ABB PFEA 113 User manual

—
A B B M E A S U R E M E N T & ANA LY T I C S
Web Tension Systems
with Tension Electronics PFEA 113
User Manual
3BSE029382R0101 en Rev C

3BSE029382R0101 Rev C
3BSE001264/B
Template: 3BSE001286/D
Use of DANGER,WA R N I N G,CAUTION, and NOTE
This publication includes, DANGER, WA R N I N G, 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 AB.
NOTICE
The information in this document is subject to change without notice and should not be construed as a commitment by ABB AB.
ABB AB assumes no responsibility for any errors that may appear in this document.
In no event shall ABB 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 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 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 PFEA113 fulfills the requirements as stated in the RoHS Directive 2011/65/EU, EMC Directive
2014/30/EU and Low Voltage Directive 2014/35/EU, 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 PFEA113 fulfills 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. 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.
Copyright ABB AB, 2004-2018.

Tension Electronics PFEA113, User Manual
Table of Contents
3BSE029382R0101 Rev C i
TABLE OF CONTENTS
Chapter 1 - Introduction
1.1 About this Manual ................................................................................................... 1-1
1.2 Cyber security disclaimer ........................................................................................ 1-1
1.3 WEEE: Waste Electrical and Electronic Equipment ............................................... 1-1
1.4 How to Use this Manual .......................................................................................... 1-2
1.4.1 Getting Started ........................................................................................ 1-2
1.4.2 Saving Actual Data and Settings at Commissioning .............................. 1-2
1.5 About this System.................................................................................................... 1-3
1.6 Safety Instructions ................................................................................................... 1-4
1.6.1 Personnel Safety ..................................................................................... 1-4
1.6.2 Equipment Safety.................................................................................... 1-4
1.7 The Measuring Technique Based on Pressductor® Technology ............................. 1-5
Chapter 2 - Installation
2.1 About this Chapter ................................................................................................... 2-1
2.2 Safety Instructions ................................................................................................... 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 PFEA113 ......................................... 2-5
2.4.2.1 IP 65-version (NEMA 4).................................................. 2-5
2.4.2.2 IP 20-version (Unsealed) ................................................. 2-6
2.4.3 Earthing................................................................................................... 2-7
2.5 Installing MNS Select Floor Cabinet....................................................................... 2-8
2.5.1 Mounting Cabinets Together .................................................................. 2-8
2.5.2 Mounting Cabinets to the Floor.............................................................. 2-8
2.5.3 Space Requirements................................................................................ 2-9
2.6 Installing Junction Box PFXC 141 ........................................................................ 2-10
2.7 Connectors on the PFEA113...................................................................................2-11
2.8 Connecting the Load Cells..................................................................................... 2-12
2.9 Connecting Analog Outputs (AO1-AO6) .............................................................. 2-12
2.10 Connecting Analog Inputs (AI1-AI2).................................................................... 2-13
2.11 Connecting Digital Outputs (DO1-DO4)............................................................... 2-13
2.12 Connecting the Digital Input (DI).......................................................................... 2-13
2.13 Connecting Optional Units .................................................................................... 2-14
2.13.1 Insulation Amplifier PXUB 201........................................................... 2-14

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Table of Contents
3BSE029382R0101 Rev C ii
CONTENTS (continued)
2.13.2 Relay Board PXKB 201........................................................................ 2-14
2.13.3 Power Supply Unit SD83x.................................................................... 2-15
Chapter 3 - Commissioning
3.1 About this Chapter ................................................................................................... 3-1
3.2 Safety Instructions ................................................................................................... 3-1
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
3.8 Performing a Fast Setup (Only for One or Two Rolls)............................................ 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 ...................................................................... 3-10
3.10 Checking Load Cell Function .................................................................................3-11
3.11 Performing a Complete Setup................................................................................ 3-12
3.11.1 Overview............................................................................................... 3-12
3.12 Complete Setup Sequence ..................................................................................... 3-14
3.12.1 Presentation Menu ................................................................................ 3-14
3.12.1.1 Set Language.................................................................. 3-14
3.12.1.2 Set Unit .......................................................................... 3-14
3.12.1.3 Set Web Width................................................................ 3-15
3.12.1.4 Set Decimals .................................................................. 3-15
3.12.2 System Definition ................................................................................. 3-16
3.12.2.1 Wrap Gain Scheduling ................................................... 3-16
3.12.3 Setting Object Type .............................................................................. 3-17
3.12.3.1 Object Types for One Roll ............................................. 3-17
3.12.3.2 Setting Object Types for Two Rolls ............................... 3-18
3.12.3.3 Setting Object Types for Segmented Roll...................... 3-19
3.12.4 Nominal Load ....................................................................................... 3-21
3.12.5 Zero Set................................................................................................. 3-22
3.12.6 Set Wrap Gain....................................................................................... 3-23
3.12.6.1 Wrap Gain Menus for One Roll, Two Rolls and
Segmented Roll .............................................................. 3-25
3.12.7 Setting Analog Outputs (AO1-AO6) .................................................... 3-28
3.12.8 Setting Digital Outputs (DO1-DO4)..................................................... 3-31
3.12.9 Setting Analog Inputs (AI1 and AI2) ................................................... 3-34
3.12.10 Setting the Digital Input........................................................................ 3-34
3.12.11 Miscellaneous Menu ............................................................................. 3-35

Tension Electronics PFEA113, User Manual
Table of Contents
3BSE029382R0101 Rev C iii
CONTENTS (continued)
3.12.11.1 Profibus .......................................................................... 3-35
3.12.11.2 Set Factory Default ........................................................ 3-35
3.12.12 Service Menu ........................................................................................ 3-36
3.12.12.1 Maximum Load / Present Offset .................................... 3-38
3.12.12.2 Reset Load Cells ............................................................ 3-38
3.12.12.3 Simulation function........................................................ 3-38
3.13 Profibus DP Communication with PFEA113 ........................................................ 3-39
3.13.1 General Data about Profibus DP........................................................... 3-39
3.13.2 Master-slave Communication ............................................................... 3-39
3.13.3 Profibus Physical Media ....................................................................... 3-40
3.13.4 Commands through Profibus ................................................................ 3-41
3.13.5 Handling of Measurement Data through Profibus................................ 3-41
3.13.5.1 Miscellaneous Menu ...................................................... 3-42
3.13.5.2 Scaling of Profibus Measuring Values ........................... 3-43
3.13.5.3 Filtering of Profibus Measuring Values ......................... 3-46
3.13.5.4 Input Buffer, Communication Block from PFEA113
to PLC ............................................................................ 3-46
3.13.5.5 Output Buffer, Communication Block from PLC to
PFEA113 ........................................................................ 3-47
3.14 Commissioning of Optional Units ......................................................................... 3-48
3.14.1 Insulation Amplifier PXUB 201........................................................... 3-48
Chapter 4 - Operation
4.1 About this Chapter ................................................................................................... 4-1
4.2 Safety Instructions ................................................................................................... 4-1
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 Measuring values on the display.............................................................................. 4-3
4.7 Operator Menus ....................................................................................................... 4-5
4.7.1 Web Tension............................................................................................ 4-6
4.7.1.1 Standard Roll (two load cells), One or Two Rolls ........... 4-6
4.7.1.2 Segmented Roll ................................................................ 4-7
4.7.1.3 Single Side Measurement (One Load Cell) ..................... 4-7
4.7.1.4 Tension Values Connected to Analog Outputs,
AO1 - AO6....................................................................... 4-8
4.7.2 Error and Warning Messages.................................................................. 4-8

Tension Electronics PFEA113, User Manual
Table of Contents
3BSE029382R0101 Rev C iv
CONTENTS (continued)
Chapter 5 - Maintenance
5.1 About this Chapter ................................................................................................... 5-1
5.2 Preventive Maintenance........................................................................................... 5-1
Chapter 6 - Fault-tracing
6.1 About this Chapter ................................................................................................... 6-1
6.2 Safety Instructions ................................................................................................... 6-1
6.3 Interchangeability .................................................................................................... 6-1
6.4 Necessary Equipment and Documentation .............................................................. 6-1
6.5 Fault-tracing Procedure............................................................................................ 6-2
6.6 Error and Warning Messages in PFEA113 .............................................................. 6-3
6.6.1 Error Messages ....................................................................................... 6-3
6.6.2 Warning Messages .................................................................................. 6-3
6.7 Fault Symptoms and Measures................................................................................ 6-4
6.8 Warnings and Errors Detected by the Tension Electronics...................................... 6-6
6.8.1 Errors ...................................................................................................... 6-6
6.8.1.1 Flash Memory Error......................................................... 6-6
6.8.1.2 EEPROM Memory Error ................................................. 6-6
6.8.1.3 Supply Error ..................................................................... 6-6
6.8.1.4 Load Cell Excitation Error............................................... 6-7
6.8.2 Warnings ................................................................................................. 6-7
6.8.2.1 Profibus Communication Problem................................... 6-7
6.8.2.2 Synchronization Problem ................................................. 6-7
6.8.3 Changing to Single Side Measurement If One Load Cell Is Faulty ....... 6-8
6.8.3.1 Menus for Changing from Standard Roll to Single Side
Measurement.................................................................... 6-9
6.9 Changing Load Cells ..............................................................................................6-11
Appendix A - Technical Data for Tension Electronics PFEA113
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 Segmented Roll Scale Factor (SRSF)......................................................................A-4
A.3.1 Simplified calculation of SRSF ..............................................................A-4
A.4 Technical Data .........................................................................................................A-7
A.5 Factory Default Settings ........................................................................................A-11
A.6 Optional Units........................................................................................................A-13
A.6.1 Insulation Amplifier PXUB 201 ...........................................................A-13
A.6.2 Relay Board PXKB 201........................................................................A-14
A.6.3 Power Supply Unit SD83x....................................................................A-14
A.6.4 Junction Box PFXC 141 .......................................................................A-15
A.7 Drawings................................................................................................................A-16

Tension Electronics PFEA113, User Manual
Table of Contents
3BSE029382R0101 Rev C v
CONTENTS (continued)
A.7.1 Dimension Drawing 3BSE017052D64, Rev D ....................................A-16
A.7.2 Dimension Drawing 3BSE029997D0064, Rev A ................................A-17
A.8 Profibus DP - GSD File for PFEA113...................................................................A-18
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 3BSE028144D0065, page 5/7, Rev. D .........................................B-11
B.10 Cable Diagram 3BSE028144D0065, page 6/7, Rev. D .........................................B-12
B.11 Mounting Instruction, Cable Connector, 3BSE019064, Rev. A ............................B-13
B.12 Dimension Drawing, 3BSE015955D0094, Rev. D................................................B-14
B.13 Assembly Drawing, 3BSE015955D0096, Rev. C .................................................B-15
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 3BSE028144D0065, Page 5/7, Rev. D .........................................C-11
C.10 Cable Diagram 3BSE028144D0065, Page 6/7, Rev. D.........................................C-12

Tension Electronics PFEA113, User Manual
Table of Contents
3BSE029382R0101 Rev C vi
CONTENTS (continued)
C.11 Mounting Instruction, Cable Connector, 3BSE019064, Rev. A ............................C-13
C.12 Dimension Drawing, 3BSE019040D0094, Rev. C................................................C-14
C.13 Assembly Drawing, 3BSE019040D0096, Rev. C .................................................C-15
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, 3BSE028144D0065, Page 1/7, Rev. D........................................D-15
D.11 Cable Diagram, 3BSE028144D0065, Page 2/7, Rev. D........................................D-16
D.12 Cable Diagram, 3BSE028144D0065, Page 3/7, Rev. D........................................D-17
D.13 Cable Diagram, 3BSE028144D0065, Page 7/7, Rev. D........................................D-18
D.14 Dimension Drawing 3BSE004042D0003, page 1/2, rev. O ..................................D-19
D.15 Dimension Drawing, 3BSE004042D0003, page 2/2, rev. O .................................D-20
D.16 Dimension Drawing, 3BSE026314, Rev. - ............................................................D-21
D.17 Dimension Drawing, 3BSE027249, Rev. - ............................................................D-22
D.18 Dimension Drawing, 3BSE004042D0066, Rev. - .................................................D-23
D.19 Dimension Drawing, 3BSE004042D0065, rev. - ..................................................D-24
D.20 Dimension Drawing, 3BSE010457, Rev. B...........................................................D-25
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

Tension Electronics PFEA113, User Manual
Table of Contents
3BSE029382R0101 Rev C vii
CONTENTS (continued)
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 3BSE028144D0065, Page 1/7, Rev. D.........................................E-12
E.10 Cable Diagram 3BSE028144D0065, Page 2/7, Rev. D.........................................E-13
E.11 Cable Diagram 3BSE028144D0065, Page 3/7, Rev. D.........................................E-14
E.12 Cable Diagram 3BSE028144D0065, Page 4/7, Rev. D.........................................E-15
E.13 Cable Diagram 3BSE028144D0065, Page 7/7, Rev. D.........................................E-16
E.14 Dimension Drawing, 3BSE004171, Rev. B...........................................................E-17
E.15 Dimension Drawing, 3BSE004995, Rev. C...........................................................E-18
E.16 Dimension Drawing, 3BSE023301D0064, Rev. B................................................E-19
E.17 Dimension Drawing, 3BSE004196, Rev. C...........................................................E-20
E.18 Dimension Drawing, 3BSE004999, Rev. C...........................................................E-21
E.19 Dimension Drawing, 3BSE023223D0064, Rev. B................................................E-22
E.20 Dimension Drawing, 3BSE012173, Rev. F ...........................................................E-23
E.21 Dimension Drawing, 3BSE012172, Rev. F ...........................................................E-24
E.22 Dimension Drawing, 3BSE012171, Rev. F ...........................................................E-25
E.23 Dimension Drawing, 3BSE012170, Rev. F ...........................................................E-26
Appendix F - PFCL 201 - Designing the Load Cell Installation
F.1 About This Appendix............................................................................................... F-1
F.2 Basic Application Considerations............................................................................ F-1
F.3 Step-by-Step Guide for Designing the Load Cell Installation ................................. F-2
F.4 Installation Requirements ........................................................................................ F-3
F.5 Mounting Alternatives, Calculating Force and Calculating Wrap Gain.................. F-4
F.5.1 Horizontal Mounting............................................................................... F-4
F.5.2 Inclined Mounting................................................................................... F-5
F.6 Force Calculation for Measurement with a Single Load Cell ................................. F-6
F.6.1 The Most Common and Simple Solution ............................................... F-6
F.6.2 Force Calculation when the Web is not Centered on the Roll ................ F-7
F.7 Mounting the Load Cells ......................................................................................... F-8
F.7.1 Preparations ............................................................................................ F-8
F.7.2 Mounting................................................................................................. F-8
F.7.3 Cabling for Load Cell PFCL 201CE..................................................... F-10
F.8 Technical Data Load Cell PFCL 201 ..................................................................... F-11
F.9 Cable Diagram 3BSE028144D0065, Page 1/7, Rev. D......................................... F-13
F.10 Cable Diagram 3BSE028144D0065, Page 2/7, Rev. D......................................... F-14

Tension Electronics PFEA113, User Manual
Table of Contents
3BSE029382R0101 Rev C viii
CONTENTS (continued)
F.11 Cable Diagram 3BSE028144D0065, Page 3/7, Rev. D......................................... F-15
F.12 Cable Diagram 3BSE028144D0065, Page 7/7, Rev. D......................................... F-16
F.13 Dimension Drawing, 3BSE006699D0003, Rev. F ................................................ F-17
F.14 Dimension Drawing, 3BSE029522D0001, Rev. B................................................ F-18
F.15 Dimension Drawing, 3BSE006699D0006, Rev. - ................................................. F-19
F.16 Dimension Drawing, 3BSE006699D0005, Rev. J................................................. F-20
F.17 Dimension Drawing, 3BSE006699D0004, Rev. H................................................ F-21
Appendix G - PFTL 201 - Designing the Load Cell Installation
G.1 About This Appendix...............................................................................................G-1
G.2 Basic Application Considerations............................................................................G-1
G.3 Step-by-Step Guide for Designing the Load Cell Installation .................................G-2
G.4 Installation Requirements ........................................................................................G-3
G.5 Mounting Alternatives, Calculating Force and Calculating Wrap Gain..................G-4
G.5.1 Horizontal Mounting...............................................................................G-4
G.5.2 Inclined Mounting...................................................................................G-5
G.6 Force Calculation for Measurement with a Single Load Cell .................................G-6
G.6.1 The Most Common and Simple Solution ...............................................G-6
G.6.2 Force Calculation when the Web is not Centered on the Roll ................G-7
G.7 Mounting the Load Cells .........................................................................................G-8
G.7.1 Preparations ............................................................................................G-8
G.7.2 Adapter plates .........................................................................................G-8
G.7.3 Mounting.................................................................................................G-8
G.7.4 Cabling..................................................................................................G-10
G.8 Technical data load cell PFTL 201 ........................................................................G-11
G.9 Cable Diagram 3BSE028144D0065, Page 1/7, Rev. D.........................................G-13
G.10 Cable Diagram 3BSE028144D0065, Page 2/7, Rev. D.........................................G-14
G.11 Cable Diagram 3BSE028144D0065, Page 3/7, Rev. D.........................................G-15
G.12 Cable Diagram 3BSE028144D0065, Page 7/7, Rev. D.........................................G-16
G.13 Dimension Drawing, 3BSE008723, Rev. D ..........................................................G-17
G.14 Dimension Drawing, 3BSE008904, Rev. D ..........................................................G-18
G.15 Dimension Drawing, 3BSE008724, Rev. F ...........................................................G-19
G.16 Dimension Drawing, 3BSE008905, Rev. G ..........................................................G-20
G.17 Dimension Drawing, 3BSE008917, Rev. H ..........................................................G-21
G.18 Dimension Drawing, 3BSE008918, Rev. G ..........................................................G-22
Appendix H - Actual Data and Settings at Commissioning
H.1 Document the Commissioning in this Form............................................................H-1

Tension Electronics PFEA113, User Manual
Section 1.1 About this Manual
3BSE029382R0101 Rev C 1-1
Chapter 1 Introduction
1.1 About this Manual
This User Manual describes your new 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 Cyber security disclaimer
This product has been designed to be connected and communicate data and information via a
network interface which should be connected to a secure network. It is the sole responsibility of
the person or entity responsible for network administration to ensure a secure connection to the
network and to take the necessary measures (such as, but not limited to, installation of firewalls,
application of authentication measures, encryption of data, installation of antivirus programs,
etc.) to protect the product and the network, its system and interface included, against any kind
of security breaches, unauthorized access, interference, intrusion, leakage and/or theft of data or
information. ABB is not liable for any such damages and/or losses.
1.3 WEEE: Waste Electrical and Electronic Equipment
The crossed – out wheeled bin symbol on the product(s) and / or accompanying documents
means that used electrical and electronic equipment (WEEE) should not be mixed with general
household waste.
If you wish to discard electrical and electronic equipment (EEE), in the European Union, please
contact your dealer or supplier for further information.
Outside of the European Union, contact your local authorities or dealer and ask for the correct
method of disposal.
Disposing of this product correctly will help save valuable resources and prevent any potential
negative effects on human health and the environment, which could otherwise arise from
inappropriate waste handling.

Tension Electronics PFEA113, User Manual
Chapter 1 Introduction
1-2 3BSE029382R0101 Rev C
1.4 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 Tensiometer PFRL 101 (Appendix D)
- Horizontal-force sensing load cell PFTL 101 (Appendix E)
- Vertical-force sensing load cell PFCL 201 (Appendix F)
- Horizontal-force sensing load cell PFTL 201 (Appendix G)
Each appendix contains detailed information about one of the above load cell types when
used in web tension systems with Tension Electronics PFEA113.
1.4.1 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 (Only for One or Two Rolls)
For extended functionality, use “Performing a Complete Setup”.
See Section 3.11 Performing a Complete Setup.
1.4.2 Saving Actual Data and Settings at Commissioning
When commissioning is completed you can use the form in Appendix H, where actual
commissioning data and settings can be filled in and saved for future use.

Tension Electronics PFEA113, User Manual
Section 1.5 About this System
3BSE029382R0101 Rev C 1-3
1.5 About this System
Your system for tension measurement consists of:
• Tension Electronics PFEA113
• Load cells of type PFCL 301E, PFTL 301E, PFRL 101, PFTL 101, PFCL 201
and PFTL 201
• Junction Box PFXC 141
This advanced tension electronics can supply up to four load cells and has six configurable
analog outputs for control and/or monitoring of web tension. The output signals are also
available on Profibus-DP. Another useful feature is the possibility to, via the digital input or
Profibus, switch the gain for two different web paths (gain scheduling) and zero set. This unit
also includes a self-diagnostic function and four configurable digital outputs for alarms and
level detection. Status of self-diagnostic functions are also available on Profibus-DP. By
combining up to three PFEA113 the system can handle segmented roll applications, for example
winders, with up to 12 load cells. The high level of functionality and user friendliness make the
PFEA113 one of the most complete tension electronics on the market.
Covering a wide range of applications the Tension Electronics comes in three versions (PFEA
111 and PFEA 112 are 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.
The equipment is intended for use in a wide range of manufacturing processes where web
material of any kind, 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.
Figure 1-1. Typical Tension Measurement System with Tension Electronics PFEA113 (IP 20-version)
Tension Electronics PFEA113
Instrument output
Web
Load cell
Bearing housing
Measuring roll
Control output
Power supply 24 V DC
Profibus

Tension Electronics PFEA113, User Manual
Chapter 1 Introduction
1-4 3BSE029382R0101 Rev C
1.6 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.
1.6.1 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.
1.6.2 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.

Tension Electronics PFEA113, User Manual
Section 1.7 The Measuring Technique Based on Pressductor® Technology
3BSE029382R0101 Rev C 1-5
1.7 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 as 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.

Tension Electronics PFEA113, User Manual
Chapter 1 Introduction
1-6 3BSE029382R0101 Rev C
Figure 1-2. The Sensor Based on Pressductor®Technology

Tension Electronics PFEA113, User Manual
Section 2.1 About this Chapter
3BSE029382R0101 Rev C 2-1
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.
2.2 Safety Instructions
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
• Appendix F PFCL 201 - Designing the Load Cell Installation
• Appendix G PFTL 201 - Designing the Load Cell Installation

Tension Electronics PFEA113, User Manual
Chapter 2 Installation
2-2 3BSE029382R0101 Rev C
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 3BSE028144D0065 (See the
appendix for your type of load cell) or according to order-specific documentation.
Figure 2-1. Recommended Cabling
n × 0.5 mm2
+ screen
To control system
Mains supply
3 × 1.5 mm2
Junction Box
Load cell signals
4 × 2 × 0.5 mm2+ screen
Load cell excitation
2 × 2.5 mm2
4 × 1.0 mm2+ screen
max. 50 m
External indicating
instrument
(not included in
the ABB delivery)
Load cells
PFEA113
IP 65-version
Profibus-DP
Cable screens should be connected:
- 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)
(NEMA 4)
ABCD

Tension Electronics PFEA113, User Manual
Section 2.4.1 Selecting and Routing the Cabling
3BSE029382R0101 Rev C 2-3
• 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.
• 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 circuit.
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 mm2cable for the excitation and a shielded
4 × 2 × 0.5 mm2cable with twisted pair cores for the load cell signals.
• Cable for synchronization of two of more tension electronics IP-20 version (unsealed)
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 mm2cable.
• 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 cabinet IP-65 version (NEMA 4).
Table 2-1. Maximum Permitted Cable Resistance
Load cell Max. permitted cable resistance
PFCL 301E 10
PFTL 301E 10
PFRL 101 10
PFTL 101 10
PFCL 201 10
PFTL 201 10
Signal Load cell excitation
A
B
D
C

Tension Electronics PFEA113, User Manual
Chapter 2 Installation
2-4 3BSE029382R0101 Rev C
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 X3:15, of all
the units and interconnecting screw terminal X3:16 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.
Figure 2-3. Connection for Synchronization
PFEA113
PFEA113
PFEA113
X3:16 15 15 15
PFEA113
123
15
n
X3:16 X3:16 X3:16