Description

Product Overview

In continuous production equipment such as rolling mills, paper machines and coaters, the accuracy of tension measurement directly determines product quality and line stability. The PFCL201C 20kN 3BSE027070R20 pillow block tension sensor from ABB is a high-performance measuring component built on the proprietary Pressductor® magnetoelastic technology.

As a core part of ABB’s force measurement product line, this sensor is machined from a single piece of 316L stainless steel. Based on the advanced magnetoelastic measurement principle, it directly converts mechanical stress into high-precision electrical signals, delivering precise vertical force measurement solutions for industrial automation systems. Part of ABB’s PFCL200 series vertical force measurement elements, it captures material tension changes in real time and provides critical data for process control systems, ensuring process stability and product consistency at the source.

In modern industrial automation architectures, the PFCL201C 20kN serves as a core feedback unit for closed-loop tension control systems, thanks to its exceptional accuracy and reliability. It operates on the unique magnetoelastic effect: when material tension acts on the force-bearing surface, the permeability of the internal magnetic core changes with stress, and electromagnetic induction between the built-in excitation and signal coils converts the tension physical quantity into a linear analog electrical signal. This non-contact measurement method completely eliminates the mechanical wear found in traditional strain gauge sensors, fundamentally guaranteeing long-term measurement stability.

Its robust structure and wide temperature adaptability allow stable operation in harsh industrial environments from -20°C to +80°C, providing reliable tension measurement assurance for steel, non-ferrous metallurgy, papermaking, packaging and other industries.

Technical Specifications

Parameter Name	Parameter Value
Product Model	PFCL201C 20kN 3BSE027070R20
Manufacturer	ABB
Product Type	Pillow Block Tension Sensor (Vertical Force Measurement Element)
Rated Load	20 kN (20000 N)
Extended Load	30 kN
Overload Capacity	200 kN (vertical direction)
Measurement Accuracy	±0.1% Full Scale (FS)
Output Signal	4-20 mA Analog Signal (2-wire)
Supply Voltage	10-30 V DC
Operating Temperature	-20°C to +80°C
Storage Temperature	-40°C to +85°C
Protection Rating	IP67 (dust and water resistant)
Construction Material	High-strength 316L stainless steel
Response Time	≤5 ms
Mounting Type	Pillow block mounting (flange mounted)
Dimensions	220×125×50 mm (L×W×H)
Weight	21 kg

Key Features and Advantages

The core technological advantage of the PFCL201C 20kN lies in ABB’s exclusive Pressductor® magnetoelastic measurement principle, which uses the physical property of material magnetism changing with mechanical force to achieve non-contact high-precision force measurement.

Compared with traditional strain gauge sensors, it does not suffer accuracy degradation from mechanical deformation and offers industry-leading long-term stability and repeatability. The internal orthogonal coils of the sensor have no magnetic coupling under no-load conditions. When vertical force is applied, the change in steel permeability breaks the magnetic flux symmetry, and the secondary coil induces a voltage signal strictly proportional to the load. This design guarantees the linearity and accuracy of measurement results in principle.

Environmental adaptability and structural reliability are the key reasons this sensor is widely recognized in heavy industrial sites. The whole machine is made of integrally processed stainless steel with fully potted internal components, providing excellent resistance to dust, corrosion and moisture. Its IP67 protection rating allows long-term operation in extreme working conditions with chemical corrosive media and high humidity, such as galvanizing and pickling lines.

With a rated load of 20kN, it can withstand vertical overloads up to 200kN without permanent accuracy loss, effectively reducing the risk of damage from equipment misoperation. It has also passed IEC 60068-2-6 shock and vibration resistance tests, maintaining stable measurement in dynamic production environments.

The convenience of system integration and later maintenance also makes it more suitable for modern industrial needs. The standard 4-20mA analog output is compatible with most industrial control systems and PLC/DCS platforms, including ABB AC800M and System 800xA. It also supports the CANopen digital communication protocol, offering flexible integration solutions for digital factories.

The compact pillow block design simplifies mechanical installation, and standardized interfaces greatly shorten on-site construction time. The built-in self-diagnostic function monitors the sensor status in real time and provides early fault warnings. Paired with ABB PFEA series control units, it enables remote diagnostics and predictive maintenance, effectively reducing system downtime.

Application Areas

The PFCL201C 20kN has irreplaceable core value in the metal processing industry, especially in strip rolling production lines.

In cold and hot rolling processes, it provides core process parameters for the Automatic Gauge Control (AGC) system through precise measurement of strip vertical force, controlling strip thickness tolerance at the micron level. Whether for single-stand reversible mills or multi-stand tandem mills, it provides stable and reliable tension measurement solutions, helping steel enterprises achieve high-quality and high-efficiency strip production. Even under the dynamic working conditions of mill acceleration and deceleration, it maintains measurement accuracy, avoiding strip slippage and over-stretching, and ensuring process continuity and product quality.

In the paper and pulp industry, its application value is equally prominent. In paper production lines, precise tension control is the core condition for ensuring paper uniformity and preventing breaks. The PFCL201C monitors tension changes in unwinding, coating, drying and rewinding in real time, providing accurate feedback for the paper machine control system, achieving precise paper thickness control and stable quality improvement. Whether for specialty paper, packaging paper or cultural paper, its high-precision measurement capability helps paper mills meet increasingly stringent quality standards.

Packaging, textile and composite material production are also important application scenarios. In film slitting, coating lamination, textile weaving and other processes, material tension control directly affects appearance and physical properties. With a millisecond-level response speed, the PFCL201C monitors tension fluctuations in real time and quickly links to adjust parameters, ensuring stable production. In the production of high-precision materials such as lithium battery separators, optical films and carbon fiber prepregs, its ±0.1% full-scale accuracy provides reliable data support for process control, helping the domestic breakthrough of high-end materials.

Related Products

PFCL101C 10kN: Small-capacity model of ABB pillow block tension sensor, 10kN rated load, suitable for light-load tension measurement

PFCL301C 50kN: Large-capacity model of ABB pillow block tension sensor, 50kN rated load, suitable for heavy-duty rolling mills and large coiling equipment

PFCL201CD-20.0kN: Cable-sealed connector version of PFCL201C, IP66/67 protection, suitable for highly corrosive environments

PFCL201CE-20.0kN: Fixed cable connection version of PFCL201C, supports EtherCAT protocol, suitable for smart factory integration

PFTL101A: ABB pillow block tensiometer horizontal force measurement element, cylindrical plug connection, 0.2-2kN range, for horizontal tension measurement

PFTL101AER: Acid-resistant pillow block tensiometer horizontal force measurement element, fixed cable connection, IP66/67 protection, designed for paper machine wet ends

PFEA111: ABB conventional control unit, connects 2 load cells, provides signal conditioning and control for PFCL201C

PFEA113: ABB control unit with DP interface, connects 4 load cells, expands system integration for PFCL201C

PFSL201: ABB shear beam load cell, for industrial weighing requiring shear force measurement

PFIA101: ABB analog load cell signal conditioner, converts PFCL201C analog signals to digital for PLC systems

Installation and Maintenance

Pre-installation Preparation

Before installing the ABB PFCL201C 20kN, it is recommended to carefully review ABB’s official technical documents and installation guidelines to understand all safety specifications and installation requirements. First check the sensor’s appearance integrity, confirm no damage to interfaces and cables, and that the product model fully matches system requirements.

Select the installation location according to on-site working conditions, ensure the sensor’s force direction is strictly vertical, and avoid lateral force and torque interference. Prepare suitable mounting brackets and fasteners, and ensure the contact surface between the sensor and mechanical equipment is flat and clean. Prepare shielded cables and terminals according to system design, and confirm the supply voltage is within 10-30V DC. For corrosive environments, prioritize high-protection versions such as PFCL201CD or PFCL201CE.

Maintenance Recommendations

The PFCL201C is designed for long-term stable operation with very low daily maintenance. Routine maintenance only requires regular cleaning of the sensor surface to prevent dust and corrosives accumulation; check the tightness and sealing of cable connectors, and monitor sensor health and measurement performance through system software.

ABB recommends annual calibration verification to ensure measurement accuracy meets process requirements. In high-vibration environments, focus on checking the tightness of mounting bolts to prevent loosening from vibration. When replacing or reinstalling the sensor, tighten bolts to the calibrated torque – over-tightening or under-tightening will affect measurement accuracy.

Regularly check cable shielding grounding to ensure stable signal transmission. For measurement abnormalities or signal drift, conduct preliminary troubleshooting via the self-diagnostic function first. Contact ABB technical support for professional calibration services if unresolved. The sensor storage environment must be dry and clean, away from extreme temperature and humidity conditions.

Product Assurance

ABB provides comprehensive quality assurance and professional technical support for the PFCL201C 20kN 3BSE027070R20 pillow block tension sensor. All factory products undergo rigorous testing and inspection, complying with IEC international standards and OIML R60 metrology requirements, ensuring long-term reliable operation in industrial environments. The standard warranty period is 24 months from the date of product delivery, covering material and workmanship defects. ABB will provide repair or replacement services for products confirmed to have quality issues.

In addition to basic warranty, ABB offers full-dimensional technical services including telephone consultation, remote diagnostics, on-site service and calibration support. Customers can access professional technical responses through ABB’s global service network, and engineering teams can assist with various technical issues such as system integration, parameter configuration and fault diagnosis. ABB operates multiple certified calibration centers worldwide, providing traceable calibration certificates and regular calibration services for the PFCL201C, ensuring measurement accuracy continuously meets process requirements.

ABB commits to long-term spare parts supply and technical support for the PFCL201C. Even after product discontinuation, users can obtain replacement units, technical documents and engineering services through designated channels, maximizing the protection of customers’ long-term investment value. ABB’s customer-centric service philosophy makes the PFCL201C 20kN a trustworthy high-precision solution in industrial tension measurement.

Contact info

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