Emerson EPRO PR6424/010-140+CON021 16mm Eddy Current System

Emerson EPRO PR6424/010-140+CON021 - Extended-Length Eddy Current Monitoring System

The Emerson EPRO PR6424/010-140+CON021 delivers precision displacement and vibration monitoring for large-scale rotating machinery through its extended 140mm sensor configuration paired with the industry-proven CON021 signal converter. This factory-calibrated system provides turnkey installation for deep bearing housings and complex mounting scenarios where standard-length sensors cannot reach critical measurement points.

Extended Sensor Configuration - 140mm Total Length

The PR6424/010-140 variant features a 140mm total sensor length (127.5mm case + 12.5mm tip), specifically engineered for applications requiring deep penetration into bearing housings, thick-walled pressure vessels, or installations with extended standoff requirements. This configuration eliminates the need for custom mounting adapters or housing modifications, reducing installation complexity and potential leak paths in pressurized systems.

Core Measurement Capabilities

• Measurement Sensitivity: 4 V/mm (101.6 mV/mil) with ±1.5% linearity specification
• Static Displacement Range: ±2.0 mm for position tracking and thermal growth monitoring
• Dynamic Vibration Range: 0-1,000 μm peak-to-peak for oscillation analysis
• Nominal Operating Gap: 2.7 mm optimized for 80mm+ diameter shafts
• Long-Term Stability: <0.3% annual drift maintains calibration integrity
• Maximum Target Speed: 2,500 m/s surface velocity supports ultra-high-speed machinery

CON021 Signal Converter - Precision Signal Conditioning

The integrated CON021 converter transforms raw sensor impedance changes into industry-standard voltage outputs compatible with DCS systems, PLCs, and standalone monitoring equipment. Its wide 0-20 kHz bandwidth captures everything from slow thermal drift to high-frequency bearing defects, while the <15 μs rise time ensures accurate transient event detection.

Flexible Output Configuration: Dual voltage range options (-4V to -20V or -2V to -18V) accommodate different monitoring system input requirements without external scaling circuits. The converter automatically compensates for cable capacitance variations across the 4m to 10m cable length options.

Application-Specific Deployment Strategies

Deep Bearing Housing Installations: The 140mm sensor length excels in large turbine and generator applications where bearing housings exceed 100mm wall thickness. Install through pressure-rated glands without compromising vessel integrity while maintaining optimal air gap positioning on the rotating shaft.

High-Pressure Process Equipment: Deploy in compressors and pumps operating at pressures up to 10,000 hPa (145 psi) where the sensor must penetrate thick pressure boundaries. The stainless steel construction and PTFE cable insulation resist process fluid ingress and maintain measurement accuracy under pressure cycling.

Thermal Expansion Monitoring: Track axial shaft growth in steam turbines and hot gas expanders where thermal transients cause significant rotor displacement. The system's <4%/100K temperature error specification ensures accurate measurements across -35°C to +150°C operating ranges.

Magnetic Bearing Control: Provide position feedback for active magnetic bearing systems requiring precise rotor centering. The 4 V/mm sensitivity and low drift characteristics enable closed-loop control with sub-micron positioning accuracy.

API 670 Certification & Standards Compliance

This measurement system fully complies with API 670 5th Edition requirements for non-contacting vibration and position measurement in machinery protection systems. The documented temperature error, frequency response, and linearity specifications meet or exceed API criteria, enabling use in safety-critical applications including emergency shutdown systems and SIL-rated protection loops.

Environmental Performance & Durability

The PR6424 sensor withstands continuous exposure to industrial environments with its IP-rated stainless steel construction and PTFE-insulated cabling. The system tolerates 5g vibration at 60 Hz, making it suitable for mounting on vibrating structures, skid-mounted equipment, and mobile machinery. The CON021 converter's IP20 rating supports standard control cabinet installation with adequate dust protection.

Installation & Mounting Versatility

Threading Options: Choose M18x1.5 metric or 3/4"-16 UNF imperial threads for compatibility with global bearing housing standards

Cable Protection: Available with or without armored cable sheathing for high-vibration or mechanically harsh environments

Connector Configurations: Lemo self-locking connectors or open-end termination for direct wiring to junction boxes

Adapter Plug Options: With or without adapter plugs for reverse-mount installations or space-constrained applications

System Calibration & Quality Assurance

Each PR6424/010-140+CON021 system undergoes factory calibration as a matched sensor-converter pair against NIST-traceable standards. The calibration certificate documents sensitivity, linearity, and temperature coefficients across the full operating range, providing traceability for quality management systems and regulatory compliance requirements.

Multi-Sensor System Integration

The CON021 converter's universal compatibility with PR6422, PR6423, PR6424, PR6425, and PR6426 sensor families enables standardized spare parts inventory and simplified maintenance procedures. Deploy multiple sensor sizes across your facility while maintaining common converter platforms, reducing training requirements and inventory carrying costs.

Extended Range Converter Options

For applications requiring measurement ranges beyond the standard 4mm specification, extended-range CON021 variants provide:

• CON021/914-060: 6mm range with ±1.0% linearity for moderate displacement applications
• CON021/914-080: 8mm range with ±1.5% linearity for large clearance monitoring
• CON021/914-100: 10mm range with ±2.0% linearity for extreme displacement scenarios

Complementary Monitoring Solutions

Build comprehensive machinery protection systems with these compatible EPRO products:

• Emerson EPRO PR6424/010-110 Eddy Current System - Shorter 110mm variant for standard bearing housings
• Emerson EPRO PR6423/003-130+CON021 8mm System - Compact 8mm sensor for smaller shaft applications

Technical Support & Application Engineering

Industrial Control Hub provides comprehensive pre-sales and post-sales support for EPRO vibration monitoring systems. Our application engineers assist with sensor selection, mounting design, cable routing optimization, and system integration with Emerson Ovation DCS, AMS Suite, and third-party SCADA platforms. We offer installation guidance, commissioning support, and troubleshooting assistance to ensure optimal system performance.

Procurement Advantages

• Factory-Matched Systems: Pre-calibrated sensor-converter pairs eliminate field calibration
• Global Availability: Expedited shipping to industrial sites worldwide
• Genuine OEM Components: Factory-sealed Emerson EPRO products with full warranty
• Technical Documentation: Complete installation manuals, calibration certificates, and wiring diagrams
• Competitive Pricing: Volume discounts available for multi-sensor projects

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