Emerson EPRO PR6424/010-040+CON021/916-160 Extended Range System

Emerson EPRO PR6424/010-040+CON021/916-160 - Extended Range Displacement Monitoring System

The Emerson EPRO PR6424/010-040+CON021/916-160 delivers exceptional 16mm extended measurement range for monitoring large axial displacements and extreme vibration amplitudes in heavy industrial rotating equipment. This factory-calibrated system pairs the robust PR6424 16mm eddy current sensor with the specialized CON021/916-160 extended-range signal converter, engineered specifically for applications where standard 4mm measurement ranges prove insufficient.

Extended Range Technology - When Standard Systems Fall Short

Traditional eddy current systems typically offer 2-4mm measurement ranges, adequate for most machinery. However, large turbines, hydro generators, and heavy compressors often exhibit axial movements and vibration amplitudes exceeding these limits during startup, shutdown, or abnormal operating conditions. The CON021/916-160 converter extends the usable measurement range to 16mm while maintaining ±2.0% linearity - a critical capability for capturing extreme displacement events without signal saturation.

PR6424 Sensor - Engineered for Large Shaft Applications

• Sensor Diameter: 16mm - optimized for minimum shaft diameter ≥80mm
• Standard Sensitivity: 4 V/mm (101.6 mV/mil) with ±1.5% linearity
• Nominal Air Gap: 2.7mm - provides operational margin for thermal expansion
• Static Range: ±2.0mm for position tracking and slow drift monitoring
• Dynamic Range: 0-1,000μm for high-frequency vibration capture
• Maximum Surface Speed: 2,500 m/s - suitable for high-RPM turbomachinery

CON021/916-160 Extended Range Converter - Specialized Signal Processing

The /916-160 variant represents the maximum measurement range available in the CON021 converter family for PR6426 sensors, specifically calibrated to deliver:

• Extended Measurement Range: 16mm total displacement capture
• Linearity Specification: ±2.0% across full 16mm range
• Frequency Response: DC to 20 kHz bandwidth for comprehensive spectral analysis
• Ultra-Fast Response: <15μs rise time captures transient displacement events
• Output Signal: -4V to -20V (with -23V to -32V supply) for direct DCS integration

Critical Applications Requiring Extended Range Monitoring

Hydro Turbine Thrust Monitoring: Hydroelectric generators experience significant axial thrust variations during load changes and wicket gate adjustments. The 16mm range captures full thrust bearing movement from no-load to full-load conditions, enabling operators to detect bearing wear progression and prevent catastrophic thrust failures in multi-megawatt installations.

Steam Turbine Differential Expansion: Large steam turbines exhibit substantial thermal growth during startup and shutdown cycles. This system monitors rotor-to-casing differential expansion across the full thermal transient, providing critical data for startup optimization and preventing rubs that damage seals and blade tips.

Gas Turbine Axial Position Control: Heavy-duty gas turbines in power generation and mechanical drive applications require precise axial position monitoring for active magnetic bearing control and thrust balance verification. The extended range accommodates emergency bearing landings and abnormal operating conditions without measurement saturation.

Large Compressor Surge Detection: Centrifugal compressors in LNG plants and petrochemical facilities can experience violent axial oscillations during surge events. The 16mm measurement range captures the full amplitude of surge-induced displacement, providing essential data for anti-surge control system tuning and compressor protection.

Marine Propulsion Shaft Monitoring: Ship propulsion systems with controllable-pitch propellers generate substantial axial thrust forces during maneuvering. This system monitors thrust bearing displacement across the full operational envelope, from full ahead to full astern, ensuring bearing integrity in critical marine applications.

System Configuration & Installation Advantages

The PR6424/010-040 sensor configuration features:

• 3/4"-16 UNF Threading: Imperial thread standard common in North American installations
• No Armored Cable: Reduces weight and improves flexibility for routing through tight spaces
• 52.5mm Total Sensor Length: (40mm + 12.5mm base) - compact profile for space-constrained installations
• 4-Meter Cable Length: Standard length balances signal integrity with installation flexibility
• Lemo Connector: Vibration-resistant self-locking connection ensures reliable sensor-to-converter interface

Environmental Performance & Reliability

Both sensor and converter are engineered for harsh industrial environments:

• Sensor Operating Range: -35°C to 150°C (-31°F to 302°F) - handles extreme ambient conditions
• Converter Operating Range: -30°C to 100°C (-22°F to 212°F) - suitable for control room or field enclosure mounting
• Pressure Resistance: 10,000 hPa (145 psi) sensor head rating for pressurized bearing housings
• Vibration Tolerance: 5g @ 60Hz for both components - withstands installation on vibrating structures
• Long-Term Stability: <0.3% drift ensures calibration integrity over multi-year service intervals

API 670 Compliance & Safety Integration

This measurement system meets API 670 5th Edition requirements for machinery protection systems, including the critical <4%/100K temperature error specification. The documented performance characteristics enable integration into Safety Instrumented Systems (SIS) for turbomachinery protection, providing certified reliability for applications requiring functional safety compliance.

Measurement Range Selection Strategy

The CON021/916-160 extended range converter sacrifices some linearity (±2.0% vs ±1.5% for standard range) to achieve 4x greater measurement span. This trade-off is appropriate when:

• Expected displacements exceed 8mm during normal or abnormal operation
• Capturing extreme events is more critical than absolute measurement precision
• Preventing signal saturation outweighs the need for sub-1% linearity
• Monitoring startup/shutdown transients with large thermal movements

System Integration & Connectivity

The CON021/916-160 converter provides straightforward integration with industrial control systems through screw terminal connections (max 1.5mm² wire) for power supply and analog output. The -24V nominal supply voltage aligns with standard industrial power distribution, while the -4V to -20V output signal interfaces directly with PLC analog input cards, DCS monitoring modules, and vibration monitoring racks without additional signal conditioning.

Related Extended Range & Monitoring Solutions

Complete your machinery monitoring system with these complementary EPRO products:

• Emerson EPRO CON021/916-240 Eddy Current Signal Converter - Maximum 24mm extended range for extreme displacement applications
• Emerson EPRO PR6424/010-110 Eddy Current Sensor - Alternative sensor configuration for different mounting requirements
  

Factory Calibration & Quality Assurance

Each PR6424/010-040+CON021/916-160 system undergoes precision calibration as a matched sensor-converter pair at Emerson's ISO 9001-certified manufacturing facility. The calibration process verifies linearity, sensitivity, and frequency response across the full 16mm measurement range using NIST-traceable reference standards. Comprehensive calibration certificates document system performance and provide the traceability required for quality management systems and regulatory compliance.

Technical Support & Application Engineering

Selecting the optimal measurement range for your specific application requires careful analysis of expected displacement magnitudes, required accuracy, and operating conditions. Industrial Control Hub's application engineers provide expert guidance on:

• Measurement range selection based on machinery type and operating envelope
• Sensor installation best practices for optimal linearity and temperature compensation
• Integration with Emerson AMS Machinery Manager and third-party monitoring systems
• Calibration verification procedures and field testing protocols

Worldwide Shipping | Factory-Sealed Packaging | Expert Application Support | Volume Pricing Available

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

Download PDF file here: