Emerson EPRO PR6423/01M-030+CON011 Eddy Current Monitoring System

Emerson EPRO PR6423/01M-030+CON011 Complete Eddy Current Monitoring System

The Emerson EPRO PR6423/01M-030+CON011 represents a fully integrated eddy current displacement monitoring solution combining the rugged PR6423/01M-030 armored cable sensor with the advanced CON011 signal converter. This ATEX-certified system delivers reliable non-contact measurement for critical machinery protection in hazardous area applications including oil & gas, petrochemical, and explosive atmosphere environments where safety and reliability are paramount.

Integrated System Architecture

Unlike standalone components requiring field matching, the PR6423/01M-030+CON011 system arrives factory-calibrated and ready for installation. The armored cable construction (01M designation) provides mechanical protection against impact, abrasion, and crushing forces in high-vibration industrial environments, while the 30mm case thread length (configuration code '3') accommodates standard mounting bracket depths.

PR6423/01M-030 Armored Sensor Specifications

Precision Measurement Performance

The PR6423 8mm eddy current sensor delivers exceptional measurement accuracy for turbomachinery vibration monitoring and shaft position tracking:

• Linear Measurement Range: 2.0 mm (80 mils) with ±1% linearity
• Optimal Initial Gap: 0.5 mm (20 mils) for best linearity performance
• Incremental Scale Factor: 8 V/mm (203.2 mV/mil) ±5% per ISO standards
• Linearity Deviation (DSL): ±0.025 mm (±1 mil) at 0-45°C
• Minimum Target Diameter: 25 mm (0.79 inches) for ferromagnetic steel
• Target Material: 42CrMo4 or AISI/SAE 4140 ferromagnetic steel standard

Armored Cable Protection

The 01M armored cable configuration features stainless steel braided armor over PTFE-insulated conductors, providing superior mechanical protection in demanding applications:

• Resists crushing forces from equipment movement and maintenance activities
• Protects against abrasion in high-vibration environments
• Prevents cable damage from sharp edges and rotating components
• Maintains signal integrity in electrically noisy industrial settings
• Extends cable service life in harsh chemical and thermal conditions

Extreme Environment Capability

Engineered for the harshest industrial conditions, the PR6423/01M-030 sensor operates reliably across extreme temperature ranges:

• Sensor with 1m 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 water jet resistance
• Sensor Tip Material: PEEK (Polyether Ether Ketone) for chemical resistance
• Housing: Stainless steel construction for corrosion resistance
• Cable Insulation: PTFE (Polytetrafluoroethylene) rated to 150°C
• Connector: Brass nickel-plated Lemo self-locking design
• Weight: Approximately 100 grams (3.53 oz) with 1m integral cable

CON011 ATEX Certified Signal Converter

Advanced Signal Conditioning Technology

The CON011 eddy current signal converter provides high-performance signal conditioning with ATEX certification for hazardous area installations. This converter transforms the sensor's raw oscillator signal into industry-standard -2V to -18V or -4V to -20V DC outputs suitable for integration with DCS, PLC, and dedicated machinery protection systems.

Dynamic Performance Characteristics

• Frequency Response: 0 to 20,000 Hz (-3 dB) captures full vibration spectrum
• Rise Time: <15 microseconds for transient event detection
• Compatible Sensors: PR6422 (5mm), PR6423 (8mm), PR6424 (11mm), PR6425 (14mm), PR6426 (25mm)
• Extended Range Options: CON011/91x-xxx variants for extended measurement ranges
• Linearity Error: ±1.0% to ±1.5% depending on sensor and range configuration

Electrical & Power Specifications

• Supply Voltage: -23V to -32V DC (Output: -4V to -20V) or -21V to -32V DC (Output: -2V to -18V)
• Output Type: Proportional DC voltage output for direct DCS/PLC interface
• Sensor Connection: Self-locking Lemo plug prevents vibration-induced disconnection
• Power/Output Terminals: Spring-type terminals accept up to 1.5mm² wire

Robust Industrial Construction

• Housing Material: GD-ALSi9Cu3 aluminum alloy for EMI shielding and heat dissipation
• Weight: Approximately 600 grams (21.16 oz) for stable mounting
• Mounting: 4x M5x20 screws included for DIN rail or panel installation
• Operating Temperature: -30°C to 100°C (-22°F to 212°F)
• Protection Class: IP65 per IEC 60529 for dust and water jet protection
• Shock & Vibration: 5g @ 60 Hz @ 25°C withstands industrial vibration

ATEX & Hazardous Area Certifications

Explosive Atmosphere Compliance

The CON011 converter carries comprehensive ATEX certification for use in potentially explosive atmospheres, making this system ideal for oil & gas, petrochemical, and chemical processing applications:

• ATEX Directive 2014/34/EU: Equipment for explosive atmospheres
• EN 60079-0: Explosive atmospheres - General requirements
• EN 60079-11: Intrinsic safety "i" protection method
• CE 2014/30/EU: Electromagnetic compatibility (EN 61326-1)
• CE 2011/65/EU: RoHS compliance for hazardous substances restriction

Hazardous Area Installation Zones

Suitable for installation in Zone 1 and Zone 2 hazardous areas when properly installed per ATEX requirements. Consult factory documentation for specific zone classifications, temperature classes, and equipment protection levels (EPL) applicable to your installation.

Industrial Application Solutions

Offshore Oil & Gas Platform Monitoring

Deploy the PR6423/01M-030+CON011 system on offshore platforms for continuous monitoring of gas turbine generators, compressors, and pumps operating in corrosive saltwater environments. The ATEX certification enables installation in hazardous zones near wellheads and process equipment, while the armored cable withstands harsh offshore conditions including high winds, temperature extremes, and mechanical abuse.

Petrochemical Refinery Applications

Monitor critical rotating equipment in petrochemical refineries including catalytic crackers, reformers, and distillation column pumps. The system's ATEX certification permits installation in Zone 1 and Zone 2 areas near hydrocarbon processing equipment, while the IP65/IP66 protection ratings ensure reliable operation in corrosive chemical atmospheres.

Chemical Processing Plant Monitoring

Track shaft vibration and axial position in chemical process pumps, agitators, and centrifuges handling flammable or explosive materials. The armored cable construction protects against chemical spills and mechanical damage from maintenance activities, while the wide temperature range accommodates both cryogenic and high-temperature process applications.

Mining & Mineral Processing

Monitor crushers, mills, conveyors, and ventilation fans in underground mining operations where explosive methane or coal dust atmospheres require ATEX-certified instrumentation. The rugged construction withstands the extreme vibration, dust, and mechanical abuse typical of mining environments.

System Installation & Commissioning

Sensor Mounting Procedures

Install the PR6423/01M-030 sensor using these best practices for optimal performance:

• Mount sensor perpendicular to shaft surface within ±5 degrees
• Set initial air gap to 0.5 mm (20 mils) using precision feeler gauges
• Ensure rigid mounting bracket prevents sensor movement under vibration
• Verify minimum 25 mm shaft diameter at measurement location
• Route armored cable to avoid sharp bends (minimum bend radius 10x cable diameter)
• Secure cable at regular intervals to prevent whipping and fatigue
• Protect Lemo connector from moisture ingress in outdoor installations

CON011 Converter Installation

Mount the CON011 converter in a suitable electrical enclosure or control cabinet:

• Install in Zone 2 or safe area per ATEX installation requirements
• Use four M5x20 mounting screws (included) for secure attachment
• Connect sensor cable to Lemo plug ensuring positive locking engagement
• Wire -24VDC power supply (negative ground) to spring terminals
• Connect output signals to DCS/PLC analog input modules
• Ground converter housing to cabinet ground bus for EMI protection
• Verify proper polarity before energizing system

Calibration & Verification

The system ships factory-calibrated with NIST-traceable calibration documentation. Field verification procedures include:

• Verify 8 V/mm scale factor using precision gap gauges or micrometer stands
• Check output voltage at 0.5mm, 1.5mm, and 2.5mm gaps
• Confirm linearity within ±1% specification across 2mm range
• Document calibration results for machinery protection system commissioning
• Perform functional testing with machinery protection system trip points

Extended Range Configurations

CON011 Converter Variants

The CON011 converter family offers extended range options for specialized applications requiring measurement ranges beyond the standard 2mm:

• CON011/913-030: 3.0mm extended range for PR6423 sensors (±1.5% linearity)
• CON011/913-040: 4.0mm extended range for PR6423 sensors (±2.0% linearity)
• CON011/914-060: 6.0mm extended range for PR6424 11mm sensors (±1.0% linearity)
• CON011/914-080: 8.0mm extended range for PR6424 sensors (±1.5% linearity)
• CON011/914-100: 10.0mm extended range for PR6424 sensors (±2.0% linearity)

Extended range converters enable measurement of larger shaft displacements in applications with excessive bearing clearances, thermal growth, or low-speed machinery with large vibration amplitudes.

System Integration & Compatibility

Machinery Protection System Interfaces

The CON011 converter's industry-standard output interfaces directly with all major monitoring platforms:

• Bently Nevada: 3500 rack monitors, ADAPT systems, System 1 software
• Emerson AMS: 6500 machinery health monitors, AMS Suite predictive maintenance
• Rockwell Automation: ControlLogix/CompactLogix PLCs with analog input modules
• Siemens: S7-1500 PLCs, SIMATIC PCS 7 DCS, TIA Portal integration
• DCS Platforms: Emerson DeltaV, Honeywell Experion, ABB 800xA, Yokogawa CENTUM
• Safety Systems: Triconex, Hima, Siemens Safety Integrated

Multi-Channel Monitoring Architectures

Build comprehensive machinery protection systems using multiple sensor/converter pairs:

• XY vibration monitoring with two radial sensors per bearing
• Axial position monitoring with single thrust collar sensor
• Differential expansion measurement with casing-mounted sensors
• Multi-bearing monitoring on long rotor spans
• Redundant sensor configurations for critical machinery

Quality Assurance & Standards Compliance

• ATEX 2014/34/EU: Explosive atmosphere equipment directive
• EN 60079-0 & EN 60079-11: Intrinsic safety standards
• IEC 60529: IP66 (sensor) / IP65 (converter) environmental protection
• API 670: Compliant for machinery protection systems
• ISO 20816: Mechanical vibration measurement standards
• CE Marking: European conformity declaration
• RoHS Compliance: Restriction of hazardous substances
• Factory Calibration: NIST-traceable calibration certificates available

Why Partner with 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 for hazardous area applications. Our engineering team assists with ATEX compliance, system design, and field commissioning to ensure safe and reliable operation in your critical machinery protection applications.

• ✓ Genuine Emerson EPRO factory-sealed products with full traceability
• ✓ ATEX certification documentation and compliance support
• ✓ Global express shipping with protective packaging and handling
• ✓ Application engineering for hazardous area installations
• ✓ Long-term spare parts availability for legacy systems
• ✓ Volume pricing for multi-unit projects and plant-wide deployments
• ✓ Technical training and documentation library access

Complete Your Monitoring System

Build a comprehensive machinery protection solution with these compatible components:

• Emerson EPRO PR6424/000-130 - 12mm proximity probe for larger shaft applications requiring extended measurement range
• Emerson EPRO CON021+PR6424/000-030 - Alternative system with CON021 converter for non-hazardous area applications
• Emerson EPRO CON041+PR6424/006-131 - Dual-channel converter system for XY vibration monitoring pairs

Technical Support & ATEX Compliance Assistance

Our vibration monitoring specialists and ATEX compliance experts are available to assist with sensor selection, hazardous area classification, system design, and commissioning support for your Emerson EPRO PR6423/01M-030+CON011 eddy current monitoring system. Contact us for detailed technical datasheets, ATEX certificates, installation drawings, and project-specific quotations.

System Configuration: Model PR6423/01M-030+CON011 | 8mm Eddy Current Sensor | Armored Cable | 30mm Case Thread | CON011 ATEX Converter | 0-20kHz Bandwidth | 2mm Measurement Range | IP66 Sensor / IP65 Converter | -35°C to +180°C Sensor Operation | ATEX Certified | Factory Calibrated

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