It uses advanced algorithms to achieve accurate measurement and control of material tension, ensuring stable tension during production. It supports multi-language digital display (2×16 characters), can display the total tension, difference or single sensor signal in real time, quickly respond to tension changes, and switch gain through Profibus-DP or digital input to adapt to different process requirements.

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　　Tension Electronics 3BSE028144R0020

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　　ABB 3BSE028144R0020 is a high-performance tension controller designed for industrial coil processing, printing, packaging, textiles, metal processing, cable manufacturing and other fields. Its core function is to ensure the stability of the production process and product quality by accurately controlling the material tension, while reducing equipment wear.

　　Core features

　　High-precision control

　　Advanced algorithms are used to accurately measure and control the material tension to ensure stable tension during production.

　　Supports multi-language digital display (2×16 characters), which can display the total tension, difference or single sensor signal in real time.

　　Dynamic response and flexibility

　　Quickly respond to tension changes, switch gain through Profibus-DP or digital input to adapt to different process requirements.

　　Provides 6 configurable analog outputs for controlling or monitoring tension, and supports remote gain scheduling and zero adjustment.

　　High reliability

　　IP65 protection level, suitable for harsh industrial environments (such as dust and moisture).

　　Built-in self-diagnosis function, output diagnostic status through Profibus-DP to ensure stable operation of the equipment.

　　Configuration flexibility

　　Multi-language display: supports multi-language interfaces such as Chinese and English, which is convenient for global deployment.

　　Protection level: IP65 package version is suitable for harsh environments such as high temperature, high humidity, dust, etc.

　　Installation method: DIN rail and independent chassis are provided.

　　Integration capability

　　Supports Profibus-DP fieldbus communication, seamless integration into PLC, HMI or other control systems.

　　Up to three PFEA113 units can be combined to handle segmented roll applications (such as winders, up to 12 sensors).

　　Communication capabilities

　　Integrated Profibus-DP protocol supports seamless integration with PLC, HMI and other devices.

　　Remote gain scheduling function: switch gain parameters of different process paths through digital input or Profibus signal.

　　Self-diagnosis and alarm

　　Built-in fault detection module to monitor sensor status and communication link in real time.

　　4 configurable digital outputs support tension threshold alarm and system status indication.

　　Operation and maintenance guide

　　Control panel functions

　　Mode switching: short press the "Auto/Manual" key to achieve non-disturbance switching, long press for 3 seconds to synchronize the current measurement value to the set value.

　　Output control: start and stop the control signal through the "OUTPUT" key, and the LED indicates the output status.

　　Display switching: cyclically display tension units (kg/N) or output power percentage.

　　Troubleshooting

　　Alarm code: If "AL1" indicates that the tension is below the lower limit, check the sensor connection or load status.

　　Communication abnormality: Confirm that the Profibus address setting is consistent with the master station configuration, and check the terminal resistance.

　　Regular maintenance

　　Calibrate the load sensor every 6 months.

　　Avoid using corrosive solvents when cleaning the IP65 housing.

　　Common faults and solutions

　　1. Sensor signal abnormality (Err-05)

　　Phenomenon: The display shows "SENSOR FAULT" and the ALARM light flashes at 2Hz.

　　Reason:

　　Sensor damage (such as strain gauge breakage).

　　Signal line interference (shield grounding is poor).

　　Sensor range does not match controller settings.

　　Solution:

　　Use a multimeter to detect the sensor output (0V without load, 10V with full load), and replace the faulty sensor.

　　Use twisted shielded pair (such as ABB 3HAC029817-001) instead, and ground the shield at one end.

　　Recalibrate the sensor parameters (parameter group P10.01~P10.04).

　　2. Actuator overload

　　Phenomenon: The controller output suddenly returns to zero, and the ALARM light flashes at 4Hz.

　　Reason:

　　The magnetic powder brake stall current exceeds the limit.

　　The error in the winding diameter calculation causes the tension setting value to overflow.

　　Solution:

　　Measure the actuator current and upgrade the controller model (such as PFEA113-20).

　　Correct the winding diameter parameters (P20.01~P20.03) through the laser rangefinder.

　　Adjust PID gain (Ziegler-Nichols method).

　　3. Tension fluctuation

　　Phenomenon: The tension value fluctuates by ±15% during the winding and unwinding process, and the material is wrinkled or broken.

　　Reason:

　　Insufficient rigidity of the mechanical system (guide roller bearing clearance>0.1mm).

　　The coupling interference between the speed loop and the tension loop.

　　Solution:

　　Replace high-precision bearings (such as SKF 6204-2RSH) and adjust the parallelism of the guide rollers to ≤0.02mm/m.

　　Extend the inverter acceleration time to more than 1s and enable the S-shaped acceleration and deceleration curve (parameter P08.02=2).

　　Application areas

　　Printing industry: Control the tension of paper, film and other rolls to avoid breakage or wrinkling.

　　Packaging machinery: Adjust the tension of packaging materials to ensure packaging stability.

　　Textile industry: Control the tension of yarn or fabric to improve production efficiency.

　　Metal processing: Maintain the tension of metal strips/wires to ensure processing accuracy.

　　Cable manufacturing: Ensure the stability of tension during cable stretching and extrusion.

　　Paper and cardboard production: Control the flatness of rolls to improve product quality.

　　Conclusion

　　The ABB 3BSE028144R0020 tension controller has become the preferred solution in the field of industrial tension control due to its high precision, high reliability and flexible configuration. Users need to adjust parameters according to specific process requirements and perform regular maintenance to prevent failures.

　　All products on this website are special products, and market prices have been fluctuating.

　　Specific quotes are subject to customer service, because the product is a new product and the price is not real.

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