Emerson EPRO PR6423/011-010+CON021 Eddy Current Sensor & Converter Kit

Emerson EPRO PR6423/011-010+CON021 Complete Eddy Current Measurement Kit

The Emerson EPRO PR6423/011-010+CON021 delivers a factory-matched eddy current measurement solution engineered for precision shaft displacement and vibration monitoring in critical rotating machinery. This integrated kit combines the PR6423/011-010 8mm proximity sensor with 3/8"-24 UNF threading and 5-meter cable alongside the CON021 high-bandwidth signal converter, providing a plug-and-play system for turbomachinery protection and condition monitoring applications.

Complete System Integration

Unlike standalone sensors requiring separate converter selection and calibration, this PR6423/011-010+CON021 kit arrives factory-calibrated as a matched pair. The system eliminates compatibility concerns and reduces commissioning time, delivering immediate measurement capability for steam turbines, gas turbines, centrifugal compressors, and high-speed generators where shaft vibration and position monitoring are critical for safe operation.

PR6423/011-010 Sensor Configuration Details

Mechanical Specifications

The PR6423/011-010 variant features 3/8"-24 UNF case threading optimized for North American machinery installations where imperial thread standards predominate. The 8mm sensing tip diameter provides the ideal balance between spatial resolution and measurement range, while the 5-meter integral cable length accommodates typical distances between bearing housings and control cabinets without requiring field splicing.

• Thread Type: 3/8"-24 UNF (imperial standard for US machinery)
• Tip Diameter: 8mm (0.315 inches) for standard shaft applications
• Cable Length: 5.0 meters (16.4 feet) factory-terminated
• Cable Configuration: Standard non-armored PTFE insulation
• Connector Type: Lemo self-locking plug for vibration immunity
• Case Thread Extension: 35mm (1.38 inches) - Configuration "1"

Measurement Performance

Engineered for micron-level precision, the sensor delivers 2mm linear measurement range with exceptional accuracy across industrial temperature extremes. The 8 V/mm scale factor provides high signal-to-noise ratio for reliable detection of both slow thermal growth and high-frequency vibration events up to 10 kHz.

• Linear Range: 2.0 mm (80 mils) with ±1% linearity error
• Recommended Gap: 0.5 mm (20 mils) initial standoff distance
• Scale Factor: 8 V/mm (203.2 mV/mil) ±5% from 0-45°C
• Linearity Deviation: ±0.025 mm (±1 mil) maximum error
• Minimum Target Diameter: 25 mm (0.98 inches) ferromagnetic steel
• Target Material: 42CrMo4 or AISI 4140 steel (other materials on request)

Environmental Durability

Designed for the harshest industrial environments, the PR6423 sensor withstands extreme temperatures, corrosive atmospheres, and high-vibration installations. IP66 protection ensures reliable operation in outdoor installations and wash-down environments common in power generation and petrochemical facilities.

• Protection Rating: IP66 per IEC 60529 (dust-tight, water jet resistant)
• Operating Temperature: -35°C to +180°C (-31°F to +356°F) sensor with 1m cable
• Cable Temperature Rating: -35°C to +150°C (-31°F to +302°F)
• Sensor Tip Material: PEEK (Polyether Ether Ketone) high-temperature polymer
• Housing Material: Stainless steel for corrosion resistance
• Cable Insulation: PTFE (Teflon) for chemical and thermal stability
• Weight: Approximately 100 grams (3.53 oz) with 1m cable

CON021 Signal Converter Technical Specifications

Signal Processing Architecture

The CON021 converter transforms the sensor's raw oscillator signal into industry-standard voltage outputs compatible with DCS systems, PLCs, and dedicated vibration monitors. With DC to 20 kHz frequency response and sub-15 microsecond rise time, this converter captures both static position changes during thermal transients and dynamic vibration signatures including blade pass frequencies in high-speed turbomachinery.

• Frequency Response: 0 to 20,000 Hz (-3 dB bandwidth)
• Rise Time: <15 microseconds for transient event capture
• Compatible Sensors: PR6422, PR6423, PR6424, PR6425, PR6426, PR6453 families
• Extended Range Support: Use CON021/91x-xxx for PR6425 extended range sensors

Electrical Interface

Flexible power supply options accommodate various control system architectures, while dual output voltage ranges support both legacy Bently Nevada systems and modern DCS analog input modules. Screw terminal connections accept up to 1.5mm² wire for secure field terminations.

• Supply Voltage Option 1: -23V to -32V DC (Output: -4V to -20V)
• Supply Voltage Option 2: -21V to -32V DC (Output: -2V to -18V)
• Sensor Connection: Self-locking Lemo plug (vibration-proof)
• Output Connection: Screw terminals for 1.5mm² max wire gauge
• Operating Temperature: -30°C to +100°C (-22°F to +212°F)
• Protection Class: IP20 for panel/cabinet mounting

Physical Construction

• Housing Material: LMgSi 0.5 F22 aluminum alloy with EMI shielding
• Weight: Approximately 120 grams (4.24 oz)
• Mounting: 4x M5x20 screws (included in delivery)
• Shock & Vibration: 5g @ 60 Hz @ 25°C operational rating

Industrial Application Solutions

Steam & Gas Turbine Monitoring

Deploy the PR6423/011-010+CON021 system for continuous shaft vibration surveillance on utility and industrial turbines. Monitor radial vibration at each bearing location to detect unbalance, misalignment, bearing wear, and rotor rubs before they escalate to catastrophic failures. The system's 20 kHz bandwidth captures blade pass frequencies for early detection of blade cracking and aerodynamic instabilities.

Centrifugal Compressor Protection

In critical gas compression services, measure shaft displacement to protect against thrust bearing failures and surge-induced vibration. The DC-coupled response tracks slow axial position changes during load transients, while the high-frequency capability detects impeller-induced vibration and rotating stall phenomena that precede compressor surge.

Generator Rotor Monitoring

Monitor generator shaft eccentricity and vibration to comply with IEEE and IEC standards for rotating electrical machinery. Detect rotor bow during startup, track thermal growth during load changes, and identify electrical faults manifesting as 2x line frequency vibration components. The system's accuracy supports predictive maintenance programs that maximize generator availability.

Pump & Motor Diagnostics

Apply eddy current measurement to critical pumps and motors where bearing condition directly impacts process reliability. Measure shaft runout during commissioning to establish baseline signatures, then track vibration trends to schedule bearing replacements before unplanned outages occur. The non-contact measurement eliminates wear associated with contacting probes.

Installation & Commissioning Guidelines

Sensor Mounting Procedures

Install the PR6423/011-010 sensor perpendicular to the shaft surface using the 3/8"-24 UNF threads. Thread the sensor into a rigid mounting bracket or bearing housing boss, ensuring the mounting surface is flat and perpendicular to the shaft axis. Set the initial air gap to 0.5mm using feeler gauges or by advancing the sensor until contact, then backing off 0.5mm and locking with the jam nut.

Converter Installation Best Practices

Mount the CON021 converter in a clean, dry control cabinet away from high-voltage switchgear and variable frequency drives that generate electrical noise. Use the four M5x20 mounting screws to secure the converter to a DIN rail or panel. Connect the sensor Lemo plug first, ensuring positive engagement, then wire the -24VDC power supply and output signals to screw terminals with proper polarity.

System Calibration & Verification

Verify the factory calibration by measuring output voltage at known gap distances using precision shims or micrometer-controlled target positioning. The system should produce 8 V/mm scale factor across the 2mm linear range. Document baseline gap voltages at operating temperature for future reference during troubleshooting and trend analysis.

Control System Integration

DCS & PLC Connectivity

The CON021's -2V to -18V or -4V to -20V output directly interfaces with analog input modules from major automation vendors:

• Emerson DeltaV and Ovation DCS systems
• Honeywell Experion and TDC 3000 platforms
• ABB 800xA and Symphony Plus controllers
• Rockwell Automation ControlLogix and CompactLogix PLCs
• Siemens S7-1500 and PCS 7 systems

Vibration Monitor Compatibility

The system output is compatible with dedicated machinery protection monitors including:

• Bently Nevada 3500 and ADAPT monitoring systems
• Emerson AMS 6500 machinery health monitors
• SKF Multilog and IMx systems
• Brüel & Kjær Vibro VM600 platforms
• Portable analyzers from CSI, Pruftechnik, and Fluke

Quality Assurance & Compliance

• IEC 60529: IP66 environmental protection (sensor) / IP20 (converter)
• API 670: Machinery protection system compliance
• ISO 20816: Vibration severity evaluation standards
• CE Marking: European conformity declaration
• Factory Calibration: NIST-traceable calibration certificate available upon request
• Quality System: Manufactured under ISO 9001 certified processes

Why Partner with Industrial Control Hub?

As a trusted supplier of Emerson EPRO condition monitoring solutions, Industrial Control Hub delivers genuine factory-sealed products backed by comprehensive technical support. Our application engineers assist with sensor selection, system architecture design, and field commissioning to ensure optimal performance in your critical machinery applications.

• ✓ Authentic Emerson EPRO factory-matched sensor/converter kits
• ✓ Worldwide express shipping with protective packaging
• ✓ Pre-sales application engineering consultation
• ✓ Post-sales technical support and troubleshooting
• ✓ Long-term spare parts availability for lifecycle support
• ✓ Volume pricing for multi-machine projects

Complementary Products for Complete Systems

Build comprehensive vibration monitoring systems with these compatible components:

• Emerson EPRO PR6423/004-010 - 8mm sensor with 10m cable for extended distances
• Emerson EPRO CON021+PR6423/00M-030 - Alternative configuration with M10x1 threading
• Emerson EPRO PR6423/003-031 - Replacement sensor for existing installations

Technical Support & Ordering

Our experienced application engineers are available to assist with sensor selection, cable length optimization, and system integration for your Emerson EPRO PR6423/011-010+CON021 eddy current measurement system. Contact us for detailed datasheets, dimensional drawings, wiring diagrams, and project-specific quotations.

Quick Reference: Model PR6423/011-010+CON021 | 8mm Eddy Current Sensor | 3/8"-24 UNF Threading | 5m Cable Length | CON021 Converter Included | 0-20kHz Bandwidth | 2mm Measurement Range | IP66 Sensor Rating | Factory Calibrated System | NIST Traceable

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