Product Overview

• Brand: EPRO (now part of Emerson Automation Solutions)
• Model: CON021
• Type: Communication Interface Module
• Industry: Power generation (steam/gas turbines, hydro generators), oil & gas (compressors, pumps), petrochemicals, and industrial manufacturing.
• Function: Acts as a communication bridge between EPRO’s rotating equipment protection systems (e.g., MMS6000, MMS3000) and external control/monitoring platforms (e.g., DCS, SCADA, PLCs). It converts proprietary data from EPRO’s sensors and protection modules (e.g., vibration, temperature, shaft position) into standardized industrial protocols, enabling remote monitoring, data logging, and integration with plant-wide automation systems. This ensures seamless data exchange for real-time equipment health monitoring and predictive maintenance.

Key Features

1. Multi-Protocol Support for Interoperability
   • Integrates standard industrial communication protocols to enable compatibility with EPRO and third-party systems:
     • Modbus RTU/TCP: Widely used for communication with PLCs, SCADA systems, and HMs (supports baud rates up to 115.2 kbps for RTU).
     • PROFIBUS DP: A popular fieldbus protocol for industrial automation, facilitating high-speed data exchange with DCS systems (e.g., Siemens PCS 7).
     • EPRO Proprietary Protocol: Optimized for low-latency communication with EPRO’s MMS6000/MMS3000 protection systems, ensuring real-time transmission of critical fault data (e.g., vibration alarms, shutdown triggers).
   • Supports dual communication ports (e.g., one Modbus TCP, one PROFIBUS DP) for redundant network configurations, minimizing data loss risks.
2. High-Speed Data Transmission
   • Enables real-time transfer of critical equipment parameters (e.g., vibration spectra, shaft displacement, bearing temperature) with a data update rate of up to 100 ms for time-sensitive measurements.
   • Buffers up to 1,000 historical data points (e.g., peak vibration values, alarm events) during temporary network outages, ensuring data integrity until communication is restored.
3. Rugged Design for Industrial Environments
   • Built to withstand harsh conditions in power plants and oil & gas facilities:
     • Temperature Resistance: Operates in extreme temperatures (-20°C to +70°C), suitable for turbine enclosures and outdoor installations.
     • Vibration/Shock Immunity: Compliant with IEC 60068-2-6 (vibration, 5–500 Hz) and IEC 60068-2-27 (shock, 30g peak acceleration), durable for use near rotating machinery.
     • Electromagnetic Compatibility (EMC): Compliant with IEC 61000-6-2 (industrial immunity) and IEC 61000-6-4 (industrial emissions), preventing interference with nearby electrical equipment.
4. Easy Integration & Configuration
   • Designed for plug-and-play compatibility with EPRO’s MMS series protection systems. It is automatically detected by EPRO’s configuration software (e.g., EPRO Studio), simplifying setup.
   • User-friendly configuration via EPRO Studio or web-based interface (model-dependent) allows mapping of EPRO system parameters to protocol-specific registers, customizing data transmission based on application needs.

Key Specifications

1. Electrical Parameters
   • Power Supply: 24V DC (nominal), with a wide tolerance range of 18–32V DC to accommodate industrial power fluctuations.
   • Power Consumption: ≤15W under full load (varies with active communication ports and data transmission rate).
   • Communication Interfaces:
     • 1 x RS-485 port (Modbus RTU, baud rates: 9.6 kbps–115.2 kbps).
     • 1 x Ethernet port (Modbus TCP, 10/100 Mbps).
     • 1 x PROFIBUS DP port (slave mode, baud rates: 9.6 kbps–12 Mbps).
   • Digital Inputs/Outputs: 2 digital inputs (24V DC) for external triggers (e.g., system reset); 2 digital outputs (relay contacts, 2A @ 250V AC) for status signals (e.g., communication fault).
2. Physical & Environmental Attributes
   • Form Factor: Rack-mount design (compatible with EPRO’s MMS series 19-inch cabinets), 1 rack unit (U) high.
   • Dimensions: Approximately 483 mm (width) × 44 mm (height) × 180 mm (depth) (1U form factor).
   • Environmental Ratings:
     • Operating Temperature: -20°C to +70°C.
     • Storage Temperature: -40°C to +85°C.
     • Humidity: 5–95% (non-condensing), resistant to moisture in industrial settings.
     • Ingress Protection (IP): IP20 (when mounted in a control cabinet) — protected against dust and accidental contact.
3. Performance Metrics
   • Data Update Rate: Minimum 100 ms per parameter group (configurable for slower rates to reduce network load).
   • Protocol Conversion Latency: <5 ms (ensures near-real-time data exchange between EPRO systems and external platforms).
   • Event Logging: Stores up to 1,000 timestamped events (e.g., communication loss, protocol errors) for troubleshooting.

Applications

• Turbine/Generator Monitoring:
  • Transmits real-time vibration, shaft position, and temperature data from EPRO MMS6000 systems (turbine protection) to plant DCS (e.g., Emerson DeltaV, ABB 800xA) for centralized monitoring. Enables operators to track equipment health and respond to alarms remotely.
• Compressor Condition Monitoring:
  • Integrates with EPRO MMS3000 systems (compressor protection) in oil & gas refineries, sending data to SCADA systems to monitor bearing wear, unbalance, and misalignment. Supports predictive maintenance by trending vibration spectra over time.
• Power Plant Automation:
  • Facilitates communication between EPRO’s generator protection relays and utility SCADA systems, ensuring compliance with grid codes by transmitting critical parameters (e.g., rotor speed, excitation current) for grid stability monitoring.

Availability and Support

• Condition: Available as new OEM (through Emerson Automation Solutions or authorized distributors) or genuine refurbished (via specialized industrial automation suppliers, e.g., AES Industrial, Hitech Control Systems).
• Warranty: 12-month warranty for new units (covers defects in materials/workmanship); refurbished units typically include a 6-month warranty.
• Documentation:
  • Technical datasheets, wiring diagrams, and configuration guides are accessible to Emerson customers via Emerson’s Support Portal.
  • Emerson offers technical support and training for integrating the CON021 with EPRO MMS series systems and third-party DCS/SCADA platforms.

Compatibility and Similar Products

• Compatible Systems:
  • EPRO Protection Systems: MMS6000 Turbine Monitoring System, MMS3000 Machinery Monitoring System.
  • EPRO Modules: Vibration modules (e.g., VM600), temperature modules (e.g., TM600), shaft position modules (e.g., SM600).
  • Third-Party Platforms: Siemens PCS 7, Emerson DeltaV, ABB 800xA (via Modbus/PROFIBUS), and SCADA systems (e.g., OSIsoft PI).
• Similar EPRO/Emerson Models:
  • EPRO CON022: Advanced communication module with additional protocols (e.g., Ethernet/IP, Modbus RTU over TCP).
  • Emerson AMS Device Manager Interface: Software-based interface for integrating EPRO systems with Emerson’s AMS asset management platform (complementary to hardware modules like CON021).

Installation and Maintenance Notes

1. Setup Requirements:
   • Mount in a 19-inch rack within the EPRO MMS system cabinet, ensuring proper grounding to the cabinet chassis. For power plant applications, install in a climate-controlled control room to avoid extreme temperature fluctuations.
   • Configure via EPRO Studio software to select active protocols, set baud rates/IP addresses, and map EPRO system parameters to protocol registers (e.g., Modbus holding registers).
2. Wiring Guidelines:
   • Use shielded, twisted-pair cables for RS-485 and PROFIBUS DP connections to minimize EMI interference from generator exciters or turbine control systems.
   • For Ethernet connections, use Cat5e or higher cables and ensure network switches support 10/100 Mbps communication. Ground cable shields at both ends for PROFIBUS DP; ground only at the module end for RS-485.
3. Safety & Troubleshooting:
   • Follow lockout-tagout (LOTO) procedures when wiring or servicing the CON021—interrupting communication may disable remote monitoring of critical equipment, delaying fault detection.
   • Use LED indicators to diagnose status:
     • Green (Power): Module is powered on.
     • Green (Modbus): Modbus communication active.
     • Yellow (PROFIBUS): PROFIBUS DP communication active.
     • Red (Fault): Communication error or module fault.
   • For communication failures, verify network settings (IP address, baud rate, parity) in EPRO Studio and check cable continuity with a multimeter. Protocol-specific faults may require reconfiguring register maps or updating firmware.

Critical Notes

1. Firmware Compatibility: Ensure the CON021’s firmware version is compatible with the EPRO MMS system’s firmware. Mismatched versions can cause communication failures or data corruption—check Emerson’s compatibility matrix before installation.
2. Protocol Licensing: Some advanced protocols (e.g., PROFINET) may require a separate license from Emerson. Confirm protocol availability with the supplier before integrating with third-party systems.
3. Genuine Parts Recommendation: Use genuine EPRO CON021 modules for critical rotating equipment monitoring. Aftermarket alternatives may not meet EPRO’s communication latency or EMC standards, risking delayed fault detection and equipment damage.