ABB PFRL101C-1.0KN 3BSE023316R1002 | Industrial Web Tension Measurement Sensor

• Model: ABB PFRL101C-1.0KN
• Order Number: 3BSE023316R1002
• Brand: ABB
• Series: PFRL101C / Pressductor Radial Load Cell
• Part Type: Radial Load Cell / Web Tension Sensor
• Core Function: Measures web tension through a shaft-mounted radial load-cell arrangement in continuous web-processing machinery.
• Key Specs: 1.0 kN nominal load capacity, 1.5 kN extended load, approximately 225 lbf nominal / 337 lbf extended, with applications in converting, plastic film, printing, textile, and related web-processing machinery.

Product Introduction

In a web-processing line, unstable tension can quickly translate into wrinkles, registration problems, poor winding quality, or material waste. When the tension feedback device starts drifting or fails completely, replacing the correct load cell becomes a mechanical as well as an instrumentation task.

ABB PFRL101C-1.0KN 3BSE023316R1002 belongs to ABB’s Pressductor Radial Load Cell family and is designed for web-tension measurement using shaft-mounted load cells. ABB documentation identifies the PFRL101 family for web-tension applications across converting, plastic-film, printing, textile, and other web-processing machinery.

The 1.0 kN version has a nominal rated capacity of 1.0 kN / 225 lb, while the documented extended-load value is 1.5 kN / 337 lb.

One important correction for procurement: this is a load cell / tension-measurement sensor, not a PLC module, CPU, or conventional analog input card. Multiple supplier listings independently identify 3BSE023316R1002 as PFRL 101C-1K / PFRL101C-1.0KN load cell.

Core Technical Specifications

ABB -1.0KN 3BSE023316R1002

ABB’s own PFRL documentation confirms the 0.5 kN and 1.0 kN nominal capacity options and gives the corresponding extended loads of 0.75 kN and 1.5 kN.

A supplier listing reports -10°C to +70°C and IP65 for the family. Those values are useful for engineering reference, but the exact machine installation should be checked against the applicable ABB mechanical and environmental documentation.

Application Scenarios & Pain Points

On a plastic-film production line, the can monitor web tension around a roller or shaft. The 1.0 kN nominal capacity gives the system a defined measurement range for applications requiring higher tension than the 0.5 kN variant.

In printing machinery, accurate web tension is important for maintaining material transport and registration. An aging load cell can introduce unstable feedback even when the tension electronics themselves remain functional.

For textile-processing equipment, the radial load-cell arrangement allows tension measurement directly through the machine’s shaft/roller arrangement. This makes mechanical installation and shaft geometry just as important as electrical compatibility.

Within converting equipment, the PFRL101 family is intended for continuous web-processing applications. ABB specifically identifies converting machinery among its target applications.

At elevated machine temperatures approaching 50°C, environmental margin should be checked before replacement. A sensor operating near the upper end of its rated temperature range can require closer attention to mounting conditions, heat sources, and calibration stability.

Common Error Codes & Diagnostic Symptoms

The is a passive load cell, so it does not normally generate its own PLC-style error codes. Faults are generally detected by the connected tension electronics, such as an ABB PFEA-series unit.

• Tension Signal Lost / Zero Output → Diagnosis: Possible open sensor circuit, damaged cable, connector problem, or failed load cell. → Action: Check the sensor circuit and cabling; replace the if the sensor itself fails the resistance/functional test.
• Unstable Tension Reading → Diagnosis: Mechanical vibration, cable damage, poor mounting, electrical interference, or load-cell deterioration can produce unstable feedback. → Action: Check mechanical installation and wiring before replacing the sensor.
• Tension Reading Saturated / Out of Range → Diagnosis: Excessive mechanical load, incorrect sensor capacity, mechanical overload, or signal-chain problems may drive the measurement outside its normal range. → Action: Verify that the application remains within the 1.0 kN nominal / 1.5 kN extended-load range and inspect the sensor mechanically.

Cross-Reference & Lifecycle Migration

Cross-Reference

The exact 3BSE023316R1002 reference is independently associated with PFRL / .0KN by multiple industrial spare-parts sources.

Related PFRL Variants

ABB documentation identifies the PFRL101 family with 0.5 kN and 1.0 kN nominal load capacities. The 1.0 kN version should not be replaced by the 0.5 kN version simply because the mechanical body appears similar.

Tension Electronics Compatibility

ABB’s PFRL load cells are used as part of a complete tension-measurement system. ABB documentation lists PFEA111, PFEA112, PFEA122, and PFEA113 tension electronics alongside PFRL101 load-cell applications.

Therefore, replacing the sensor should include verification of the connected tension electronics and the existing calibration configuration.

Firmware

The itself is a sensor/load-cell device and does not require user firmware flashing. Firmware considerations apply to the associated tension electronics or controller, if applicable.

Lifecycle

The family is an established ABB web-tension product family with continuing aftermarket availability. For older machinery, procurement should still verify the exact mechanical version and load capacity before ordering.

For plants operating multiple web-processing machines, maintaining one correctly rated spare can be useful because a failed tension sensor can directly affect production quality even when the main automation controller remains operational.

Field Engineer’s Tech Notes

1. Do not match the sensor by capacity alone.
A 1.0 kN rating is only one part of the compatibility check. Verify the mechanical configuration, shaft arrangement, mounting geometry, cable routing, and connected tension electronics before installation.

2. Do not confuse a sensor fault with a PFEA electronics fault.
If the tension reading disappears, check the complete signal chain first. (A broken cable or poor connector can look exactly like a failed load cell from the operator’s perspective.) Test the sensor independently before condemning the .

Strict QA & Testing SOP

1. Inbound identification — Verify ABB marking, , and order number 3BSE023316R1002.
2. Nameplate inspection — Record model, serial number, rating, and manufacturing information.
3. Mechanical inspection — Examine the housing, mounting surfaces, shaft interface, and mechanical load-transfer areas.
4. Cable inspection — Check the cable jacket, strain relief, connector, and termination for damage.
5. Load-capacity verification — Confirm the unit is the 1.0 kN version rather than a lower-capacity PFRL variant.
6. Electrical inspection — Measure the applicable sensor electrical characteristics according to the ABB test procedure.
7. Zero-output test — Verify stable zero/load baseline with the sensor unloaded.
8. Controlled-load test — Apply a known mechanical load using a calibrated test arrangement.
9. Signal-chain test — Connect the sensor to compatible ABB tension electronics and verify stable measurement.
10. Linearity/response check — Compare measured values at multiple known loads where test equipment permits.
11. Final documentation — Record test results, serial number, photographs, and physical condition.
12. Protective packaging — Use suitable cushioning and moisture protection for the mechanical sensor and cable.

Test videos can be provided when available, including visual inspection, identification, and functional/load testing evidence.

Buyer’s FAQ

Q1: Is ABB 3BSE023316R1002 a PLC module?
A: No. It is the order number for the .0KN Pressductor radial load cell, used for web-tension measurement.

Q2: What is the rated capacity?
A: The nominal rated capacity is 1.0 kN / approximately 225 lbf. ABB documentation gives an extended-load value of 1.5 kN / approximately 337 lbf.

Q3: Does it connect directly to a PLC?
A: It is normally part of a complete tension-measurement system and works with compatible tension electronics. ABB lists the PFEA111/112/122/113 family alongside PFRL load-cell applications.

Q4: Can I replace a 0.5 kN PFRL sensor with this 1.0 kN version?
A: Do not make that substitution without checking the machine’s tension range, mechanical configuration, calibration, and tension-electronics setup. The two ratings are distinct PFRL variants.

Q5: Does the require firmware?
A: No user firmware is required for the passive load cell itself. Configuration and calibration are handled through the associated tension-measurement electronics.

Q6: How can I verify the correct part before ordering?
A: Confirm all three identifiers: .0KN + 3BSE023316R1002 + 1.0 kN. Also compare the mechanical mounting arrangement and the existing sensor’s nameplate before approving the replacement.