ABB PFTL 101 User manual

—
A B B M E A S U R E M E N T & ANALY T I C S
Pressductor Pillowblock Load Cells
Horizontal Measuring PFTL 101
User manual
3BSE009965R0401 en Rev E

USE OF SYMBOLS
This publication includes the following symbols with information regarding safety or other important information:
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DANGER
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ELECTRICAL
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Information
Information icon alerts the reader to relevant facts and conditions.
Tip
Tip icon advise how to design your product or how to use a certain function.
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 accord-
ance with the terms of such license.
CE-marking
This product meets the requirements specied in the RoHS Directive 2011/65/EU, EMC Directive 2014/30/EU and the Low
Voltage Directive 2014/35/EU provided the installation is carried out in accordance with the instructions given in this manual.
© Copyright 2004-2018 ABB. All rights reserved.

2Table of Contents
1 Introduction
1.1 About this Manual......................................................................................... 5
1.2 Cyber Security Disclaimer............................................................................. 5
1.3 Disposal and Recycling................................................................................. 5
1.3.1 Environmental Policy..................................................................................... 5
1.3.2 Recycling Electrical and Electronic Equipment, WEEE................................... 6
1.3.3 Recycling the Transport Material................................................................... 6
1.3.4 Disposal of the Product................................................................................. 6
1.4 Function and Design..................................................................................... 7
1.4.1 General......................................................................................................... 7
1.4.2 Loads cells PFTL 101................................................................................... 7
1.4.3 Principle of Measurement.............................................................................. 8
2 Description
2.1 General......................................................................................................... 9
2.2 Technical Data............................................................................................ 10
2.3 Denitions................................................................................................... 11
2.4 Measuring principle of the sensor................................................................ 14
2.5 Mounting Arrangement............................................................................... 14
2.5.1 Coordinate System..................................................................................... 15
2.5.2 Horizontal Mounting.................................................................................... 15
2.5.3 Inclined Mounting........................................................................................ 16
2.6 The Electrical Circuit................................................................................... 17
3 Installation
3.1 General....................................................................................................... 18
3.2 Unpacking.................................................................................................. 18
3.3 Preparations............................................................................................... 19
3.4 Adapter Plates............................................................................................ 19
3.5 Mounting.................................................................................................... 19

3.6 Cabling....................................................................................................... 21
4 Commissioning
4.1 General....................................................................................................... 23
4.2 Preparatory Calculations............................................................................. 23
5 Maintenance
5.1 General....................................................................................................... 24
5.2 Preventive Maintenance.............................................................................. 24
5.3 Spare Parts................................................................................................. 24
6 Fault Tracing
6.1 General....................................................................................................... 26
6.2 Interchangeability........................................................................................ 26
6.3 Fault Tracing Procedure.............................................................................. 26
6.4 Fault Tracing in the Mechanical Installation.................................................. 27
6.4.1 Defective Mounting Surface, Support or Adapter Plates.............................. 27
6.4.2 Force Shunting........................................................................................... 27
6.4.3 Fastening of Load cell and Adapter Plates.................................................. 27
6.4.4 Rolls and Bearings...................................................................................... 27
6.4.5 Driven Roll.................................................................................................. 27
6.5 Fault Tracing of Load Cells, Junction Boxes and wiring............................... 28
A Drawings
A.1 Load Cell PFTL 101A (0,5- 2,0 kN), Dimension Drawing............................. 30
A.2 Load Cell PFTL 101AE (0,5- 2,0 kN), Dimension Drawing........................... 31
A.3 Load Cell PFTL 101AER (0,5- 2,0 kN), Dimension Drawing......................... 32
A.4 Load Cell PFTL 101B (2,0- 20 kN), Dimension Drawing.............................. 33
A.5 Load Cell PFTL 101BE (2,0- 20 kN), Dimension Drawing............................ 34
A.6 Load Cell PFTL 101BER (2,0- 20 kN), Dimension Drawing.......................... 35
A.7 Adapter Plate Lower PFTL 101A/AE/AER, Dimension drawing.................... 36
A.8 Adapter Plate Upper PFTL 101A/AE/AER, Dimension drawing.................... 37
A.9 Adapter Plate Lower PFTL 101B/BE/BER, Dimension drawing................... 38
A.10 Adapter Plate Upper PFTL 101B/BE/BER, Dimension drawing................... 39
Alphabetical index

1Introduction
1.1 About this Manual
This manual describes load cells PFTL 101A, PFTL 101AE, PFTL 101AER, PFTL 101B, PFTL
101BE and PFTL 101BER in a Pressductor® Tension Measuring System.
The purpose of this manual is to describe the general function and design of the load cells and also
to be a guidance at installation, commissioning, preventive maintenance and fault tracing.
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 rewalls,
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 Disposal and Recycling
1.3.1 Environmental Policy
ABB is committed to its environmental policy. We strive continuously to make our products envi-
ronmentally more sound by applying results obtained in recyclability and life cycle analyses. Prod-
ucts, manufacturing process as well as logistics have been designed taking into account the envi-
ronmental aspects.
Our environmental management system, certied to ISO 14001, is the tool for carrying out our
environmental policy. However it is on the customer’s responsibility to ensure that local legislation is
followed.
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1.3.2 Recycling Electrical and Electronic Equipment, WEEE
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 neg-
ative effects on human health and the environment, which could otherwise arise from inappropriate
waste handling.
1.3.3 Recycling the Transport Material
ABB designs all transport material to be recyclable where practical. The recycling of the transport
material depends on the material type and availability of local recycling programs.
After receiving the system into the site, the package and the transportation locking have to be
removed. Recycle the transport material according to local regulations.
1.3.4 Disposal of the Product
When the product is to be disposed, it should be dismantled and the components recycled
according to local regulations.
1.3.4.1 Dismantling and Recycling of the Product
Dismantle and recycle the components of the product according to local regulations.
CAUTION
Some of the components are heavy! The person who performs the dismantling of
the system must have the necessary knowledge and skills to handle heavy
components to avoid the risk of accidents and injury from occurring.
• Load cell: These parts are made of structural steel, which can be recycled according to
local instructions. All the auxiliary equipment, such as cabling or hoses must be removed
before recycling the material.
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1.4 Function and Design
1.4.1 General
A complete measuring system normally consists of two load cells, a junction box, one control unit
with two measurement channels and cabling.
A
B
SUM A+B
DIFFERENCE A-B
Load cell
Junction box Control unit
Load cell cabling
Adapter plates
Output signals
Figure 1. Complete Measuring System
1.4.2 Loads cells PFTL 101
The load cells are installed under the roll bearings, where they measure forces parallel to the
mounting surface.
The reactive force from the web/strip, which is proportional to the web/strip tension, is transferred
to the load cells via the roll and the bearings
The load cells are connected to the control unit via a junction box. The control unit converts the
load cell signals to DC voltages that are proportional to the reaction force. Depending on which
control unit is chosen, it is possible to have the analog signals for the two individual load cells (A
and B), the sum of the load cell signals (A+B), and/or the difference between the load cell signals
(A-B).
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1.4.3 Principle of Measurement
The load cell only measures force in the direction FR. The measurement force may be positive or
negative. The load cell is normally installed under the roll bearings. When there is a web/strip in
tension over the roll, the tension (T) gives rise to two force components, one in the direction of
measurement of the load cell (FR) and one at right angles (FV).
The measuring force depends on the relationship between the tension (T) and the wrap angle
formed by the web/strip around the measuring roll.
T
T
FR
FV
W
a
p
an
Wrap angle
Figure 2. Measuring roll with Force Vectors
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2Description
2.1 General
The load cells in the PFTL 101 family are available in six different measuring ranges from 0.5 to 20
kN and two different sizes (see 2.2 Technical Data). Each load cell is individually calibrated and
temperature compensated.
The load cells are usually mounted and xed to a base and a bearing housing with six screws, four
on one side of the load cells and two on the opposite side.
For all load cells of type PFTL 101 the load cell house is machined from a single block of steel.
A sensor is then welded into the load cell house and oriented so that it is sensitive to force in the
direction of measurement and insensitive in other directions.
The load cell types PFTL 101A, PFTL 101AE, PFTL 101B and PFTL 101BE are made of stainless
steel.
PFTL 101A and PFTL 101B are equipped with a connector for the pluggable connection cable.
PFTL 101AE and PFTL 101BE are equipped with a xed connection cable.
Load cell types PFTL 101AER and PFTL 101BER are specially designed for installation in corrosive
environment. They are made of acid resistant stainless steel and they also have a xed connection
cable.
Dimensions for all load cell types are given in A Drawings.
Connector or fixed connection cable
Measuring direction
Figure 3. Load cells PFTL 101 A/AE/AER
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Connector or fixed connection cable
Figure 4. Load cells PFTL 101 B/BE/BER
2.2 Technical Data
Table 1 Technical Data Load Cell PFTL 101
PFTL 101 Type Data Unit
Nominal Loads 1)
Nominal load in meas-
uring direction, Fnom
A/AE/AER 0,5 1,0 2,0 kN
B/BE/BER 2,0 5,0 10 20
Permitted transverse
force within the accu-
racy, FVnom
A/AE/AER 5 10 10
B/BE/BER 30 30 30 40
Permitted axial load
within the accuracy,
FAnom
A/AE/AER 2 5 5
B/BE/BER 5 10 10 10
Overload capacity
Max. load in measure-
ment direction without
permanent change of
data, Fmax
A/AE/AER 2,5 5 10 kN
B/BE/BER 10 25 50 80
Spring constant A/AE/AER 32 65 130 kN/mm
B/BE/BER 130 325 650 1300
Mechanical data
Length A/AE/AER 230 230 230 mm
B/BE/BER 360 360 360 360
Width A/AE/AER 84 84 84
B/BE/BER 104 104 104 104
Height A/AE/AER 125 125 125
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B/BE/BER 125 125 125 125
Weight A/AE/AER 9 9 10 kg
B/BE/BER 20 21 21 23
Material A/AE/B/BE Stainless steel SIS 2383
DIN 17440 X12CrMoS17
Werkstoffnr 1.4104
AISI 430F
AER/BER Acid resistant steel:
DIN 17440 X2CrNiMo17 13 2
Werkstoffnr 1.4404
AISI 316L
Accuracy
Accuracy class A/AE/AER
B/BE/BER
± 0,5 %
Linearity deviation < ± 0,3
Repeatability error < ± 0,05
Hysteresis <0,2
Compensated temper-
ature range
+20 - +80 °C
Zero point drift 30 (80 2))ppm/K
Sensitivity drift 150
Working temperature
range
-10 - +105 °C
Zero point drift 50 (100 1))ppm/K
Sensitivity drift 250
Storage temperature
range
-40 - +105 °C
1) Denitions of directions designations “V”and “A” in FV and FA are given in 2.5.1 Coordinate System.
2) PFTL 101AER -0.5 kN/ -1.0 kN
2.3 Denitions
Nominal load
Nominal load, Fnom, is the maximum load in the measurement direction for which the load cell is
dimensioned to measure within the specied accuracy class. The load cell is calibrated up to Fnom.
Sensitivity
Sensitivity is dened as the difference in output values between nominal load and zero load.
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Signal
Rated output value
at nominal load
Force
Sensitivity
Fnom
Figure 5. Sensitivity
Accuracy and Accuracy Class
Accuracy class is dened as the maximum deviation, and is expressed as a percentage of the sen-
sitivity at nominal load. This includes linearity deviation, hysteresis and repeatability error.
Linearity Deviation
Linearity deviation is the maximum deviation from a straight line drawn between the output values
at zero load and nominal load. Linearity deviation is related to the sensitivity.
Signal
Force
Fnom
Figure 6. Linearity Deviation
Hysteresis
Hysteresis is the maximum difference in the output signal at the same load during a cycle from zero
load to nominal load and back to zero load, related to the sensitivity at nominal load. The hysteresis
of a Pressductor transducer is proportional to the load cycle.
Signal
Force
Fnom
Figure 7. Hysteresis
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Repeatability error
Repeatability error is dened as the maximum deviation between repeated readings under identical
conditions. It is expressed as a percentage of the sensitivity at nominal load.
Compensated temperature range
The temperature drifts of the load cell have been compensated for in certain temperature
ranges. That is the temperature range within which the specied permitted temperature drifts (i.e.
zero point and sensitivity drifts) of the load cell are maintained.
Working temperature range
Working temperature range is the temperature range within which the load cell can operate within
a specied accuracy. The maximum permitted temperature drifts (i.e. zero point and sensitivity
drifts) of the load cell are not necessarily maintained in the whole working temperature range.
Storage temperature range
Storage temperature range is the temperature range within which the load can be stored.
Zero point drift with temperature
Zero point drift is dened as the signal change with temperature, related to the sensitivity, when
there is zero load on the load cell.
Sensitivity drift with temperature
Sensitivity drift is dened as the signal change with temperature at nominal load, related to the sen-
sitivity, excluding the zero point drift.
Signal
Force
Fnom
Sensitivity
drift
Zero
point
drift
Figure 8. Sensitivity drift with temperature
Deection
Deection is the total deformation in the measuring direction of the load cell when the load is
increased from zero to the nominal value.
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2.4 Measuring principle of the sensor
The measuring principle of the sensor is based on the Pressductor® technology and the fact that
the permeability of a magnetic material changes under mechanical stress.
The transducer is made up of a stack of specially treated laminates, forming the measuring body.
Primary and secondary windings are wound through four holes in the sensor so that they cross at
right angles.
The primary winding is supplied with an alternating current which creates a magnetic eld around
the primary winding. Since the two windings are at right angles to each other, there will be no mag-
netic eld around the secondary winding, as long as there is no load on the sensor.
When the sensor is subjected to a mechanical force in the direction of measurement, the propaga-
tion of the magnetic eld changes so that it surrounds the secondary winding, inducing an alternat-
ing voltage in that winding.
The control unit converts this alternating voltage into a DC voltage proportional to the applied
force. If the measurement force changes direction, the sensor signal changes also polarity.
Figure 9. Propagation of magnetic eld around secondary winding due to mechanical force on sensor
2.5 Mounting Arrangement
When choosing a mounting arrangement it is important to remember to position the load cell in a
direction that gives sufcient measuring force (FR) to achieve the highest possible accuracy.
The load cell has no particular correct orientation; it is positioned in the orientation best suited for
the application, bearing in mind the positions of the screw holes. The load cell can also be installed
with the roll suspended under the load cell.
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The load cell has the same sensitivity in both directions, so that the load cell can be installed in
the easiest manner.
Typical mounting arrangements are horizontal and inclined mounting.
2.5.1 Coordinate System
A coordinate system is dened 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 sufxes for force components, F, this
represents the force component in the respective direction. The sufx R may be omitted, when
measuring direction is implied by the context.
R
V
V
R
A
A
R= Measuring direction
V= Transverse direction
A= Axial direction
Figure 10. Coordinate system dening directions used in force calculation
2.5.2 Horizontal Mounting
In the majority of cases horizontal mounting is the most obvious and easiest mounting method.
When calculating the force, the equations below must be used:
FR = T × (cos β - cos α)
FRT = 0
FRtot = FR + FRT = T × (cos β - cos α)
FV = T × (sin α + sin β)
FVT = Tare
FVtot = FV + FVT = T × (sin α + sin β) + Tare
where:
T = Web/strip tension
FR = Force component from web/strip tension in measurement direction, R
FRT = Force component from Tare in measurement direction, R
FRtot = Total force in measurement direction, R
FV = Force component from web/strip tension in transverse direction, V
FVT = Force component from Tare in transverse direction, V
FVtot = Total force in transverse direction, V
Tare = Force due to tare weight
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α = Deection angle on one side of the roll relative the horizontal plane
β = Deection angle on the other side of the roll relative the horizontal plane
T
T
FR
FV
Tare
+α +β
Figure 11. Horizontal Mounting
2.5.3 Inclined Mounting
Inclined mounting means arrangements in which the load cell is inclined relative to the horizontal
plane. In some cases this is the only option.
When calculating the force, the equations below must be used:
FR = T × [cos (β + γ) - cos (α - γ)]
FRT = Tare × sin γ
FRtot = FR + FRT = T × [cos (β + γ) - cos (α - γ)] + (- Tare x sin γ)
FV = T × [sin (α - γ) + sin (β + γ)]
FVT = - Tare × cos γ
FVtot = FV + FVT = T × [sin (α - γ) + sin (β + γ)] + Tare × cos γ
where:
T = Web/strip tension
FR = Force component from web/strip tension in measurement direction, R
FRT = Force component from Tare in measurement direction, R
FRtot = Total force in measurement direction, R
FV = Force component from web/strip tension in transverse direction, V
FVT = Force component from Tare in transverse direction, V
FVtot = Total force in transverse direction, V
Tare = Force due to tare weight
α = Deection angle on one side of the roll relative the horizontal plane
β = Deection angle on the other side of the roll relative the horizontal plane
γ = Angle for load cell mounting surface relative the horizontal plane
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When calculating it is important that the angles are set into the equations with the correct signs in
relation to the horizontal plane, see Figure 12. Inclined Mounting page 17.
F
RTare
Tare F
V
F
V
F
R
T
T
T
T
+β +α
-α Horizontal plane
-γ
-β
+γ
Figure 12. Inclined Mounting
2.6 The Electrical Circuit
The electrical circuit of the load cell is shown in the diagram below.
(signal)
Secondary
circuit
Primary
circuit
C
D
A
B
T
0.5 A/330 Hz
R1
R2
Secondary circuit
(signal)
(supply current)
Figure 13. Load cell circuit diagram
The load cell is supplied with a 0.5 A, 330 Hz alternating current. The secondary signal is calibrated
for the correct sensitivity with a voltage divider R1 - R2, and temperature compensation is provided
by thermistors T.
All resistances on the secondary side are relatively low. The output impedance is typically 1-3 Ω ,
which helps to suppress interference.
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3Installation
3.1 General
The equipment is a precision instrument which, although intended for severe operating conditions,
must be handled with care. The load cells should not be unpacked until it is time for installation.
To achieve the specied accuracy, the best possible reliability and long-term stability, the load cells
must be installed in accordance with the instructions below. See also 6.4 Fault Tracing in the
Mechanical Installation.
• When a load cell type PFTL 101AER or PFTL 101BER is used for an acid resistant
application it is recommended to use adapter plates and screws of austenitic, acid resistant
steel.
Information
For all types of installations of these load cell types, austenitic steel must be used,
preferably acid resistant or stainless steel.
• The foundation for the load cell must be made as stable as possible. A sturdy construction
reduces the vibration energy of the measuring roll and bearing arrangement.
• The surfaces closest to the load cell, and other surfaces that affect the t, must be machined
at to within 0.05 mm.
• There must not be any shims immediately above or below the load cell, as this may
adversely affect the atness. Instead, shims may be placed between the adapter plate and
the foundation or between the adapter plate and the bearing housing.
• The screws that secure the load cell must be tightened with a torque wrench.
• The bearing arrangement for the measuring roll must be designed to allow axial expansion of
the roll with changes in temperature.
• Any drive to the roll must be applied in such a way that interfering forces from the drive are
kept to a minimum.
• The measuring roll must be dynamically balanced.
• The mounting surfaces of the load cells must be on the same height and parallel with the
measuring roll.
• In a corrosive environment, galvanic corrosion may occur between the load cell,
galvanized screws and adapter plates. This makes it necessary to use stainless steel screws
and adapter plates of stainless steel or equivalent. See adapter plates in A Drawings.
3.2 Unpacking
When the equipment arrives, check against the delivery document. Inform ABB of any complaint,
so that errors can be corrected immediately and delays avoided.
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3.3 Preparations
Prepare the installation in good time by checking that the necessary documents and material are
available, as follows:
• Installation drawings and this manual.
• Standard tools, torque wrench and instruments.
• Rust protection, if additional protection is to be given to machined surfaces. Choose TEC-
TYL 511 (Valvoline) or FERRYL (104), for example.
• Load cells, adapter plates, bearing housings, etc.
• Screws as listed in Table 2. page 20 to secure the load cell, and other screws
for bearing housing, etc.
3.4 Adapter Plates
The adapter plates for all load cell types in the PFTL 101 family must be machined and have a
atness deviation of maximum 0.05 mm, required surface nish should be Ra 3,2.
For PFTL 101A the thickness of the adapter plates should be minimum 30 mm, and for PFTL 101B
35 mm, see Figure 15. Installation of Adapter Plates and Alignment of Load Cells page 21
Information
When installing PFTL 101AER and PFTL 101BER adapter plates of austenitic steel must be used,
preferably acid resistant or stainless steel.
3.5 Mounting
The instructions below apply to a typical mounting arrangement. Variations are allowed, provided
that the requirements of 3.1 General are complied with.
If it is necessary to use tubular dowel pins to secure the position of the load cell,
see instructions in Figure 14. Typical Installation page 21.
1. Clean the foundation and other mounting surfaces.
2. Fit the lower adapter plate to the load cell. Tighten the screws to the torque stated in Table 2.
page 20.
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. Tighten the screws to the torque stated in Table 2.
page 20.
5. Fit the bearing housing and the roll to the upper adapter plate, but do not fully tighten the
screws.
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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 Figure 15. Installation of Adapter Plates and Align-
ment of Load Cells page 21.
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 Figure 15. Installation of Adapter Plates and Alignment of
Load Cells page 21.
Table 2 Tightening Torques for Load Cell PFTL 101
Option Type of screws Strength
class
Type of
lubrication
Dimension Tightening
torque
[Nm] ± 5%
1
(Recommended)
Alloyed steel
screws
Strength class
according to ISO
898/1
12.9 Oil M12 136
M16 333
M20 649
2
(Recommended)
Alloyed steel
screws
Strength class
according to ISO
898/1
12,9 MoS2M12 117
M16 286
M20 558
3Stainless steel
(A2-80)
or acid resistant
steel (A4-80),
Strength class
according to ISO
3506
A2-80
or
A4-80
Wax M12 76
M16 187
M20 364
4Stainless steel
(A2-80)
or acid resistant
steel (A4-80),
Strength class
according to ISO
3506
A2-80
or
A4-80
Oil
or
emulsion
M12 65
M16 161
M20 313
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