Emerson EPRO PR6424/010-120+CON011 16mm Eddy Current System

Emerson EPRO PR6424/010-120+CON011 - Advanced 16mm Eddy Current Measurement System

The Emerson EPRO PR6424/010-120+CON011 represents a premium factory-matched eddy current measurement solution that pairs the proven PR6424 16mm sensor with the high-performance CON011 signal converter. Engineered for demanding industrial applications requiring extended measurement ranges and superior signal processing, this system delivers exceptional accuracy and reliability for turbomachinery monitoring, compressor protection, and critical asset management programs.

CON011 Converter - Extended Range Performance

The CON011 signal converter distinguishes itself from standard CON021 models through its extended measurement range capabilities and enhanced signal processing architecture. Designed specifically for applications requiring larger displacement monitoring or higher vibration amplitudes, the CON011 provides the measurement headroom needed for startup/shutdown transients, surge events, and abnormal operating conditions.

CON011 Converter Specifications:

• Extended Measurement Range: Up to 16mm with PR6424 sensor (model-dependent)
• Frequency Response: DC to 10 kHz (-3dB) optimized for machinery vibration
• Output Signal: -2V to -18V or -4V to -20V (configuration-dependent)
• Supply Voltage: -21V to -32V DC standard industrial power
• Linearity: ±2.0% maximum over extended range
• Operating Temperature: -30°C to 100°C (-22°F to 212°F)
• Housing: Rugged aluminum alloy with IP20 protection

PR6424 16mm Sensor - Proven Reliability

The PR6424/010-120 sensor configuration provides optimal performance for medium to large shaft applications with the flexibility to accommodate various installation requirements through its configurable length and connector options.

Sensor Performance Characteristics:

• Sensor Diameter: 16mm - ideal for 80mm+ shaft diameters
• Measurement Sensitivity: 4 V/mm (101.6 mV/mil) with ±1.5% linearity
• Static Range: ±2.0 mm (±79 mils) from nominal air gap
• Nominal Air Gap: 2.7 mm (106 mils) optimized operating point
• Operating Temperature: -35°C to 150°C (-31°F to 302°F)
• Pressure Rating: 10,000 hPa (145 psi) at sensor head
• Threading: 3/4"-16 UNF (010 designation)
• Total Length: 120mm configuration with adapter plug

System Architecture and Integration Benefits

Purchasing the PR6424 sensor and CON011 converter as a factory-matched system ensures optimal performance through precision calibration and impedance matching. This integrated approach eliminates field calibration uncertainties, reduces commissioning time, and provides documented traceability for quality assurance and regulatory compliance.

System Integration Advantages:

• Factory Calibration: Sensor and converter calibrated as matched pair
• Verified Performance: System-level testing ensures specification compliance
• Simplified Procurement: Single part number streamlines ordering and inventory
• Comprehensive Documentation: Unified calibration certificates and installation guides
• Extended Warranty: System-level warranty coverage protects your investment

Critical Application Scenarios

High-Vibration Compressor Monitoring: Reciprocating and centrifugal compressors operating near surge conditions or experiencing high vibration levels benefit from the CON011's extended measurement range. The system captures large displacement excursions during abnormal events while maintaining accuracy for normal operating vibration, providing comprehensive condition monitoring without range saturation.

Startup/Shutdown Transient Analysis: Large rotating equipment experiences significant displacement variations during startup and shutdown as thermal growth, bearing clearances, and rotor dynamics change. The PR6424/CON011 system's extended range captures these transient events completely, enabling engineers to analyze startup behavior, optimize procedures, and detect developing problems before they impact reliability.

Thrust Bearing Position Monitoring: Steam turbines, gas turbines, and large compressors use thrust bearings to control axial rotor position. The CON011's extended range accommodates the large axial movements during load changes, startup, and shutdown while providing the resolution needed for precise position control and wear monitoring.

Magnetic Bearing Control Systems: Active magnetic bearing systems require continuous position feedback with extended range capability to handle transient events and provide safe landing during power loss. The PR6424/CON011 system delivers the measurement range, bandwidth, and reliability required for closed-loop magnetic bearing control applications.

Advanced Signal Processing Features

The CON011 converter incorporates sophisticated signal conditioning that optimizes the sensor's raw output for integration with DCS systems, PLCs, and dedicated vibration monitoring platforms. Temperature compensation maintains measurement accuracy across the full operating range, while electromagnetic shielding and grounding design minimize electrical noise interference.

Signal Quality Optimization:

• Temperature Compensation: Maintains accuracy across -30°C to 100°C range
• EMI/RFI Filtering: Rejects electrical noise from VFDs, motors, and power systems
• Ground Loop Isolation: Minimizes common-mode interference
• Cable Length Compensation: Maintains performance with cable lengths to 10m

Installation and Mounting Considerations

The PR6424/010-120 sensor features 3/4"-16 UNF threading for secure mounting in bearing housings and machinery casings common in North American installations. The 120mm total length configuration provides flexibility for various mounting depths while maintaining proper sensor positioning relative to the shaft surface.

Installation Best Practices:

• Mount sensor perpendicular to shaft surface within ±2 degrees
• Set initial air gap to 2.7mm nominal using precision shims or adjustable brackets
• Ensure target surface is clean, smooth ferromagnetic steel (42CrMo4 / AISI 4140)
• Route sensor cable away from high-voltage cables and electromagnetic sources
• Secure cable with strain relief to prevent mechanical stress on connections
• Mount CON011 converter in control cabinet or junction box with adequate ventilation

System Configuration and Customization

The model designation PR6424/010-120+CON011 specifies the complete system configuration:

• PR6424: 16mm sensor platform optimized for 80mm+ shafts
• 010: 3/4"-16 UNF threading (use 000 for M18x1.5 metric)
• 120: 120mm total sensor length with specific cable and connector configuration
• CON011: Extended-range signal converter with enhanced processing

Compatibility and Interchangeability

The PR6424 sensor is compatible with multiple EPRO converter families, allowing system upgrades or replacements without complete sensor replacement. The CON011 converter works with PR6422, PR6423, PR6424, PR6425, and PR6426 sensor families, providing flexibility for mixed sensor installations and future system expansion.

Converter Compatibility Matrix:

• CON011 Standard: 4mm range with PR6424 sensor
• CON011/914-060: 6mm extended range option
• CON011/914-080: 8mm extended range option
• CON011/916-160: 16mm maximum extended range for extreme applications

Maintenance and Lifecycle Support

Eddy current measurement systems require minimal maintenance due to their non-contact operation and solid-state electronics. Periodic inspection of sensor tips, target surfaces, and cable connections ensures continued performance. The robust construction of both sensor and converter typically provides 15-20 years of reliable service in properly maintained installations.

Preventive Maintenance Guidelines:

• Quarterly: Inspect sensor tip and target surface for contamination or damage
• Semi-annually: Verify air gap measurement and adjust if necessary
• Annually: Check cable insulation and connector integrity
• Bi-annually: Verify system calibration against known standards

Expand Your Monitoring Capabilities

Build a comprehensive machinery protection system with these complementary EPRO solutions:

• Emerson EPRO PR6424/003-030+CON021 16mm Eddy Current System - Standard range alternative with CON021 converter

Application Engineering and Technical Support

Selecting the optimal eddy current measurement system requires careful analysis of shaft diameter, operating speed, vibration characteristics, temperature environment, and measurement range requirements. Our application engineering team provides expert guidance on system selection, sensor positioning, converter configuration, and integration with existing monitoring infrastructure.

Technical Support Services:

• System sizing and configuration recommendations
• Installation design and sensor positioning analysis
• Cable routing and grounding optimization
• Integration with DCS, PLC, and vibration monitoring systems
• Troubleshooting and performance optimization
• Training on installation, commissioning, and maintenance procedures

Quality Assurance and Certification

Every PR6424/CON011 system undergoes rigorous factory testing and calibration to ensure compliance with published specifications. The system ships with comprehensive documentation including calibration certificates traceable to national standards, installation drawings, wiring diagrams, and configuration records that support quality management and regulatory compliance requirements.

Industrial Control Hub - Your EPRO System Specialist

As an authorized distributor of Emerson EPRO vibration monitoring systems, we maintain extensive inventory of sensors, converters, cables, and accessories for immediate shipment worldwide. Our technical team brings decades of experience in machinery monitoring system design, installation, commissioning, and troubleshooting across diverse industrial sectors including power generation, oil & gas, chemical processing, and manufacturing.

Fast Global Shipping | Factory-Sealed Systems | Expert Application Support | Competitive System Pricing

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