Emerson EPRO PR6423/010-030+CON021 Eddy Current Sensor with CON021 Converter

Emerson EPRO PR6423/010-030+CON021 Complete Eddy Current Measurement System

The Emerson EPRO PR6423/010-030+CON021 delivers a factory-matched eddy current displacement measurement solution engineered for precision machinery monitoring. This integrated system combines the PR6423 8mm proximity sensor with 3-meter cable and the CON021 high-bandwidth signal converter, providing turnkey installation for turbomachinery vibration analysis, shaft position tracking, and critical equipment protection applications.

System Configuration & Cable Specifications

This PR6423/010-030 configuration features a 3-meter (approximately 10 feet) PTFE-insulated cable with Lemo connector termination, optimized for installations where sensor-to-converter distances require extended reach beyond standard 1-meter cables. The 010-030 designation indicates specific case thread depth and cable length parameters, ensuring proper fit in confined mounting locations while maintaining signal integrity across the cable run.

PR6423/010-030 Sensor Technical Performance

Precision Measurement Capabilities

The PR6423 8mm eddy current sensor provides 2mm (80 mils) linear measurement range with exceptional ±1% linearity across the full span. With an incremental scale factor of 8 V/mm (203.2 mV/mil) ±5% from 0-45°C, this sensor delivers consistent, repeatable measurements for both static position monitoring and dynamic vibration analysis in rotating machinery applications.

• Linear Range: 2.0 mm (80 mils) with ±1.0% linearity error
• Recommended Air Gap: 0.5 mm (20 mils) initial standoff distance
• Scale Factor: 8 V/mm (203.2 mV/mil) ±5% temperature stability
• Linearity Deviation: ±0.025 mm (±1 mil) best-fit straight line @ 0-45°C
• Target Requirements: Minimum 25mm diameter ferromagnetic steel shaft

Industrial-Grade Environmental Protection

Designed for harsh process environments, the PR6423/010-030 sensor achieves IP66 ingress protection rating, safeguarding internal electronics from dust infiltration and high-pressure water jets. The sensor operates reliably from -35°C to +180°C (-31°F to 356°F) with the 3-meter cable assembly rated to 150°C, enabling installation in high-temperature zones near turbine casings, bearing housings, and steam systems.

Robust Material Construction

• Sensor Tip: PEEK (Polyether Ether Ketone) - exceptional thermal and chemical resistance
• Body Housing: Stainless steel construction for corrosive atmosphere protection
• Cable Insulation: PTFE (Teflon) rated to 150°C continuous operation
• Connector: Brass nickel-plated Lemo self-locking design prevents vibration loosening
• System Weight: Approximately 100 grams (3.53 oz) with 3m cable

CON021 Signal Converter Advanced Features

High-Frequency Dynamic Response

The CON021 signal conditioning module transforms the sensor's raw eddy current oscillation into industry-standard -2V to -18V or -4V to -20V linear output signals. With DC to 20 kHz frequency response (-3dB) and sub-15 microsecond rise time, this converter captures both slow thermal expansion events and high-frequency blade passing vibrations, making it ideal for comprehensive machinery health monitoring per API 670 standards.

• Bandwidth: 0 to 20,000 Hz (-3 dB) for full spectrum capture
• Transient Response: <15 μs rise time for shock and impact detection
• Sensor Compatibility: PR6422, PR6423, PR6424, PR6425, PR6426, PR6453 families
• Output Scaling: -23V to -32V supply yields -4V to -20V output | -21V to -32V supply yields -2V to -18V output
• Extended Range Option: CON021/91x-xxx variant available for PR6425 14mm sensors

Converter Physical Specifications

• Enclosure Material: LMgSi 0.5 F22 aluminum alloy with EMI shielding properties
• Unit Weight: Approximately 120 grams (4.24 oz)
• Mounting Hardware: Four M5x20 screws included for panel/DIN rail installation
• Sensor Interface: Self-locking Lemo receptacle for vibration-proof connection
• Power/Output Terminals: Screw-type accepting up to 1.5mm² (16 AWG) wire
• Operating Range: -30°C to 100°C (-22°F to 212°F) ambient temperature
• Protection Rating: IP20 for enclosed cabinet mounting environments

Application Engineering Solutions

Steam & Gas Turbine Vibration Monitoring

Deploy the PR6423/010-030+CON021 system for continuous radial vibration monitoring on steam turbines, gas turbines, and turbo-generators. The 3-meter cable length accommodates installations where converters must be located away from high-temperature bearing housings, while the 2mm measurement range captures normal operating vibration plus abnormal excursions indicating bearing degradation, rotor unbalance, or shaft misalignment.

Compressor Shaft Position & Thrust Bearing Protection

Monitor axial shaft position in centrifugal compressors to detect thrust bearing wear before catastrophic failure. The system's DC response capability tracks slow thermal growth during startup sequences, while high-frequency response captures dynamic thrust oscillations under varying load conditions. Alarm setpoints integrated with emergency shutdown systems prevent rotor-to-stator contact damage.

Pump Rotor Dynamics & Critical Speed Analysis

In high-energy pumps handling hydrocarbons or process fluids, measure shaft displacement to identify operation near critical speeds where resonance amplifies vibration. The 20 kHz bandwidth enables capture of blade pass frequencies and vane passing events, while the linear output facilitates Bode plot generation and modal analysis during commissioning and troubleshooting activities.

Generator Bearing Clearance & Eccentricity Monitoring

Track generator rotor position relative to stator bore to maintain optimal air gap clearances in large rotating electrical machines. The system's high linearity enables precise eccentricity calculations, while dual-sensor installations provide X-Y orbit analysis for detecting rotor bow, bearing wear patterns, and electromagnetic pull conditions in synchronous generators.

Installation Guidelines & Best Practices

Sensor Mounting Procedures

Install the PR6423/010-030 sensor perpendicular to the shaft surface with 0.5mm (20 mils) initial air gap using precision feeler gauges. Ensure the target shaft diameter exceeds 25mm minimum and consists of ferromagnetic steel (42CrMo4 or AISI 4140 preferred). Thread the sensor into a rigid mounting bracket to prevent movement under machinery vibration, and route the 3-meter cable away from high-voltage cables to minimize electrical interference.

CON021 Converter Installation & Wiring

Mount the CON021 converter in a control cabinet or junction box using the four M5x20 mounting screws, ensuring adequate ventilation for heat dissipation. Connect the sensor's Lemo plug to the converter receptacle with positive engagement confirmation. Wire the -24VDC power supply (negative ground) and output signals to screw terminals, maintaining proper polarity and using shielded twisted-pair cable for output runs exceeding 10 meters to monitoring systems.

System Calibration & Validation

Verify the factory-calibrated 8 V/mm scale factor using micrometer-controlled gap adjustment or precision shim stock. Measure output voltage at 0.5mm, 1.5mm, and 2.5mm gaps to confirm linearity within ±1% specification. Document baseline readings during commissioning for future trending analysis, and establish alarm setpoints based on machinery manufacturer recommendations or industry standards like API 670 or ISO 20816.

Monitoring System Integration

Compatible Vibration Monitoring Platforms

The CON021 converter's industry-standard output voltage interfaces seamlessly with:

• Bently Nevada 3500 and ADAPT machinery protection systems
• Emerson AMS 6500 ATG and AMS Machinery Manager platforms
• Rockwell Automation ControlLogix and CompactLogix PLCs with analog input modules
• Siemens S7-1500 and TIA Portal with high-resolution analog cards
• DCS platforms including Emerson DeltaV, Honeywell Experion, ABB 800xA
• Portable analyzers from SKF, Pruftechnik, and CSI for diagnostic testing

Sensor Family Interchangeability

The CON021 converter supports the complete Emerson EPRO proximity sensor portfolio including PR6422 (5mm tip), PR6423 (8mm tip), PR6424 (11mm tip), PR6425 (14mm extended range), PR6426 (25mm tip), and PR6453 (high-temperature) models. This flexibility enables standardization on a single converter platform while selecting optimal sensor sizes for different shaft diameters and measurement range requirements across your facility.

Compliance & Quality Certifications

• IEC 60529: IP66 environmental sealing (sensor) / IP20 (converter)
• API 670: Machinery protection system compliance for critical equipment
• ISO 20816: Vibration severity evaluation standards compatibility
• CE Marking: European conformity for industrial machinery applications
• Factory Calibration: NIST-traceable calibration certificates available upon request
• RoHS Compliant: Lead-free construction meeting environmental directives

Why Partner with Industrial Control Hub?

As a trusted supplier of Emerson EPRO condition monitoring solutions, Industrial Control Hub delivers factory-genuine products backed by comprehensive technical support. Our application engineers assist with sensor selection, system architecture design, and post-installation troubleshooting to maximize uptime in your critical rotating equipment assets.

• ✓ Authentic Emerson EPRO factory-sealed components with full traceability
• ✓ Worldwide express shipping with protective packaging for delicate sensors
• ✓ Pre-sales application engineering consultation and system design support
• ✓ Long-term spare parts inventory for legacy and current product lines
• ✓ Volume pricing programs for multi-unit projects and plant-wide deployments

Complementary Products for Complete Systems

Build comprehensive vibration monitoring solutions with these compatible components:

• Emerson EPRO PR6423/003-020 - 8mm eddy current sensor with 2m cable for medium-distance installations
• Emerson EPRO PR6424/000-130 - 12mm proximity probe for larger shaft diameters and extended measurement ranges
• Emerson EPRO PR6426/010-100 - 32mm eddy current sensor for heavy industrial machinery and large turbines

Technical Support & Procurement

Our experienced team provides expert guidance on Emerson EPRO PR6423/010-030+CON021 system integration, calibration procedures, and troubleshooting support. Contact us for detailed technical datasheets, dimensional drawings, wiring diagrams, and project-specific quotations tailored to your machinery monitoring requirements.

Quick Reference: Model PR6423/010-030+CON021 | 8mm Eddy Current Sensor | 3m Cable Length | CON021 Converter | 2mm Measurement Range | 0-20kHz Bandwidth | IP66 Sensor Rating | -35°C to +180°C Operation | M10x1 Threading | Lemo Connector | Factory Calibrated System

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