Emerson EPRO PR6424/010-040+CON021 Vibration Monitoring System

Emerson EPRO PR6424/010-040+CON021 - Factory-Calibrated Vibration Monitoring System

The Emerson EPRO PR6424/010-040+CON021 delivers a turnkey vibration monitoring solution for critical rotating machinery protection. This factory-matched system pairs the precision-engineered PR6424 16mm eddy current sensor with the high-bandwidth CON021 signal converter, providing reliable displacement and vibration measurement for turbines, compressors, generators, and pumps in demanding industrial environments.

Turnkey Solution Advantages

Unlike field-assembled monitoring systems that require extensive calibration and compatibility verification, this pre-configured package arrives ready for installation. Each sensor-converter pair undergoes factory testing to verify linearity, sensitivity, and frequency response across the full operating range. This eliminates installation errors, reduces commissioning time by 50-70%, and ensures measurement accuracy from day one.

Core Performance Characteristics

Measurement Precision: The PR6424 sensor delivers 4 V/mm (101.6 mV/mil) output sensitivity with ±1.5% linearity across its ±2.0 mm static range. This high sensitivity enables detection of shaft displacement changes as small as 10 microns, critical for early identification of bearing wear, thermal growth, and rotor imbalance.

Dynamic Response: With a frequency bandwidth extending from DC to 20 kHz, the CON021 converter captures both slow thermal drift and high-frequency vibration phenomena. The <15 μs rise time ensures accurate reproduction of transient events such as blade rubs, surge conditions, and impact loads.

Long-Term Stability: Drift specification of <0.3% ensures measurement integrity over years of continuous operation without recalibration. This stability is essential for trending analysis and predictive maintenance programs that rely on detecting gradual changes in machinery condition.

Application-Specific Deployment Strategies

Power Generation Turbines: Monitor journal bearing clearances and rotor eccentricity in steam and gas turbines where shaft diameters exceed 80mm. The 2.7mm nominal air gap accommodates thermal expansion during startup and shutdown cycles, while the wide temperature range (-35°C to 150°C) handles turbine casing environments.

Centrifugal Compressor Arrays: Deploy in multi-stage compressor trains for continuous thrust position monitoring and radial vibration measurement. The system's API 670 compliance with <4% temperature error per 100K meets machinery protection system requirements for critical process applications.

Large Motor-Generator Sets: Track rotor position in synchronous generators and large induction motors where air gap variations affect electromagnetic performance and efficiency. The 16mm sensor diameter provides robust signal strength even with non-ideal target materials or surface conditions.

Industrial Pump Stations: Install in high-energy pumps handling corrosive fluids or operating at elevated temperatures. The sensor's 10,000 hPa (145 psi) pressure rating and stainless steel construction withstand harsh process environments, while the IP20-rated converter mounts safely in control room enclosures.

Technical Specifications Breakdown

Sensor Configuration (PR6424/010-040):

• 16mm sensing diameter optimized for shafts ≥80mm
• Static measurement range: ±2.0mm (±79 mils)
• Dynamic vibration range: 0-1,000 μm peak-to-peak
• Maximum target surface speed: 2,500 m/s (8,200 fps)
• Calibrated for ferromagnetic steel (42CrMo4/AISI 4140)
• Operating temperature: -35°C to +150°C sensor tip
• Shock/vibration resistance: 5g @ 60Hz
• Construction: Stainless steel sleeve, PTFE cable insulation

Converter Specifications (CON021):

• Frequency response: DC to 20,000 Hz (-3dB points)
• Signal rise time: <15 microseconds
• Output voltage: -4V to -20V (with -23V to -32V supply)
• Alternative output: -2V to -18V (with -21V to -32V supply)
• Operating temperature: -30°C to +100°C
• Protection rating: IP20 (control cabinet mounting)
• Housing: LMgSi 0.5 F22 aluminum alloy
• Weight: 120 grams (4.24 oz)

Installation Flexibility & Configuration

The PR6424 sensor offers multiple mounting configurations to accommodate diverse machinery geometries:

Threading Options: Available in M18x1.5 metric or 3/4"-16 UNF imperial threads for compatibility with global machinery standards and existing mounting provisions.

Sensor Length Variants: Total sensor length equals Cx + 12.5mm, where Cx ranges from 40mm to 290mm. This extensive range accommodates shallow bearing housings through thick-walled pressure vessels.

Cable Protection: Choose standard PTFE-insulated cable for benign environments or armored cable construction for high-vibration installations and areas with mechanical hazard exposure.

Cable Termination: Standard lengths of 4m, 5m, 8m, or 10m with either self-locking Lemo connectors for quick sensor replacement or open-end termination for permanent installations.

Signal Converter Integration

The CON021 converter features dual-interface connectivity optimized for industrial installations. The sensor input uses a vibration-resistant Lemo connector that maintains signal integrity in high-vibration environments. Power supply and output signals connect via screw terminals accepting up to 1.5mm² wire, compatible with standard industrial control wiring practices.

Mounting hardware (four M5x20 screws) is included for DIN rail, panel, or chassis installation. The compact footprint (approximately 120g weight) enables installation in crowded control cabinets alongside other monitoring and protection equipment.

Extended Range Capabilities

While the standard CON021 provides 4mm measurement range with the PR6424 sensor, extended-range converter variants enable larger displacement monitoring:

• CON021/914-060: 6mm range with ±1.0% linearity - for moderate thermal growth applications
• CON021/914-080: 8mm range with ±1.5% linearity - for high-temperature process equipment
• CON021/914-100: 10mm range with ±2.0% linearity - for extreme displacement scenarios

API 670 Compliance & Safety Integration

This measurement system meets API Standard 670 5th Edition requirements for vibration, axial position, and bearing temperature monitoring systems. Compliance includes temperature error specifications, frequency response characteristics, and installation guidelines. When integrated with certified monitoring racks and trip logic, the system supports Safety Integrity Level (SIL) applications in machinery protection systems.

Complementary Monitoring Solutions

Build a comprehensive machinery health monitoring system with these compatible products:

• Emerson EPRO PR6423/10R-030+CON021 Eddy Current Measurement System - 8mm sensor variant for smaller shaft applications
• Emerson EPRO CON021+PR6423/003-030 Eddy Current Converter - Alternative configuration for different mounting requirements
• Emerson EPRO CON021/916-240 Eddy Current Signal Converter - Extended range converter for 24mm measurement span

Quality Assurance & Documentation

Each system ships with comprehensive documentation including:

• Factory calibration certificates with traceability to national standards
• Sensor-converter pairing verification test results
• Installation drawings with dimensional specifications
• Wiring diagrams for power supply and output connections
• Integration guidelines for common DCS and PLC platforms

Why Partner with Industrial Control Hub?

As a specialized distributor of Emerson EPRO machinery monitoring systems, we provide more than just product supply. Our technical team offers application engineering support to optimize sensor selection, placement, and integration with your existing monitoring infrastructure. We maintain extensive inventory of sensors, converters, cables, and accessories for rapid deployment and emergency replacement needs.

Our global logistics network ensures fast delivery to project sites worldwide, while our quality assurance processes guarantee authentic Emerson EPRO components with full manufacturer warranty coverage.

Expert Application Support | Rapid Global Shipping | Genuine OEM Components | Competitive System Pricing

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