Emerson Machinery Health PR 642 Series User manual

Installation Guide
MHM-97857 , Rev 1.5
January 2020
Machinery Health™ Sensor
PR 642x, Eddy Current Sensors

Copyright
© 2020 by Emerson. All rights reserved.
No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any
language in any form by any means without the written permission of Emerson.
Disclaimer
This manual is provided for informational purposes. EMERSON MAKES NO WARRANTY OF ANY KIND WITH REGARD TO THIS
MATERIAL, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE. Emerson shall not be liable for errors, omissions, or inconsistencies that may be contained herein or for incidental or
consequential damages in connection with the furnishing, performance, or use of this material. Information in this document is
subject to change without notice and does not represent a commitment on the part of Emerson. The information in this manual is
not all-inclusive and cannot cover all unique situations.
Patents
The product(s) described in this manual are covered under existing and pending patents.
2

Contents
Chapter 1 General.......................................................................................................................... 5
1.1 Using this manual............................................................................................................................. 5
1.2 Symbol explanation..........................................................................................................................5
1.3 Liability and guarantee..................................................................................................................... 6
1.4 Incoming goods inspection.............................................................................................................. 6
1.5 Technical support.............................................................................................................................6
1.6 Storage and transport.......................................................................................................................7
1.7 Disposal of the device.......................................................................................................................7
1.8 China RoHS Compliance................................................................................................................... 7
1.9 Installation awareness...................................................................................................................... 8
Chapter 2 Safety Instructions......................................................................................................... 9
2.1 Using the device............................................................................................................................... 9
2.2 Owner's responsibility.......................................................................................................................9
Chapter 3 Application and Design................................................................................................ 11
3.1 The Measuring Chain...................................................................................................................... 11
3.2 The Sensors.................................................................................................................................... 11
Chapter 4 Installation and Mounting............................................................................................13
4.1 Measuring chain and material of measuring target......................................................................... 13
4.2 Choosing the measuring place........................................................................................................13
4.3 Mount the sensor........................................................................................................................... 14
4.3.1 Requirements and hints for the sensor mounting........................................................................ 14
4.3.2 PR 6426 installation.....................................................................................................................19
4.4 Wiring hints....................................................................................................................................20
4.5 Sensor cables with LEMO adapter plug........................................................................................... 21
Chapter 5 Technical data..............................................................................................................23
5.1 Measuring targets.......................................................................................................................... 23
5.2 Measuring ranges and sensitivity.................................................................................................... 24
5.3 Environmental conditions...............................................................................................................25
Chapter 6 Drawings..................................................................................................................... 27
Chapter 7 Order Matrix................................................................................................................ 33
Chapter 8 Certificates.................................................................................................................. 37
Installation Guide Contents
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Contents Installation Guide
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1 General
1.1 Using this manual
This manual contains information concerning the proper and correct use of the PR 6422,
PR 6423, PR 6424, PR 6425 and PR 6426 eddy current transducers.
For correct and safe use of this device read the entire operating manual prior to installing
and operating the device. In particular, comply with all safety instructions contained in the
manual.
Do not transfer the device to third parties without including the operating manual.
Note
When requesting technical support for this device, please indicate type and serial number
as shown on the type plate as well as the used converter type.
Table 1-1 shows a list of documents that are referred to in this installation guide.
Table 1-1: Referenced documents
DfU_GA_CON011 HWRev04 Operating manual of CON 011 eddy current
signal converter
DfU_GA_CON 021_031 HWRev04 Operating manual of CON 021 and CON 031
eddy current signal converters
DfU_GA_CON 041 HWRev04 Operating manual of CON 041 eddy current
signal converter
OM CSI 9360 Operating manual of CSI 9360 4-20 mA loop
powered eddy current transmitter
DfU_MMS_3110; DfU_ MMS_3210;
DfU_MMS_3220; OM_MMS_3311
Operating manuals of the devices of the MMS
3000 System which use eddy current sensors
1.2 Symbol explanation
Note
This symbol marks passages that contain important information.
CAUTION
Operations that may lead to malfunctions or faulty measurements, without damaging the
device, are marked with this symbol.
DANGER
A Danger indicates actions that can lead to property damage or personal injuries.
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1.3 Liability and guarantee
Emerson Process Management is not liable for damages that occur due to improper use.
Proper use also includes knowledge of, and compliance with this operating manual.
Customer changes to the device that have not been approved expressly by Emerson, will
result in the loss of guarantee.
Due to continuous research and further development Emerson reserves the right to
change technical specifications without notice.
1.4 Incoming goods inspection
Check the content of the shipment to ensure that it is complete; visibly inspect the goods
to determine if the device has been damaged during transport. The following parts are
included in the scope of delivery and must be contained in the shipment.
•Eddy current sensor PR 6422, PR 6423, PR 6423, PR 6425 or PR 6426 (with protection
cap)
•Lemo connection cable (only PR 642x/xxx-0xx types)
•Mounting nuts (respectively screws at PR 6426)
•Shrink sleeve for isolating the adapter plug (only PR642x/xxx-0xx types)
•Operating manual for installing and using the sensor
If the contents are incomplete, or if you observe any defects, file a complaint with the
carrier immediately. Moreover, inform the responsible Emerson sales organization so your
device can be replaced. In this case, attache to the device a non-detachable tag with
customer name and the observed defect.
1.5 Technical support
You may need to ship this product for return, replacement, or repair to an Emerson
Product Service Center. Before shipping this product, contact Emerson Product Support to
obtain a Return Materials Authorization (RMA) number and receive additional instructions.
Product Support
Emerson provides a variety of ways to reach your Product Support team to get the answers
you need when you need them:
Phone Toll free 800.833.8314 (U.S. and Canada)
+1.512.832.3774 (Latin America)
+63.2702.1111 (Asia Pacific, Europe, and Middle East)
Email [email protected]
Web http://www.emerson.com/en-us/contact-us
To search for documentation, visit http://www.emerson.com.
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To view toll free numbers for specific countries, visit http://www.emersonprocess.com/
technicalsupport.
Note
If the equipment has been exposed to a hazardous substance, a Material Safety Data Sheet
(MSDS) must be included with the returned materials. An MSDS is required by law to be
available to people exposed to specific hazardous substances.
1.6 Storage and transport
Store and transport the device only in its original packaging. x, "Technical Data", specifies
the environmental conditions for storage and support.
1.7 Disposal of the device
Provided that no repurchase or disposal agreement exists, recycle the following
components at appropriate facilities:
•Recyclable metal
•Plastic elements
Sort the remaining components for disposal, based on their condition. National laws or
provisions on waste disposal and protection of the environment apply.
Note
Environmental hazards! Electrical waste and electronic components are subject to
treatment as special waste and may only be disposed by approved specialized companies.
1.8 China RoHS Compliance
Our products manufactured later than June 30, 2016 and those which are sold in the
People's Republic of China are marked with one of the following two logos to indicate the
Environmental Friendly Use Period in which it can be used safely under normal operating
conditions.
Products without below mentioned marking are either manufactured before June 30 or
are non-electrical equipment products (EEP).
Circling arrow symbol with "e": The product contains no hazardous substances over
the Maximum Concentration Value and it has an indefinite Environmental Friendly
Use Period.
Circling arrow symbol with a number: This product contains certain hazardous
substances over the Maximum Concentration Value and it can be used safely under
normal operating conditions for the number of years indicated in the symbol. The
names and contents of hazardous substances can be found in the folder "China
RoHS Compliance Certificates" on the documentation CD or DVD enclosed with the
product.
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1.9 Installation awareness
Note
When planning a measurement, observe the following items:
•Consider environmental conditions which might have an influence on the
measurement such as temperature, humidity, substances aggressive to the sensor,
and pollution.
•Always use a stiff and vibration-free sensor holder.
•Define a suitable measuring range, not larger than necessary, in consultation with the
operator of the plant.
•Define the trip limit in consultation with the operator of the plant.
•Take measurement deviations into account when defining the trip limit.
•Use a sensor that meets the requirements of the defined measuring range.
•Ensure an EMC-compatible installation including the use of proper cables.
•Ensure proper function of the measurement before activating the measurement for
regular operation.
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2 Safety Instructions
To ensure safe operation, carefully observe all instructions in this manual.
The correct and safe use of this device requires that operating and service personnel both
understand and comply with general safety guidelines and observe the special safety
comments listed in this manual. Where necessary, safety-sensitive points on the device
are marked.
DANGER
Since the sensor is electrical equipment, commissioning and service may be performed
only by trained personnel. Maintenance may be carried out only by trained, specialized,
and experienced personnel.
2.1 Using the device
Measuring systems with eddy current sensors as PR 6422, PR 6423, PR 6424; PR 6425 and
PR 6426 serve in conjunction with eddy current converters as CON 011, CON 021, CON
041, the transmitters with integrated converters of the MMS 3000 series or the
transmitter CSI 9360 the measurement of mechanical quantities, such as shaft vibration,
shaft displacement and speed (not if CSI 9360 is used).
2.2 Owner's responsibility
If there is a reason to suspect that hazard-free operation and thus adequate machine
protection is no longer possible, take the device out of operation and safeguard it from
unintentional operation. This is the case:
•if the device shows visible damage
•if the device no longer works
•after any kind of overload that has exceeded the permissible limits (such as those
detailed in Environmental conditions).
DANGER
If sensor tests have to be completed during operation, or if the sensor has to be replaced
or decommissioned, it will impair the machine protection and may cause the machine to
shut down. Make sure to deactivate machine protection before starting such work, and
reactivate it after work has been completed.
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3 Application and Design
3.1 The Measuring Chain
Together with signal converters of the series CON 0x1, integrated converters of the MMS
3000 series, or the CSI 9360 transmitter, the sensors PR 6422 to PR 6426 form eddy
current measuring chains for contactless distance, vibration and speed measurements.
Different types of sensors and converters allow an optimal adaption to the requirements
of the machine to be monitored.
A additional electronic components, like the CSI 6500 system, allow static and dynamic
distance measurements, which means it is possible to measure slow axial displacements
and quick axial shaft vibrations of rotating machines.
To achieve a high accuracy, the measuring chains consisting of both converter and sensor
are adjusted together and delivered as complete measuring chain.
3.2 The Sensors
The PR 642x series includes five eddy current sensor types in different variants as shown in
chapter Order Matrix.
Which sensor type is applicable for a measuring application depends on several
requirements as desired measuring range, available measuring track, and maximum
environmental temperature.
The characteristics of the measuring chain are adapted to the material mainly used for
turbo machinery (reference material: 42 Cr Mo 4, according to SAE 4140). The standard
adjustment of the measuring chains is generally related to this material; during installation
at the machine, you only need to adjust the distance between the head of the sensor and
the measuring target. The signal output of the converter determines how you should
adjust the sensor.
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4 Installation and Mounting
4.1 Measuring chain and material of measuring
target
To achieve a high accuracy of relative distance measurements, you must adjust the
measuring chain precisely on the target material. For this reason, the manufacturer
requires information on the material to adjust the converter. For the materials listed in the
table in section Measuring targets, it is sufficient to indicate only the material. If you use
another material, a sample of the target material with the following dimensions must be
sent to the workshop: thickness ≥5 mm, diameter ≥50 mm.
If, while ordering, information regarding your material is not available, the measuring
chain will be adjusted on the standard material 42 CrMo 4 (SAE 4140).
4.2 Choosing the measuring place
Figure 4-1 is an example scheme for how to place the sensors at a turbine shaft to measure
the axial displacement, shaft vibration, or speed. You must consider the minimum shaft
diameter for this type of sensor, the minimum material width in front of the sensor head,
and the minimum gap (refer to Requirements and hints for the sensor mounting).
To measure shaft vibration, Emerson recommends using a sensor holder between bearing
and turbine housing as close as possible to the rotor.
Figure 4-1: Example scheme where to place the sensors
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4.3 Mount the sensor
The following steps describe the mounting of sensor types PR 6422, PR 6423, PR 6424 and
PR 6425. For mounting hints regarding the PR 6426 see PR 6426 installation. See also the
respective converter manuals as listed inTable 1-1 for further details regarding sensor
adjustment.
Procedure
1. Screw in the sensor into the holder.
Ensure that the threads are clean and smooth-running.
Do not bend or twist the sensor cable. If the sensor cable has a LEMO adapter plug
open it.
To avoid touching the shaft during installation, the maximum distance between
measuring target and sensor head must be adjusted first - screw in the sensor until
the converter output voltage starts changing (approximately at -20V DC). Close the
LEMO adapter plug for measuring the converter output voltage.
2. Adjust the distance between measuring target and sensor head in accordance to
the measuring task.
Use a voltmeter connected to the converter output to measure the output voltage.
Open the LEMO adapter plug at every two turns of the sensor to untwist the cable.
Ensure that in direction to the sensor head at least two of the threads remain free as
shown in Figure 4-2.
3. Secure the sensor by fixing the nuts.
The maximum torque for fixing the nuts is:
•PR 6422: 1 Nm (0,1 kpm)
•PR 6423: 15 Nm (1,5 kpm)
•PR 6424, PR 6425: 98 Nm (10 kpm)
4.3.1 Requirements and hints for the sensor mounting
This section contains information and installation requirements for the sensor. The final
adjustment of the sensor depends on the measuring task and requires a complete
measuring chain. The converter, MMS 3000 and CSI 9360 manuals, and the manuals for
the evaluation electronics, contain detailed information regarding the final adjustment.
General holder requirement
To mount the sensor, use a stiff and vibration-free holder with a mounting thread for the
relevant sensor (PR 6422 to PR6425).
General distance adjustment
For distance adjustment the complete measuring chain consisting of sensor and converter
is required as the distance will be generally adjusted by means of the converter output
voltage.
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Sensor fastening
•Use the enclosed nuts when installing sensors with mounting threads
•When installing sensors with mounting threads captive nuts must be used to avoid
loosen of the sensor. Loose parts can fall into the machine and cause damages. A
medium grade removable thread locked (for example Loctite® 242, blue) is
recommended to secure the sensor.
Measuring track on the measuring target
The measuring track on the measuring target must be free from irregularities as scratches,
corrosion, stress concentrations, metallurgical segregation, high concentricity, etc. These
irregularities may cause changes in the sensor output voltage which are not related to a
real position or vibration signal. The signal caused by these irregularities is called runout.
For the measuring track a surface finish of 0.41 µm to 0.76 µm is recommended.
Free space
Ensure there is 45° of free space around the sensor head for all sensor types except PR
6426, as shown in the left diagram of Figure 4-2. The right drawing in Figure 4-2 shows the
required free space around the PR 6426.
Figure 4-2: Free space around sensor head
Free space PR 6422, PR 6423, PR 6424 and PR 6425: ± 45°
Free space PR 6426: minimum = 80 mm; for nominal range ±4 mm and for extended
ranges
CAUTION
If you do not ensure the free space specifications, the measuring range at the upper end
reduces and the linearity error increases.
Maximum axial tilting angle
Ensure that the maximum axial tilting angle alpha is < 2° if using PR 6422, PR 6423, PR
6424 or PR 6425 as shown in Figure 4-3, or alpha < 1.6° if using PR 6426 as shown in Figure
4-4. There is no significant influence on the measuring result in this case.
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Figure 4-3: Maximum axial tilting if using PR 6422, PR 6423, PR 6424 or PR 6425
S: distance between measuring target and sensor head
Alpha: max. axial tilting angle < 2°
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Figure 4-4: Maximum axial tilting if using PR 6426
S: distance between measuring target and sensor head
Alpha: max. axial tilting angle < 1.6°
Maximum tangential offset
Ensure the maximum tangential offset matches the values in Table 4-1. Figure 4-5 shows
the definition of the tangential offset.
Table 4-1: Maximum tangential offset
Sensor type Max. offset X Shaft diameter D
PR 6422 0.2 mm ≥ 15 mm
PR 6423 0.5 mm ≥ 28 mm
PR 6424 0.5 mm ≥ 60 mm
PR 6425 0.5 mm ≥ 60 mm
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Figure 4-5: Maximum tangential offset
X: max. tangential offset
D: shaft diameter
Minimum measuring area
Ensure that the minimum measuring area matches the values in Table 4-2. Figure 4-6
defines of the minimum measuring area.
Table 4-2: Minimum measuring area
Sensor type X minimum Sensor head diameter
PR 6422 5 mm 5.2 mm
PR 6423 3 mm 8 mm
PR 6424 3 mm 16 mm
PR 6425 2 mm 15.8 mm
PR 6426 2 mm 32 mm
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Figure 4-6: Minimum measuring area
4.3.2 PR 6426 installation
Figure 4-7 shows an installation example for the sensor PR 6426. Its reference area is the
mounting plate. The nominal distance of the mounting plate to the measuring target in
the center position is approx. 39.5 mm. After you fix the mounting screws, bend the safety
plate (anti-twisting plate) to prevent the screws from getting loose.
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Figure 4-7: Mounting example PR 6426
4.4 Wiring hints
This section contains general information and wiring hints regarding the sensor cable
installation. The necessary measures for the proper cable installation depend always on
the situation on-site. Observe the following points for a reliable cable installation:
•Do not bend or twist the sensor cables. Cables and connectors must be movable when
the sensor is adjusted in its holder.
•Install the cable strain-free and spin-free such that it is protected against mechanical
damages.
•Do not shorten the sensor cable or the extension cable of PR 6422 and PR 6423. Rollup
the excess cable (rolling diameter ≥100 mm).
•Ensure that no parts of the cable, including the adapter plug, touch any rotating parts
of the machine.
•Note that machines can expand or shrink due to temperature influences. Always install
the sensor cable with a cable length reserve to compensate for the thermal behavior of
the machine.
•Only install cables with a minimum bending radius of 25 mm. For sensor cables with
metal protection tubes, the minimum bending radius is 35 mm.
•Avoid oil stream areas for sensor cableways. Be sure that no oil stream or other
agitations will permanently move the cable.
•Avoid sensor cableways where the cable is permanently submerged into oil.
•Affix the sensor cable at recurring short distances.
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