Emerson EPRO PR6424/000-000+CON021 16mm Eddy Current Sensor System

Emerson EPRO PR6424/000-000+CON021 16mm Eddy Current Sensor System

The Emerson EPRO PR6424/000-000+CON021 represents a premium eddy current displacement measurement solution specifically engineered for large-diameter shaft monitoring in heavy-duty turbomachinery. This factory-matched system integrates the robust PR6424 16mm eddy current sensor with the high-performance CON021 signal converter, delivering exceptional reliability for vibration monitoring, axial position tracking, and machinery protection in power generation, petrochemical, and heavy industrial applications where shaft diameters exceed 80mm.

Large Shaft Monitoring Expertise

Unlike smaller 8mm sensors designed for compact machinery, the PR6424 16mm sensor is purpose-built for large turbines, generators, and compressors with shaft diameters of 80mm and above. The larger sensing element provides superior electromagnetic field penetration and reduced edge effects on large-diameter targets, ensuring measurement accuracy that smaller sensors cannot achieve on heavy rotating equipment.

PR6424 16mm Sensor Technical Performance

Measurement Specifications

The PR6424/000-000 sensor delivers precision displacement measurement optimized for large rotating machinery:

• Sensitivity/Linearity: 4 V/mm (101.6 mV/mil) with ±1.5% linearity specification
• Static Measurement Range: ±2.0 mm (±79 mils) for position tracking
• Dynamic Measurement Range: 0 to 1,000 μm (0 to 39 mils) for vibration amplitude
• Nominal Air Gap: Approximately 2.7 mm (0.11 inches) center point
• Long-Term Drift: <0.3% for stable baseline measurements
• Temperature Error: <4% per 100°K, API 670 compliant

Target Material Requirements

For specified performance, the PR6424 sensor requires appropriate target characteristics:

• Minimum Shaft Diameter: 80 mm (3.15 inches) to avoid curvature-induced errors
• Standard Target Material: Ferromagnetic steel (42CrMo4 standard)
• Maximum Surface Speed: 2,500 m/s (98,425 inches per second)
• Surface Finish: Smooth, clean ferromagnetic surface free from coatings
• Alternative Materials: Custom calibration available for non-standard targets

Industrial-Grade Environmental Protection

Extreme Temperature Performance

Engineered for the harshest industrial environments, the PR6424/000-000 operates reliably across an extended temperature range:

• Operating Temperature Range: -35°C to +150°C (-31°F to +302°F)
• Temperature Coefficient: <4% per 100°K per API 670 standards
• Thermal Stability: Maintains accuracy through thermal transients
• Storage Temperature: -40°C to +85°C for long-term reliability

Pressure & Vibration Resistance

The sensor's robust construction withstands demanding operating conditions:

• Pressure Resistance: 10,000 hPa (145 psi) at sensor head
• Shock & Vibration: 5g @ 60 Hz @ 25°C operational rating
• Mechanical Durability: Stainless steel sleeve construction
• Cable Protection: PTFE insulation for chemical and thermal resistance

Premium Construction Materials

• Sleeve Material: Stainless steel for corrosion resistance and mechanical strength
• Cable Insulation: PTFE (Polytetrafluoroethylene) rated to 150°C continuous
• Connector: Lemo self-locking design prevents vibration-induced disconnection
• Weight: Approximately 200 grams (7.05 oz) with 1m cable (unarmored)
• Threading: M18x1.5 metric threads for secure mounting

CON021 Signal Converter Specifications

High-Bandwidth Signal Processing

The CON021 eddy current signal converter provides precision signal conditioning for the PR6424 sensor:

• Frequency Response: DC to 20,000 Hz (-3 dB) captures full vibration spectrum
• Rise Time: <15 microseconds for transient event capture
• Output Voltage: -4V to -20V or -2V to -18V depending on supply voltage
• Linearity Error: ±1.0% maximum across measurement range
• Compatible Sensors: PR6422, PR6423, PR6424, PR6425, PR6426, PR6453 series

Converter Physical Specifications

• Housing Material: LMgSi 0.5 F22 aluminum alloy for EMI shielding
• Weight: Approximately 120 grams (4.24 oz)
• Mounting: 4x M5x20 screws included for panel or DIN rail installation
• Sensor Connection: Self-locking Lemo plug with positive engagement
• Output Terminals: Screw terminals accept up to 1.5mm² (16 AWG) wire
• Operating Temperature: -30°C to 100°C (-22°F to 212°F)
• Protection Rating: IP20 for indoor electrical enclosure mounting
• Power Supply: -21V to -32V DC (negative ground)

Application Solutions for Heavy Machinery

Large Steam Turbine Vibration Monitoring

Deploy the PR6424/000-000+CON021 system for radial vibration monitoring on large steam turbines in power generation facilities. The 16mm sensor's larger electromagnetic field provides accurate measurements on shaft diameters from 80mm to 500mm, where smaller sensors would suffer from curvature effects and reduced sensitivity. Install in XY pairs at each bearing to measure shaft displacement in two perpendicular planes, enabling comprehensive orbit analysis and early fault detection.

Gas Turbine Rotor Position Tracking

Monitor rotor position in industrial gas turbines and aero-derivative turbines to detect bearing wear, thermal growth, and rotor dynamics issues. The ±2mm static range accommodates normal bearing clearances and thermal expansion during startup sequences, while the 20 kHz bandwidth captures blade pass frequencies for comprehensive machinery health assessment.

Large Compressor Thrust Bearing Protection

Protect critical thrust bearings in centrifugal compressors and axial compressors by monitoring axial shaft position. The sensor's 2.7mm nominal air gap and ±2mm range provide adequate measurement span for thrust collar monitoring, while alarm setpoints trigger protective shutdowns before thrust bearing failure occurs. This application is essential for high-pressure compressors in petrochemical and gas processing facilities.

Generator Rotor Eccentricity Measurement

In large generators and synchronous motors, measure rotor eccentricity to detect magnetic center shifts, bearing wear, and foundation settlement. The PR6424 sensor's stability and accuracy enable detection of subtle changes in rotor position that indicate developing mechanical or magnetic problems before they cause catastrophic failure.

Installation & Configuration Guidelines

Sensor Mounting Best Practices

Proper installation ensures measurement accuracy and long-term reliability:

• Mount sensor perpendicular to shaft surface within ±5 degrees angular tolerance
• Set initial air gap to 2.7mm nominal using precision gap gauges or micrometer
• Ensure rigid mounting bracket prevents sensor movement under vibration
• Verify minimum 80mm shaft diameter at measurement location
• Maintain adequate clearance for maximum expected shaft runout and vibration
• Use M18x1.5 threading for secure installation in mounting bracket
• Protect sensor from direct mechanical impact with rotating components

Model Configuration Options

The PR6424/000-000 configuration specifies:

• First Digit (0): M18x1.5 metric threading (alternative: 1 = 3/4"-16 UNF)
• Second Digit (0): Standard cable without armor (alternative: 1 = armored cable)
• Third Digit (0): 40mm total sensor length (alternatives: 1-6, B, G, M, R for 50-290mm)
• Fourth Digit (0): Without adapter plug (alternative: 1 = with adapter plug)
• Fifth Digit (0): 4.0m cable length (alternatives: 1=5m, 3=8m, 4=10m)
• Sixth Digit (0): Lemo connector termination (alternative: 1 = open end)

CON021 Converter Installation

Mount the CON021 converter in a control cabinet or junction box using the four M5x20 mounting screws. Connect the sensor cable to the Lemo plug, ensuring the locking collar engages fully. Wire the -24VDC power supply and output signals to screw terminals, maintaining proper polarity. Ground the converter housing to prevent EMI interference in electrically noisy environments.

System Calibration Procedures

While factory-calibrated to 4 V/mm scale factor, field verification ensures measurement accuracy after installation. Use precision micrometer stands or calibrated gap gauges to verify output voltage at known displacement values across the ±2mm range. Document calibration results for machinery protection system commissioning and regulatory compliance per API 670 requirements.

System Integration & Compatibility

Machinery Protection System Interfaces

The CON021 converter's industry-standard output directly interfaces with:

• Bently Nevada: 3500 rack monitors, ADAPT condition monitoring, System 1 software platform
• Emerson AMS: 6500 machinery health monitors, AMS Suite predictive maintenance software
• Rockwell Automation: ControlLogix PLCs with 1756-IF16 analog input modules
• Siemens: S7-1500 PLCs with SM 1231 analog input modules, SIMATIC PCS 7 DCS
• DCS Platforms: Emerson DeltaV, Honeywell Experion PKS, ABB 800xA, Yokogawa CENTUM
• Portable Analyzers: SKF Microlog, Emerson CSI 2140, Fluke 810 vibration testers
• Data Acquisition: National Instruments, Brüel & Kjær, HBM systems

Sensor Family Standardization

The CON021 converter supports the complete Emerson EPRO eddy current sensor family, enabling standardization across your facility. Compatible sensors include PR6422 (5mm), PR6423 (8mm), PR6424 (11mm/16mm), PR6425 (14mm extended range), PR6426 (25mm), and PR6453 (high-temperature). This flexibility simplifies spare parts inventory and reduces technician training requirements.

Quality Standards & Regulatory Compliance

• API 670: Compliant for non-contacting vibration and axial position monitoring systems
• ISO 20816: Suitable for mechanical vibration measurement per rotating machinery standards
• ISO 7919: Applicable for shaft vibration measurement in rotating machinery
• IEC 60529: IP20 protection rating for converter (sensor suitable for industrial environments)
• CE Marking: European conformity declaration for industrial machinery applications
• Factory Calibration: NIST-traceable calibration certificate available upon request
• RoHS Compliance: Restriction of Hazardous Substances directive compliant

Why Partner with Industrial Control Hub?

As an authorized distributor of Emerson EPRO condition monitoring solutions, Industrial Control Hub delivers genuine factory-certified products with comprehensive technical support. Our application engineers provide sensor selection assistance, system architecture design, and field commissioning support to ensure optimal performance in your critical machinery protection applications.

• ✓ Genuine Emerson EPRO factory-sealed products with full manufacturer warranty
• ✓ Express global shipping with protective packaging and careful handling
• ✓ Application engineering support for system design and troubleshooting
• ✓ Long-term spare parts availability for legacy and current systems
• ✓ Competitive volume pricing for multi-unit projects and plant-wide deployments
• ✓ Technical training resources and comprehensive documentation library
• ✓ Calibration certificates and compliance documentation included

Complementary Large Shaft Monitoring Products

Complete your heavy machinery monitoring system with these compatible components:

• Emerson EPRO PR6424/000-130 - 12mm proximity probe with alternative configuration for medium shaft applications
• Emerson EPRO CON021+PR6424/010-110 - Complete sensor and converter system with extended sensor length
• Emerson EPRO PR6424/010-040 - Alternative PR6424 sensor configuration for specific mounting requirements

Technical Support & Engineering Services

Our vibration monitoring specialists are available to assist with sensor selection, mounting bracket design, cable routing, signal conditioning configuration, and system commissioning for your Emerson EPRO PR6424/000-000+CON021 eddy current sensor system. Contact us for detailed technical datasheets, AutoCAD mounting drawings, calibration certificates, and project-specific quotations for multi-channel monitoring systems.

System Configuration: Model PR6424/000-000+CON021 | 16mm Eddy Current Sensor | M18x1.5 Threading | 40mm Sensor Length | 4m Cable | Lemo Connector | CON021 Converter | 4 V/mm Sensitivity | ±2mm Static Range | 0-20kHz Bandwidth | -35°C to +150°C Operation | 10,000 hPa Pressure Rating | API 670 Compliant | Factory Calibrated

© 2025 INDUSTRIAL CONTROL HUB. All rights reserved.
Original Source: https://www.indctrlhub.com
Contact: sales@indctrlhub.com | +0086 18359243191

Download PDF file here: