a screw driver to unload the spring at the bottom of the insulation amplifier.
2. Press down the snap-locks on both sides of the insulation amplifier.
3. Pull the top lid open, until you see both the switches S1 and S2.
4. Set the switches S1 and S2.
5. Slide back the top lid to locked position.
6. Remount the insulation amplifier on the DIN rail.
3-28 3BSE029380R0001 Rev B

Section 3.14.1 Insulation Amplifier PXUB 201
PXUB 201
3 Output: 0 to ± 10 V
Signal +
0V 4 - Input: 0 to ± 10 V
5
7 +
+ S1 S2
+24 V ON ON
0V 8 - – 6
1 2 3 1 2 3
Earth
PXUB 201 Output: 4 to 20 mA

3 5 Input: 0 to 10 V
Signal + +
0V 4 -
S1 S2
6
7 – ON ON
+24 V + 1 2 3 1 2 3
0V 8 -
Earth
Figure 3-18. Typical Connection of the Insulation Amplifier
Table 3-5. Setting of Input and Output Range
Range S1 S2
Default
Input Output 1 2 3 1 2 3
× 0 to ±10 V 0 to ±10 V × ×
0 to 5 V 4 to 20 mA ×
0 to 10 V 4 to 20 mA ×
0 to 5 V 0 to 20 mA × ×
0 ± 10 V 0 ± 20 mA ×
Table 3-6. Setting of Bandwidth
S2, position 3
Default Bandwidth
(× = ON)
× 10 kHz
10 Hz ×
3BSE029380R0001 Rev B 3-29

3-30 3BSE029380R0001 Rev B

Chapter 4 Operation

Your measurement system does not need any attention during normal operation. Measurement
runs continuously as long as the system is switched on. However, you need to know how to start
and shut down the system, see Section 4.4 Start-up and shut-down.

Read and follow the safety instructions given in Chapter 1 Introduction, before starting any
operation work. However, local statutory regulations, if stricter, are to take precedence.
4.3 Operating Devices

The LED-indicators and operator keys are described in Figure 4-1.
LED “Power” LED “Status”
Power Status
Backlit LCD display
Step back Step up Step down OK (acknowledgment)

or cancel
Figure 4-1. Operating Devices
3BSE029380R0001 Rev B 4-1

Chapter 4 Operation
4.4 Start-up and shut-down
4.4.1 Start-up
The tension electronics is started and shut down using an external ON/OFF switch (not supplied
by ABB). During normal service no action from the operator is required.
1. Check that the main tension control machinery is ready for normal run.
2. Switch on the tension electronics by setting the external ON/OFF switch to position ON.
For the IP 65-version (NEMA 4) also set the internal switch to “ON”.
3. Check that:
- the display is illuminated
- the “Power” indicator is lit
- the “Status” indicator is lit (green light). Red light indicates an error.
“Power” indicator “Status” indicator
Power Status
Display
4.4.2 Shut-down
Shut-down the tension electronics by setting the external ON/OFF switch to position OFF.
4.5 Normal Run

The measurement equipment should be permanently on to achieve best measuring result. This
allows the load cells and electronics to operate under even temperature conditions.
The measuring equipment is designed for continuous duty.
4-2 3BSE029380R0001 Rev B

Section 4.6 Operator Menus
4.6 Operator Menus

This section describes the operator menus. The updating time for displayed values is 500 ms.
Use up and to switch between menus.
WebTension
Value
Tension A
Value
Tension B
Value
TensionDiff A-B
Value
Error and
warning messages
Figure 4-2. Operator Menus
4.6.1 Web Tension
4.6.1.1 Standard Roll (two load cells)

The following menus are available when a standard roll (two load cells) is connected to the
tension electronics:
• WebTension
Shows the total web tension measured by load cell A and load cell B
• Tension A
Shows the part of web tension measured by load cell A
• Tension B
Shows the part of web tension measured by load cell B
• TensionDiff A-B
Shows the difference between Tension A and Tension B
4.6.1.2 Single Side Measurement (one load cell)

The following menu is shown when only one load cell (single side measurement) is connected
to the tension electronics:
• WebTension
Web Tension is displayed for single side measurement (only load cell A connected).
Web tension is the tension measured by load cell A multiplied by 2.
3BSE029380R0001 Rev B 4-3

Chapter 4 Operation
4.6.2 Error and Warning Messages

An ERROR is something that causes the tension electronics to function incorrectly.
A WARNING is something that might affect the accuracy of the measurement.
When a warning or an error occurs, a warning or an error message is displayed on the
Operator Panel and the “Status” indication turns from green to red.
When is pressed the message disappears from the display.
If the problem that activated the warning or error message has disappeared the
“Status” indication turns to green.
If the error or warning remains the “Status” indication is red. Use the to step to the last
menu, where you can read the error or warning message.
For handling Error and Warning messages, see Chapter 6 Fault-tracing.
4-4 3BSE029380R0001 Rev B

Chapter 5 Maintenance

Under normal operating conditions, your system does not require any maintenance. However,
we recommend you to perform regular checks. The following preventive measures may be
taken depending on the type of environment in which your system operates.
5.2 Preventive Maintenance
Unit Measures
Load cells Protect the load cells from prolonged contact with
corrosive elements.
Check the fixing screws and re-tighten if necessary.
Check the gaps between load cell and adapter plates
to ensure that they are not clogged with dirt, which
can cause a shunt force into the load cell.
Clean the gaps with compressed air if necessary.
Tension Electronics Check that the circuit boards are properly secured
and that cables or wires are not damaged.
Check that all terminal screws and cable glands
are properly tightened.
Connection cables Check that the connection cables between the
load cells and the tension electronics are not
damaged.
3BSE029380R0001 Rev B 5-1

Chapter 5 Maintenance
5-2 3BSE029380R0001 Rev B

Chapter 6 Fault-tracing

During the working life of your measurement system, events may occur that disturb it and your
process. These disturbances may appear in many different ways and the reason for the fault can
be difficult to find. However, disturbances similar in character can be grouped together and
usually they have the same or similar sources of error.
The fault-tracing instructions in this chapter will help you to quickly find and correct the most
common faults.

Read and follow the safety instructions given in Chapter 1 Introduction when tracing faults.
However, local statutory regulations, if stricter, are to take precedence.
3BSE029380R0001 Rev B 6-1

6.3 Interchangeability
Unit Measures
Tension Electronics The tension electronics PFEA111/112 is
interchangeable with a tension electronics of the
same type.
A new setup is required.

Load cells The load cells are directly interchangeable
with other load cells of the same type.
Zero setting PFEA111/112 and resetting “Maximum
Load A” or “Maximum Load B” are required after a
load cell has been replaced.
6.4 Necessary Equipment and Documentation

The following items are required to perform fault-tracing and repairs:
• Cable diagrams, see Appendix (B, C, D or E for) for installed load cell type
• Service tools
• Torque wrench
• Multimeter
6-2 3BSE029380R0001 Rev B

Section 6.5 Fault-tracing Procedure
6.5 Fault-tracing Procedure
Faults in the... Fault symptoms

Mechanical installation Faults in the mechanical installation usually manifest
themselves as an unstable zero point or incorrect
sensitivity.
If a fault is associated with a process parameter, such
as the temperature, or can be linked with a particular
operation, the fault is likely to emanate from the
mechanical part of the installation.
Load cells Calibration data for a load cell do not change
gradually. A load cell, depending on its size and type,
can withstand up to five times(1) the nominal load in
the measuring direction. An event in the process line,
such as web breakage, may cause an overloading
large enough to alter load cell data. Depending on the
amount of overload, it may be sufficient to zero set.
Cabling Problems such as malfunctions or unstable zero point
may arise from faulty cables or wiring.
Proximity to noisy cables may cause interference
problems.
Incorrect installation, such as cable cores connected
asymmetrically or screens earthed at both ends
instead of only at one end, may show up as an
unstable zero point.
If the polarity of load cell signals is not correct,
the cabling has to be checked.
Tension Electronics Intermittent loss of a function is usually due to a fault
in the tension electronics.
Instability problems seldom originate from the tension
electronics.
Faults in devices connected to the tension electronics
may affect its operation.
(1) Read more about the overload capacity for your load cell type in Appendix B, C, D or E.
3BSE029380R0001 Rev B 6-3

6.6 Error and Warning Messages in PFEA111/112

An ERROR is something that causes the electronics to function incorrectly.
A WARNING is something that might affect the accuracy of the measurement.
When a warning or an error occurs, a warning or an error message is displayed on the
Operator Panel and the “Status” indication turns from green to red.
When is pressed the message disappears from the display.
If the problem that activated the warning or error message has disappeared the
“Status” indication turns to green.
If the error or warning remains the “Status” indication is red. Use the to step to the last
operator menu, where you can read the error or warning message.
6.6.1 Error Messages

The following errors can be detected:
• Flash (memory) error
• EEPROM (memory) error
• Supply error
• Load cell excitation error
See Section 6.8 Warnings and Errors Detected by the Tension Electronics.
6.6.2 Warning Messages

The following warnings can be detected:
• Profibus communication problem
• Synchronization problem
See Section 6.8 Warnings and Errors Detected by the Tension Electronics.
6-4 3BSE029380R0001 Rev B

Section 6.7 Fault Symptoms and Measures
6.7 Fault Symptoms and Measures

General remark:
If the free (unscreened) cable length exceeds 0.1 m (4 in.) the individual pairs of power and
signal conductors must be twisted.
Free length exceeding 0.1 m can cause unstable zero point or incorrect absolute measurement
value.
Table 6-1. Fault Symptoms and Measures
Fault symptom Measures

Noisy signals - Check that cable shields are connected to earth
according to cable diagram.
- Proximity to noisy cables can cause interference
problems.
Unstable zero point - Check that cable screens are not connected in
both ends.
- Check that cable between load cell and electronic
has diagonal pairs, one pair for signal circuit and
one par for excitation circuit, see Figure 2-2.
- Check, if a junction box is installed, that load cell
signal and load cell excitation between junction
box and electronics are routed in separate cables.
- Check, if two or more IP 20 units are mounted
close to each other in the same cabinet, that they
are synchronized (cable for synchronizing the
units, see cable diagram and Section 2.4.1.3
Synchronization).
Display and LED indictors are If the Operator panel display is not illuminated and
not illuminated the “Power” and “Status” indications on the
Operator Panel are “OFF”, check the following:
- Check that the cables are correctly connected to
the electronics power supply.
- Check that the power supply connected to the
electronics is correct.
- Check that the power switch is “ON” (inside the IP
65-version (NEMA 4) enclosure).
- If power supply SD 82x is used as power supply
for PFEA111/112 IP 20-version (unsealed), check
that the mains voltage selection switch on SD 82x
is set to correct position (115 or 230)
corresponding to the connected mains supply
voltage.
- Further tests are described in Section 6.8.1.3
Supply Error.
3BSE029380R0001 Rev B 6-5

Table 6-1. Fault Symptoms and Measures
Fault symptom Measures

No signal when load is applied 1. Check that cables to the electronics are
correctly connected.
2. Check that the load cells are connected with
correct polarity. If not, the load cell signals cancel
out each other. This is displayed on the operator
panel as described below:
a. The sum signal (A+B) is low
b. The difference signal (A-B) is high
c. The output signal of the individual load cells
have opposite signs (polarity) when a force is
applied on the middle of the roll.
To check load cell signal polarity, see Section 3.9
Checking Load Cell Signal Polarity.
For connecting the load cells to give positive
signals for increased web tension, see cable
diagram for the installed load cell type.
3. Switch off the tension electronics and measure
the cable resistance in the load cell signal circuit
between terminals X1:5 and X1:6 and between
X1:9 and X1:10.
a. The resistance is > 25 ohm:
Check cabling and load cells.
b. The resistance is < 25 ohm:
Check the mechanics.
6-6 3BSE029380R0001 Rev B

Section 6.8 Warnings and Errors Detected by the Tension Electronics
6.8 Warnings and Errors Detected by the Tension Electronics
6.8.1 Errors
6.8.1.1 Flash Memory Error

• Replace PFEA111/112.
6.8.1.2 EEPROM Memory Error

• Replace PFEA111/112.
6.8.1.3 Supply Error

IP 20-version (unsealed):
When the PFEA111/112 is connected to the 24 VDC power supply the voltage between
terminals X1:1 and X1:2 should be 18 - 36 V.
• If the voltage is lower than 18 V:
– Check the power supplies rating. Rating should be 18-36 V DC.
– Check that the power supply has sufficient capacity. See power requirements in
Section 2.6.2 Power Supply Unit.
• If the power supply has sufficient capacity, check cabling and cable resistance between
power supply and PFEA111/112.
• If power supply and cabling are correct, the tension electronics is probably defect.
Replace PFEA111/112.
IP 65-version (NEMA 4):
• Check the mains voltage connected to terminals X9:1 and X9:2.
Mains voltage must be:
85 - 264 V AC (100 V -15% to 240 V +10%)
Frequency range: 45 - 65 Hz
3BSE029380R0001 Rev B 6-7

6.8.1.4 Load Cell Excitation Error

• Check that cables are correctly connected to the electronics.
• If single side measurement is used and only load cell A is connected to the electronics,
check that a shorting wire is connected between terminals X1:7 and X1:8.
– Switch off the tension electronics and measure the resistance between terminals X1:3
and X1:8.
The resistance is > 8 ohm:
Check that the total cable resistance between electronics and load cells does not
exceed 5 ohm. If cable resistance does not exceed 5 ohm, check cabling and load
cells.
The resistance is < 7 ohm:
If cabling is correct, the electronics is probably defect.
6.8.2 Warnings
6.8.2.1 Profibus Communication Problem

Check:
• that the bus is correctly terminated.
• the Profibus address.
• cabling and connectors.
6.8.2.2 Synchronization Problem

Check the cabling and shield.
If the cabling is correct the tension electronics is probably defect.
6-8 3BSE029380R0001 Rev B

Section 6.8.3 Changing to Single Side Measurement If One Load Cell Is Faulty
6.8.3 Changing to Single Side Measurement If One Load Cell Is Faulty

If one load cell is faulty it is possible to change from Standard Roll to Single Side Measurement.
For load cell connections, please refer to cable diagrams in Appendix B, C, D or E for the load
cell type used in the installation.
Depending on which load cell that is faulty, do the following:
Load cell A is faulty:
1. Disconnect load cell A from the Tension Electronics.
2. Move connections for load cell B to the terminals where load cell A was connected.
3. Connect a shorting wire for the load cell excitation circuit between X1:7 and X1:8.
Load cell B is faulty:
1. Disconnect load cell B from the Tension Electronics.
2. Connect a shorting wire for the load cell excitation circuit between X1:7 and X1:8.
After having changed the load cell connections, one parameter setting in the Tension Electronics
must be changed.
Use the menu below to change from StandardRoll to SingleSide.
From PresentationMenu
WebTension
>5s SetObject AreYouSure SetObject

FastSetUp ZZ [ZZ]
Presentation-
Menu
To NominalLoad
SetObject
NominalLoad
Single side measurement
One load cell signal PFEA111/112
ZeroSet
A Signal input
SetWrapGain
A
VoltageOutput
CurrentOutput
Miscellaneous
Menu
ServiceMenu
3BSE029380R0001 Rev B 6-9

6.9 Changing Load Cells

1. Before starting work, read the safety instructions stated in Chapter 1 Introduction.
2. For load cells equipped with an extension cable and connector:
Disconnect the connection cable from the load cell and protect the connection cable from
dirt and damage.
For load cells equipped with a fixed cable:
Disconnect the load cell connection in the tension electronics or junction box and protect
the loose cable ends from dirt and damage.
3. Clean the old load cell before it is unfastened and removed.
4. Unfasten and remove the old load cell.
5. Unfasten and remove the adapter plates from the old load cell.
6. Clean the support structure, adapter plates and other mounting surfaces.
7. For mounting instructions for the new load cell, see:
– Appendix B PFCL 301E - Designing the Load Cell Installation
– Appendix C PFTL 301E - Designing the Load Cell Installation
– Appendix D PFRL 101 - Designing the Load Cell Installation
– Appendix E PFTL 101 - Designing the Load Cell Installation
8. Set the zero point, see Section 3.12.4 Zero Set.
6-10 3BSE029380R0001 Rev B

Section A.1 About this Appendix
Appendix A Technical Data for Tension Electronics PFEA111/112
A.1 About this Appendix

This appendix comprises technical data for tension electronics PFEA111/112.
Data for the load cells are given in:
• Appendix B PFCL 301E - Designing the Load Cell Installation
• Appendix C PFTL 301E - Designing the Load Cell Installation
• Appendix D PFRL 101 - Designing the Load Cell Installation
• Appendix E PFTL 101 - Designing the Load Cell Installation
The definitions used in the load cell appendices are explained in Section A.6, Profibus DP -
GSD File for PFEA112.
3BSE029380R0001 Rev B A-1

A.2 Definitions used in the Web Tension Systems
Table A-1. Definitions
Nominal load, Fnom, is the load for which the load cell is Linearity deviation
dimensioned and calibrated, i.e. the sum of the stationary
U
load and the maximum measured load in the measuring
direction.
Fext = Extended range. Between Fnom and Fext some

decline in measurement accuracy may be experienced.
Sensitivity is defined as the difference in output signal

between nominal load and no load.
Fnom
Accuracy class is defined as the maximum deviation, and Hysteresis
is expressed as a percentage of the sensitivity at nominal
load. This includes linearity deviation, hysteresis and U
repeatability error.
Linearity deviation is the maximum deviation from a

straight line drawn between the output values of zero and
nominal load, related to the nominal load.
Hysteresis is the maximum deviation of the output signal at

the same load during a cycle from zero to nominal load and Fnom
back to zero, related to the sensitivity at nominal load.
The hysteresis is proportional to the cycle. Temperature dependence
U
Repeatability error is defined as the maximum deviation Sensitivity
between repeated readings under identical conditions. drift
It is expressed as a percentage of the sensitivity at
nominal load.
Temperature dependence is the drift in %/K related to the

sensitivity at nominal load. Zero
point
Zero point drift is defined as the drift in the output signal drift Fnom
when there is no load on the load cell.
Sensitivity drift is defined as the drift in the output signal at

nominal load, excluding the zero point drift.
A-2 3BSE029380R0001 Rev B

Section A.2.1 Coordinate System
Table A-1. Definitions
Example:
T = Web tension.
Tare = Force of tare (weight of roll and bearing arrangement Wrap angle
T
mounted on the load cells)
FR = Measured force (force component of the web tension

in the measuring direction of the load cell).
T FR
FRT = Applied force component of tare in the measuring
direction of the load cell. FR = T
FRtot = Total applied force in the measuring direction of the
Wrap gain = FT
load cell. R
Wrap Gain = The ratio between web tension, T, and Wrap gain = T = 1.00
T
measured force, FR. Wrap gain = 1.00
A.2.1 Coordinate System

A coordinate system is defined for the load cell. This is used in force calculations to derive force
components in the load cell principal directions.
Where direction designations R, V and A are recognized as suffixes for force components, F,
this represents the force component in the respective direction. The suffix R may be omitted,
when measuring direction is implied by the context.
R V
V R
A A A A
V R = Measuring direction R
R V = Transverse direction V
A = Axial direction
Figure A-1. Coordinate System Defining Directions used in Force Calculations
3BSE029380R0001 Rev B A-3

A.3 Technical Data
Table A-2. Data for Supply Voltage
Data Comments
Supply voltage
IP 20-unit (unsealed) 24 V DC 18 - 36 V DC
IP 65-unit (NEMA 4) 24 V DC 18 - 36 V DC
85 - 264 V AC 100 V -15% to 240 V +10%
Mains frequency 45 - 65 Hz 100 - 240 V AC, 0.2 - 0.1 A
Power 7.5 W (24 V)
consumption
Fuse
IP 20-unit (unsealed) Automatic reset
IP 65-unit (NEMA 4) Slow blow, 2 A, 250 V
Table A-3. Data for Load Cell Excitation
Data Comments
Current 0.5 A rms, 330 Hz Regulated
Max. load Two load cells + max. 5 Ω Load cells of type:
cable resistance (1 µF cable PFCL 301E, PFTL 301E,
capacitance). PFRL 101 and PFTL 101.
Table A-4. Data for Load Cell Inputs
Data Comments
Number of inputs 2
Input impedance 10 kohm
A-4 3BSE029380R0001 Rev B

Section A.3 Technical Data
Table A-5. Data for Signal Outputs
Data Comments
Voltage output 0 - 10 V Range -5 to +11 V
Max. load 5 mA
Ripple <10 mVp-p Wrap gain = 1
Step response time 15 ms
Band width 35 Hz
Current output 4 - 20 mA Range 0 to 21 mA
Max. load 550 Ω
Step response time 15 ms
Band width 35 Hz
Extra filtering for
voltage and current
output
Step response time 75 ms 250 ms 750 ms
Cut-off frequency 5 Hz 1.5 Hz 0.5 Hz
Wrap gain 0.5 - 10
adjustment
Table A-6. Measurement Ranges for the Tension Electronics
Type Range (1)

Zero Setting Range ±2.0 × Fnom
Dynamic Measurement Range –2.5 × Fnom to + 3.5 × Fnom
(including zero set)
(1) Fnom = Load cell nominal load
Table A-7. Communication PFEA112
Data Comments
Profibus 1 12 Mbit
Communication Profibus DP slave According to EN 50 170
protocol
Transfer speed Max. 12 Mbits / s
Address range 0 - 125
3BSE029380R0001 Rev B A-5

Table A-8. Environmental Data
Data Comments
Temperature dependence
Zero point drift < 50 ppm/K (28 ppm/°F)
Sensitivity drift < 75 ppm/K (42 ppm/°F)
Operating temperature +5 to +55 °C (32 - 131 °F)
Outside the IP 20-version
(unsealed) and IP 65-version
(NEMA 4)
Non-operating temperature -40 to +70 °C (-40 - 158 °F)
Degree of protection
DIN-rail version IP 20 (unsealed)
Wall mounting unit IP 65 (NEMA 4) According to EN 60 529
Table A-9. Dimensions
Data Comments
Dimensions
IP 20-version (unsealed) 86 x 136 x 58 Width x Height x Depth
IP 65-version (NEMA 4) 120 x 180 x 100 Width x Height x Depth
Weight
IP 20-version (unsealed) 0.3 kg
IP 65-version (NEMA 4) 1.9 kg
A-6 3BSE029380R0001 Rev B

Section A.4 Factory Default Settings
A.4 Factory Default Settings

Table A-10. Factory Default Settings
PFEA111 PFEA112
Display language English English
Display unit N N
Load cells per roll 2 2
Object type Standard roll Standard roll
Load cell nominal load 1.0 kN 225 lbs 1.0 kN 225 lbs
Wrap gain 1 1
Current output
Step response time 15 ms 15 ms
High tension 2000 N 2000 N
High output 20.00 mA 20.00 mA
Low tension 0N 0N
Low output 4.00 mA 4.00 mA
High limit 21.00 mA 21.00 mA
Low limit 0.00 mA 0.00 mA
Voltage output
Step response time 15 ms 15 ms
High tension 2000 N 2000 N
Low tension 0N 0N
High output +10.00 V +10.00 V
Low output 0.00 V 0.00 V
High limit +11.00 V +11.00 V
Low limit -5.00 V -5.00 V
Profibus - Off
Address - 126
3BSE029380R0001 Rev B A-7

A.5 Optional Units
A.5.1 Insulation Amplifier PXUB 201
+
+
Input Output
–
–
+24VV
+24
Figure 1-2. Insulation Amplifier PXUB 201
Table 1-11. Data for Insulation Amplifier PXUB 201
Type Data
Power supply 20 - 253 V AC/DC
AC: 48 - 62 Hz, 2 VA
DC: 1 W
Current consumption 10 mA + external load, at 24 V
Signal range Input Output
0 ± 10 V 0 ± 10 V
0 - 10 V 4 - 20 mA
0-5V 4 - 20 mA
0 ± 10 V 0 ± 20 mA
0-5V 0 - 20 mA
Input resistance 1 MΩ at 10 V input
500 kΩ at 5 V input
Max. load 10 mA for voltage output
500 Ω for current output
Rise time 50 µs or 50 ms, selectable
Ripple 10 mVp-p
Bandwidth (-3 dB) 10 kHz or 10 Hz
Rated insulation voltage 600 V, basic insulation
Insulation test voltage 4 kV
Dimensions (l × w × d) 99 × 12.5 × 111 mm
Weight 150 g
A-8 3BSE029380R0001 Rev B

Section A.5.2 Power Supply Unit
A.5.2 Power Supply Unit
Table A-12. Mains Supply Voltage
Data Remarks
Mains supply voltage 115 V AC (85 - 132 V), (Mains voltage
100 V -15% to 120 V + 10% selection switch in
position 115)
230 V AC (176 - 264 V), (Mains voltage
207 V -15% to 240 V + 10% selection switch in
position 230)
Table A-13. Power Supply Unit
Unit Dimensions (l x w x d) Weight

SD821 125 x 50 x 103 mm 0.5 kg
SD822 125 x 65 x 103 mm 0.6 kg
SD823 125 x 120 x 103 mm 1.0 kg
A.5.3 Junction Box PFXC 141
Degree of protection Dimensions (l x w x d) Weight

IP 65 (NEMA 4) 220 x 120 x 80 mm 2.0 kg
3BSE029380R0001 Rev B A-9

A.6 Profibus DP - GSD File for PFEA112
;====================== GSD file:ABB_0716.GSD ======================

;
; DEVICE NAME: Tension Electronics PFEA112
; AUTHOR: M.Sollander
; REVISION DATE: January 27, 2003
;
;==================================================================
#Profibus_DP
GSD_Revision =2
;====================== PRODUCT SPECIFICATION =====================
Vendor_Name = "ABB Automation Techn. Products"

Model_Name = "Tension Electronics PFEA112"
Ident_Number = 0x0716
Revision = "2.0"
Hardware_Release = "1.0"
Software_Release = "1.0"
;====================== OVERALL PROFIBUS SPECIFICATIONS ===========
FMS_supp =0
Protocol_Ident =0
Station_Type =0
Slave_Family =0
;====================== HARDWARE CONFIGURATION ===================
Implementation_type = "SPC3"
Redundancy =0
Repeater_Ctrl_Sig =0
24V_Pins =0
A-10 3BSE029380R0001 Rev B

Section A.6 Profibus DP - GSD File for PFEA112
;====================== PROTOCOL CONFIGURATION ====================
Set_Slave_Add_supp =0
Auto_Baud_supp =1
Min_Slave_Intervall =1
Freeze_Mode_supp =1
Sync_Mode_supp =1
Fail_Safe =0
;====================== SUPPORTED BAUDRATES =======================
9.6_supp =1
19.2_supp =1
45.45_supp =1
93.75_supp =1
187.5_supp =1
500_supp =1
1.5M_supp =1
3M_supp =1
6M_supp =1
12M_supp =1
MaxTsdr_9.6 = 60
MaxTsdr_19.2 = 60
MaxTsdr_45.45 = 60
MaxTsdr_93.75 = 60
MaxTsdr_187.5 = 60
MaxTsdr_500 = 100
MaxTsdr_1.5M = 150
MaxTsdr_3M = 250
MaxTsdr_6M = 450
MaxTsdr_12M = 800
3BSE029380R0001 Rev B A-11

;====================== DIAGNOSTIC DEFINITIONS ====================
Max_Diag_Data_Len =6
;====================== PARAMETER DEFINITIONS =====================
User_Prm_Data_Len =3
User_Prm_Data = 0, 0, 0
;====================== MODULE DEFINITIONS ========================
Modular_Station =0
Module = "PFEA112" 0x51,0x11,0x21

EndModule
;==================================================================
A-12 3BSE029380R0001 Rev B

Section B.1 About This Appendix
Appendix B PFCL 301E - Designing the Load Cell Installation
B.1 About This Appendix

This appendix describes the procedure for designing the load cell installation.
The following sections are included:
• Basic application considerations
• Designing the load cell installation (step-by-step guide)
• Installation requirements
• Force and wrap gain calculation
– Horizontal mounting
– Inclined mounting
– Single side measurement
• Mounting the load cells
• Technical data
• Drawings
– Cable diagram(s)
– Mounting instruction for load cell extension cable
– Dimension drawing
– Assembly drawing
B.2 Basic Application Considerations

Each application has its own individual demands that have to be considered; though a few basic
considerations tend to repeat themselves.
• What type of process is involved (papermaking, converting, etc.)?
Is the environment demanding (temperature, chemicals, etc.)?
• What is the tension measurement purpose; indication or closed loop control?
Are there any specific accuracy demands involved?
• What is the machine design like? Is there the possibility to modify the design,
in order to fit the most suitable load cell, or is the machine design fixed?
• What are the forces acting on the roll like (size and direction)?
Can they be altered by redesign?
If these questions are dealt with thoroughly, the installation is very likely to be successful.
However, the extent to which measurement accuracy is needed, defines the requirements when
designing a load cell installation.
3BSE029380R0001 Rev B B-1

B.3 Step-by-Step Guide for Designing the Load Cell Installation

The procedure below defines the main considerations involved in designing a load cell
installation.
1. Check load cell data so that environmental demands are met.
2. Calculate forces; vertical, horizontal and axial (cross directional).
3. Size and orientate load cell so that the guidelines below are met:
a. Try to achieve a measured value no less than 10% of web tension, in the load cell
measurement direction!
b. Select load cell size so that it is loaded as close as possible to its nominal load! Do
not dimension Force component of Tension in measuring direction, FR, for less than
10% of the load cell nominal load!
c. If the span between maximum and minimum tension in the process is large, select
load cell so that the maximum tension will be in the load cell extended range (when
applicable)!
d. The measured force component of web tension is recommended to be at least 30% of
tare force component (roll weight) acting in load cell measurement direction. The
reason for this recommendation is load cell signal stability, especially when the
system operates in a large temperature span.
This means that if FRT < 1/3 of Fnom, FR should be at least 10% of Fnom.
For larger FRT, lowest FR is recommended to be at least 30% of FRT.
T T
Rule 1: If FRT < 1/3 of Fnom
FR should be at least 10% of Fnom
FR
> 30% Rule 2: If FRT > 1/3 of Fnom
FR is recommended to be at least 30% of FRT
100%
FRT
FR = Force component of web tension in measuring direction
FRT = Tare force in measurement direction
e. Check load cell data so that limits for building height, transverse and axial forces are
not exceeded.
4. Design base frame and/or adapter plates.
B-2 3BSE029380R0001 Rev B

Section B.4 Installation Requirements
B.4 Installation Requirements

To achieve the specified accuracy, the best possible reliability and long-term stability, install the
load cells in accordance with the requirements below.
Dynamically balanced
measuring roll
that fulfills at least
Grade G-2.5 ISO 1940-1.
Self aligning bearings
Allow axial expansion

when using long rolls
and large temperature Shims may be placed
changes are expected. between the upper adapter
plate and the bearing housing
and between the lower adapter
Mounting surface
plate and the foundation.
must be flat within
0.1 mm (0.004 in.)
Shims must not be placed
Stable foundation immediately above or below
the load cell.
If the measuring roll is driven, Correct torque for delivered screws intended
always consult ABB to ensure for the adapter plates is 24 Nm (18 ft.-lb).
a solution with minimised risk Follow the manufacturer´s recommendation
of disturbances. for other screws.
Alignment of the load cells
mm (inches)
a)
Web
228
(8.98)
6 7 mm
(2.64)
b)
a) Max. 0.5 mm (0.02 in.)

b) Max. 1.0 mm (0.04 in.)
c) Max. 5 mm/m (0.06 in./ft.)
c)
Figure B-1. Installation Requirements
3BSE029380R0001 Rev B B-3

B.5 Mounting Alternatives, Calculating Force and Calculating Wrap Gain
B.5.1 Horizontal Mounting
PFCL 301E In most cases, horizontal mounting is the most obvious

T
and simplest solution. The load cell should thus be
mounted horizontally when possible.
Tare However, should the machine design require inclined
T
mounting of the load cell or should the web path not give
a sufficient vertical force, see figure, the inclined
mounting is permitted and the calculations are somewhat
more complex, (see Appendix B.5.2).
No vertical web tension force
applied to the load cell.
β The PFCL 301E load cell measures the vertical forces

α
T applied to its top surface. The horizontal applied forces are
not measured and do not influence the vertical
Tare
T measurement. There are two sources of vertical forces; the
forces from the web tension and the tare weight of the roll.
FR
Divide the total vertical force FRtot by two to get the
required capacity of each load cell.
FR = T × (sin α + sin β)
Do not oversize an ABB load cell for overload purposes
FRT = Tare
as the load cell has sufficient overload capacity.
FRtot = FR + FRT = T × (sin α + sin β) + Tare
T (Tension) = Wrap gain × F

R
T T
Wrap gain = -------- = ----------------------------------------
R T ( sin α + sin β )
F
1
Wrap gain = -------------------------------
sin α + sin β
FR A PFCL 301E load cell can measure tension as well as

compression.
T T If the T (sin α + sin β) is larger than the tare weight, the
Tare load cell will be in tension.
α β
To get the capacity of each load cell:

FR = T × (sin α + sin β)
FRT = Tare 1. Divide (FR - Tare) by two
FRtot = FRT − FR = Tare − T × (sin α + sin β) if FR is greater than or equal to (Tare × two).
2. Divide Tare by two
T (Tension) = Wrap gain × F if FR is smaller than (Tare × two).
R
T T
Wrap gain = -------- = ----------------------------------------
R T ( sin α + sin β )
F
1
Wrap gain = -------------------------------
sin α + sin β
B-4 3BSE029380R0001 Rev B

Section B.5.2 Inclined Mounting
B.5.2 Inclined Mounting
PFCL 301E Sometimes it is necessary to mount the load cell on an

β incline due to mechanical design constraints of the
α
T machine or the need to have a proper force component
FRT applied to the load cell.
Tare In this case, the incline angle modifies the tare load and
T
FR the force components as shown.
γ
FR = T × [(sin (α −γ) + sin (β + γ)]

FRT = Tare × cos γ
FRtot = FR + FRT =
T × [(sin (α −γ) + sin (β + γ)] + Tare × cos γ

R
T T
Wrap gain = -------- = -------------------------------------------------------------------
F T [ sin ( α – γ ) + sin ( β + γ ) ]
R
1
Wrap gain = ----------------------------------------------------------
sin ( α – γ ) + sin ( β + γ )
3BSE029380R0001 Rev B B-5

B.6 Force Calculation for Measurement with a Single Load Cell

In some cases, it is sufficient to measure the tension with only a single load cell mounted at one
end of the roll. The roll should nevertheless be supported at both ends.
B.6.1 The Most Common and Simple Solution

The most obvious and simple solution is horizontal mounting with the web evenly distributed
and centered on the roll.
As long as the roll is supported at both ends, the same calculations given in Section B.5,
Mounting Alternatives, Calculating Force and Calculating Wrap Gain are valid.
NOTE
The accuracy of a single load cell measurement is highly dependent on how well
the center of force can be determined. Since the cross-directional stress
distribution generally is somewhat uneven, this is not easily done. The load cell
will, however, produce a stable and repeatable measurement.
Figure B-2. Cross-directional stress distribution
B-6 3BSE029380R0001 Rev B

Section B.6.2 Force Calculation when the Web is not Centered on the Roll
B.6.2 Force Calculation when the Web is not Centered on the Roll
Use the calculations below for horizontal and inclined mounting when the web is not centered
on the roll.
The applied force at the load cell will be proportional to the distance between the tension force
center and the load cell centerline.
L
a
b
Tension force center

Tare force center
Load cell
PFCL 301E
Calculation procedure:
1. Horizontal or inclined mounting?
2. Calculate FR and FRT, see Section B.5, Mounting Alternatives, Calculating Force and
Calculating Wrap Gain
3. Use the following equations:
L–b
FR for single load cell = F R × ------------
L
L – a-
FRT for single load cell = F RT × -----------
L
FRtot for single load cell = FR for single load cell + FRT for single load cell
where:
L = Distance between load cell centerline and the opposite bearing centerline
a = Distance between tare force center and load cell centerline
b = Distance between tension force center and load cell centerline
3BSE029380R0001 Rev B B-7

B.7 Mounting the Load Cells

The instructions below apply to a typical mounting arrangement. Variations may be allowed,
provided that they comply with the requirements in Appendix B.4.
1. Clean the foundation and other mounting surfaces.
2. Fit the lower adapter plate to the load cell.
Tighten the screws (included in delivery) with a torque wrench to 24 Nm (18 ft.-lb).
3. Fit the load cell and the lower adapter plate to the foundation,
but do not fully tighten the screws.
4. Fit the upper adapter plate to the load cell.
5. Fit the bearing housing and the roll to the upper adapter plate,
CAUTION
When mounting bearings or other adjacent details to adapter plates, screws must
not protrude into the load cell. The load cell can be damaged by an excessive
applied force.
L<T
Note! L T
The screw must not
protrude into the load cell.
6. Adjust the load cells according to the installation requirements.

Tighten the foundation screws.
7. Adjust the roll according to the installation requirements.
Tighten the screws in the upper adapter plate.
B.7.1 Routing the Load Cell Cable

The cable must be supported with clamps and routed to prevent force shunting through the
cable.
B.7.2 Connecting the Load Cell Extension Cable

See Section B.10, Mounting Instruction, Cable Connector, 3BSE019064, Rev. A.
B-8 3BSE029380R0001 Rev B

Section B.8 Technical Data
B.8 Technical Data
PFCL 301E Unit

Nominal load
Nominal load in measuring direction, Fnom 0.2 0.5 1.0
(45) (112) (225)
Permitted transverse load within the accuracy, FVnom 0.05 0.125 0.25
For h = 135 mm (5.3 inch) (11) (28) (56) kN
Permitted axial load within the accuracy, FAnom 0.05 0.125 0.25 (lbs)
For h = 135 mm (5.3 inch) (11) (28) (56)
Extended load in measuring direction with 0.3 0.75 1.5
accuracy class, compressive force ± 2%, Fext (67) (169) (337)
Overload capacity
Max. load in measuring direction 0.6 1.5 3
without permanent change of data, Fmax 1) (135) (337) (674) kN
Max. load in transverse direction without permanent 0.3 0.75 1.5 (lbs)
change of data, FVmax (1). For h = 135 mm (5.3 inch) (67) (169) (337)
Spring constant kN/mm
9 22 34
(1000
(52) (124) (197)
lbs/inch)
Accuracy
Accuracy class, compressive force ± 1.0
Linearity deviation < ± 0.5
%
Repeatability error < ± 0.1
Hysteresis < ± 0.3
Mechanical data
approx. 2.5
Weight without adapter plates
(approx. 5.5) kg
approx. 5.4 (lbs)
Weight including adapter plates
(approx. 11.9)
Length, width and height are given in Section B.11, Dimension Drawing, 3BSE015955D0094, Rev. C.
Material
Load cell SS 2387 stainless steel, DIN X4CrNiMo 165.
Corrosion resistance properties similar to AISI 304.
Adapter plates SS 1312, finished by black chromating.
ASTM A 238-79 Grade C.
(1) Fmax and FVmax are allowed at the same time.
Figure 2-3. Building height
3BSE029380R0001 Rev B B-9

Table B-1. Environmental data for load cell PFCL 301E
PFCL 301E Unit
Compensated temperature range

+20 - +60 °C
(68 - 140) (°F)
< ± 150
Zero point drift
(83) ppm/K
< ± 250 (ppm/F)
Sensitivity drift
(139)
Working temperature range

-10 - +80 °C
(14 - 176) (°F)
< ± 250
Zero point drift
(139) ppm/K
< ± 350 (ppm/F)
Sensitivity drift
(194)
Storage temperature range

-40 - +90 °C
(-40 - 194) (°F)
Degree of protection IP 66 acc. to EN 60 529
Table B-2. Mounting screws
Tightening
Type of screws Strength class Dimension
torque
Electro-zincplated steel screws,
24 Nm
lubricated with oil or emulsion. 8.8 M8
(18 ft-lb)
Strength class according to ISO 898/1.
B-10 3BSE029380R0001 Rev B

Section B.9 Cable Diagram 3BSE028140D0065, page 2/5, Rev. B
B.9 Cable Diagram 3BSE028140D0065, page 2/5, Rev. B
3BSE029380R0001 Rev B B-11

B.10 Mounting Instruction, Cable Connector, 3BSE019064, Rev. A
B-12 3BSE029380R0001 Rev B

Section B.11 Dimension Drawing, 3BSE015955D0094, Rev. C
B.11 Dimension Drawing, 3BSE015955D0094, Rev. C
3BSE029380R0001 Rev B B-13

B.12 Assembly Drawing, 3BSE015955D0096, Rev. B
B-14 3BSE029380R0001 Rev B

Section C.1 About This Appendix
Appendix C PFTL 301E - Designing the Load Cell Installation
C.1 About This Appendix

• Technical data
• Drawings
– Mounting instruction for load cell extension cable
– Dimension drawing
– Assembly drawing
C.2 Basic Application Considerations

3BSE029380R0001 Rev B C-1

C.3 Step-by-Step Guide for Designing the Load Cell Installation

installation.
3. Size and orient load cell so that the guidelines below are met:
applicable)!
T T
FR
100%
FRT
not exceeded.
C-2 3BSE029380R0001 Rev B

Section C.4 Installation Requirements
C.4 Installation Requirements

measuring roll
Grade G-2.5 ISO 1940-1.

when using long rolls
and large temperature Shims may be placed
changes are expected. between the upper adapter
and between the lower adapter
Mounting surface
plate and the foundation.
must be flat within
0.1 mm (0.004 in.)
Shims must not be placed
Stable foundation immediately above or below
the load cell.
If the measuring roll is driven, Correct torque for delivered screws intended
always consult ABB to ensure for the adapter plates is 24 Nm (18 ft.-lb).
a solution with minimised risk Follow the manufacturer´s recommendation
of disturbances. for other screws.
mm (inches)
a)
Web
228
(8.98)
6 7 mm
(2.64) b)
a) Max. 0.5 mm (0.02 in.)

b) Max. 1.0 mm (0.04 in.)
c) Max. 5 mm/m (0.06 in./ft.)
c)
Figure C-1. Installation Requirements
3BSE029380R0001 Rev B C-3

C.5 Mounting Alternatives, Calculating Force and Calculating Wrap Gain
C.5.1 Horizontal Mounting
PFTL 301E In most cases, horizontal mounting is the most obvious

mounted horizontally when possible.
Tare
However, should the machine design require inclined
T T mounting of the load cell or should the web path not give
a sufficient horizontal force, see figure, the inclined
more complex, (see Section C.5.2, Inclined Mounting).
No horizontal web tension force
= Measurement direction
PFTL 301E The PFTL 301E load cell measures the horizontal forces
α β applied to its top surface. The load cell can measure in
both directions. The vertical applied forces are not
FR T measured and do not influence the horizontal
Tare measurement. There is one source of horizontal forces;
T the force from the web tension (the tare weight has no
force component in measuring direction). See the force
calculations in the figure.
= Measurement direction
Divide the total horizontal force FRtot by two to get the
FR = T × (cos β − cos α) Do not oversize an ABB load cell for overload purposes
as the load cell has sufficient overload capacity.
FRT = 0 (Tare force is not measured)
FRtot = FR + FRT = T × (cos β − cos α)

R
T T
Wrap gain = -------- = ------------------------------------------
R T ( cos β – cos α )
F
1
Wrap gain = ---------------------------------
cos β – cos α
C-4 3BSE029380R0001 Rev B

Section C.5.2 Inclined Mounting
C.5.2 Inclined Mounting
PFTL 301E Sometimes it is necessary to mount the load cell on an

T incline due to mechanical design constraints of the
−α
machine or the need to have a proper force component
+β
Inclined mounting adds a component of tare force in the
FRT measuring direction and modifies the force components
Tare T as shown.
NOTE
FR
When calculating, it is important that the angles
are set into the equations with the correct signs
in relation to the horizontal plane.
−γ
T
−β
+α
FR
FRT
Tare
+γ
FR = T × [cos(β + γ) − cos(α −γ)]
FRT = − Tare × sin γ
FRtot = FR + FRT =
T × [cos(β + γ) − cos(α −γ)] + (−Tare × sin γ)

R
T T
Wrap gain = -------- = ----------------------------------------------------------------------
F T [ cos ( β + γ ) – cos ( α – γ ) ]
R
1
Wrap gain = -------------------------------------------------------------
cos ( β + γ ) – cos ( α – γ )
3BSE029380R0001 Rev B C-5

C.6 Force Calculation for Measurement with a Single Load Cell

C.6.1 The Most Common and Simple Solution

As long as the roll is supported at both ends, the same calculations given in Section C.5,
NOTE
Figure C-2. Cross-directional stress distribution
C-6 3BSE029380R0001 Rev B

Section C.6.2 Force Calculation when the Web is not Centered on the Roll
C.6.2 Force Calculation when the Web is not Centered on the Roll
on the roll.
center and the load cell centerline, see figure.
L
a
b

Tare force center
Load cell
PFTL 301E
2. Calculate FR and FRT, see Section C.5, Mounting Alternatives, Calculating Force and
Calculating Wrap Gain.
L–b
L
L – a-
FRT for single load cell = RT
F × -----------
L
where:
3BSE029380R0001 Rev B C-7

C.7 Mounting the Load Cells

The instructions below apply to a typical mounting arrangement. Variations may be allowed,
provided that they comply with the requirements in Section C.4, Installation Requirements.
CAUTION
When mounting bearings or other adjacent details to adapter plates, screws must
not protrude into the load cell. The load cell can be damaged by an excessive
applied force.
L<T
Note! L T
The screw must not
protrude into the load cell.
6. Adjust the load cells according to the installation requirements.

Tighten the foundation screws.
7. Adjust the roll according to the installation requirements.
Tighten the screws in the upper adapter plate.
C.7.1 Routing the Load Cell Cable

cable.
C.7.2 Connecting the Load Cell Extension Cable

See Section C.10, Mounting Instruction, Cable Connector, 3BSE019064, Rev. A.
C-8 3BSE029380R0001 Rev B

Section C.8 Technical Data
C.8 Technical Data
PFTL 301E Unit

Nominal load
Nominal load in measuring direction, Fnom 0.1 0.2 0.5 1.0
For h = 135 mm (5.3 inch) (22) (45) (112) (225)
Permitted transverse load within the accuracy, FVnom 0.3 0.6 1.5 3.0
(67) (135) (337) (675) kN
Permitted axial load within the accuracy, FAnom 0.5 0.5 1.0 1.0 (lbs)
For h = 135 mm (5.3 inch) (112) (112) (225) (225)
Extended load in measuring direction with accuracy 0.15 0.3 0.75 1.5
class, bidirectional measurement ± 2%, Fext (33) (67) (169) (337)
Overload capacity
Max. load in measuring direction without permanent 0.3 0.6 1.5 3.0
change of data, Fmax 1). For h = 135 mm (5.3 inch) (67) (135) (337) (674)
Max. load in transverse direction without permanent 0.5 1.0 2.5 5.0
change of data, FVmax (1) (112) (225) (562) (1125) kN
(lbs)
Max. load in axial direction without permanent change of 0.5 0.5 1.0 1.0
data, FAmax. For h = 135 mm (5.3 inch) (112) (112) (225) (225)
Spring constant kN/mm
2 4 7 8
(1000
(11.3) (22.6) (39.7) (44.6)
lbs/inch)
Accuracy
Accuracy class ± 1.0
Linearity deviation < ± 0.5
%
Hysteresis < ± 0.3
Mechanical data
approx. 2.5
Weight without adapter plates
(approx. 5.5) kg
approx. 5.4 (lbs)
Weight including adapter plates
(approx. 11.9)
Length, width and height are given in Section C.11, Dimension Drawing, 3BSE019040D0094, Rev. B.
Material
Load cell SS 2387 stainless steel, DIN X4CrNiMo 165.
Adapter plates SS 1312, finished by black chromating.
ASTM A 238-79 Grade C.
(1) Fmax and FVmax are allowed at the same time.
Figure 3-3. Building height
3BSE029380R0001 Rev B C-9

Table C-1. Environmental data for load cell PFTL 301E
PFTL 301E Unit
Compensated temperature range

+20 - +60 °C
(68 - 140) (°F)
< ± 150
Zero point drift
(83) ppm/K
< ± 250 (ppm/F)
Sensitivity drift
(139)
Working temperature range

-10 - +80 °C
(14 - 176) (°F)
< ± 250
Zero point drift
(139) ppm/K
< ± 350 (ppm/F)
Sensitivity drift
(194)
Storage temperature range

-40 - +90 °C
(-40 - 194) (°F)
Degree of protection IP 66 acc. to EN 60 529
Table 3-2. Mounting screws
Tightening
Type of screws Strength class Dimension
torque
Electro-zincplated steel screws, 24 Nm
lubricated with oil or emulsion. 8.8 M8
Strength class according to ISO 898/1. (18 ft-lb)
C-10 3BSE029380R0001 Rev B

Section C.9 Cable Diagram 3BSE028140D0065, Page 1/5, Rev. B
C.9 Cable Diagram 3BSE028140D0065, Page 1/5, Rev. B
3BSE029380R0001 Rev B C-11

C.10 Mounting Instruction, Cable Connector, 3BSE019064, Rev. A
C-12 3BSE029380R0001 Rev B

Section C.11 Dimension Drawing, 3BSE019040D0094, Rev. B
C.11 Dimension Drawing, 3BSE019040D0094, Rev. B
3BSE029380R0001 Rev B C-13

C.12 Assembly Drawing, 3BSE019040D0096, Rev. B
C-14 3BSE029380R0001 Rev B

Section D.1 About This Appendix
Appendix D PFRL 101 - Designing the Load Cell Installation
D.1 About This Appendix

• Technical data
• Drawings
– Dimension drawing(s)
D.2 Basic Application Considerations

3BSE029380R0001 Rev B D-1

D.3 Step-by-Step Guide for Designing the Load Cell Installation

installation.
applicable)!
T T
FR
100%
FRT
not exceeded.
D-2 3BSE029380R0001 Rev B

Section D.4 Installation Requirements
D.4 Installation Requirements

Dynamically balanced Mounting surface

measuring roll that must be flat within
fulfills at least 0.1 mm (0.004 in.)
Grade G-2.5 ISO 1940-1
If the measuring roll is driven,
always consult ABB to ensure The mounting screws
a solution with minimized risk shall be tightened
of disturbances according to the
manufacturer´s
recommendations
by using bearings
with one fixed side Stable foundation
and one loose side

Max. 0.5°
Max.
10 mm/m Web
(0.12 in./ft)
Figure D-1. Installation requirements
3BSE029380R0001 Rev B D-3

D.5 Load Cell Orientation Depending on Measurement Direction

The radial load cell will only measure forces along the axis as shown in the figure to the left.
Positive Therefore the orientation of the measurement direction is important to the amount of signal
measurement output. To help understand how the orientation of the measurement direction affects the output
direction see the figures below.
+
Orientation of Effects
measurement direction (Two load cells are assumed)
Tension
Horizontal The load cells measure 2 × Tension, but do not

plane
– + measure the roll weight (Tare).
Negative
measurement Tension
direction
Tension The load cells measure no Tension, but do

measure the roll weight (Tare).
Rotating the load cells counterclockwise will
begin to gain in signal from the web tension
and will eliminate the output due to roll weight
Tension (Tare). Maximum tension signal will occur at
+ 90° of rotation.
Tension
The load cells measure 1 × Tension, but do not
+ measure the roll weight (Tare).
Rotate the load cells 45° clockwise and the
45 ° load cells sense 1.4 × Tension and 70% of the
roll weight.
Tension
D-4 3BSE029380R0001 Rev B

Section D.6 Mounting Alternatives, Calculating Force and Calculating Wrap Gain
D.6 Mounting Alternatives, Calculating Force and Calculating Wrap Gain
D.6.1 Horizontal Mounting
The PFRL 101 load cells can be mounted at any incline

angle, 0 - 360°. However, it is recommended to minimize
the influence of forces other than the tension to be
measured. In most cases this means an orientation where
Tare the tare force (vertical) is perpendicular to the measured
T T force (horizontal).
However, should the machine design require inclined
mounting of the load cell or should the web path not give
No horizontal web tension force
applied to the load cell. a sufficient horizontal force, see figure, the inclined
more complex, (see Section D.6.2, Inclined Mounting).
The load cell measures the horizontal forces. The load

Horizontal plane cell can measure in both directions. The vertical applied
+α +β
forces are not measured and do not influence the
T
horizontal measurement. There is one source of
FR horizontal forces, the force from the web tension (the tare
T
weight has no force component in measuring direction).
See force calculations in figure.
Tare
Divide the total vertical force FRtot by two to get the
FR = T × (cos β − cos α)
Do not oversize an ABB load cell for overload purposes
FRT = 0 (Tare force is not measured) as the load cell has sufficient overload capacity.
FRtot / load cell = FRtot / 2

R
T T
Wrap gain = -------- = ------------------------------------------
F
1
Wrap gain = ---------------------------------
cos β – cos α
3BSE029380R0001 Rev B D-5

D.6.2 Inclined Mounting
T Sometimes it is necessary to mount the load cell on an

−α incline due to mechanical design constraints of the
machine or due to the need to have a proper force
+β component applied to the load cell.
Inclined mounting adds a component of tare force and
modifies the force components as shown.
−γ NOTE
T
When calculating it is important that the
angles are set into the equations with the
Tare FR
correct signs relative to the horizontal
FV plane.
FR = T × [cos(β + γ) − cos(α −γ)]
FRtot = FR + FRT =

R
T T
Wrap gain = -------- = ----------------------------------------------------------------------
F T [ cos ( β + γ ) – cos ( α – γ ) ]
R
1
Wrap gain = -------------------------------------------------------------
cos ( β + γ ) – cos ( α – γ )
−β
+α
FR
+γ
FV
T Tare
D-6 3BSE029380R0001 Rev B

Section D.7 Force Calculation for Measurement with a Single Load Cell
D.7 Force Calculation for Measurement with a Single Load Cell

D.7.1 The Most Common and Simple Solution

As long as the roll is supported at both ends, the calculations given in Section D.6, Mounting
Alternatives, Calculating Force and Calculating Wrap Gain are valid. Note that the output signal
is a summation.
NOTE
Figure D-2. Cross-directional stress distribution
3BSE029380R0001 Rev B D-7

D.7.2 Force Calculation when the Web is not Centered on the Roll
on the roll.
center and the load cell centerline.
L
a
b
Load cell
PFRL 101

Tare force center
2. Calculate FR and FRT, see Section D.6, Mounting Alternatives, Calculating Force and
L–b
L
L –a
FRT for single load cell = F RT × ------------
L
where:
L = Distance between load cell centerline and the opposite bearing center line
D-8 3BSE029380R0001 Rev B

Section D.8 Mounting the Load Cells
D.8 Mounting the Load Cells

1. Mount the bearings in the load cells.
NOTE
Use tools and materials that not will damage the bearing or the load cell.
NOTE
One of the bearings is locked in position with retaining rings while the
other bearing is only pressed into the correct position to allow axial expansion.
a. Mount one of the retaining rings into the load cell.

b. Arrange a counterstay as shown in the figure below.
c. Press the bearing to correct position.
NOTE
The bearing bed has only a slight interference fit, and, therefore, no heavy forces
should be used.
d. Mount the other retaining ring into the load cell.
Fixed bearing Fixed bearing

without distance rings with distance rings
Retaining ring
Press on the outer ring Distance ring
Counterstay Counterstay
Loose bearing Press on the outer ring
Counterstay
3BSE029380R0001 Rev B D-9

Inner lid
Example of
load cell
mounting
2. Mount distance spacers and shaft sealings, if necessary.

3. Put the inner load cell lids in position, and also four mounting screws in their holes.
4. Press the load cells onto the shaft (press on the inner rings of the bearings only).
Grooves for
retaining rings Retaining
in the load cell ring on
(not to be used the shaft
for loose bearings)
5. Mount the retaining rings for the bearings on the shaft.

Put the outer lids in position.
6. Position the measuring roll complete with the load cells
into the correct position on the machine.
The load cell with the loose bearing is displaced towards the roll,
in order to reduce the total length, so that the measuring roll with
the load cells can be fitted in.
When the roll is in position pull the load cell with the
loose bearing back to its proper position.
7. Fix each load cell by using the four mounting screws.
(tightening torque according to the manufacturer´s recommendations)
8. Adjust the shaft sealings, if necessary.
D-10 3BSE029380R0001 Rev B

Section D.8.1 Mounting with Brackets
D.8.1 Mounting with Brackets

The optional bracket is intended to facilitate mounting on horizontal surfaces.
To achieve the best Mounting

measuring direction, hole
turn the load cell to
a suitable position
before drilling the
bracket.
Possible ways of mounting using brackets.
1. Mark the location of the mounting holes.

2. Drill the holes and cut threads, according to Section D.15, Dimension Drawing,
3BSE010457, Rev. A.
3. Install according to the instructions in Section D.8, Mounting the Load Cells.
3BSE029380R0001 Rev B D-11

D.8.2 Mounting Screws for the Load Cells

The load cell shall be mounted with screws according to Table D-1.
NOTE
The screws shall be tightened according to the manufacturer´s recommendations.
Screws with strength class 8.8 are sufficient for normal applications without large transverse
forces or overloads.
Measuring
direction Screws with strength class 12.9 and a higher tightening torque are recommended in applications
where large transverse forces or overloads can occur.
Transverse
direction Prior to mounting, check that the mounting surfaces are clean and flat, e.g. free of burrs and
other damage.
Table D-1. Mounting Screws
Load cell PFRL 101 Screw dimension

A M8 (5/16 UNC)
B M8 (5/16 UNC)
C M10 (3/8 UNC)
D M12 (1/2 UNC)
D.8.3 Routing the Load Cell Cable

cable.
D-12 3BSE029380R0001 Rev B

Section D.9 Technical Data
D.9 Technical Data
Table D-2. Technical Data for Different Types of Load Cell PFRL 101
PFRL 101 Type Data Unit

Nominal load
Nominal load, Fnom A 0.5 (112)
B 1 (225)
C 0.5 (112) 1 (225) 2 (450)
D 5 (1125)
Accepted transverse load within the A 2.5 (562)
accuracy class, FVnom
B 3 (674) kN
C 1.25 (281) 2.5 (562) 5 (1125) (lbs)
D 10 (2250)
Accepted axial load within the A 2.5 (562)
accuracy class, FAnom
B 5 (1125)
C 2.5 (562) 5 (1125) 10 (2250)
D 25 (5625)
Overload capacity
Maximal load in the direction of A 2.5 (562)
measurement without permanent
change of data, Fmax B 5 (1125) kN
C 2.5 (562) 5 (1125) 10 (2250) (lbs)
D 25 (5625)
Spring constant A 50 (286)
B 100 (572) kN/mm
(1000
C 50 (286) 100 (572) 200 (1143) lbs/inch)
D 500 (2858)
Mechanical data
Weight A 1.5 (3.3)
B 2.0 (4.4) kg
C 5.0 (11) 5.0 (11) 5.0 (11) (lbs)
D 8.5 (18.7)
3BSE029380R0001 Rev B D-13

Table D-2. Technical Data for Different Types of Load Cell PFRL 101
PFRL 101 Type Data Unit

Material SS 2387 stainless steel, DIN X4CrNiMo 16 5.
Accuracy
Accuracy class ± 0.5 %
Compensated temperature range +20 - +80 °C
A (68 - 176) (°F)
B ppm/K
Zero point drift 150 (83)
C
Sensitivity drift D 150 (83) (ppm/F)
Working temperature range –10 - +80 °C

(14 - 176) (°F)
Zero point drift 300 (167) ppm/K
Sensitivity drift 300 (167) (ppm/F)
Storage temperature range –40 - +80 °C

(–40 - 176) (°F)
D-14 3BSE029380R0001 Rev B

Section D.10 Cable Diagram, 3BSE028140D0065, Page 3/5, Rev. B
D.10 Cable Diagram, 3BSE028140D0065, Page 3/5, Rev. B
3BSE029380R0001 Rev B D-15

D.11 Cable Diagram, 3BSE028140D0065, Page 4/5, Rev. B
D-16 3BSE029380R0001 Rev B

Section D.12 Dimension Drawing 3BSE004042D0003, page 1/2, Rev. N
D.12 Dimension Drawing 3BSE004042D0003, page 1/2, Rev. N
3BSE029380R0001 Rev B D-17

D.13 Dimension Drawing, 3BSE004042D0003, page 2/2, Rev. N
D-18 3BSE029380R0001 Rev B

Section D.14 Dimension Drawing, 3BSE004042D0065, Rev. -
D.14 Dimension Drawing, 3BSE004042D0065, Rev. -
3BSE029380R0001 Rev B D-19

D.15 Dimension Drawing, 3BSE010457, Rev. A
D-20 3BSE029380R0001 Rev B

Section E.1 About This Appendix
Appendix E PFTL 101 - Designing the Load Cell Installation
E.1 About This Appendix

• Technical data
• Drawings
– Dimension drawing(s)
– Assembly drawing(s)
E.2 Basic Application Considerations

3BSE029380R0001 Rev B E-1

E.3 Step-by-Step Guide for Designing the Load Cell Installation

installation.
a. Try to achieve as large portion as possible no less than 10% of web tension, in the
load cell measurement direction!
applicable)!
T T
FR
100%
FRT
not exceeded.
E-2 3BSE029380R0001 Rev B

Section E.4 Installation Requirements
E.4 Installation Requirements

measuring roll
Grade G-2.5 ISO 1940-1.
To allow axial expansion,
use SKF CARB bearings,
or as a second choice,
sliding spherical roller
bearings at one end of Shims may be placed
the shaft. between the upper adapter
Use fixed spherical roller
bearings at the other and between the lower adapter
end of the shaft. plate and the foundation.
Mounting surface Shims must not be placed

must be flat within immediately above or below
0.05 mm (0.002 in.) the load cell.
Stable foundation For correct tightening torques,
see table E-1.
If the measuring roll is driven,
always consult ABB to ensure
a solution with minimized risk
of disturbances. Alignment of the load cells
mm (inches)
90° Adapter plate thickness
PFTL 101A
min. 30 mm (1.18 in.)
PFTL 101B
min. 35 mm (1.38 in.)
Web
a)
In level
1.0 mm (0.04 in.)
PFTL 101A/AE/AER a) 230 mm (9 in.)

PFTL 101B/BE/BER a) 360 mm (14 in.)
Figure E-1. Installation Requirements
3BSE029380R0001 Rev B E-3

E.5 Mounting Alternatives, Calculating Force and Calculating Wrap Gain
E.5.1 Horizontal Mounting
In most cases, horizontal mounting is the most obvious

+α +β
FR T mounted horizontally when possible.
Tare
FR = T × (cos β − cos α)
FRT = 0 (Tare force is not measured)

R
T T
Wrap gain = -------- = ------------------------------------------
F
1
Wrap gain = ---------------------------------
cos β – cos α
E-4 3BSE029380R0001 Rev B

Section E.5.2 Inclined Mounting
E.5.2 Inclined Mounting
T Sometimes it is necessary to mount the load cell on an

incline due to mechanical design constraints of the
−α
machine or the need to have a sufficient force component
+β applied to the load cell.
FRT Inclined mounting adds a component of tare force in the
Tare T measuring direction and modifies the force components
as shown.
FR
NOTE
−γ
When calculating, it is important that the angles
are set into the equations with the correct signs
in relation to the horizontal plane.
T
Horizontal plane −β
+α
FR
FRT
Tare
+γ
FR = T × [cos(β + γ) − cos(α −γ)]
FRtot = FR + FRT =

R
T T
Wrap gain = -------- = ----------------------------------------------------------------------
F T [ cos ( β + γ ) – cos ( α – γ ) ]
R
1
Wrap gain = -------------------------------------------------------------
cos ( β + γ ) – cos ( α – γ )
3BSE029380R0001 Rev B E-5

E.6 Force Calculation for Measurement with a Single Load Cell

E.6.1 The Most Common and Simple Solution

As long as the roll is supported at both ends, the same calculations given in Section E.5,
NOTE
Figure E-2. Cross-directional stress distribution
E-6 3BSE029380R0001 Rev B

Section E.6.2 Force Calculation when the Web is not Centered on the Roll
E.6.2 Force Calculation when the Web is not Centered on the Roll
on the roll.
center and the load cell centerline, see figure.
L
a
b

Tare force center
Load cell
PFTL 101
2. Calculate FR and FRT, see Section E.5, Mounting Alternatives, Calculating Force and
L–b
L
L – a-
FRT for single load cell = RT
F × -----------
L
where:
3BSE029380R0001 Rev B E-7

E.7 Mounting the Load Cells

The instructions below apply to a typical mounting arrangement. Variations are allowed,
provided that the requirements of Section E.4, Installation Requirements are complied with.
If it is necessary to use tubular dowel pins to secure the position of the load cell,
see instructions in Figure E-3.
Tighten the screws to the torque stated in Table E-1.
Tighten the screws to the torque stated in Table E-1.
CAUTION
During this operation it is possible to over load the load cells if the operation is
done not careful enough, especially if the roll is heavy. The most critical load
cells are naturally the PFTL 101A-0.5 kN and PFTL 101B-2 kN. Applications
with inclined mounting are most critical.
6. Adjust the load cells so that they are in parallel with each other and in line with the axial
direction of the roll. Tighten the foundation screws, see Table E-1.
7. Adjust the roll so that it is at right angles to the longitudinal direction of the load cells.
Tighten the screws in the upper adapter plate, see Table E-1.
Table E-1. Tightening Torques for Load Cell PFTL 101
Tightening
Strength Type of
Alternative Type of screws Dimension torque
class lubrication
[Nm] ± 5%
M12 136 Nm
1 Alloyed steel screws
12.9 Oil M16 333 Nm
(Recommended) Strength class according to ISO 898/1
M20 649 Nm
M12 117 Nm
2 Alloyed steel screws
12.9 MoS2 M16 286 Nm
(Recommended) Strength class according to ISO 898/1
M20 558 Nm
Stainless steel (A2-80) A2-80 M12 76 Nm
3 or acid resistant steel (A4-80), or Wax M16 187 Nm
Strength class according to ISO 3506 A4-80 M20 364 Nm
Stainless steel (A2-80) A2-80 Oil M12 65 Nm
4 or acid resistant steel (A4-80), or or M16 161 Nm
Strength class according to ISO 3506 A4-80 emulsion M20 313 Nm
E-8 3BSE029380R0001 Rev B

Section E.7.1 Routing the Load Cell Cable
∅a c
NOTE
Do not drill in this
area, as internal
wiring may be
damaged.
c
∅a
b
∅a ∅a
Load cell PFTL 101 ∅ a b c Tubular

dowel pin
A/AE/AER 8 15 15 ∅ 8.4
B/BE/BER 12 15 20 ∅ 12.5
Figure E-3. Drilling Dowel Pin Holes
E.7.1 Routing the Load Cell Cable

cable.
3BSE029380R0001 Rev B E-9

E.8 Technical Data

Table E-2. Technical Data for Different Types of Load Cell PFTL 101
PFTL 101 Type Data Unit
Nominal load
A/AE/AER 0.5 1.0 2.0
Nominal load in measuring direction, Fnom (112) (225) (450)
B/BE/BER 2.0 5.0 10.0 20.0
(450) (1120) (2250) (4500)
Permitted transverse load A/AE/AER 5 10 10
within the accuracy, FVnom (1120) (2250) (2250)
B/BE/BER 30 30 30 40
(6740) (6740) (6740) (9000)
kN
Permitted axial load A/AE/AER 2 5 5
(lbs)
within the accuracy, FAnom (450) (1120) (1120)
B/BE/BER 5 10 10 10
(1120) (2250) (2250) (2250)
Overload capacity
Max. load in measuring direction without A/AE/AER 2.5 5 10
permanent change of data, Fmax (562) (1120) (2250)
B/BE/BER 10 25 50 80
(2250) (5620) (11200) (18000)
A/AE/AER 32 65 130
Spring constant (183) (372) (744) kN/mm
(1000
B/BE/BER 130 325 650 1300 lbs/in.)
(744) (1860) (3718) (7440)
Mechanical data
A/AE/AER 230 230 230
Length (9) (9) (9)
B/BE/BER 360 360 360 360
(14) (14) (14) (14)
A/AE/AER 84 84 84
Width (3.3) (3.3) (3.3)
mm
B/BE/BER 104 104 104 104 (inch)
(4) (4) (4) (4)
A/AE/AER 125 125 125
Height (5) (5) (5)
B/BE/BER 125 125 125 125
(5) (5) (5) (5)
E-10 3BSE029380R0001 Rev B

Section E.8 Technical Data
Table E-2. Technical Data for Different Types of Load Cell PFTL 101
PFTL 101 Type Data Unit
Weight A/AE/AER 9 9 10
(20) (20) (22) kg
B/BE/BER 20 21 21 23 (lbs)
(44) (46) (46) (51)
Material A/AE/B/BE Stainless steel:
SS 2383
DIN 17440 X12CrMoS17
Werkstoffnr 1.4104
AISI 430F
AER/BER Acid resistant steel:

SS 2348
DIN 17440 X2CrNiMo17 13 2
Werkstoffnr 1.4404
AISI 316L
Accuracy
Accuracy class ± 0.5
Linearity deviation ± 0.3
%
Hysteresis <0.2
Compensated temperature range +20 - +80 (68 - 176) °C (°F)
A/AE/AER 30 / 80(1)
Zero point drift (17 / 44(1)) ppm/K
B/BE/BER (ppm/F)
Sensitivity drift 150 (83)
Working temperature range –10 - +105 (14 - 221) °C (°F)
Zero point drift 50 / 100(1) / (28 / 56(1)) ppm/K
(ppm/F)
Sensitivity drift 250 (139)
Storage temperature range –40 - +105 (–40 - +105) °C (°F)
Degree of protection A/B IP 65
AE/BE IP 66 According. to EN 60 529
AER/BER IP 66/67
(1) PFTL 101AER -0.5 kN/ -1.0 kN
3BSE029380R0001 Rev B E-11

E.9 Cable Diagram 3BSE028140D0065, Page 3/5, Rev. B
E-12 3BSE029380R0001 Rev B

Section E.10 Cable Diagram 3BSE028140D0065, Page 4/5, Rev. B
3BSE029380R0001 Rev B E-13

E-14 3BSE029380R0001 Rev B

Section E.12 Dimension Drawing, 3BSE004171, Rev. B
E.12 Dimension Drawing, 3BSE004171, Rev. B
3BSE029380R0001 Rev B E-15

E.13 Dimension Drawing, 3BSE004995, Rev. C
E-16 3BSE029380R0001 Rev B

Section E.14 Dimension Drawing, 3BSE023301D0064, Rev. B
E.14 Dimension Drawing, 3BSE023301D0064, Rev. B
3BSE029380R0001 Rev B E-17

E-18 3BSE029380R0001 Rev B

Section E.16 Dimension Drawing, 3BSE004999, Rev. C
3BSE029380R0001 Rev B E-19

E.17 Dimension Drawing, 3BSE023223D0064, Rev. B
E-20 3BSE029380R0001 Rev B

3BSE029380R0001 Rev B E-21

E-22 3BSE029380R0001 Rev B

3BSE029380R0001 Rev B E-23

E-24 3BSE029380R0001 Rev B

Section F.1 Document the Commissioning in this Form
Appendix F Actual Data and Settings at Commissioning
F.1 Document the Commissioning in this Form

Fill in actual data and settings to document the commissioning.
Data and Settings PFEA111 PFEA112 Unit

Display language
Display unit N, kN, kg, lbs
Object type Standard roll Standard roll
(Load cells per roll) (2 load cells) (2 load cells)
Single side Single side
(1 load cell) (1 load cell)
Load cell nominal load kN, lbs
Set wrap gain
- Wrap gain*
Voltage output
- Step response time ms
- High Tension N, kN, kg, lbs
- High Output V
- Low Tension N, kN, kg, lbs
- Low Output V
- High Limit V
- Low Limit V
Current output
- Step response time ms
- High Tension N, kN, kg, lbs
- High Output mA
- Low Tension N, kN, kg, lbs
- Low Output mA
- High Limit mA
- Low Limit mA
PROFIBUS
- Address -
* If HangWeight has been used at commissioning, go to menu “EnterWrapGain”, read

the Wrap gain value calculated by the electronics and fill in this Wrap gain value in the
table.
3BSE029380R0001 Rev B F-1

Appendix F Actual Data and Settings at Commissioning
F-2 3BSE029380R0001 Rev B

ABB Automation Technologies AB 3BSE029380R0001 Rev B
Force Measurement 2004-08
SE-721 59 Västerås, Sweden
Telephone: +46 (0) 21 34 20 00
Telefax: +46 (0) 21 34 00 05
Internet: www.abb.com/pressductor

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Web Tension Systems

Copyright  ABB Automation Technologies AB, 2004.

3BSE029380R0001 Rev B iii

Appendix B - PFCL 301E - Designing the Load Cell Installation

Appendix D - PFRL 101 - Designing the Load Cell Installation

Appendix F - Actual Data and Settings at Commissioning

1.1 About this Manual

1.2 How to Use this Manual

1.2.1 Getting Started

1.2.2 Saving Actual Data and Settings at Commissioning

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1.3 About this System

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1.4 Safety Instructions

1.4.1 Personnel Safety

1.4.2 Equipment Safety

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1.5 The Measuring Technique Based on Pressductor Technology

Figure 1-2. The Sensor Based on Pressductor® Technology

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2.1 About this Chapter

2.2 Safety Instructions

2.3 Mounting the Load Cells

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2.4 Installing the Electronic Unit

2.4.1 Selecting and Routing the Cabling

2.4.1.1 Recommended Cabling

Mains supply n × 0.5 mm2

Load cell signals

4 × 1.0 mm2 + screen Load cell excitation

Load cell A Load cell B

Figure 2-1. Recommended Cabling

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Table 2-1. Maximum Permitted Cable Resistance

Load cell Max. permitted cable resistance

Signal Load cell excitation

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PFEA111/112 PFEA111/112 PFEA111/112 PFEA111/112

X1:15 14 X1:15 14 X1:15 14 X1:15 14

Figure 2-3. Connection for Synchronization

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2.4.2 Mounting the Tension Electronics PFEA111/112

2.4.2.1 IP 65-version (NEMA 4)

Note.To fulfill UL-requirements, the cable

1 x for cable ∅ 6-12 [0.24”-0.47”]

Figure 2-4. Installation Dimensions for PFEA 111/112

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Figure 2-5. Cable Glands PFEA 112

Connect the cables to terminals according cable diagrams in Appendix (B, C, D, or E)

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2.4.2.2 IP 20-version (Unsealed)

Figure 2-6. Installation Dimensions

Connect the cables to terminals according cable diagrams in Appendix (B, C, D, or E)

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Figure 2-7. Connection to a superior system with an insulated or differential input

Figure 2-8. Connection to a superior system through a separate insulation amplifier

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2.5 Connecting the Load Cells

Type of load cell Cable diagrams in Appendix

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2.6 Connecting Optional Units

2.6.1 Insulation Amplifier PXUB 201 (only for the IP 20-version)

PFEA111/112 PXUB 201

Figure 2-9. Typical Connection of Insulation Amplifier PXUB 201

2.6.2 Power Supply Unit

Table 2-2. Number of PFEA111/112 that can be supplied

Power Supply Unit PFEA111 PFEA112

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3.1 About this Chapter

3.2 Safety Instructions

3.3 Necessary Equipment and Documentation

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3.4 Using the Panel Buttons

3.4.1 Navigating and Confirming

Display Button How to use it

Steps down in a list.

3.4.2 Changing Numerical Values and Parameters

• X indicates a numerical value.