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Help CenterABB PFCL201CE-50KN 3BSX802939-108 Tension/Vertical Force Measurement Sensor
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ABB PFCL201CE-50KN 3BSX802939-108 is an industrial-grade high-precision tension/vertical force measurement sensor belonging to the ABB Pressductor® series. It is core-positioned as a precision measuring device for strip tension and vertical component force in industrial scenarios. Developed based on patented magnetostrictive technology, it is custom-designed for industrial applications requiring stable tension control such as metal rolling, paper winding, and textile yarn adjustment.
Machined from a single block of stainless steel, the sensor integrates a high-precision measurement core with a robust and durable structural design, featuring high measurement accuracy, strong overload capacity and excellent anti-interference performance. It can accurately capture force changes under a rated load of 50kN and output stable measurement signals synchronously, seamlessly adapting to automation control systems and drives of ABB and mainstream brands, and undertaking core tasks such as tension monitoring, force feedback and overload protection.
With its outstanding adaptability to harsh environments, it can effectively resist the impacts of industrial working conditions such as high temperature, high humidity, dust and corrosion, and is widely used in metallurgy, papermaking, textile, heavy machinery and other fields. Backed by original factory quality control and a comprehensive adaptation system, it serves as a key measuring component to meet the maintenance and upgrading needs of existing production lines, providing reliable measurement support for precise control of industrial production processes and improvement of product quality.
I. Positioning and Value
As a precision sensing unit in industrial production processes, this tension/vertical force measurement sensor effectively fills the demand gap for high-precision tension and vertical component force measurement under complex working conditions. Relying on ABB Pressductor® magnetostrictive technology, it realizes force measurement without physical deformation, combining high sensitivity with ultra-strong overload resistance—ensuring both the accuracy of measurement data and the ability to withstand instantaneous overload impacts in industrial sites.
Its stable signal output and flexible protocol compatibility enable rapid linkage with existing automation systems and actuators, realizing flexible switching between closed-loop and open-loop tension control. This avoids production issues such as material breakage, thickness deviation and deformation, and improves product qualification rate and production efficiency.
Meanwhile, the sensor adopts a fully stainless steel sealed structure with dust and corrosion resistance, adapting to various harsh industrial environments with no frequent maintenance required, greatly reducing operation and maintenance costs. Its modular installation design facilitates integration and replacement, shortens downtime, and provides stable and precise force measurement guarantee for key industrial links such as metal rolling, coil processing and heavy machinery load monitoring, meeting the requirements of long-term continuous industrial operation.
II. Technical Parameters
1. Electrical and Measurement Parameters
| Parameter Item | Specification Details |
|---|---|
| Core Function | Strip tension measurement, vertical component force measurement, real-time force monitoring and signal feedback, overload protection; supports closed-loop/open-loop tension control and adapts to automation system linkage |
| Core Technology | ABB Pressductor® magnetostrictive technology (patented in 1954). Based on the principle that the magnetic properties of materials change with mechanical force, it achieves precise measurement without physical deformation, integrating high sensitivity and overload resistance. |
| Rated Load | 50kN (kilonewton), equivalent to 11250Lbs; measurement accuracy ≤±0.1%FS (Full Scale), ensuring the precision and consistency of force measurement |
| Load-related Parameters | Extended load (instantaneous): 75kN (150% of rated load); Allowable lateral load: 25kN (h=300mm); Vertical overload capacity: 500kN; Lateral overload capacity: 125kN (h=300mm) — with ultra-strong impact and overload resistance |
| Measurement Characteristics | Offset: 0.02mm (0.8/1000 inch); Elastic coefficient: 2500kN/mm (14300×1000Lbs/inch); Response time ≤350ms, capable of quickly capturing force changes and feeding back signals |
| Signal and Communication | Output signal: 4-20mA/0-10V standard signal; Supports industrial communication protocols such as Profibus, Modbus, EtherCAT and Ethernet/IP; Accessible to ABB Ability™ platform and mainstream PLC systems; supports remote diagnosis and data interaction |
| Operating Voltage | 24V DC redundant power supply (adapts to industrial standard control power supply); supports generator power supply in some scenarios; ripple ≤100mV to ensure stable signal output |
2. Environmental and Reliability Parameters
| Parameter Item | Specification Details |
|---|---|
| Operating Temperature | -40℃ to +85℃; stable operation in a wide temperature range, adapting to complex industrial sites with high and low temperatures; no additional temperature control equipment required; applicable to harsh temperature working conditions such as galvanizing and pickling |
| Storage Temperature | -40℃ to +85℃; facilitates transportation and long-term storage, adapts to transportation and warehousing conditions in different regions, and avoids equipment performance degradation caused by ambient temperature |
| Environmental Humidity | 5%-95% (non-condensing); resists erosion from humid environments, applicable to wet working conditions such as electroplating, water treatment and papermaking with no performance attenuation |
| Protection Grade | IP66/67; dustproof, waterproof and corrosion-resistant; adapts to harsh industrial scenarios with heavy dust, high moisture and strong corrosion such as heavy machinery, port equipment and metallurgical workshops, effectively protecting internal components |
| Anti-interference and Durability | Compliant with IEC 60068-2-6 shock and vibration resistance standards; outputs high-power, low-impedance AC signals with strong resistance to electromagnetic interference and ground faults; machined from a single stainless steel block with encapsulated internal components, dustproof and corrosion-resistant, adapting to extreme harsh working conditions |
| Mean Time Between Failures (MTBF) | ＞100,000 hours; adopts industrial-grade high-quality components and one-piece molding process with no wearing parts, ensuring long-term stable operation and reducing the frequency of spare part replacement and operation & maintenance costs |
3. Structural and Installation Parameters
| Parameter Item | Specification Details |
|---|---|
| Structural Form | Machined from a single block of stainless steel with modular and compact design; internal components are encapsulated with epoxy resin; non-deformable measurement structure integrating high strength and high sealing performance, adapting to harsh industrial environments |
| Overall Dimensions | 200mm (width) ×250mm (height) ×300mm (depth); standard Pressductor® series module size; weight approx. 2.5kg; compatible with installation space of mainstream production lines and distribution cabinets |
| Mounting Method | 35mm standard DIN rail snap-on installation or bolt fixation; supports horizontal and inclined installation; mounting screws are fixed with medium-strength locking fluid; the bearing box is mounted on the top of the sensor with four screws—easy to install, enabling quick assembly and replacement, complying with industrial standard installation specifications; cable routing shall avoid force affecting the measurement direction |
| Wiring Method | Screw terminal wiring with firm contact and vibration resistance, facilitating wiring and later maintenance; cables shall be equipped with protective hoses to avoid measurement accuracy deviation caused by cable weight and bending; adapts to 1.0-2.5mm² specification cables; supports separate wiring for power and signal circuits; cable bending at wiring points is prohibited |
| Debugging Method | Supports USB local debugging and Ethernet remote debugging; compatible with ABB special debugging software and mainstream automation system debugging tools; enables quick parameter calibration, signal calibration and fault diagnosis; controller debugging shall follow the specifications of the corresponding manual |
III. Features and Advantages
Precise Measurement & Excellent PerformanceAdopts ABB patented Pressductor® magnetostrictive technology to realize force measurement without physical deformation. With a measurement accuracy of ≤±0.1%FS under 50kN rated load and a response time of ≤350ms, it can quickly and accurately capture instantaneous force changes and output stable signals, effectively avoiding production quality problems caused by measurement deviation, and adapting to high-precision tension control scenarios.
Ultra-durable & Harsh Environment AdaptationMachined from a single block of stainless steel with encapsulated internal components, it has extremely high resistance to overload, impact and vibration (vertical overload capacity up to 500kN). With an IP66/67 protection grade, it is dustproof, waterproof and corrosion-resistant, adapting to extreme harsh industrial environments such as galvanizing, pickling, metallurgical workshops and port equipment. The wear-free design ensures a long service life.
Flexible Compatibility & Strong LinkageSupports both closed-loop and open-loop control modes, and can be used with various drives, sensors and actuators to form a complete tension control system. Compatible with multiple industrial communication protocols such as Profibus and Modbus, it can be seamlessly connected to ABB and mainstream PLC systems (Siemens, Rockwell, etc.) and ABB Ability™ platform, realizing data interaction, remote monitoring and predictive maintenance, and reducing unplanned downtime by more than 30%.
Easy Installation & Low Operation CostModular design and standardized installation methods support multiple mounting angles (horizontal, inclined) and can be installed and replaced without complex tools. Clear cable routing specifications with protective hoses avoid external force affecting measurement accuracy. With an MTBF of over 100,000 hours, it features a low failure rate and no frequent maintenance required. Remote diagnosis is supported for quick problem location, reducing operation and maintenance workload and costs.
Safe & Reliable & Wide ApplicationEquipped with instantaneous overload protection of 150% rated load, it can effectively resist instantaneous impacts in industrial sites and protect equipment and loads from damage. Certified with CE, UL and ATEX Zone 2 explosion-proof certification, it complies with relevant IEC standards and adapts to industrial scenarios in multiple regions and industries worldwide. It stably performs in both conventional scenarios (metal rolling, paper winding) and special scenarios (port equipment, wind power blade tension monitoring).
IV. Application Fields
Metallurgical IndustryUsed for strip tension measurement and control in metal rolling (steel strip, aluminum plate, etc.), annealing, pickling and galvanizing production lines to ensure stable tension during rolling, avoid material deformation and breakage, and improve product flatness and quality. It also meets the force monitoring needs of equipment such as electrolysis units and rolling mills.
Coil Processing IndustryApplied in papermaking, plastic film and textile industries for scenarios such as paper winding, slitting, printing, plastic film stretching and textile yarn tension adjustment. It ensures uniform coil tension, avoids breakage and thickness deviation, and improves product quality and production efficiency, adapting to the tension control needs of equipment such as rewinding machines.
Heavy Machinery & Port EquipmentUsed for load monitoring and tension control in cranes, stamping machines and port cable traction equipment; in the wind power industry, it is applied for blade tension monitoring, adapting to harsh working conditions of high temperature, high humidity and strong vibration to ensure stable equipment operation and guarantee production safety and efficiency.
Other Industrial ScenariosUtilized for load monitoring and force feedback of key equipment in power substations, automated production lines and traffic signal systems; in humid and corrosive scenarios such as chemical industry and water treatment, it undertakes various force measurement tasks, adapting to diverse industrial measurement needs and promoting the upgrading of production automation and quality improvement.
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