Description
Key Technical Specifications
- Product Model: PU516A 3BSE032402R1
- Manufacturer: ABB
- Sensor Technology: Pressductor (Electromagnetic/Magnetic Flux)
- Measurement Type: Horizontal force component (Web Tension)
- Construction: Machined from solid steel block
- Electrical Impedance: Extremely low (a few Ohms)
- Output Signal: Induced AC voltage proportional to applied force
- Signal Output Config: Active or Passive mode (4…20 mA standard)
- Fieldbus Compatibility: PROFIBUS PA (Profile 3.01)
- Environmental Resistance: Immune to dirt, liquids, and EMI/RFI interference
- Mechanical Feature: High overload protection and extended measurement range
- Vibration Impact: Negligible (does not induce machine vibration)
Product Introduction
You’re running a high-speed paper machine or plastic foil line, and traditional strain gauges keep failing from mechanical fatigue. The ABB PU516A 3BSE032402R1 solves this by ditching physical movement entirely. It uses ABB’s exclusive Pressductor technology to measure web tension based on metallurgical phenomena—specifically, how mechanical forces alter the magnetic flux capacity of its solid steel core. It only measures the horizontal force component, keeping the sheet or web tension perfectly constant without dragging down the machine.
Why do engineers prefer this over LVDTs or strain gauges? Because there are no moving parts to wear out. The sensor operates via two perpendicular copper windings around a steel core. When force is applied, the magnetic field couples with the secondary winding, inducing a strong AC voltage signal. With an impedance of just a few Ohms, it practically eliminates susceptibility to electromagnetic interference. Bottom line—it delivers high repeatability, zero drift, and survives harsh industrial environments where physical transducers would simply give up.
ABB-PU516A-3BSE032402R1
Troubleshooting Quick Reference
- Fault: Erratic or noisy tension signal.
- Cause: EMI interference or incorrect signal mode configuration.
- Relevancy: High (80% chance it’s a wiring/config issue).
- Quick Check: Verify if the current output is configured as “active” or “passive”.
- Fix: Ensure no external power is supplied if in “active” mode. Check PROFIBUS PA address.
- Fault: Zero output despite physical web tension.
- Cause: Missing external power supply.
- Relevancy: High.
- Quick Check: Check the terminal box marking for signal configuration.
- Fix: If configured in “passive” mode, you MUST supply external power to the current output.
- Fault: PROFIBUS PA communication failure.
- Cause: Invalid bus address or duplicate address on segment.
- Relevancy: Medium.
- Quick Check: Read the bus address via Asset Vision Basic or DIP switches.
- Fix: Reset address to a valid range (0…125). Ensure no duplicates exist on the segment.
- Fault: Sensor reading drift over time.
- Cause: Physical damage to the steel core or winding.
- Relevancy: Low (Pressductor tech is highly resistant to drift).
- Quick Check: Inspect the solid steel block for severe mechanical overload damage.
- Fix: Replace the PU516A unit. Recalibrate the tension control system.
Application Scenarios & Pain Points
- High-Speed Paper Processing: Traditional strain gauges stretch and lose calibration. The PU516A relies purely on magnetic flux, ensuring zero drift and maintaining top-tier paper quality without constant recalibration.
- Plastic Foil & Film Lines: Harsh environments with conductive dust or coolants destroy physical transducers. The sealed solid steel core of the Pressductor ignores environmental dirt and liquids completely.
- Precision Web Tension Control: Machines require fast, precise inputs to drive motors. The negligible vibration footprint of this horizontal cell allows for tighter tension tolerances and prevents mechanical resonance.
Real-World Case Study: An engineer at a packaging plant struggled with constant tension drops on a high-speed foil line. They were replacing strain-gauge load cells every three months due to mechanical fatigue from machine vibration. They swapped to the PU516A Pressductor sensor. Because it measures only the horizontal force component and generates a signal magnetically, the vibration stopped affecting the readings entirely. They haven’t replaced a tension sensor in over two years.
ABB-PU516A-3BSE032402R1
Compatible Replacement Models
- ✅ Drop-in Replacement: PU516A 3BSE032402R1. This is the exact horizontal Pressductor load cell. Fully compatible with existing ABB tension control electronics. No mechanical or software changes required.
- ⚠️ Software/Signal Compatible: PU515A 3BSE032401R1. The PU515A is a closely related model in the same Pressductor family. It uses the same electromagnetic operating principle and interfaces. However, verify the physical mounting dimensions and exact capacity rating before swapping, as mechanical adaptation may be required.
- ❌ Hardware Incompatible: Standard Strain Gauge Load Cells. Do not attempt to replace a with a generic strain gauge. The ABB tension control electronics expect the specific low-impedance AC voltage signal generated by the Pressductor magnetic flux. Rewiring and replacing the entire control amplifier would be mandatory.
