Emerson EPRO PR6423/011-000+CON011 Eddy Current Sensor with CON011 Converter

Emerson EPRO PR6423/011-000+CON011 Complete Eddy Current Measurement System

The Emerson EPRO PR6423/011-000+CON011 delivers a fully integrated eddy current displacement measurement solution, pairing the industry-proven PR6423 8mm proximity sensor with the robust CON011 signal converter. This ATEX-certified system provides reliable shaft displacement and vibration monitoring for critical rotating machinery in hazardous area applications, including oil & gas, petrochemical, and power generation facilities.

System Integration & Design Philosophy

Unlike standalone sensor solutions, this PR6423/011-000+CON011 system arrives as a matched pair, factory-calibrated to deliver optimal linearity and scale factor accuracy. The CON011 converter's IP65 environmental protection enables installation in harsh industrial enclosures, while its ATEX Zone 2 certification permits deployment in potentially explosive atmospheres where traditional monitoring equipment cannot operate.

PR6423 Eddy Current Proximity Sensor Specifications

Precision Measurement Capabilities

The PR6423 sensor utilizes advanced eddy current technology to measure shaft displacement with exceptional accuracy across a 2mm linear range. The 8mm tip diameter provides optimal sensitivity for standard industrial shaft sizes, while the 8 V/mm scale factor delivers high signal-to-noise ratio for both static position and dynamic vibration measurements.

• Linear Measurement Range: 2.0 mm (80 mils) with ≤1.0% linearity error
• Recommended Initial Gap: 0.5 mm (20 mils) for optimal linearity
• Incremental Scale Factor: 8 V/mm (203.2 mV/mil) ±5% from 0-45°C
• Linearity Deviation: ±0.025 mm (±1 mil) across temperature range
• Minimum Target Diameter: 25 mm (0.79 inches) ferromagnetic steel
• Target Material: 42CrMo4 or AISI 4140 steel (other materials available)

Extreme Environment Performance

Engineered for the harshest industrial conditions, the PR6423 proximity sensor operates reliably from -35°C to +180°C (-31°F to 356°F) with 1-meter integral cable. The sensor tip features PEEK (Polyether Ether Ketone) construction for superior chemical resistance and dimensional stability at elevated temperatures, while the stainless steel housing withstands corrosive process environments.

Rugged Construction Details

• Protection Rating: IP66 per IEC 60529 (dust-tight, high-pressure water jets)
• Sensor Tip: PEEK thermoplastic for 180°C continuous operation
• Housing: Stainless steel for corrosion resistance
• Cable: PTFE insulation rated to 150°C continuous
• Connector: Brass nickel-plated Lemo self-locking design
• Weight: 100 grams (3.53 oz) with 1m cable
• Thread Options: M10x1 metric or 3/8"-24 UNF

CON011 Signal Converter Technical Specifications

High-Performance Signal Conditioning

The CON011 signal converter transforms the sensor's raw eddy current oscillation into industry-standard -2V to -18V or -4V to -20V DC outputs suitable for DCS, PLC, and machinery protection systems. With DC to 20 kHz frequency response and sub-15 microsecond rise time, this converter captures both slow thermal expansion and high-frequency rotor dynamics including blade pass frequencies.

• Frequency Response: 0 to 20,000 Hz (-3 dB) for full dynamic range
• Rise Time: <15 microseconds for transient event capture
• Compatible Sensors: PR6422 (5mm), PR6423 (8mm), PR6424 (11mm), PR6425 (14mm), PR6426 (25mm)
• Output Voltage Options: -4V to -20V (with -23V to -32V supply) or -2V to -18V (with -21V to -32V supply)
• Linearity Error: ≤1.0% to ≤1.5% depending on sensor and range

Hazardous Area Certification

The CON011 converter carries full ATEX certification per EN 60079-0 and EN 60079-11, enabling installation in Zone 2 hazardous areas without additional barriers or purge systems. This certification significantly reduces installation costs and complexity in refineries, offshore platforms, and chemical processing facilities.

• ATEX Certification: EN 60079-0, EN 60079-11 for Zone 2 applications
• CE Compliance: 2014/30/EU (EN 61326-1) EMC directive
• Environmental Directives: 2014/34/EU, 2011/65/EU (RoHS)
• Protection Class: IP65 (dust-tight, low-pressure water jets)

Physical & Electrical Characteristics

• Housing Material: GD-ALSi9Cu3 aluminum alloy for EMI shielding
• Weight: 600 grams (21.16 oz) for robust construction
• Mounting: 4x M5x20 screws (included in package)
• Sensor Connection: Self-locking Lemo plug prevents vibration loosening
• Power/Output: Spring-type terminals accepting 1.5mm² wire
• Operating Temperature: -30°C to 100°C (-22°F to 212°F)
• Shock & Vibration: 5g @ 60 Hz @ 25°C per IEC standards

Application-Specific Solutions

Steam & Gas Turbine Monitoring

Deploy the PR6423/011-000+CON011 system for continuous shaft vibration and position monitoring on steam turbines, gas turbines, and turbo-expanders. The 2mm measurement range accommodates normal bearing clearances while detecting abnormal vibration that indicates bearing degradation, rotor unbalance, or alignment issues before catastrophic failure occurs.

Compressor Protection Systems

Monitor axial and radial shaft position in centrifugal and axial compressors to protect against thrust bearing failure and rotor-to-stator contact. The system's DC response tracks slow thermal growth during startup, while the 20 kHz bandwidth captures surge events and aerodynamic instabilities that can destroy compressor internals.

Generator & Motor Shaft Monitoring

Measure shaft displacement in large generators and motors to detect electrical and mechanical faults. The system identifies rotor eccentricity, magnetic pull, and bearing wear patterns that reduce efficiency and lead to unplanned outages. Integration with protection relays enables automatic shutdown before damage occurs.

Pump Reliability Monitoring

Install on critical pumps handling hazardous or high-value fluids to monitor bearing condition and detect cavitation, recirculation, and hydraulic instabilities. The ATEX certification permits installation in Zone 2 pump houses without expensive explosion-proof enclosures, reducing total cost of ownership.

Hazardous Area Applications

The CON011's ATEX Zone 2 certification makes this system ideal for offshore oil platforms, LNG facilities, refineries, and chemical plants where explosive atmospheres may occur during abnormal conditions. The IP65 rating protects against salt spray, chemical vapors, and high-pressure washdown common in these environments.

Installation & Configuration Best Practices

Sensor Mounting Procedures

Mount the PR6423 sensor perpendicular to the shaft surface using the M10x1 or 3/8"-24 UNF threads. Set the initial air gap to 0.5mm using precision shims or gap gauges to center the measurement range. Ensure the target shaft diameter exceeds 25mm and uses ferromagnetic steel (42CrMo4 or AISI 4140) for specified performance. Secure the sensor body to prevent movement under vibration.

Converter Installation Guidelines

Mount the CON011 converter in a control cabinet or junction box using the four M5x20 mounting screws. Connect the sensor via the Lemo plug, ensuring the self-locking mechanism fully engages. Wire the -24VDC power supply and output signals to the spring terminals, maintaining correct polarity. Ground the converter housing to the cabinet ground bus to prevent EMI interference.

System Calibration & Validation

Verify the 8 V/mm scale factor using precision gap gauges or micrometer-controlled target positioning. The system ships factory-calibrated, but field verification confirms measurement accuracy after installation. Check output voltage at 0.5mm, 1.5mm, and 2.5mm gaps to verify linearity within specification. Document calibration results for compliance with API 670 and ISO 20816 standards.

Wiring & Grounding for Hazardous Areas

In ATEX Zone 2 installations, follow EN 60079-14 wiring practices. Use appropriate cable glands rated for the area classification. Maintain proper cable segregation between intrinsically safe and non-intrinsically safe circuits. Ground the converter housing and cable shields at a single point to prevent ground loops while maintaining safety earth continuity.

System Integration & Compatibility

Monitoring System Interfaces

The CON011 converter's -2V to -18V or -4V to -20V output directly connects to:

• Bently Nevada 3500, ADAPT, and Orbit 60 monitoring systems
• Emerson AMS 6500 and CSI 6500 machinery health monitors
• Rockwell ControlLogix and CompactLogix with analog input modules
• Siemens S7-1500 and TIA Portal with high-resolution AI cards
• DCS platforms: Emerson DeltaV, Honeywell Experion, Yokogawa Centum
• Portable analyzers: SKF Microlog, Pruftechnik Vibxpert

Extended Range Options

For applications requiring measurement ranges beyond 2mm, the CON011 converter supports extended range variants including CON011/913-030 (3mm), CON011/913-040 (4mm), and larger ranges up to 24mm with PR6426 sensors. Consult the ordering information table to select the appropriate converter model for your measurement requirements.

Quality Certifications & Standards Compliance

• ATEX: EN 60079-0, EN 60079-11 for Zone 2 hazardous areas
• CE Marking: 2014/30/EU (EMC), 2014/34/EU (ATEX), 2011/65/EU (RoHS)
• IEC 60529: IP66 (sensor) / IP65 (converter) environmental protection
• API 670: Suitable for machinery protection system applications
• ISO 20816: Compatible with vibration severity assessment standards
• Factory Calibration: NIST-traceable calibration documentation available

Why Choose Industrial Control Hub?

As a trusted supplier of Emerson EPRO condition monitoring solutions, Industrial Control Hub delivers genuine factory-certified products backed by comprehensive technical support. Our engineering team provides application assistance, system design consultation, and post-installation troubleshooting to ensure optimal performance in your critical machinery applications.

• ✓ Genuine Emerson EPRO factory-sealed components
• ✓ Worldwide express shipping with protective packaging
• ✓ Application engineering and technical support
• ✓ Long-term spare parts availability and lifecycle support
• ✓ Competitive pricing for multi-unit projects
• ✓ ATEX and hazardous area application expertise

Recommended Complementary Products

Expand your machinery monitoring capabilities with these compatible Emerson EPRO components:

• Emerson EPRO PR6423/000-001 - Replacement 8mm eddy current sensor for system upgrades
• Emerson EPRO PR6424/000-130 - 12mm proximity probe for larger shaft applications
• Emerson EPRO PR6453/110-101 - High-temperature eddy current sensor for extreme environments

Technical Support & Ordering

Our application engineers are available to assist with sensor selection, system configuration, ATEX compliance, and integration support for your Emerson EPRO PR6423/011-000+CON011 eddy current measurement system. Contact us for detailed datasheets, ATEX certificates, CAD models, and project-specific quotations.

Key Specifications: Model PR6423/011-000+CON011 | 8mm Eddy Current Sensor | 2mm Linear Range | CON011 IP65 Converter | 0-20kHz Bandwidth | ATEX Zone 2 Certified | -35°C to +180°C Sensor | M10x1 Threading | Factory Matched System

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