Emerson EPRO PR6424/000-130+CON021/914-080 Extended Range Eddy Current System

Emerson EPRO PR6424/000-130+CON021/914-080 Extended Range Eddy Current System

The Emerson EPRO PR6424/000-130+CON021/914-080 represents a specialized extended-range eddy current measurement solution engineered for large-diameter shaft monitoring in heavy-duty rotating machinery. This factory-matched system pairs the robust PR6424/000-130 16mm proximity sensor with the CON021/914-080 extended-range signal converter, delivering 8mm measurement capability—double the standard range—for applications requiring greater displacement tracking in turbines, generators, and industrial compressors.

Extended Range Measurement Architecture

Unlike standard 4mm range systems, the PR6424/000-130+CON021/914-080 provides 8mm (0.315 inches) total measurement span through specialized signal conditioning algorithms in the CON021/914-080 converter. This extended range accommodates larger bearing clearances, greater thermal growth, and higher vibration amplitudes typical of large utility turbines, hydro generators, and heavy industrial machinery operating at lower speeds with substantial rotor mass.

PR6424/000-130 16mm Sensor Specifications

Large Shaft Measurement Performance

The PR6424 16mm eddy current sensor is specifically designed for shafts 80mm diameter and larger, providing reliable non-contact displacement measurement with these performance characteristics:

• Sensitivity/Linearity: 4 V/mm (101.6 mV/mil) ±1.5% across full range
• Nominal Air Gap: 2.7 mm (0.11 inches) center position for optimal linearity
• Static Measurement Range: ±2.0 mm (±0.079 inches) from center gap
• Dynamic Measurement Range: 0 to 1,000 μm (0 to 0.039 inches) peak-to-peak vibration
• Long-Term Drift: <0.3% for stable baseline measurements over extended operation
• Temperature Error: <4% per 100°K, meeting API 670 requirements for machinery protection

Large Diameter Shaft Compatibility

Optimized for heavy industrial rotating equipment:

• Minimum Shaft Diameter: 80 mm (3.15 inches) for specified performance
• Target Material: Ferromagnetic steel (42CrMo4 standard) for maximum sensitivity
• Maximum Surface Speed: 2,500 m/s (98,425 inches/second) for high-speed applications
• Surface Finish: Standard machined finish acceptable; no special preparation required

Extreme Environment Durability

The PR6424/000-130 withstands harsh industrial conditions:

• Operating Temperature: -35°C to +150°C (-31°F to +302°F) continuous operation
• Pressure Resistance: 10,000 hPa (145 psi) at sensor head for pressurized environments
• Shock & Vibration: 5g @ 60 Hz @ 25°C withstands severe mechanical environments
• Protection Rating: IP67 equivalent with proper cable gland installation

Industrial-Grade Construction

• Sleeve Material: Stainless steel for 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 yet manageable
• Threading: M18x1.5 metric (code 0) or 3/4"-16 UNF (code 1) for versatile mounting

CON021/914-080 Extended Range Converter

Specialized Signal Conditioning

The CON021/914-080 extended range converter provides specialized signal conditioning for the PR6424 sensor, enabling 8mm measurement range—double the standard CON021 capability. This extended range converter employs advanced linearization algorithms to maintain ±1.5% linearity across the full 8mm span, critical for accurate position tracking in large machinery with substantial thermal growth and vibration amplitudes.

• Measurement Range: 8.0 mm (0.315 inches) extended range for PR6424 sensors
• Frequency Response: DC to 20,000 Hz (-3dB) captures both static position and dynamic vibration
• Rise Time: <15 microseconds for transient event capture
• Linearity Error: ±1.5% maximum across full 8mm range
• Output Voltage: -4V to -20V (with -23V to -32V supply) or -2V to -18V (with -21V to -32V supply)

Converter Physical Specifications

• Housing Material: LMgSi 0.5 F22 aluminum alloy for EMI shielding and heat dissipation
• Weight: Approximately 120 grams (4.24 oz) for panel or DIN rail mounting
• Mounting Hardware: 4x M5x20 screws included for secure installation
• Sensor Connection: Self-locking Lemo plug with positive engagement indicator
• Output Terminals: Screw terminals accept up to 1.5mm² (16 AWG) wire
• Operating Temperature: -30°C to +100°C (-22°F to +212°F) for control room or field cabinet
• Protection Class: IP20 for indoor electrical enclosure mounting

Application Solutions for Heavy Machinery

Large Steam Turbine Monitoring

Deploy the PR6424/000-130+CON021/914-080 system on utility-scale steam turbines where large shaft diameters (200-500mm) and substantial bearing clearances require extended measurement range. The 8mm span accommodates thermal growth during cold starts, load changes, and trip events, while the 4 V/mm sensitivity provides adequate signal-to-noise ratio for vibration analysis. Install in XY pairs at journal bearings and thrust positions for comprehensive rotor dynamics monitoring per API 670 standards.

Hydro Generator Shaft Position Tracking

In vertical hydro generators with massive rotors and magnetic pull forces, monitor shaft position and eccentricity using the extended 8mm range to track slow roll movements, magnetic center shifts, and hydraulic thrust variations. The system's DC response and low drift characteristics enable precise position trending over months of continuous operation, detecting gradual bearing wear or guide bearing degradation before catastrophic failure.

Large Compressor Axial Position Monitoring

Protect high-pressure centrifugal compressors and axial compressors from thrust bearing failure by monitoring axial shaft position with the extended 8mm range. This accommodates the larger thrust collar movements typical of multi-stage compressors handling variable process conditions. Set alarm and trip points at appropriate distances to provide early warning of thrust bearing degradation while avoiding nuisance trips during normal load transients.

Low-Speed Heavy Industrial Machinery

Monitor large crushers, mills, kilns, and other heavy industrial rotating equipment where substantial shaft runout, thermal expansion, and mechanical clearances exceed standard 4mm measurement capabilities. The robust 16mm sensor withstands the harsh environments typical of mining, cement, and steel production facilities, while the extended range accommodates the larger displacements inherent in these massive, slow-speed machines.

System Configuration & Installation

Sensor Configuration Options (PR6424/000-130)

The model code PR6424/000-130 specifies:

• First digit (0): M18x1.5 metric threading for European standard mounting
• Second digit (0): No armored cable—standard PTFE insulation
• Third digit (0): 40mm total sensor length for standard mounting depth
• Fourth digit (1): Without adapter plug for direct cable connection
• Fifth digit (3): 8-meter cable length for remote converter mounting
• Sixth digit (0): Lemo connector termination for quick disconnect

Installation Best Practices

Proper installation ensures measurement accuracy and system reliability:

• Mount sensor perpendicular to shaft surface within ±3 degrees for large diameter shafts
• Set initial air gap to 2.7 mm (0.11 inches) for optimal linearity across 8mm range
• Ensure rigid mounting bracket prevents sensor movement under vibration and thermal expansion
• Verify minimum 80mm shaft diameter at measurement location
• Route 8-meter cable away from high-voltage power cables to minimize EMI interference
• Ground converter housing to equipment ground to prevent ground loops

Converter Wiring & Commissioning

Install the CON021/914-080 converter in a control cabinet or junction box using the four M5x20 mounting screws. Connect the sensor's Lemo plug, ensuring the locking collar engages fully. Wire the -24VDC power supply (negative ground) and output signals to screw terminals, maintaining proper polarity. Verify the extended range configuration by checking output voltage at known gaps across the full 8mm span using precision gap gauges or micrometer positioning.

System Integration & Monitoring Platforms

Machinery Protection System Compatibility

The CON021/914-080's industry-standard output interfaces directly with:

• Bently Nevada: 3500/42M proximitor monitors, 3500/45 position monitors, ADAPT systems
• Emerson AMS: 6500 machinery health monitors with extended range input modules
• GE Hydro: Hydran monitoring systems for hydro generator applications
• Rockwell Automation: ControlLogix PLCs with 1756-IF16 or 1756-IF8 analog input modules
• Siemens: S7-1500 PLCs with SM 1231 AI modules, SIMATIC PCS 7 DCS
• DCS Platforms: Emerson DeltaV, Honeywell Experion, ABB 800xA, Yokogawa CENTUM

API 670 Compliance

The system meets API 670 5th Edition requirements for non-contacting vibration and position monitoring systems in petroleum, chemical, and gas industry services. The <4%/100°K temperature error specification ensures measurement accuracy across the wide temperature ranges typical of turbomachinery applications, while the extended range capability accommodates the larger clearances specified for large machinery protection systems.

Quality Standards & Certifications

• API 670: Compliant for machinery protection systems in petroleum and chemical industries
• ISO 20816: Suitable for mechanical vibration measurement on rotating machinery
• ISO 7919: Applicable for shaft vibration measurement standards
• IEC 60529: IP20 converter, IP67-capable sensor with proper installation
• CE Marking: European conformity for industrial control and monitoring equipment
• Factory Calibration: NIST-traceable calibration certificate available upon request

Why Choose Industrial Control Hub?

As an authorized distributor of Emerson EPRO extended-range monitoring solutions, Industrial Control Hub provides genuine factory-certified products with comprehensive technical support. Our application engineers specialize in large machinery monitoring systems and can assist with sensor selection, system architecture, and field commissioning for your critical equipment protection applications.

• ✓ Genuine Emerson EPRO factory-sealed products with full warranty and traceability
• ✓ Express global shipping with specialized packaging for precision instruments
• ✓ Application engineering support for large machinery monitoring systems
• ✓ Long-term spare parts availability for legacy and current systems
• ✓ Project pricing for multi-channel installations and plant-wide deployments
• ✓ Technical training and documentation library access

Related Extended Range Monitoring Products

Complete your large machinery monitoring system with these compatible components:

• Emerson EPRO PR6424/000-130 - 16mm proximity sensor for large shaft applications
• Emerson EPRO CON021+PR6424/010-110 - Standard 4mm range system for comparison
• Emerson EPRO PR6426/010-140 - 32mm sensor for extremely large shaft applications

Technical Support & Engineering Services

Our machinery monitoring specialists are available to assist with extended-range system selection, mounting design, signal conditioning configuration, and commissioning support for your Emerson EPRO PR6424/000-130+CON021/914-080 installation. Contact us for detailed technical datasheets, AutoCAD mounting drawings, API 670 compliance documentation, and project-specific quotations for multi-channel monitoring systems.

System Configuration: Model PR6424/000-130+CON021/914-080 | 16mm Sensor Tip | 8mm Extended Measurement Range | 4 V/mm Sensitivity | M18x1.5 Threading | 8m Cable Length | Lemo Connector | CON021/914-080 Extended Range Converter | 0-20kHz Bandwidth | API 670 Compliant | -35°C to +150°C Operation | Factory Calibrated

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