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- PR6426/010-000+CON021/916-120
- 32 mm Eddy Current Sensor+Eddy Current Signal Converter
- Germany
- 32 mm
- 0.92 kg
- Xiamen, China
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Product Overview
The Epro PR6426/010-000+CON021/916-120 is a combined eddy current measurement assembly consisting of a PR6426 32 mm sensor and a CON021 signal converter configured for the PR6426 extended measuring range. It is intended for non-contact shaft-displacement measurement in critical rotating machinery, including turbines, compressors, pumps, and industrial fans.
This combination is particularly relevant where the monitoring system needs to track shaft movement over an extended displacement range. For example, in a turbine bearing arrangement, the sensor measures the position of a conductive shaft surface relative to the stationary probe. In a large compressor, the same measurement principle can help engineers monitor rotor movement and investigate changes in shaft position during startup, load changes, or abnormal operating conditions.
The PR6426/010-000 detects changes in the distance between its sensing head and the metal target. The CON021/916-120 then conditions the sensor signal for use by the associated monitoring equipment. The two components perform different tasks: the sensor detects displacement, while the converter establishes the electrical measuring characteristics and output signal.
The /916-120 converter designation is significant because it identifies an extended-range configuration for the PR6426 sensor family. This version supports a nominal 12.0 mm measuring range, with a specified linearity error of no more than 1.5%. These characteristics distinguish the combined assembly from a standard-range PR6426 measuring chain.
When replacing an existing assembly, engineers should verify the complete sensor and converter designations, the receiving system’s input requirements, and the required displacement range. Matching only the sensor-head diameter is insufficient when the application depends on a particular converter calibration.
Technical Specifications
| Parameter | Specification |
|---|---|
| Manufacturer | Epro |
| Sensor Model | PR6426/010-000 |
| Signal Converter Model | CON021/916-120 |
| Product Type | Eddy Current Sensor and Eddy Current Signal Converter |
| Sensor Head Diameter | 32 mm |
| Measurement Principle | Non-contact eddy current |
| Measuring Range | 12.0 mm, extended-range configuration |
| Linearity Error | ≤ 1.5% |
| Converter Frequency Range (-3 dB) | 0–20,000 Hz |
| Converter Rise Time | < 15 µs |
| Converter Operating Temperature | -30 to +100°C |
| Converter Protection Class | IP20 |
| Converter Supply Voltage | -23 to -32 V for the -4 to -20 V output range; -21 to -32 V for the -2 to -18 V output range |
| Sensor Sleeve Material | Stainless steel |
| Sensor Cable Material | PTFE |
| Weight | 0.92 kg |
Product Features
- Extended-range displacement measurement: The CON021/916-120 configuration supports a nominal 12.0 mm measuring range for compatible PR6426 sensors, making the assembly suitable for applications requiring more displacement travel than the standard measuring configuration.
- Matched sensing and signal conditioning: Combines the PR6426 sensor with the corresponding CON021 converter configuration, reducing the risk of selecting a converter with an unsuitable measuring range.
- Defined linearity performance: The extended-range converter specification gives a maximum linearity error of 1.5%, allowing the measurement system’s expected behavior to be assessed during commissioning.
- High-frequency response: The converter has a specified frequency range of 0–20,000 Hz at -3 dB and a rise time below 15 µs, supporting measurement of dynamic shaft movement within the system’s operating limits.
- Non-contact operation: The sensor measures the relative position of a conductive target without physical contact, avoiding wear caused by a contacting measurement element.
- Industrial sensor construction: The PR6426 sensor uses a stainless-steel sleeve and PTFE cable construction for the specified machinery-monitoring environment.
- Configurable voltage output: The CON021 converter supports specified negative-voltage output ranges, allowing the measuring chain to be matched to compatible monitoring inputs.
- Integration with machinery monitoring: The conditioned displacement signal can be used by compatible monitoring equipment for measurement display, trending, and alarm evaluation.
Working Principle
The assembly measures shaft displacement through electromagnetic interaction between the PR6426 sensing head and a conductive metal target. The sensor coil is excited by the compatible converter, producing an electromagnetic field at the probe tip. Eddy currents develop in the target and influence the sensor’s electrical response.
When the shaft moves relative to the fixed sensor, the electromagnetic coupling changes. The CON021 converter processes this change and produces a voltage signal related to the target’s position within the configured measuring range.
The measurement path is:
Conductive Shaft Target → PR6426/010-000 Sensor → CON021/916-120 Signal Converter → Monitoring System
The extended-range configuration is the key distinction in this assembly. The CON021/916-120 is specified for a 12.0 mm measuring range with a linearity error of no more than 1.5%. The actual usable range depends on the correct sensor-converter combination, target material, calibration, and initial gap.
During installation, the probe must be positioned so that the shaft’s expected movement remains within the calibrated measuring range. An incorrect initial gap can leave insufficient travel in one direction or place the measurement outside its intended operating region.
The converter’s output is also important when integrating the assembly into an existing monitoring system. The selected output range must match the receiving input’s electrical requirements and configured measurement scaling. A signal that is electrically connected but incorrectly scaled can produce misleading displacement readings.
In operation, the resulting signal can be used to observe shaft position and movement. Whether a particular reading indicates an abnormal mechanical condition depends on the machine’s operating state, the monitoring configuration, and established alarm limits. The sensor-converter assembly supplies the measurement; the monitoring system and engineering assessment determine its significance.
Role in the Machinery Monitoring Architecture
This assembly combines the sensing element and signal-conditioning stage of a shaft-displacement measurement channel. The PR6426/010-000 detects the physical movement, while the CON021/916-120 converts the sensor response into an electrical output suitable for a compatible monitoring input.
| System Element | Function |
|---|---|
| PR6426/010-000 Sensor | Detects relative displacement between the sensing head and the conductive target |
| Rotating Shaft | Provides the target surface for displacement measurement |
| CON021/916-120 Converter | Processes the sensor response using the specified extended-range configuration |
| Converter Output Circuit | Supplies the configured voltage signal to compatible receiving equipment |
| Monitoring Input | Receives and scales the displacement signal |
| Machinery Monitoring System | Displays measurements, records trends, and evaluates configured alarm conditions |
| Plant Control or Diagnostic Interface | Makes measurement information available to operators and maintenance personnel |
For a turbine, the assembly can be used in a shaft-position measurement channel near a bearing location. For a compressor, displacement readings can be evaluated alongside vibration, rotational speed, and process conditions to investigate changes in rotor behavior.
The extended-range converter must be selected deliberately. A standard-range converter and a CON021/916-120 may use sensors from the same family, but they do not necessarily produce equivalent measurement scaling. Replacement work should preserve the intended measuring range and output configuration so that the monitoring system continues to interpret the signal correctly.
Industrial Applications
| Application | Practical Use |
|---|---|
| Steam Turbines | Monitoring shaft displacement during startup, steady operation, and load changes |
| Gas Turbines | Measuring rotor movement in critical rotating assemblies |
| Hydro Turbines | Observing shaft position in large turbine machinery |
| Industrial Compressors | Tracking shaft displacement and investigating changes in rotor behavior |
| Centrifugal Pumps | Measuring relative shaft movement where non-contact sensing is required |
| Large Industrial Fans | Monitoring shaft-position changes in rotating equipment |
| Power Generation Plants | Supplying displacement measurements to machinery monitoring channels |
| Petrochemical Facilities | Monitoring critical rotating equipment under changing operating conditions |
| Turbine and Compressor Overhauls | Replacing a complete sensor-converter assembly while preserving the intended measurement configuration |
| Machinery Diagnostics | Comparing displacement trends with vibration and operating data during fault investigation |
Installation and Maintenance
- Verify both component designations: Confirm PR6426/010-000 and CON021/916-120 against the installed assembly and maintenance records. The sensor and converter should be identified separately during replacement.
- Confirm the required measuring range: Verify that the 12.0 mm extended-range configuration matches the application. Check the expected shaft travel and the receiving system’s configured measurement span.
- Check target material compatibility: Confirm that the shaft surface meets the requirements of the calibrated measuring chain. A change in target material can affect the sensor’s measurement characteristics.
- Prepare the sensor mounting position: Inspect the mounting bracket and installation surface. The probe must remain fixed relative to the machine structure so that mounting movement does not distort the measured displacement.
- Adjust the initial sensor gap: Follow the applicable installation and converter-calibration procedure to establish the correct operating point. Do not apply a standard-range gap setting without confirming that it is appropriate for the extended-range configuration.
- Inspect surrounding metal clearance: Check for nearby ferrous components that could influence the sensor’s electromagnetic field. Maintain the clearance specified for the actual sensor installation.
- Inspect the sensor and cable: Examine the sensing head, sleeve, and cable for mechanical damage, abrasion, crushing, or deterioration. Check the cable route for exposure to temperatures beyond the applicable limits.
- Verify the sensor-to-converter connection: Confirm that the sensor connector and cable arrangement match the CON021 input. Ensure that connections are secure before energizing the measuring chain.
- Check converter supply and output selection: Verify the converter supply voltage and the selected output range against the monitoring input. Confirm the correct signal polarity and scaling before commissioning.
- Test the measurement response: Follow the approved commissioning procedure to verify that target movement produces the expected change in output. Check that the signal remains within the calibrated measuring range.
- Validate monitoring-system scaling: Confirm that the receiving equipment converts the voltage signal into the intended displacement units and that the configured measurement span corresponds to the 12.0 mm extended-range setup.
- Record the completed configuration: Document the sensor and converter part numbers, measuring range, output selection, initial gap, and commissioning results. These records help preserve consistency during future maintenance and replacement.
Compatible System Components
| Component | Function |
|---|---|
| PR6426/010-000 Eddy Current Sensor | Detects displacement of the conductive shaft target |
| CON021/916-120 Signal Converter | Conditions the PR6426 signal for the 12.0 mm extended measuring range |
| Compatible Monitoring Input | Receives the converter’s configured voltage output |
| Machinery Monitoring Module | Processes displacement measurements for display and alarm evaluation |
| Sensor Mounting Hardware | Maintains the required sensor alignment and initial gap |
| Sensor Cable and Connector Assembly | Establishes the connection between the probe and converter |
| Control Cabinet Power Supply | Supplies the converter within its specified voltage range |
| Conductive Shaft Target | Provides the measurement surface for the eddy current sensor |
The sensor, converter, and receiving input must be assessed as one measurement channel. A replacement converter with a different range or output configuration may require corresponding changes to calibration and monitoring-system scaling.
Recommended Related Models
| Model | Product Type | Selection Consideration |
|---|---|---|
| Epro PR6426/010-000 | 32 mm Eddy Current Sensor | Sensor component used in the combined assembly; requires a compatible converter |
| Epro CON021/916-160 | Eddy Current Signal Converter | PR6426 extended-range converter with a nominal 16.0 mm measuring range and linearity error ≤ 2.0% |
| Epro CON021/916-200 | Eddy Current Signal Converter | PR6426 extended-range converter with a nominal 20.0 mm measuring range and linearity error ≤ 2.5% |
| Epro CON021/916-240 | Eddy Current Signal Converter | PR6426 extended-range converter with a nominal 24.0 mm measuring range and linearity error ≤ 3.5% |
| Epro CON021 | Eddy Current Signal Converter | Standard converter configuration for supported sensor types; the PR6426 standard range differs from the extended-range versions |
Key Advantages
- Combines a PR6426 sensor with its specified extended-range signal converter.
- Supports a nominal 12.0 mm measuring range.
- Specifies a maximum linearity error of 1.5%.
- Offers a converter frequency range of 0–20,000 Hz at -3 dB.
- Supports integration with compatible machinery monitoring inputs.
Technical FAQs
What does the CON021/916-120 suffix specify in this assembly?
The /916-120 designation identifies a CON021 extended-range converter configuration for the PR6426 sensor family. It specifies a nominal 12.0 mm measuring range and a maximum linearity error of 1.5%.
Why should the monitoring input be checked when replacing this assembly?
The converter’s voltage output range and the monitoring input’s scaling must match. If the receiving equipment is configured for a different signal span, the displayed displacement may not correspond correctly to the actual shaft movement.
Can the CON021/916-120 be replaced with a CON021/916-160 without changing the configuration?
Not automatically. The CON021/916-160 has a nominal 16.0 mm measuring range and a different specified linearity error. A change of converter may require the measuring-chain calibration and monitoring-system scaling to be reviewed and adjusted.
What should be investigated if the output reaches its limit during normal operation?
Check the initial sensor gap, actual shaft movement, converter configuration, and receiving-system scaling. Determine whether the shaft is moving beyond the calibrated range or whether the measurement chain has been configured incorrectly before changing alarm limits.