Emerson EPRO PR6423/011-100 Eddy Current Sensor + CON021 Converter

Emerson EPRO PR6423/011-100 Eddy Current Sensor + CON021 Converter System

The Emerson EPRO PR6423/011-100 + CON021 is a complete eddy current displacement measurement system combining a high-precision 8mm proximity probe with an advanced signal converter. This integrated solution delivers non-contact monitoring of shaft position, vibration amplitude, and axial displacement in rotating machinery applications where reliability and accuracy are mission-critical.

Technical Specifications

PR6423/011-100 Sensor Probe:

• Model Number: PR6423/011-100
• Probe Diameter: 8mm (M8 × 1 thread)
• Measurement Range: 0 to 2.0mm (0 to 80 mils)
• Linearity: ±1% of full scale over calibrated range
• Frequency Response: DC to 10 kHz (-3dB point)
• Operating Temperature: -200°C to +350°C (-328°F to +662°F)
• Cable Length: 1 meter standard (custom lengths available)
• Cable Type: Low-noise coaxial with PTFE insulation
• Housing Material: Stainless steel 316L for corrosion resistance
• Protection Rating: IP67 when properly installed

CON021 Signal Converter:

• Model Number: CON021
• Input: Eddy current probe signal (capacitance-based)
• Output Signal: 4-20mA current loop or ±10V voltage
• Output Scaling: User-configurable via DIP switches or software
• Power Supply: 18-30 VDC, 50mA typical consumption
• Accuracy: ±0.5% of full scale including linearity and temperature effects
• Temperature Coefficient: <0.02% per °C
• Response Time: <1ms for 90% of step change
• Diagnostic Outputs: Probe fault detection, cable break alarm
• Mounting: DIN rail or panel mount options
• Operating Environment: -20°C to +70°C, 5-95% RH non-condensing
• Certifications: CE, ATEX Zone 2, IECEx compliant

System Architecture & Operating Principle

The PR6423/011-100 probe generates a high-frequency electromagnetic field at its sensing tip. When positioned near a conductive target (typically a rotating shaft), eddy currents are induced in the target material. Changes in the gap between probe and target alter the electromagnetic coupling, which the probe detects as variations in impedance. The CON021 converter processes this impedance change, linearizes the response curve, and produces a proportional output signal suitable for PLC, DCS, or vibration monitoring systems.

This non-contact measurement principle offers several advantages: zero mechanical wear, immunity to contamination from oil or process fluids, and the ability to measure through thin non-conductive barriers. The system maintains calibration stability over millions of measurement cycles without drift or degradation.

Key Features & Performance Advantages

• Wide Temperature Range: Probe operates from cryogenic to high-temperature environments, enabling monitoring in extreme applications like LNG pumps and steam turbines
• High-Frequency Response: 10 kHz bandwidth captures transient events and high-speed vibration phenomena that slower sensors miss
• Integrated Diagnostics: CON021 continuously monitors probe health, detecting cable damage, connector issues, or target material changes before they cause measurement errors
• Flexible Output Options: Configurable 4-20mA or ±10V outputs interface seamlessly with existing control and monitoring infrastructure
• Rugged Construction: 316L stainless steel probe withstands corrosive chemicals, high vibration, and mechanical shock in harsh industrial environments
• Calibration Stability: Temperature-compensated electronics maintain ±0.5% accuracy across full operating range without field recalibration

Industrial Application Scenarios

Steam & Gas Turbine Monitoring: Measure axial thrust position and differential expansion in power generation turbines. The PR6423/011-100's high-temperature capability enables direct mounting near turbine casings where temperatures exceed 300°C. Real-time thrust monitoring prevents catastrophic bearing failures by detecting abnormal axial movement before contact occurs. Typical installations monitor both active and inactive thrust faces with dual-probe configurations.

Centrifugal Compressor Protection: Track shaft radial vibration and position in multi-stage compressors handling natural gas, air, or refrigerants. The system's 10 kHz bandwidth captures blade-pass frequencies and subsynchronous instabilities that indicate impending surge or bearing wear. Integration with API 670 machinery protection systems enables automatic shutdown when vibration exceeds alarm thresholds, preventing secondary damage to seals and impellers.

Large Motor & Generator Monitoring: Monitor rotor eccentricity and air gap uniformity in motors exceeding 1 MW. Uneven air gaps cause electromagnetic imbalance, leading to increased vibration and premature bearing failure. The PR6423/011-100 system detects air gap variations as small as 50 microns, allowing maintenance teams to schedule corrective action during planned outages rather than responding to emergency failures.

Pump Shaft Position Monitoring: Measure axial and radial position in critical pumps handling corrosive or high-temperature fluids. In vertical pumps, axial position monitoring detects thrust bearing wear before catastrophic failure. In horizontal pumps, radial measurements identify misalignment, foundation settling, or coupling degradation. The probe's IP67 rating and corrosion-resistant construction enable installation in wet or chemically aggressive environments.

Rolling Mill & Metal Processing: Monitor roll position and eccentricity in steel, aluminum, and paper mills. Precise gap control between work rolls and backup rolls ensures consistent product thickness and surface finish. The eddy current system's immunity to scale, coolant, and lubricants makes it ideal for harsh mill environments where optical or mechanical sensors fail rapidly.

Technical Solutions & Integration Strategies

Target Material Optimization: The system is factory-calibrated for carbon steel targets but can be field-adjusted for stainless steel, aluminum, or other conductive materials. Target surface finish affects measurement accuracy—machined surfaces with Ra <3.2 μm provide optimal results. For rough or irregular surfaces, the CON021's averaging function reduces noise while maintaining adequate response time.

Installation Best Practices: Mount the probe perpendicular to the target surface with the sensing tip positioned at the mid-range gap (typically 1.0mm for a 2.0mm range probe). This provides equal headroom for positive and negative displacement. Use thread-locking compound to prevent vibration-induced loosening, and route cables away from high-voltage power lines to minimize electromagnetic interference. The CON021 converter should be installed in a temperature-controlled enclosure when ambient conditions exceed its operating range.

Multi-Channel Systems: For comprehensive machinery monitoring, deploy multiple PR6423 probes at 90° intervals around the shaft to measure X-Y displacement and calculate orbit patterns. The CON021 converters feed individual channels into vibration monitors like the Emerson AMS 6500 or Bently Nevada 3500 systems. Synchronized sampling across channels enables advanced diagnostics including mode shape analysis and unbalance vector calculations.

Redundancy & Safety Integration: In SIL-rated safety systems, deploy dual-probe configurations with independent CON021 converters feeding 2oo3 voting logic. This architecture provides fault tolerance while maintaining safety integrity levels required for emergency shutdown systems. The CON021's diagnostic outputs integrate with safety PLCs to annunciate probe faults without triggering spurious trips.

Calibration & Commissioning

The PR6423/011-100 + CON021 system ships with factory calibration certificates traceable to national standards. Field verification requires a precision micrometer or calibrated gap gauge to establish known displacement points. Adjust the CON021's zero and span potentiometers (or digital settings) to match the desired output range. For critical applications, perform dynamic calibration using a shaker table to verify frequency response and phase characteristics across the operating bandwidth.

Maintenance & Troubleshooting

Eddy current systems require minimal maintenance due to their non-contact design. Quarterly inspections should verify cable integrity, connector tightness, and target surface condition. The CON021's diagnostic LEDs provide instant status indication: green for normal operation, yellow for marginal signal quality, and red for probe fault conditions. Common issues include target surface contamination (resolved by cleaning), cable damage from vibration (requiring cable replacement), and incorrect gap setting (corrected by probe repositioning).

Signal drift over time typically indicates target material changes (corrosion or plating) rather than sensor degradation. Recalibration restores accuracy without hardware replacement. The system's MTBF exceeds 200,000 hours under normal industrial conditions, with probe life limited primarily by mechanical damage rather than electrical failure.

System Compatibility & Expansion

The CON021 converter interfaces with all Emerson EPRO PR6423 series probes, allowing system expansion or probe replacement without converter changes. Output signals connect directly to Emerson AMS machinery health monitoring systems, DeltaV DCS analog input cards, or third-party vibration monitors supporting 4-20mA or ±10V inputs. For legacy systems using ±5V or 0-10V ranges, external signal conditioning modules provide interface compatibility.

Why Choose INDUSTRIAL CONTROL HUB?

• ✓ Genuine Emerson EPRO Components: Factory-sealed sensors and converters with full calibration certificates and traceability
• ✓ Global Express Shipping: Fast delivery to US, UK, EU, and Asia-Pacific industrial facilities with customs documentation support
• ✓ Application Engineering Support: Expert guidance on probe selection, installation design, and system integration
• ✓ Competitive Pricing: Direct sourcing ensures best value for critical vibration monitoring components
• ✓ Quality Assurance: Pre-shipment functional testing and inspection verify system performance before dispatch
• ✓ Long-Term Availability: Extensive inventory of current and legacy EPRO sensors for ongoing maintenance and expansion

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