Emerson EPRO PR6424/000-130+CON021/914-100 Extended Range Eddy Current System

Emerson EPRO PR6424/000-130+CON021/914-100 Extended Range Eddy Current System

The Emerson EPRO PR6424/000-130+CON021/914-100 represents a premium extended-range 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 CON021/914-100 extended-range signal converter, delivering 10mm measurement capability with ±2% linearity for applications requiring greater displacement tracking range than standard proximity systems.

Extended Range Measurement Architecture

Unlike standard 2mm range eddy current systems, the PR6424/000-130+CON021/914-100 provides 10mm (0.39 inch) extended measurement range, making it ideal for monitoring large turbines, generators, and compressors where shaft excursions exceed conventional proximity sensor capabilities. The 130mm total sensor length configuration accommodates deep bearing housing installations, while the extended range converter ensures accurate signal conditioning across the full 10mm displacement span.

PR6424 16mm Eddy Current Sensor Specifications

Enhanced Measurement Performance

The PR6424 16mm sensor delivers precision non-contact displacement measurement optimized for large rotating machinery:

• Sensitivity/Scale Factor: 4 V/mm (101.6 mV/mil) ±1.5% for high signal-to-noise ratio
• Nominal Air Gap: Approximately 2.7 mm (0.11 inches) center position
• Static Measurement Range: ±2.0 mm (±0.079 inches) from center
• Dynamic Range: 0 to 1,000 μm (0 to 0.039 inches) for vibration capture
• Long-Term Drift: <0.3% ensures measurement stability over extended operation
• Temperature Error: <4% per 100°K meets API 670 compliance requirements

Large Shaft Application Design

Engineered specifically for heavy industrial rotating equipment, the PR6424 sensor accommodates large shaft diameters and high surface speeds:

• Minimum Shaft Diameter: ≥80 mm (3.15 inches) for specified performance
• Target Material: Ferromagnetic steel (42CrMo4 standard) with custom calibration available
• Maximum Surface Speed: 2,500 m/s (98,425 inches/second) for high-RPM applications
• Surface Finish Requirements: Smooth, clean ferromagnetic steel free from coatings

Industrial-Grade Environmental Protection

Built to withstand the harshest industrial environments, the PR6424/000-130 features exceptional durability:

• Operating Temperature Range: -35°C to +150°C (-31°F to +302°F)
• Pressure Resistance: 10,000 hPa (145 psi) at sensor head for pressurized applications
• Shock & Vibration: 5g @ 60 Hz @ 25°C withstands severe mechanical environments
• Protection Rating: IP67 equivalent for dust and water ingress protection

Robust Physical Construction

• Sleeve Material: Stainless steel construction resists corrosion and mechanical damage
• Cable Insulation: PTFE (Polytetrafluoroethylene) maintains signal integrity at elevated temperatures
• Connector: Lemo self-locking design prevents vibration-induced disconnection
• Total Sensor Length: 130mm provides installation flexibility for deep housings
• Weight: Approximately 200 grams (7.05 oz) with integral cable
• Threading Options: M18x1.5 metric or 3/4"-16 UNF for global compatibility

CON021/914-100 Extended Range Converter

Specialized Signal Conditioning

The CON021/914-100 extended range converter is specifically calibrated for the PR6424 sensor's 10mm measurement range, providing optimized signal conditioning that standard converters cannot deliver:

• Measurement Range: 10.0 mm (0.39 inches) extended range capability
• Linearity Error: ±2.0% across full 10mm span maintains accuracy
• Frequency Response: DC to 20,000 Hz (-3dB) captures both static position and dynamic vibration
• Rise Time: <15 microseconds enables transient event detection
• Output Voltage: -4V to -20V or -2V to -18V depending on supply voltage

Converter Electronics Design

• Housing Material: LMgSi 0.5 F22 aluminum alloy provides EMI/RFI shielding
• Operating Temperature: -30°C to +100°C (-22°F to +212°F) for control room or field mounting
• Protection Class: IP20 suitable for indoor electrical enclosures
• Power Supply: -23V to -32V DC (Output: -4V to -20V) or -21V to -32V DC (Output: -2V to -18V)
• Mounting: 4x M5x20 screws included for DIN rail or panel installation
• Sensor Connection: Self-locking Lemo plug with positive engagement
• Output Terminals: Screw terminals accept up to 1.5mm² (16 AWG) wire
• Weight: Approximately 120 grams (4.24 oz)

Critical Application Solutions

Large Steam Turbine Monitoring

Deploy the PR6424/000-130+CON021/914-100 system for radial vibration monitoring on large steam turbines where shaft excursions during startup, load changes, and transient events exceed standard 2mm proximity sensor ranges. The 10mm measurement capability accommodates thermal growth, bearing clearance variations, and abnormal vibration conditions while maintaining measurement accuracy throughout the extended range.

Heavy-Duty Gas Turbine Protection

In industrial and power generation gas turbines, monitor shaft displacement during all operating modes including startup, synchronization, load ramping, and shutdown sequences. The extended range ensures continuous measurement even during severe vibration events caused by surge, blade loss, or bearing failures, providing critical data for machinery protection systems and post-event analysis.

Large Compressor Thrust Monitoring

Monitor axial position in large centrifugal and axial compressors where thrust bearing clearances and thermal expansion require extended measurement range. The system's 10mm range accommodates the greater axial movement typical of large compressors, while the 4 V/mm sensitivity provides sufficient resolution for detecting gradual thrust bearing wear before catastrophic failure occurs.

Generator Rotor Eccentricity Measurement

In large generators and synchronous motors, measure rotor eccentricity and magnetic center position where air gap variations exceed standard proximity sensor ranges. The extended measurement capability enables monitoring of rotor position relative to stator bore throughout all operating conditions, supporting predictive maintenance programs and preventing catastrophic magnetic pull failures.

Installation Engineering Guidelines

Sensor Mounting for Large Shafts

Proper installation is critical for extended range measurement accuracy:

• Verify minimum shaft diameter of 80mm at measurement location
• Mount sensor perpendicular to shaft surface within ±3 degrees
• Set nominal air gap to 2.7mm using precision gap gauges or voltage measurement
• Ensure rigid mounting bracket prevents sensor movement under vibration
• Verify adequate clearance for maximum expected shaft excursion (10mm range)
• Protect sensor from direct impact with rotating or moving components
• Consider thermal expansion of mounting structure during temperature changes

Extended Range Converter Configuration

The CON021/914-100 requires specific installation considerations:

• Mount converter in control cabinet or junction box using included M5x20 screws
• Connect sensor cable to Lemo plug ensuring full locking collar engagement
• Wire -24VDC power supply (negative ground) to screw terminals with proper polarity
• Route output signals to monitoring system analog inputs using shielded cable
• Ground converter housing to cabinet ground bus for EMI immunity
• Verify output voltage range matches monitoring system input specifications
• Document converter serial number and calibration date for maintenance records

System Calibration & Validation

Extended range systems require careful calibration verification:

• Verify 4 V/mm scale factor using precision micrometer stands or calibrated gap gauges
• Check linearity at multiple points across 10mm range (0mm, 2.5mm, 5mm, 7.5mm, 10mm)
• Confirm ±2% linearity specification is met across full measurement span
• Document calibration results and compare to factory calibration certificate
• Perform dynamic response testing if monitoring high-frequency vibration components
• Establish baseline measurements during normal operation for trending analysis

System Integration & Compatibility

Machinery Protection System Interfaces

The PR6424/000-130+CON021/914-100 integrates seamlessly with all major monitoring platforms:

• Bently Nevada: 3500/42M proximitor monitors, 3500/45 position monitors, ADAPT systems
• Emerson AMS: 6500 machinery health monitors with extended range input modules
• Rockwell Automation: ControlLogix 1756-IF16 and CompactLogix analog input modules
• Siemens: S7-1500 SM 1231 analog inputs, SIMATIC PCS 7 DCS integration
• DCS Platforms: Emerson DeltaV, Honeywell Experion, ABB 800xA, Yokogawa CENTUM
• Vibration Analyzers: SKF Microlog, Emerson CSI 2140, portable data acquisition systems

API 670 Compliance & Standards

The system meets critical industry standards for machinery protection:

• API 670: Compliant for non-contacting vibration and axial position monitoring
• ISO 20816: Suitable for mechanical vibration measurement and evaluation
• ISO 7919: Applicable for shaft vibration measurement in rotating machinery
• IEC 60529: Environmental protection rating for industrial applications
• CE Marking: European conformity for industrial control equipment
• Factory Calibration: NIST-traceable calibration documentation provided

Why Choose Industrial Control Hub?

As an authorized distributor of Emerson EPRO extended range monitoring solutions, Industrial Control Hub provides genuine factory-certified systems with comprehensive engineering support. Our technical team assists with sensor selection, system design, installation planning, and commissioning to ensure optimal performance in your critical turbomachinery 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 system architecture and sensor placement
• ✓ Long-term spare parts availability for legacy and current systems
• ✓ Volume project pricing for multi-machine installations and plant-wide upgrades
• ✓ Technical documentation including calibration certificates and CAD drawings
• ✓ Post-installation support and troubleshooting assistance

Complementary Extended Range Products

Complete your large machinery monitoring system with these compatible components:

• Emerson EPRO PR6424/000-130 - 16mm proximity probe for replacement or additional measurement points
• Emerson EPRO CON021+PR6424/010-110 - Alternative system configuration with different sensor length
• Emerson EPRO PR6424/010-110 - Standard range converter for 2mm measurement applications

Technical Support & Engineering Services

Our extended range monitoring specialists provide comprehensive support for your Emerson EPRO PR6424/000-130+CON021/914-100 system implementation. Contact us for detailed technical datasheets, installation drawings, calibration certificates, system integration guidance, and project-specific quotations for multi-channel monitoring systems on large turbomachinery.

System Configuration: Model PR6424/000-130+CON021/914-100 | 16mm Eddy Current Sensor | 10mm Extended Measurement Range | 4 V/mm Sensitivity | 130mm Sensor Length | CON021/914-100 Extended Range Converter | 0-20kHz Bandwidth | ±2% Linearity | API 670 Compliant | -35°C to +150°C Operation | Stainless Steel Construction | Factory Calibrated

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