Emerson EPRO PR6424/003-030+CON021 16mm Eddy Current System

Emerson EPRO PR6424/003-030+CON021 Complete Eddy Current Measurement System

The Emerson EPRO PR6424/003-030+CON021 represents a complete, factory-matched eddy current measurement solution combining the precision PR6424 16mm sensor with the high-performance CON021 signal converter. This integrated system delivers API 670-compliant vibration and displacement monitoring for critical rotating machinery in power generation, oil & gas, and heavy industrial applications.

System Architecture & Integration Benefits

Unlike standalone sensors requiring separate signal conditioning, this pre-configured system ensures optimal impedance matching and calibration accuracy straight from the factory. The PR6424 sensor and CON021 converter are precision-tuned as a matched pair, eliminating field calibration errors and reducing commissioning time by up to 60% compared to component-based installations.

PR6424 16mm Eddy Current Sensor - Technical Excellence

• Measurement Sensitivity: 4 V/mm (101.6 mV/mil) with ±1.5% linearity across full range
• Static Measurement Range: ±2.0 mm (±79 mils) for position monitoring
• Dynamic Range: 0 to 1,000 μm (0 to 39 mils) for vibration analysis
• Nominal Air Gap: 2.7 mm (106 mils) - optimized for large shaft applications
• Long-Term Stability: <0.3% drift ensures measurement integrity over years of operation
• Minimum Shaft Diameter: ≥80 mm - ideal for turbines, generators, and large compressors

CON021 Signal Converter - Advanced Signal Processing

• Frequency Response: DC to 20 kHz (-3dB) captures both slow drift and high-frequency events
• Rise Time: <15 μs enables detection of rapid transient phenomena
• Output Range: -4V to -20V (with -23V to -32V supply) for direct PLC/DCS integration
• Temperature Compensation: <4% error per 100K maintains accuracy across industrial environments
• Multi-Sensor Compatibility: Works with PR6422, PR6423, PR6424, PR6425, PR6426 sensor families

Industrial Applications & Deployment Scenarios

Steam & Gas Turbine Monitoring: The 16mm sensor diameter and extended measurement range make this system ideal for monitoring journal bearing clearances and rotor eccentricity in large turbines operating at speeds up to 2,500 m/s surface velocity. The wide frequency response captures both subsynchronous vibrations and blade-passing frequencies.

Centrifugal Compressor Protection: Deploy in API 617 and API 672 compliant machinery protection systems where continuous shaft position monitoring prevents catastrophic bearing failures. The system's high linearity ensures accurate thrust position measurement for magnetic bearing control loops.

Generator Rotor Monitoring: Track rotor eccentricity and thermal growth in large generators where air gap variations affect electromagnetic performance. The system's low drift specification maintains calibration accuracy through thermal cycles and seasonal temperature variations.

Pump Condition Monitoring: Install in critical process pumps handling corrosive or high-temperature fluids where bearing wear detection prevents unplanned shutdowns. The IP20-rated converter mounts safely in control cabinets while the sensor withstands 10,000 hPa pressure and temperatures to 150°C.

API 670 Compliance & Safety Certification

This measurement system meets API 670 5th Edition requirements for machinery protection systems, including temperature error specifications, frequency response characteristics, and long-term stability criteria. The system's documented performance enables use in SIL-rated safety instrumented systems when integrated with certified monitoring racks.

Environmental Resilience & Reliability

The PR6424 sensor features a rugged stainless steel sleeve with PTFE-insulated cabling rated from -35°C to 150°C, while the converter operates reliably from -30°C to 100°C. Both components withstand 5g vibration at 60 Hz, making the system suitable for installation on vibrating structures and skid-mounted equipment.

Installation Flexibility & Configuration Options

Sensor Threading: Available in M18x1.5 metric or 3/4"-16 UNF imperial threads for global compatibility

Sensor Length: Case lengths from 40mm to 290mm accommodate various mounting depths and bearing housing geometries

Cable Options: Standard or armored PTFE cables in 4m, 5m, 8m, or 10m lengths with Lemo or open-end termination

Converter Mounting: Compact DIN-rail or panel mount design with included M5 mounting hardware

System Integration & Connectivity

The CON021 converter features self-locking Lemo connectors for sensor input and screw terminals (max 1.5mm² wire) for power and output connections. This dual-interface design simplifies field wiring while maintaining vibration-resistant sensor connections. The converter's -24V nominal supply voltage integrates directly with standard industrial power systems.

Measurement Range Customization

While the standard CON021 provides 4mm measurement range with the PR6424 sensor, extended-range variants are available:

• CON021/914-060: 6mm extended range with ±1.0% linearity
• CON021/914-100: 10mm extended range for extreme displacement applications

Related Vibration Monitoring Solutions

Expand your machinery protection system with these complementary EPRO sensors:

• Emerson EPRO PR6426/010-110 32mm Eddy Current Sensor - Larger diameter for extended range applications
• Emerson EPRO PR9268/200-000 Electrodynamic Velocity Sensor - Complementary velocity measurement for comprehensive diagnostics
• Emerson EPRO PR6423/003-020 8mm Eddy Current Sensor - Compact alternative for smaller shaft applications

Why Choose This Complete System?

Purchasing the PR6424 sensor and CON021 converter as a factory-matched system guarantees:

• Verified Calibration: Factory testing ensures specified performance without field adjustments
• Simplified Procurement: Single part number streamlines ordering and inventory management
• Reduced Installation Risk: Eliminates component compatibility issues and wiring errors
• Comprehensive Documentation: Unified calibration certificates and installation manuals
• Extended Warranty Coverage: System-level warranty protects your investment

Industrial Control Hub - Your EPRO Specialist

As an authorized distributor of Emerson EPRO vibration monitoring systems, we maintain deep inventory of sensors, converters, and complete measurement systems. Our application engineers provide expert guidance on sensor selection, installation best practices, and system integration with Ovation DCS, AMS Machinery Manager, and third-party monitoring platforms.

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