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Help CenterABB PFTL101A-0.5KN 3BSE004160R1 Tension Sensor
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ABB PFTL101A-0.5KN 3BSE004160R1 is an industrial high‑precision tension sensor. It is designed to provide an integrated solution for accurate tension measurement, real‑time signal transmission, and stable data feedback for medium and light‑duty industrial tension control applications, balancing measurement accuracy, anti‑interference performance, and industrial‑grade durability.
Based on strain‑gauge sensing technology, it has a nominal tension rating of 0.5 kN (500 N) and is specially engineered for low‑tension, high‑precision control scenarios.It serves as a core tension detection component in production lines for metallurgy, textiles, papermaking, wire and cable, and other industries, suitable for tension control in belt conveying, film traction, wire drawing, fabric dyeing and finishing, etc.With high measurement accuracy, strong environmental adaptability, and easy installation, it operates reliably in industrial environments with dust and mild vibration.It can be seamlessly integrated with ABB AC 800M, AC500 series PLCs and third‑party control systems to provide reliable data support for closed‑loop tension control of production lines.
1 Basic Parameters
1.1 Core Measurement Parameters
Product Type: Industrial strain‑gauge tension sensor with dual‑direction tension/compression measurement, dedicated to high‑precision detection in low‑tension applications.Mainly used for real‑time monitoring and feedback of line tension, suitable for closed‑loop tension control systems.
Range and Accuracy:Nominal tension: 0.5 kN (500 N); measuring range: 0–0.6 kN (120% overload capacity).Measurement accuracy: ±0.1% FS (full scale).Non‑linearity error: ≤ 0.05% FS.Hysteresis error: ≤ 0.03% FS, ensuring high precision in low‑tension applications.
Measuring Principle:High‑precision metal strain‑gauge sensing with built‑in temperature compensation to effectively offset the influence of ambient temperature changes on measurement accuracy.Temperature drift: ≤ 0.01% FS/°C (-10°C to +60°C), ensuring stable measurement under various working conditions.
1.2 Electrical and Output Parameters
| Parameter Category | Specification |
|---|---|
| Supply Voltage | 10–30V DC (nominal 24V DC), wide voltage range, supports standard industrial power |
| Output Signal | Standard 4–20 mA analog output; 2‑wire / 3‑wire configurable (default 2‑wire); signal load ≤ 500 Ω |
| Insulation Resistance | > 100 MΩ between sensor body and signal terminals (tested at 500V DC), excellent electrical isolation |
| Immunity | Compliant with IEC 61000‑6‑2/6‑4; resistant to EFT, ESD, and RF radiation, suitable for strong EMI industrial environments |
| Response Time | ≤ 10 ms, quickly captures tension changes to meet real‑time control requirements |
1.3 Mechanical and Installation Parameters
Structure Type: S‑type tension sensor (beam structure); body made of high‑strength alloy steel with anti‑corrosion surface treatment, high tensile strength, suitable for low‑tension traction applications.
Installation: Bolt‑mounted (supplied with M8/M10 mounting bolts); supports horizontal and vertical installation.Mounting base with positioning holes for accurate fixing and calibration.Lifting eyes / threaded interfaces at both ends for easy connection to traction parts and fixed brackets.
Mechanical Dimensions: Length approx. 120 mm, diameter approx. 30 mm (subject to original datasheet); net weight approx. 0.8 kg.Compact design saves installation space and fits narrow production line areas.
Protection Class: IP65 (dustproof, splash‑proof), can be directly installed outdoors or in dusty industrial sites without additional enclosures.
1.4 Environmental and Reliability Parameters
Environmental Adaptability:Operating temperature: -10°C to +60°C;Storage temperature: -40°C to +85°C;Relative humidity: 5%–95% (non‑condensing);Vibration resistance: 5–150 Hz, amplitude 0.1 mm, compliant with IEC 60068‑2‑6, withstands mild line vibration.
Reliability:Mean Time Between Failures (MTBF) > 60,000 hours;Design service life ≥ 8 years;CE and RoHS certified.Excellent fatigue resistance, can withstand 1,000,000 cycles of nominal tension loading without significant performance degradation.
Calibration: Supports on‑site zero and full‑scale calibration; calibration accuracy ≤ 0.02% FS.Equipped with calibration interface for fast calibration using dedicated tools to ensure long‑term measurement accuracy.
2 Structural and Functional Features
2.1 Structural Design
High‑Strength Construction:One‑piece alloy steel body with heat treatment, high tensile strength and low deformation coefficient.Withstands long‑term nominal tension without deformation affecting accuracy.Zinc plating + anti‑corrosion coating resists dust, moisture, and mild corrosion in industrial environments.
Integrated Sensing Design:Built‑in high‑precision strain gauges and temperature compensation; integrated signal amplifier.Directly outputs standard 4–20 mA analog signal without external signal conditioner, simplifying system integration and reducing cost.Shielded signal cable reduces electromagnetic interference on measurement signals.
Easy Installation and Maintenance:Standardized mounting interfaces and bolts allow quick installation and removal.Equipped with status indicators (power, normal, fault) for clear operational status and fast on‑site troubleshooting.Reserved calibration port enables simple and convenient calibration.
2.2 Core Functions
High‑Precision Tension Measurement:Strain‑gauge principle plus temperature compensation delivers accuracy of ±0.1% FS with extremely low non‑linearity and hysteresis.Precisely captures small tension variations within 0.5 kN range, ideal for low‑tension high‑precision applications such as film traction and fine wire drawing.
Real‑Time Signal Transmission:4–20 mA standard analog output with stable, high‑immunity signal and long transmission distance (up to 1000 m).Feeds tension data in real time to PLC, HMI, or tension controller for reliable closed‑loop control.
Full Environmental Adaptability:IP65 protection withstands dust, splashing water, and mild vibration.Wide operating temperature range plus temperature compensation maintains accuracy, suitable for textiles, papermaking, metallurgy, and other industrial sites.
Strong Compatibility and Easy Integration:Seamless connection with ABB AC 800M and AC500 PLCs; also compatible with third‑party PLCs, tension controllers, and SCADA systems.2‑wire power supply simplifies wiring; no complex configuration required for fast integration into existing control systems.
High Reliability and Easy Maintenance:Fatigue‑resistant and anti‑corrosion design supports long‑term continuous operation and reduces downtime.On‑site calibration without disassembly lowers maintenance costs.Real‑time status indicators enable efficient fault diagnosis.
3 Application Areas
This sensor is specially designed for 0.5 kN low‑tension applications.With high precision, reliability, and easy integration, it is widely used in tension control in textiles, papermaking, wire and cable, metallurgy, packaging, and other industries:
Textile Industry: Tension detection for cotton yarn, chemical fiber, silk and other fiber traction; yarn tension control in knitting and weaving lines.Ensures uniform tension during fiber drawing to prevent broken yarn and wrinkling.
Papermaking and Packaging Industry: Tension measurement for paper, film, aluminum foil and other thin materials; closed‑loop tension control in printing, laminating, slitting lines.Ensures flat material and avoids stretching, deformation, or breakage.
Wire and Cable Industry: Tension detection during drawing of fine wires and enameled wires.Stabilizes tension during drawing, improves diameter uniformity, and prevents wire breakage or diameter deviation.
Metallurgy Industry: Tension measurement for small metal wires and strips; auxiliary tension control in cold rolling and annealing lines.Suitable for low‑tension, high‑precision metal processing.
General Industry: Tension monitoring for small belt conveyors and traction mechanisms of automated equipment.Also used in other applications requiring accurate low‑tension measurement to support stable equipment operation.
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