Emerson EPRO PR6424/010-110+CON021 16mm Eddy Current System

Emerson EPRO PR6424/010-110+CON021 - Factory-Matched Proximity Measurement System

The Emerson EPRO PR6424/010-110+CON021 delivers a turnkey proximity measurement solution for critical machinery protection applications. This factory-calibrated system pairs the robust PR6424 16mm eddy current sensor with the versatile CON021 signal converter, providing reliable shaft displacement and vibration monitoring in the harshest industrial environments.

Why Choose a Pre-Configured System?

Traditional proximity measurement installations require time-consuming field calibration, impedance matching verification, and extensive commissioning documentation. This integrated system eliminates those challenges through factory pairing and testing, reducing installation time by 50-70% while ensuring measurement accuracy from day one. Each system ships with traceable calibration certificates and performance verification data.

PR6424 Sensor - Engineered for Large Rotating Equipment

Precision Measurement Capabilities:

• Output Sensitivity: 4 V/mm (101.6 mV/mil) with exceptional ±1.5% linearity
• Static Displacement Range: ±2.0 mm for position tracking and thermal growth monitoring
• Dynamic Vibration Range: 0-1,000 μm captures both low-frequency rotor dynamics and high-frequency bearing defects
• Optimal Air Gap: 2.7 mm nominal provides installation tolerance while maintaining accuracy
• Stability Performance: <0.3% long-term drift ensures consistent measurements over multi-year service intervals

Mechanical Design for Reliability: The 16mm sensor diameter provides superior electromagnetic field penetration for large shaft applications (≥80mm diameter), making it the preferred choice for steam turbines, industrial gas turbines, and large centrifugal compressors. The stainless steel sleeve withstands corrosive atmospheres, while PTFE cable insulation maintains signal integrity at temperatures reaching 150°C.

CON021 Converter - Universal Signal Conditioning Platform

Advanced Signal Processing:

• Bandwidth: DC to 20 kHz (-3dB) enables simultaneous monitoring of slow thermal transients and rapid vibration events
• Response Speed: <15 μs rise time captures shock events and blade-passing frequencies in high-speed machinery
• Output Signal: -4V to -20V (standard) or -2V to -18V (alternate) for direct interface with monitoring systems
• Power Flexibility: Operates across -23V to -32V supply range, compatible with global DCS power standards

Multi-Sensor Compatibility: While factory-configured for the PR6424 sensor, the CON021 converter supports the entire EPRO proximity sensor family (PR6422, PR6423, PR6424, PR6425, PR6426, PR6453), providing upgrade flexibility as your monitoring requirements evolve.

Real-World Application Solutions

Power Generation Turbine Monitoring: Deploy this system for journal bearing clearance monitoring in steam turbines where shaft thermal expansion during startup and shutdown cycles must be tracked to prevent rubs. The wide static range accommodates thermal growth while the high-frequency response detects emerging bearing wear patterns.

Compressor Train Protection: Install in multi-stage centrifugal compressor trains where axial position monitoring prevents thrust bearing failures. The system's API 670 compliance and low temperature error (<4%/100K) ensure reliable operation across seasonal ambient temperature variations in outdoor installations.

Motor-Driven Equipment: Monitor large induction motors and synchronous motors where rotor eccentricity affects electromagnetic performance and bearing life. The system detects both mechanical unbalance and electromagnetic pull conditions that lead to premature bearing failures.

Hydroelectric Generator Monitoring: Track guide bearing clearances in vertical shaft hydro generators where water ingress and sediment contamination create challenging measurement environments. The sensor's 10,000 hPa pressure rating and sealed construction ensure reliable operation in high-humidity conditions.

API 670 Certification & Standards Compliance

This measurement system meets API Standard 670 5th Edition requirements for vibration, axial position, and bearing temperature monitoring systems in petroleum, chemical, and gas industry services. Compliance includes temperature error specifications, frequency response verification, and long-term stability documentation required for machinery protection system certification.

Installation Configuration Options

Sensor Threading Variants:

• M18x1.5 metric thread (standard European installations)
• 3/4"-16 UNF imperial thread (North American applications)

Sensor Length Selection: Available in case lengths from 52.5mm to 302.5mm (40mm to 290mm Cx dimension plus 12.5mm base), accommodating various bearing housing depths and mounting bracket configurations.

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

Cable Termination: Factory-installed Lemo connectors ensure vibration-resistant connections, or specify open-end termination for custom field wiring to junction boxes.

System Integration & Wiring

The CON021 converter's compact design (120g weight) enables DIN-rail mounting in crowded control panels or direct panel mounting using included M5 hardware. Self-locking Lemo sensor connections prevent vibration-induced disconnections, while screw terminal power/output connections (max 1.5mm² wire) simplify field wiring and troubleshooting.

Extended Range Capabilities

While this standard system provides 4mm measurement range, extended-range CON021 variants enable specialized applications:

• CON021/914-060: 6mm range with ±1.0% linearity for increased clearance monitoring
• CON021/914-080: 8mm range for extreme thermal growth applications
• CON021/914-100: 10mm range for slow-speed equipment with large displacement amplitudes

Environmental Performance Specifications

The PR6424 sensor operates reliably from -35°C to 150°C, covering arctic outdoor installations to high-temperature turbine applications. The CON021 converter's -30°C to 100°C range suits control room and field-mounted enclosure installations. Both components withstand 5g vibration at 60 Hz, enabling mounting on vibrating structures and skid-mounted equipment packages.

Complementary Monitoring Components

Build a comprehensive machinery protection system with these compatible EPRO products:

• Emerson EPRO PR6423/10R-010+CON021 Measurement System - Compact 8mm system for smaller shaft applications
• Emerson EPRO PR9268/200-000 Electrodynamic Velocity Sensor - Velocity measurement for comprehensive vibration analysis

Quality Assurance & Documentation

Every system undergoes rigorous factory testing including linearity verification, frequency response analysis, and temperature coefficient measurement. Comprehensive documentation packages include:

• Individual sensor and converter calibration certificates with traceability to national standards
• System-level performance verification data showing matched pair characteristics
• Installation drawings with dimensional specifications and mounting torque requirements
• Wiring diagrams for common DCS and PLC integration scenarios
• Recommended spare parts list for long-term maintenance planning

Industrial Control Hub - Your Machinery Protection Partner

As a specialized supplier of Emerson EPRO vibration monitoring and machinery protection systems, we provide complete solutions from individual sensors to integrated monitoring racks. Our technical team offers application engineering support including sensor selection, installation design review, and system commissioning assistance.

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