Emerson EPRO PR6423/00R-010+CON021 Eddy Current Sensor System

Emerson EPRO PR6423/00R-010+CON021 Eddy Current Sensor System Overview

The Emerson EPRO PR6423/00R-010+CON021 represents a complete eddy current displacement measurement solution, combining the precision PR6423 8mm sensor with the high-performance CON021 signal converter. This integrated system delivers exceptional accuracy for turbomachinery vibration monitoring, shaft displacement measurement, and critical rotating equipment protection in demanding industrial environments.

System Architecture & Integration

This turnkey measurement system pairs the PR6423/00R-010 eddy current proximity sensor with the CON021 signal conditioning module, creating a seamless interface between mechanical displacement and control system inputs. The sensor's 8mm tip diameter and M10x1 threading enable installation in tight spaces, while the converter's wide frequency response ensures capture of both static position and dynamic vibration signatures up to 20 kHz.

PR6423 Eddy Current Sensor Technical Specifications

Measurement Performance

• Linear Measurement Range: 2.0 mm (80 mils) with ±1.0% linearity
• Initial Air Gap: 0.5 mm (20 mils) recommended standoff
• Incremental Scale Factor (ISF): 8 V/mm (203.2 mV/mil) ±5% @ 0-45°C
• Deviation from Best Fit Straight Line: ±0.025 mm (±1 mil) @ 0-45°C
• Minimum Target Diameter: 25 mm (0.79 inches) for ferromagnetic steel

Environmental Ruggedness

Engineered for extreme industrial conditions, the PR6423 sensor features IP66 protection rating and operates reliably from -35°C to +180°C (-31°F to 356°F) with 1m cable. The sensor tip utilizes PEEK (Polyether Ether Ketone) for chemical resistance and thermal stability, while the stainless steel housing withstands corrosive atmospheres. PTFE-insulated cabling maintains signal integrity in high-temperature zones up to 150°C.

Construction & Materials

• Sensor Tip Material: PEEK (Polyether Ether Ketone) - high temperature polymer
• Housing: Stainless steel for corrosion resistance
• Cable Insulation: PTFE (Polytetrafluoroethylene) rated to 150°C
• Connector: Brass, nickel-plated Lemo self-locking design
• Weight: Approximately 100 grams (3.53 oz) with 1m cable

CON021 Signal Converter Specifications

Dynamic Performance Characteristics

The CON021 signal converter transforms the sensor's raw eddy current signal into industry-standard -2V to -18V or -4V to -20V outputs compatible with DCS, PLC, and vibration monitoring systems. With frequency response from DC to 20 kHz (-3dB) and rise time under 15 microseconds, this converter captures both slow thermal growth and high-frequency blade pass events.

• Frequency Range: 0 to 20,000 Hz (-3 dB bandwidth)
• Rise Time: <15 microseconds for transient capture
• Compatible Sensors: PR6422, PR6423, PR6424, PR6425, PR6426, PR6453 series
• Output Voltage: -23V to -32V supply: -4V to -20V output | -21V to -32V supply: -2V to -18V output

Physical & Electrical Design

• Housing Material: LMgSi 0.5 F22 aluminum alloy for EMI shielding
• Weight: Approximately 120 grams (4.24 oz)
• Mounting: 4x M5x20 screws (included)
• Sensor Connection: Self-locking Lemo plug for vibration resistance
• Output Connection: Screw terminals accepting up to 1.5mm² wire
• Operating Temperature: -30°C to 100°C (-22°F to 212°F)
• Protection Class: IP20 for panel/cabinet mounting

Application Solutions

Turbomachinery Vibration Monitoring

Deploy the PR6423/00R-010+CON021 system for continuous shaft vibration monitoring on steam turbines, gas turbines, compressors, and generators. The 2mm measurement range accommodates normal operating clearances while detecting abnormal vibration amplitudes that indicate bearing wear, unbalance, misalignment, or rotor rubs before catastrophic failure occurs.

Axial Position & Thrust Monitoring

Monitor axial shaft position to detect thrust bearing degradation in rotating equipment. The system's DC response and high linearity enable precise tracking of thermal growth during startup and load changes, while alarm setpoints protect against thrust bearing failure that could destroy machinery.

Blade Tip Timing & Clearance

In turbine applications, measure blade tip clearance to optimize efficiency and prevent blade rubs. The 20 kHz bandwidth captures individual blade passing events, enabling blade tip timing analysis for crack detection and vibration mode identification in high-speed turbomachinery.

Seismic Monitoring & Casing Vibration

When mounted to machinery casings or bearing housings, the system measures absolute vibration for seismic monitoring applications. This complements shaft-relative measurements to provide complete machinery health diagnostics per API 670 and ISO 20816 standards.

Installation & Configuration Guidelines

Sensor Mounting Best Practices

Install the PR6423 sensor perpendicular to the target shaft surface with 0.5mm initial air gap. Ensure the minimum shaft diameter of 25mm and use ferromagnetic steel targets (42CrMo4 or AISI 4140) for specified performance. Thread the M10x1 case threads into a rigid mounting bracket to prevent sensor movement under vibration.

Converter Wiring & Grounding

Mount the CON021 converter in a control cabinet using the four M5x20 mounting screws. Connect the sensor via the Lemo plug, ensuring positive locking engagement. Wire the -24VDC power supply and output signals to screw terminals, maintaining proper polarity. Ground the converter housing to prevent EMI interference in electrically noisy environments.

System Calibration & Verification

Verify the 8 V/mm scale factor using precision gap gauges or micrometer-controlled target positioning. The system ships factory-calibrated, but field verification ensures measurement accuracy after installation. Check output voltage at known gaps to confirm linearity within ±1% specification across the 2mm range.

Compatibility & System Integration

Monitoring System Interfaces

The CON021 converter's -2V to -18V or -4V to -20V output directly interfaces with:

• Bently Nevada 3500 and ADAPT monitoring systems
• Emerson AMS 6500 machinery health monitors
• Rockwell Automation and Siemens PLCs with analog input modules
• DCS systems (Emerson DeltaV, Honeywell Experion, ABB 800xA)
• Portable vibration analyzers and data acquisition systems

Sensor Family Compatibility

The CON021 converter supports the complete Emerson EPRO eddy current sensor family including PR6422 (5mm), PR6423 (8mm), PR6424 (11mm), PR6425 (14mm extended range), PR6426 (25mm), and PR6453 (high-temperature) models. For PR6425 extended range sensors, specify CON021/91x-xxx extended range converter variant.

Quality Standards & Certifications

• IEC 60529: IP66 environmental protection (sensor) / IP20 (converter)
• API 670: Compliant for machinery protection systems
• ISO 20816: Suitable for vibration severity assessment
• CE Marking: European conformity for industrial environments
• Factory Calibration: NIST-traceable calibration certificate available

Why Choose Industrial Control Hub?

As an authorized distributor of Emerson EPRO vibration monitoring solutions, Industrial Control Hub provides genuine factory-certified products with full technical support. Our engineering team assists with sensor selection, system design, and troubleshooting to ensure optimal performance in your critical machinery applications.

• ✓ Genuine Emerson EPRO factory-sealed products
• ✓ Global express shipping with secure packaging
• ✓ Technical application engineering support
• ✓ Long-term spare parts availability
• ✓ Competitive pricing for volume projects

Related Products You May Need

Complete your vibration monitoring system with these compatible components:

• Emerson EPRO CON021+PR6424/010-110 - 11mm eddy current sensor system for larger shafts
• Emerson EPRO PR6423/000-001 - Replacement 8mm eddy current sensor
• Emerson EPRO PR6424/000-130 - 12mm proximity probe for extended range applications

Technical Support & Ordering Information

Our application engineers are available to assist with sensor selection, system configuration, and integration support for your Emerson EPRO PR6423/00R-010+CON021 eddy current measurement system. Contact us for technical datasheets, CAD drawings, and project-specific quotations.

Product Specifications Summary: Model PR6423/00R-010+CON021 | 8mm Eddy Current Sensor | 2mm Range | CON021 Converter | 0-20kHz Bandwidth | IP66 Sensor | -35°C to +180°C | M10x1 Threading | Lemo Connector | Factory Calibrated

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