Key Technical Specifications

• Product Model: PFRL101C
• Order Number: 3BSE023316R0002
• Manufacturer: ABB
• Sensor Type: Radial Pressductor Load Cell
• Rated Load Capacity: 2.0 kN
• Measurement Principle: Magnetoelastic Effect (Pressductor)
• Typical Application: Web tension measurement (Paper, Film, Steel)
• Output Signal: High-power, low-impedance AC signal
• Electrical Immunity: Highly resistant to EMI and ground faults
• Mechanical Overload Tolerance: Exceptional (No internal strain limits)

 

Product Introduction

Web tension control in paper or steel mills is brutal on sensors. If a load cell can’t handle shock loads from a sudden web break or a jammed roller, you get false alarms and ruined product. The ABB PFRL101C 2.0kN (3BSE023316R0002) is built specifically for this abuse. Instead of relying on fragile strain gauges, it uses ABB’s Pressductor magnetoelastic technology. When the 2.0 kN radial force hits the steel core, the magnetic permeability changes. No physical deformation means no mechanical fatigue.I’ve installed hundreds of these over the years. The reason engineers keep specifying the ABB PFRL101C 2.0kN is its immunity to electrical noise. It generates a high-power AC signal that laughs off the EMI and ground loops that typically corrupt standard DC sensors in heavy industrial environments. Just be careful with the mounting surface; this specific revision demands a perfectly flat, clean machined face to prevent localized crushing.

Quality SOP & Tech Pitfalls (The Reality Check)

Before this ABB PFRL101C 2.0kN leaves our facility, it goes through a strict QA protocol. We start with a visual inspection to check for corrosion on the polished surfaces. Next, it goes on a live test rack where we apply a known radial load and verify the AC output signal matches the 2.0 kN rating. We log the serial number, perform an insulation resistance check with a megger, and finally seal it in anti-static packaging. I can provide the test report if you need it for your PM records.Here is a brutal field warning: Do not ignore the mounting surface prep. I once saw a mill tech slap a new load cell onto a dirty, pitted roller bearing block. The uneven surface caused localized overloading, and the sensor read 15% high until it eventually cracked. Also, never drop this unit. While the magnetoelastic core is tough, dropping it can shift the internal magnetic alignment, ruining your calibration.

 

Installation & Configuration Guide

1. Pre-Installation: Lock out and tag out the tension stand. Wait for the roller to stop completely. ⚠️ Take clear photos of the existing wiring and note the exact orientation of the old load cell before touching anything.
2. Removal: Label the sensor cables. Carefully release the retaining hardware and slide the old sensor out. Inspect the bearing block bore for burrs or debris; clean it with a lint-free rag.
3. Installation: Copy the DIP switch or jumper settings from the old unit to the new one. This step prevents 90% of startup calibration errors. Slide the ABB PFRL101C 2.0kN into place, ensuring it seats flush against the machined surface.
4. Power-On & Testing: Restore power and check the LED status on the connected amplifier (like a PFEA111). Verify the baseline tension reading is stable before downloading any tension setpoints.

Compatible Replacement Models

• ✅ Drop-in Replacement: PFRL101C 1.0kN (3BSE023316R0502) or PFRL101C 0.5kN. Same physical footprint and wiring, but you must adjust the amplifier scaling parameters to match the new kN rating.
• ✅ Drop-in Replacement: PFRL101B (1.0kN) or PFRL101A (0.5kN). Direct mechanical fit, but verify the exact shaft diameter and load requirements before swapping.
• ❌ Hardware Mod Required: PFCL201C (Pillow block type). Do not use this as a direct swap. It requires a completely different mechanical housing and mounting bracket.

 

Frequently Asked Questions (FAQ)

• Can I use standard DC shielded cable for this sensor?
  No. The Pressductor tech outputs a high-power AC signal. You must use the specific ABB coaxial or twisted-pair cable designed for this sensor to prevent signal degradation.
• What happens if I overload this 2.0kN sensor?
  Unlike strain gauges that permanently deform, the magnetoelastic core has virtually no mechanical overload limit. It will likely survive massive shock loads, though extreme force could shift the calibration.
• Does this sensor need regular recalibration?
  Rarely. Because there is no physical movement or strain, the calibration is highly stable. I usually only recommend a check if the web breaks constantly or if the amplifier shows a drift error.
• Is this the right sensor for wet paper machines?
  The standard PFRL101C is fine for most areas, but if it’s directly in the spray zone, you need the IP66/67 rated version (like the PFTL101AER) to prevent water ingress.
• How do I know if the sensor is actually dead?
  Disconnect it from the amplifier and measure the AC output resistance with a multimeter. Compare it to the OEM datasheet. An open circuit means the internal coil is broken.