General Information

Core Description

Engineered for critical turbomachinery protection, the CON021 is an Emerson AMS eddy current signal converter designed to translate high-frequency proximity variables from PR6423 sensors into continuous analog outputs. Operating within a dynamic response window featuring a rise time of under 15 µs and a -3 dB frequency range of 0 to 20,000 Hz, this lightweight housing conditions precise measurement gaps. It delivers seamless loop integration across dual-range configurations, converting physical shaft behavior into a stable output range of -4V to -20V or -2V to -18V to eliminate localized data corruption in harsh multi-stage turbine housings.

Specific Application

• Critical Turbomachinery Displacement Tracking: Measuring radial shaft vibration, axial position, eccentricity, and key/speed metrics on industrial steam, gas, and hydro turbines, compressors, pumps, and fans.
• High-Frequency Transient Monitoring: Tracking rapid dynamic shaft movements in high-speed auxiliary machinery where the signal rise time must remain below 15 µs to prevent unmonitored bearing degradation.

Ordering Information

System Compatibility

• System Compatibility: The CON021 converter features a factory-integrated self-locking Lemo-plug connection to secure the sensor leading cable, alongside screw terminal blocks accommodating field wire sizes up to 1.5mm². It is optimized to drive loops for standard proximity sensors, including PR6422, PR6423, PR6424, PR6426, and PR6453. The hardware requires a stable negative supply voltage range of -23V to -32V (for -4V to -20V output loops) or -21V to -32V (for -2V to -18V output loops) and mounts securely using 4 included M5x20 screws.
• Direct Application Alternate: CON021/913-030 (Extended Range 3.0mm Converter) or CON021/913-040 (Extended Range 4.0mm Converter).
• Key Differences from Alternates (Standard CON021 vs. CON021/913-xxx Extended Series):
• Measuring Range & Linearity Tuning: The standard CON021 paired with a PR6423 sensor is factory-calibrated strictly for a 2.0mm standard measuring range, maintaining a tight linearity error limit of ≤ 1.0%. In contrast, the CON021/913-030 and CON021/913-040 are customized extended-range converters that scale the PR6423 sensor's tracking field up to 3.0mm (≤ 1.5% linearity error) or 4.0mm (≤ 2.0% linearity error), allowing wider mechanical gaps behind thick-walled casing layouts.
• Sensor Interchangeability: While the standard baseline CON021 module can be cross-shared to handle standard ranges for the PR6422, PR6423, PR6424, or PR6426 lines via field adjustments, the extended 91x-xxx series converters are component-matched and cannot be interchanged across different sensor types without altering calibration slopes. Note that the PR6425 sensor always requires an extended range converter and cannot operate with the standard CON021.

Installation & Troubleshooting FAQ

Q1: What are the exact physical wiring terminal requirements for landing the power and output lines on the CON021?

A: Field wiring loops for the supply voltage input and analog signal output must be terminated at the built-in screw terminal block on the lower faceplate. To maintain certified signal integrity and prevent terminal cross-talk, you must utilize stranded instrument conductors with a maximum cross-sectional area of 1.5mm². Ensure the terminal screws are snug to prevent localized signal dropouts under industrial vibrations.

Q2: The monitoring system is showing a clipping fault. How do the supply voltage bounds affect the CON021 analog output range?

A: The analog output span is dependent on your external negative DC power configuration. If you require a standard -4V to -20V output range, your input power network must supply a stable supply voltage between -23V and -32V. If your monitoring platform scales across a -2V to -18V output range, the required input supply bounds shift to between -21V and -32V. Supplying a voltage drops below these thresholds will cause signal clipping or trigger a loop calibration fault.

Q3: What mechanical footprint and mounting orientation steps must be followed when placing the CON021 housing?

A: The CON021 features a rugged LMgSi 0.5 F22 aluminum alloy housing weighing approximately 120 grams. The physical layout demands a mounting footprint measuring 50.8 mm x 50.8 mm between the screw centers, with an overall width profile of 56 mm. To lock down the module against plant floor resonance, you must utilize the 4 included M5x20 screws driven into the designated 4.2mm or 5.3mm flange eyelets, ensuring a clean vertical or horizontal orientation inside the junction box.

Q4: Can I install a standard CON021 converter directly inside an unventilated cabinet near a steam pipe manifold?

A: You must verify your thermal metrics before deployment. The CON021 features an operating temperature envelope rated from -30 to 100°C, and is rated to withstand structural shock profiles up to 5g @ 60 Hz @ 25°C. If your cabinet ambient temperature climbs past 100°C due to steam radiation, the internal components will experience thermal drift. For extreme locations, you must house the converter inside an insulated, cooled junction enclosure maintaining an IP20 environment.

Q5: What are the specific barrier requirements when deploying the CON021 inside a hazardous certified explosive gas zone?

A: The CON021 carries extensive global hazardous approvals, including ATEX/IEC-Ex Intrinsic Safety (II 2 G Ex ia IIC T4 Gb) and CSA Class I Division 1 (Groups A, B, C, D T4) metrics across a restricted ambient frame of -20°C ≤ Ta ≤ 80°C (-25°C for CSA). Crucially, for the intrinsic safety protection layer to remain active, the module must be paired with external current-limiting safety barriers. Never connect the field loops directly to an un-isolated supply loop within gas environments to prevent accidental spark hazards.