Emerson EPRO PR6424/013-130+CON021 16mm Eddy Current System

Emerson EPRO PR6424/013-130+CON021 - Factory-Calibrated Eddy Current Monitoring System

The Emerson EPRO PR6424/013-130+CON021 delivers a turnkey eddy current measurement solution for critical machinery monitoring applications. This factory-matched system pairs the robust PR6424 16mm sensor (130mm case length, 3/8"-24 UNF threading) with the versatile CON021 signal converter, providing immediate deployment capability for turbomachinery protection, bearing clearance monitoring, and shaft displacement analysis.

System Configuration & Specifications

PR6424/013-130 Sensor Configuration:

• Sensor Diameter: 16mm - optimized for medium to large rotating machinery
• Case Thread: 3/8"-24 UNF (imperial standard) for North American installations
• Case Length: 130mm total length (117.5mm + 12.5mm base) for deep bearing housing penetration
• Measurement Sensitivity: 4 V/mm (101.6 mV/mil) with ±1.5% linearity
• Static Range: ±2.0 mm for position and eccentricity measurement
• Dynamic Range: 0-1,000 μm for vibration amplitude tracking
• Nominal Air Gap: 2.7 mm optimized for 80mm+ shaft diameters

CON021 Signal Converter Performance:

• Frequency Bandwidth: DC to 20 kHz (-3dB) captures subsynchronous to ultrasonic events
• Signal Processing Speed: <15 μs rise time for transient detection
• Output Signal: -4V to -20V proportional to displacement
• Power Supply: -23V to -32V DC (standard industrial negative rail)
• Temperature Range: -30°C to +100°C for control room mounting

Engineering Advantages of Pre-Matched Systems

Guaranteed Calibration Accuracy: Each PR6424/CON021 system undergoes paired calibration at the Emerson factory, ensuring the specified 4 V/mm sensitivity and linearity specifications are met as a complete measurement chain. This eliminates the ±3-5% tolerance stack-up that occurs when purchasing sensors and converters separately.

Simplified Commissioning: Pre-configured systems arrive ready for installation with documented calibration certificates, wiring diagrams, and installation guidelines specific to your sensor/converter pairing. Commissioning time is reduced by 40-60% compared to field-calibrated component systems.

Extended Warranty Coverage: Factory-matched systems carry unified warranty protection covering both sensor and converter as a single measurement system, eliminating potential disputes about component-level failures versus system integration issues.

Critical Machinery Applications

Steam Turbine Journal Bearing Monitoring: The 130mm case length enables installation through thick bearing housings common in large steam turbines. The 16mm diameter provides clearance in confined radial spaces while maintaining measurement accuracy on 80-200mm diameter journals. Monitor bearing wear, thermal growth, and rotor eccentricity with 0.025mm resolution.

Gas Turbine Rotor Positioning: Track axial and radial rotor position in gas turbines where magnetic bearing control systems require continuous feedback. The CON021's 20 kHz bandwidth captures blade-passing frequencies and high-order harmonics critical for aerodynamic instability detection.

Centrifugal Compressor Thrust Monitoring: Deploy in API 617-compliant machinery protection systems where thrust bearing failure can cause catastrophic rotor-to-stator contact. The system's <0.3% long-term drift maintains calibration accuracy through years of continuous operation without field recalibration.

Large Motor Shaft Runout Measurement: Install on electric motors driving critical processes (pumps, fans, compressors) to detect shaft bending, coupling misalignment, and bearing degradation before catastrophic failure. The 3/8"-24 UNF threading simplifies retrofit installations in existing motor bearing housings.

Installation Flexibility & Mounting Options

The 130mm case length (013 designation) provides optimal reach for installations requiring:

• Penetration through thick insulation layers on high-temperature equipment
• Mounting through double-wall bearing housings with thermal barriers
• Installation in recessed bearing caps or extended mounting bosses
• Clearance over coupling guards or shaft protection sleeves

The 3/8"-24 UNF threading (1-series designation) offers advantages in North American facilities standardized on imperial hardware, eliminating the need for metric tap-and-die sets during installation or sensor replacement.

Signal Converter Integration & Connectivity

The CON021 converter features dual-interface connectivity optimized for industrial installations:

Sensor Input: Self-locking Lemo connector provides vibration-resistant connection to the PR6424 sensor cable, preventing signal degradation from connector loosening in high-vibration environments.

Power & Output: Screw terminal blocks (max 1.5mm² wire) enable direct connection to DCS I/O cards, PLC analog inputs, or dedicated machinery protection systems. The -24V nominal supply voltage integrates with standard industrial power distribution.

Mounting: Compact aluminum housing (120g weight) mounts via four M5 screws on DIN rail, panel surfaces, or equipment enclosures. IP20 protection rating suits control cabinet environments.

Measurement Range Customization

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

• CON021/914-060: 6mm range with ±1.0% linearity for increased clearance monitoring
• CON021/914-100: 10mm range for extreme displacement applications (thermal growth, seismic events)

Environmental Durability & Reliability

Sensor Construction: Stainless steel sleeve withstands 10,000 hPa (145 psi) pressure and temperatures from -35°C to 150°C. PTFE cable insulation resists chemical attack from lubricants, coolants, and process fluids.

Vibration Resistance: Both sensor and converter are rated for 5g @ 60 Hz continuous vibration, enabling installation on vibrating structures, skid-mounted equipment, and mobile machinery.

Long-Term Stability: <0.3% drift specification ensures measurement accuracy over multi-year operating periods, reducing recalibration frequency and maintenance costs.

Complementary Monitoring Solutions

Build comprehensive machinery protection systems with these compatible EPRO products:

• Emerson EPRO PR6424/010-110 Eddy Current System - Alternative configuration with 110mm case length
• Emerson EPRO PR6423/003-130+CON021 8mm Eddy Current System - Smaller diameter for compact installations

Quality Assurance & Documentation

Every PR6424/013-130+CON021 system ships with:

• Factory calibration certificate with traceability to national standards
• System-level performance verification test results
• Installation drawings showing sensor dimensions and mounting requirements
• Wiring diagrams for sensor-to-converter and converter-to-DCS connections
• Configuration documentation for extended-range or custom calibrations

Industrial Control Hub - Your Machinery Monitoring Partner

As a specialized distributor of Emerson EPRO vibration monitoring systems, we maintain extensive inventory of factory-matched sensor/converter systems, replacement sensors, and spare converters. Our application engineers provide expert guidance on sensor selection, installation best practices, and integration with Ovation DCS, AMS Suite, and third-party SCADA platforms.

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