1. Introduction
The ABB PFEA113-65 Tension Electronics (Order Code: 3BSE050092R65) is a high-performance, multi-functional tension measurement and control unit designed for demanding web processing applications. Part of ABB's renowned PFEA113 series, this advanced tension electronics module provides precise, reliable tension monitoring and control across a wide range of industries, including paper and pulp, printing, converting, textile manufacturing, film and foil production, and metal strip processing.
With its comprehensive input/output configuration, flexible measurement modes, and robust communication capabilities, the PFEA113-65 delivers the accuracy, stability, and operational intelligence required to maintain consistent product quality and maximize production efficiency.
2. Key Specifications
| Parameter | Specification |
|---|---|
| Model | PFEA113-65 |
| Order Code | 3BSE050092R65 |
| Weight | 6 kg |
| Mounting | DIN rail or panel mount |
| Power Supply | 24V DC |
| Ambient Temperature | 0°C to +55°C (operation) |
3. Input and Output Configuration
The PFEA113-65 offers a comprehensive I/O suite, making it suitable for complex tension control applications:
| I/O Type | Specification | Function |
|---|---|---|
| Load Cell Inputs | 4 load cells – high-impedance differential inputs | Connect up to four tension load cells (full-bridge or half-bridge) for multi-point tension measurement |
| Analog Outputs | 6 AO (selectable V/C) – voltage or current output (0-10V or 4-20mA) | Drive actuators, or transmit tension signals to PLCs, drives, or chart recorders |
| Digital Outputs | 4 DO – relay outputs (configurable) | Alarm outputs, status signaling, or actuator control |
| Digital Inputs | 1 DI – 24V DC | External start/stop, reset, or mode selection |
| Analog Inputs | 2 AI – 0-10V or 4-20mA (configurable) | Accept external setpoints or compensation signals |
Key Advantage: The ability to connect up to four load cells enables sum, difference, or individual measurement modes – essential for applications such as measuring total web tension across multiple zones or detecting web misalignment.
4. Measurement Modes – Display Capabilities
The PFEA113-65 features an integrated display with multiple measurement views, providing operators with real-time visibility into tension conditions:
| Display Mode | Description | Application |
|---|---|---|
| Sum | Displays the combined tension from all connected load cells | Overall web tension measurement – ideal for center-driven winders/unwinders |
| Difference | Displays the tension differential between load cell pairs | Detects web misalignment, edge tracking, or uneven tension distribution |
| Individual | Displays tension values from each load cell individually | Diagnosing load cell faults or analyzing tension profile across web width |
Operational Benefit: Operators can switch between modes at the touch of a button, enabling quick diagnostics without needing external monitoring equipment.
5. Insulation Amplifier – Signal Integrity
The PFEA113-65 includes an integrated insulation amplifier connected to AO1 (voltage output) , providing:
| Feature | Benefit |
|---|---|
| Galvanic Isolation | Electrically isolates the analog output from the measurement circuit, eliminating ground loops and protecting against common-mode voltage spikes |
| Voltage Output (AO1) | Provides a clean, stable 0-10V signal to external devices – PLCs, drives, or recorders |
| Noise Rejection | Filters out electrical interference from drives, motors, and other industrial equipment |
Why This Matters: In industrial environments, ground potential differences between sensors, controllers, and drives can introduce measurement errors. The insulation amplifier ensures that the signal transmitted to external devices remains accurate and noise-free.
6. Communication – Profibus-DP Interface
The PFEA113-65 is equipped with a Profibus-DP communication interface, enabling seamless integration with ABB and third-party control systems:
| Feature | Capability |
|---|---|
| Profibus-DP | High-speed, deterministic fieldbus communication – ideal for real-time tension control |
| Data Exchange | Transmits tension values, status flags, diagnostic data, and alarm information to the PLC or DCS |
| Configuration | Remote parameterization and monitoring via Profibus master (e.g., ABB 800xA, Siemens S7) |
Integration Example: In a printing press, the PFEA113-65 sends real-time tension data to the PLC, which adjusts drive speeds to maintain constant tension – all within the Profibus scan cycle.
7. Technical Details – Insulation Amplifier
The integrated insulation amplifier connected to AO1 provides a voltage output with the following characteristics:
| Parameter | Specification |
|---|---|
| Output Type | Voltage output (0-10V) |
| Isolation | Galvanically insulated from measurement circuit (500V) |
| Load Impedance | ≥ 2 kΩ |
| Accuracy | ±0.1% of full scale |
| Response Time | < 50 ms (configurable) |
Application: This output is commonly used to drive a tension display, provide a signal to a drive for closed-loop tension control, or feed data into a data acquisition system.
8. Included Documentation
Each PFEA113-65 unit is supplied with a CD-ROM containing the user manual in multiple languages. The manual includes:
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Installation instructions and wiring diagrams
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Configuration and calibration procedures
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Parameter lists and descriptions
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Troubleshooting guide and error codes
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Profibus-DP communication setup
Benefit: Comprehensive documentation simplifies commissioning and reduces engineering time.
9. Typical Applications
The PFEA113-65 is ideally suited for:
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