Emerson EPRO PR6424/000-030+CON021 16mm Eddy Current Sensor System

Emerson EPRO PR6424/000-030+CON021 16mm Eddy Current Sensor System

The Emerson EPRO PR6424/000-030+CON021 represents a high-performance eddy current displacement measurement system specifically engineered for large-diameter shaft monitoring in heavy-duty turbomachinery. This factory-matched system pairs the robust PR6424 16mm eddy current sensor with the versatile CON021 signal converter, delivering exceptional measurement accuracy for steam turbines, gas turbines, generators, and large industrial compressors operating in the most demanding power generation and process industry environments.

Large Shaft Monitoring Solution

Unlike smaller 8mm sensors designed for compact machinery, the PR6424 16mm sensor is purpose-built for shafts 80mm diameter and larger, providing superior electromagnetic field penetration and measurement stability on large rotating equipment. The 70mm total sensor length (configuration code '3') with 8-meter cable (configuration code '3') enables installation in deep bearing housings typical of large turbomachinery, while the M18x1.5 threading (configuration code '0') provides secure mounting in heavy-duty brackets.

PR6424 16mm Sensor Technical Performance

Enhanced Measurement Specifications

The PR6424/000-030 sensor delivers robust measurement performance optimized for large shaft applications:

• 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 and thermal growth
• Dynamic Measurement Range: 0 to 1,000 μm (0 to 39 mils) for vibration amplitude measurement
• Nominal Air Gap: Approximately 2.7 mm (106 mils) center point for optimal linearity
• Long-Term Stability: <0.3% drift ensures reliable continuous monitoring
• Temperature Coefficient: <4% per 100°K meets API 670 requirements

Large Shaft Target Requirements

Engineered specifically for heavy industrial rotating equipment:

• Minimum Shaft Diameter: 80 mm (3.15 inches) - significantly larger than 8mm sensor requirements
• Target Material: Ferromagnetic steel (42CrMo4 standard) for specified performance
• Maximum Surface Speed: 2,500 m/s (98,425 inches per second) for high-speed turbine applications
• Surface Finish: Clean, smooth ferromagnetic steel surface free from coatings

Extreme Industrial Environment Capability

High-Temperature Operation

The PR6424 sensor withstands extreme thermal conditions common in power generation:

• Operating Temperature Range: -35°C to +150°C (-31°F to +302°F)
• Temperature Error: <4% per 100°K complies with API 670 standards
• Thermal Stability: Maintains accuracy through startup thermal transients

Pressure & Vibration Resistance

• Pressure Resistance: 10,000 hPa (145 psi) to sensor head for pressurized applications
• Shock & Vibration: 5g @ 60 Hz @ 25°C withstands severe machinery vibration
• Mechanical Robustness: Stainless steel sleeve construction resists impact and corrosion

Industrial-Grade Construction

• Sleeve Material: Stainless steel for maximum corrosion resistance and mechanical strength
• Cable Insulation: PTFE (Polytetrafluoroethylene) maintains signal integrity at elevated temperatures
• Connector: Lemo self-locking design prevents vibration-induced disconnection
• Weight: Approximately 200 grams (7.05 oz) with 1m cable - robust construction for industrial durability

CON021 Signal Converter Specifications

Wide-Bandwidth Signal Conditioning

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

• Frequency Response: DC to 20,000 Hz (-3dB) captures both static position and dynamic vibration
• Rise Time: <15 microseconds for fast transient capture
• Output Voltage: -4V to -20V or -2V to -18V proportional to gap distance
• Supply Voltage: -23V to -32V or -21V to -32V negative ground operation
• Linearity: ±1.0% maximum error across measurement range

Converter Physical Design

• Housing Material: LMgSi 0.5 F22 aluminum alloy for EMI shielding
• Weight: Approximately 120 grams (4.24 oz) for panel or DIN rail mounting
• Mounting: 4x M5x20 screws included for secure installation
• Sensor Connection: Self-locking Lemo plug with positive engagement
• Output Connection: Screw terminals accept up to 1.5mm² wire
• Operating Temperature: -30°C to 100°C (-22°F to 212°F)
• Protection Class: IP20 for control cabinet mounting

Critical Machinery Application Solutions

Large Steam Turbine Monitoring

Deploy the PR6424/000-030+CON021 system for radial vibration monitoring on large steam turbines in power plants. The 16mm sensor's enhanced electromagnetic field strength provides stable measurements on 200mm+ diameter shafts common in utility-scale turbines. Install XY probe pairs at each journal bearing to measure shaft displacement, enabling orbit analysis, vibration trending, and early fault detection including unbalance, misalignment, bearing wear, steam whirl, and oil whip instabilities.

Gas Turbine Shaft Position Tracking

Monitor both radial vibration and axial position in industrial gas turbines driving generators or mechanical loads. The sensor's ±2mm static range accommodates thermal growth during startup sequences, while the 1,000 μm dynamic range captures vibration amplitudes during steady-state operation. Interface with turbine control systems for automatic trip protection per API 670 machinery protection standards.

Large Compressor Thrust Bearing Protection

Protect critical thrust bearings in centrifugal compressors by monitoring axial shaft position. The PR6424 sensor's 4 V/mm sensitivity provides high-resolution position measurement, enabling detection of thrust bearing wear before catastrophic failure occurs. Set alarm and trip setpoints based on maximum allowable thrust collar movement to prevent rotor-to-stator contact that could destroy the compressor.

Generator Rotor Vibration & Eccentricity

In large synchronous generators, measure rotor vibration and eccentricity to detect electrical and mechanical faults. The 16mm sensor accommodates the large shaft diameters typical of utility generators (300mm+), while the 20 kHz bandwidth captures twice-line-frequency vibration components caused by electrical unbalance, shorted turns, or rotor winding faults.

Installation Engineering Guidelines

Sensor Mounting for Large Shafts

Proper installation ensures measurement accuracy on large-diameter shafts:

• Mount sensor perpendicular to shaft surface within ±5 degrees angular tolerance
• Set initial air gap to 2.7 mm (106 mils) nominal center point using precision gap gauges
• Ensure rigid mounting bracket prevents sensor movement under vibration and thermal expansion
• Verify minimum 80 mm shaft diameter at measurement location
• Maintain adequate clearance for maximum expected shaft runout and vibration amplitudes
• Use M18x1.5 threading for secure installation in heavy-duty mounting brackets

Cable Routing & EMI Protection

The 8-meter PTFE-insulated cable enables flexible routing from bearing housing to control cabinet:

• Route cable away from high-voltage power cables and VFD wiring to minimize EMI
• Use cable trays or conduit for mechanical protection in high-traffic areas
• Avoid sharp bends that could damage PTFE insulation or internal conductors
• Ground cable shield at converter end only to prevent ground loops
• Protect Lemo connector from moisture, dirt, and mechanical damage

CON021 Converter Configuration

Install the CON021 converter in a climate-controlled cabinet using the four M5x20 mounting screws. Connect the sensor cable to the Lemo plug, ensuring the locking collar fully engages. Wire the -24VDC power supply and output signals to screw terminals, maintaining proper polarity. Connect output to DCS, PLC, or machinery protection system analog inputs configured for -4V to -20V or -2V to -18V range.

System Calibration & Commissioning

Verify the 4 V/mm scale factor using precision micrometer stands or calibrated gap gauges. The system ships factory-calibrated with NIST-traceable documentation, but field verification confirms measurement accuracy after installation. Check output voltage at 1.7mm, 2.7mm, and 3.7mm gaps (±1mm from center) to verify linearity within ±1.5% specification. Document calibration results for machinery protection system commissioning and regulatory compliance.

Machinery Protection System Integration

Compatible Monitoring Platforms

The PR6424/000-030+CON021 system integrates seamlessly with all major machinery protection systems:

• Bently Nevada: 3500/42M proximitor monitors, 3500/53 overspeed detection, ADAPT condition monitoring
• Emerson AMS: 6500 machinery health monitors, AMS Suite predictive maintenance platform
• Rockwell Automation: ControlLogix PLCs with 1756-IF16 analog input modules
• Siemens: S7-1500 PLCs with SM 1231 analog inputs, SIMATIC PCS 7 DCS
• DCS Platforms: Emerson DeltaV, Honeywell Experion PKS, ABB 800xA, Yokogawa CENTUM VP
• Turbine Controls: GE Mark VIe, Siemens T3000, Emerson Ovation turbine control systems

Sensor Family Compatibility

The CON021 converter supports the complete Emerson EPRO eddy current sensor family:

• PR6422: 5mm sensor for small shafts (15mm minimum diameter)
• PR6423: 8mm sensor for medium shafts (25mm minimum diameter)
• PR6424: 16mm sensor for large shafts (80mm minimum diameter)
• PR6425: Extended range sensor (requires CON021/91x-xxx extended range converter)
• PR6426: 25mm sensor for extra-large shafts
• PR6453: High-temperature variant for extreme environments

Quality Standards & Regulatory Compliance

• API 670: Compliant for non-contacting vibration and axial position monitoring systems
• ISO 20816: Suitable for mechanical vibration measurement on rotating machinery
• ISO 7919: Applicable for shaft vibration measurement standards
• IEC 60529: IP20 protection rating for converter (cabinet mounting)
• CE Marking: European conformity declaration for industrial control equipment
• Factory Calibration: NIST-traceable calibration certificate included
• RoHS Compliance: Restriction of Hazardous Substances directive compliant

Why Choose Industrial Control Hub?

As an authorized distributor of Emerson EPRO machinery protection solutions, Industrial Control Hub provides genuine factory-certified products with comprehensive engineering support. Our turbomachinery specialists assist with sensor selection, mounting design, system integration, and field commissioning to ensure optimal performance in your critical power generation and process industry applications.

• ✓ Genuine Emerson EPRO factory-sealed products with full warranty and traceability
• ✓ Express global shipping with protective packaging for industrial components
• ✓ Application engineering support for large turbomachinery installations
• ✓ Long-term spare parts availability for legacy power plant systems
• ✓ Volume project pricing for multi-unit power generation facilities
• ✓ Technical training and commissioning assistance available

Related Large Shaft Monitoring Products

Complete your turbomachinery protection system with these compatible components:

• Emerson EPRO PR6424/000-130 - 12mm proximity probe for alternative shaft size applications
• Emerson EPRO CON021+PR6424/010-110 - Complete system with alternative sensor configuration
• Emerson EPRO PR6424/010-040+CON021 - System with 3/4"-16 UNF threading for North American installations

Technical Support & Engineering Services

Our turbomachinery monitoring specialists provide comprehensive support for your Emerson EPRO PR6424/000-030+CON021 sensor system installation. Contact us for detailed technical datasheets, AutoCAD mounting drawings, API 670 compliance documentation, calibration certificates, and project-specific quotations for power plant and heavy industrial applications.

System Configuration: Model PR6424/000-030+CON021 | 16mm Eddy Current Sensor | 70mm Total Length | 8m Cable | M18x1.5 Threading | Lemo Connector | CON021 Converter | 4 V/mm Sensitivity | ±2mm Static Range | 1000μm Dynamic Range | 20kHz Bandwidth | API 670 Compliant | 80mm Minimum Shaft | -35°C to +150°C Operation | 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: