Emerson EPRO PR6423/10R-030+CON021 Eddy Current Measurement System

Emerson EPRO PR6423/10R-030+CON021 Complete Eddy Current Measurement System

The Emerson EPRO PR6423/10R-030+CON021 represents a fully integrated eddy current displacement measurement solution specifically configured for North American industrial applications. This turnkey system combines the PR6423/10R-030 8mm eddy current sensor featuring 3/8"-24 UNF threading with reverse mount capability and the high-performance CON021 signal converter, delivering factory-matched precision for turbomachinery vibration monitoring, shaft position tracking, and rotating equipment protection systems.

North American Standard Configuration

Unlike metric-threaded variants, the PR6423/10R-030 features 3/8"-24 UNF (Unified National Fine) threading that directly matches North American mounting hardware standards. The 'R' designation indicates reverse mount configuration, enabling installation in space-constrained applications where standard forward mounting is impractical. The '030' suffix specifies a 55mm case thread length with 8-meter cable terminated in a Lemo connector, providing installation flexibility for deep bearing housings and remote signal conditioning locations.

PR6423/10R-030 Sensor Engineering Specifications

Measurement Performance Parameters

The PR6423 8mm eddy current sensor delivers industry-leading measurement accuracy for rotating machinery applications:

• Linear Measurement Range: 2.0 mm (80 mils) with ±1% linearity specification
• Optimal Initial Gap: 0.5 mm (20 mils) for maximum linearity and signal quality
• Incremental Scale Factor (ISF): 8 V/mm (203.2 mV/mil) ±5% from 0-45°C
• Linearity Deviation (DSL): ±0.025 mm (±1 mil) maximum across operating temperature
• Frequency Response: DC to 10 kHz sensor bandwidth (limited by converter to 20 kHz system bandwidth)

Target Material Specifications

For specified performance, the PR6423/10R-030 requires proper target material selection:

• Minimum Shaft Diameter: 25 mm (0.79 inches) to minimize curvature effects on linearity
• Standard Target Material: Ferromagnetic steel (42CrMo4 or AISI/SAE 4140)
• Surface Finish: Smooth, clean surface without coatings, rust, or contamination
• Surface Roughness: Ra < 3.2 μm (125 μin) recommended for optimal performance
• Alternative Materials: Custom calibration available for stainless steel, aluminum, or other conductive materials

Extreme Environment Capability

Engineered for the harshest industrial conditions, the sensor provides reliable operation across extreme temperature ranges:

• Sensor with 1m Integral Cable: -35°C to +180°C (-31°F to +356°F)
• Extended Cable & Connector: -35°C to +150°C (-31°F to +302°F)
• Protection Rating: IP66 per IEC 60529 - complete dust protection and high-pressure water jet resistance
• Vibration Resistance: 10g peak, 10-2000 Hz for mounting on vibrating machinery structures

Industrial-Grade Material Construction

• Sensor Tip Material: PEEK (Polyether Ether Ketone) - exceptional thermal stability to 250°C and chemical resistance
• Housing Material: 316 stainless steel for superior corrosion resistance in marine and chemical environments
• Cable Insulation: PTFE (Polytetrafluoroethylene) maintains dielectric properties at elevated temperatures
• Connector Type: Brass nickel-plated Lemo self-locking design prevents vibration-induced disconnection
• Weight: Approximately 100 grams (3.53 oz) with 1m integral cable - lightweight for minimal mounting stress
• Threading: 3/8"-24 UNF precision threads for secure installation in North American mounting brackets

CON021 Signal Converter Technical Specifications

High-Performance Signal Conditioning

The CON021 eddy current signal converter provides precision signal conditioning that transforms the sensor's raw oscillator signal into industry-standard DC voltage outputs:

• Frequency Response: DC to 20,000 Hz (-3 dB) captures both static position and dynamic vibration
• Rise Time: <15 microseconds enables detection of rapid transient events
• Output Voltage Options: -23V to -32V supply yields -4V to -20V output | -21V to -32V supply yields -2V to -18V output
• Linearity Error: ±1.0% maximum across full 2mm measurement range
• Temperature Coefficient: <0.05%/°C output drift for stable long-term measurements

Universal Sensor Compatibility

The CON021 converter supports the complete Emerson EPRO eddy current sensor family:

• PR6422 Series: 5mm tip diameter sensors for small shaft applications
• PR6423 Series: 8mm tip diameter sensors (standard range) - this product
• PR6424 Series: 11mm tip diameter sensors for larger shafts
• PR6426 Series: 25mm tip diameter sensors for very large machinery
• PR6453 Series: High-temperature variants for extreme thermal environments
• Note: PR6425 extended range sensors require CON021/91x-xxx extended range converter variant

Robust Electronics Design

• Housing Material: LMgSi 0.5 F22 aluminum alloy provides EMI/RFI shielding and heat dissipation
• Weight: Approximately 120 grams (4.24 oz) for easy panel or DIN rail mounting
• Mounting Hardware: 4x M5x20 screws included for secure installation
• Sensor Connection: Self-locking Lemo plug with positive engagement indicator
• Output Terminals: Screw terminals accept up to 1.5mm² (16 AWG) wire for field connections
• Operating Temperature: -30°C to 100°C (-22°F to 212°F) for control room or field cabinet mounting
• Protection Class: IP20 suitable for indoor electrical enclosures
• Shock & Vibration: 5g @ 60 Hz @ 25°C withstands industrial vibration environments

Industrial Application Solutions

Steam Turbine Vibration Monitoring

Deploy the PR6423/10R-030+CON021 system for continuous shaft vibration monitoring on steam turbines in power generation facilities. Install sensors in XY pairs at each bearing location to measure radial shaft displacement in two perpendicular planes. The system's 20 kHz bandwidth captures blade pass frequencies and higher-order harmonics, enabling comprehensive vibration analysis including orbit plots, Bode diagrams, and waterfall displays for predictive maintenance and machinery protection per API 670 standards.

Gas Turbine Rotor Dynamics Analysis

In gas turbine applications, monitor shaft vibration during startup, steady-state operation, and shutdown sequences to detect rotor dynamic instabilities. The sensor's high-temperature capability withstands the thermal environment near turbine bearings, while the CON021's DC response tracks slow thermal growth as the rotor expands during heat-up. This dual capability enables both vibration monitoring and differential expansion measurement in a single sensor system.

Centrifugal Compressor Thrust Monitoring

Protect critical thrust bearings in centrifugal compressors by monitoring axial shaft position. Install the PR6423/10R-030 perpendicular to the thrust collar with 0.5mm initial gap, then connect the CON021 output to your machinery protection system. Set alarm and trip setpoints to detect excessive thrust bearing wear or hydraulic thrust loads before catastrophic failure occurs. The system's ±0.025mm linearity ensures accurate position tracking for early fault detection.

Generator Rotor Eccentricity Measurement

In large generators, measure rotor eccentricity to detect magnetic center shifts, bearing wear, and foundation settlement. The reverse mount configuration enables installation in tight spaces around generator bearing housings where standard forward-mount sensors cannot fit. The 8-meter cable length accommodates routing from bearing pedestals to remote junction boxes or control rooms.

Installation Engineering Guidelines

Reverse Mount Installation Procedures

The reverse mount configuration requires specific installation techniques:

• Thread sensor into mounting bracket from the back side, allowing sensor tip to protrude through mounting surface
• Ensure 3/8"-24 UNF threads engage fully with minimum 3 full thread turns for secure mounting
• Set initial air gap to 0.5 mm (20 mils) using precision feeler gauges or gap measurement tools
• Verify sensor perpendicularity to shaft surface within ±5 degrees using alignment fixtures
• Route 8-meter cable to avoid sharp bends (minimum bend radius 25mm) and high-temperature zones
• Secure cable at regular intervals to prevent vibration-induced fatigue failures

CON021 Converter Wiring & Configuration

Proper converter installation ensures measurement accuracy and system reliability:

• Mount converter in control cabinet or junction box using four M5x20 screws (included)
• Connect 8-meter sensor cable to Lemo plug, ensuring locking collar engages fully
• Wire -24VDC power supply (negative ground) to screw terminals with proper polarity
• Connect output signals to DCS, PLC, or vibration monitor analog inputs
• Ground converter housing to cabinet ground bus to prevent EMI interference
• Verify output voltage at known gaps to confirm 8 V/mm scale factor

System Commissioning & Calibration

Commission the system following these best practices:

• Verify factory calibration using precision gap gauges at 0.5mm, 1.5mm, and 2.5mm gaps
• Document output voltages and compare to theoretical values (8 V/mm scale factor)
• Check linearity across full 2mm range to confirm ±1% specification
• Perform dynamic testing by rotating machinery and verifying vibration signal quality
• Set alarm and trip setpoints based on machinery vibration limits per API 670 or ISO 20816
• Document all calibration results for regulatory compliance and future reference

System Integration & Compatibility

Machinery Protection System Interfaces

The PR6423/10R-030+CON021 system integrates seamlessly with all major monitoring platforms:

• Bently Nevada: 3500/42M proximitor monitors, 3500/45 position monitors, ADAPT condition monitoring
• Emerson AMS: 6500 machinery health monitors, AMS Suite predictive maintenance software
• Rockwell Automation: ControlLogix 1756-IF16 analog input modules, FactoryTalk AssetCentre
• Siemens: S7-1500 PLC with SM 1231 analog inputs, SIMATIC PCS 7 DCS, SIPLUS CMS
• DCS Platforms: Emerson DeltaV, Honeywell Experion PKS, ABB 800xA, Yokogawa CENTUM VP
• Portable Analyzers: SKF Microlog, Emerson CSI 2140, Fluke 810, Pruftechnik Vibxpert

North American Installation Standards

The 3/8"-24 UNF threading complies with North American machinery standards:

• Direct compatibility with standard proximity probe mounting brackets
• Matches API 670 recommended mounting hardware specifications
• Interchangeable with legacy Bently Nevada 3300 XL 8mm proximity probes
• Simplifies retrofit installations in existing North American facilities

Quality Assurance & Regulatory Compliance

• IEC 60529: IP66 environmental protection (sensor) / IP20 (converter)
• API 670: Compliant for non-contacting vibration and axial position monitoring systems
• ISO 20816: Suitable for mechanical vibration measurement on rotating machinery
• ISO 7919: Applicable for shaft vibration measurement standards
• ATEX/IECEx: Intrinsically safe barriers available for hazardous area installations
• CE Marking: European conformity declaration for industrial control equipment
• Factory Calibration: NIST-traceable calibration certificate included with each system
• RoHS Compliance: Restriction of Hazardous Substances directive compliant

Why Choose Industrial Control Hub?

As an authorized distributor of Emerson EPRO condition monitoring solutions, Industrial Control Hub provides genuine factory-certified products with comprehensive technical support. Our application engineers offer system design consultation, installation guidance, and commissioning assistance to ensure optimal performance in your critical machinery protection applications.

• ✓ Genuine Emerson EPRO factory-sealed products with full manufacturer warranty
• ✓ Express global shipping with protective packaging and handling
• ✓ Application engineering support for sensor selection and system design
• ✓ Installation training and commissioning assistance available
• ✓ Long-term spare parts availability for legacy and current systems
• ✓ Volume project pricing for multi-sensor installations
• ✓ NIST-traceable calibration certificates and technical documentation

Compatible System Components

Complete your machinery monitoring installation with these related products:

• Emerson EPRO PR6424/000-130 - 12mm proximity probe for larger shaft diameter applications
• Emerson EPRO CON021+PR6424/010-110 - Complete 11mm sensor and converter system
• Emerson EPRO PR6424/010-040+CON021 - Alternative configuration with different cable length

Technical Support & Engineering Services

Our vibration monitoring specialists provide comprehensive support for your Emerson EPRO PR6423/10R-030+CON021 system implementation. Contact us for detailed technical datasheets, AutoCAD mounting drawings, installation procedures, calibration certificates, and project-specific quotations for multi-channel monitoring systems.

System Configuration: Model PR6423/10R-030+CON021 | 8mm Eddy Current Sensor | 3/8"-24 UNF Threading | Reverse Mount | 55mm Case Thread | 8m Cable | Lemo Connector | CON021 Converter | 2mm Range | 20kHz Bandwidth | IP66 Sensor | -35°C to +180°C | Factory Calibrated | API 670 Compliant

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