Product Overview

The Epro PR6424/010-120 + CON010 16 mm Eddy Current Sensor is an industrial measurement solution designed for non-contact monitoring of shaft displacement, vibration, and relative movement in rotating machinery. It belongs to the EPRO PR6424 series, which is used in machinery condition-monitoring and protection applications.

The system is particularly relevant to equipment such as steam turbines, gas turbines, hydro turbines, compressors, pumps, and industrial fans. These machines operate with rotating shafts and bearings that require continuous condition monitoring. Changes in shaft position, vibration amplitude, and mechanical clearance can provide important information about equipment operating conditions.

Unlike contact-based measurement devices, an eddy current sensor measures the distance between the probe and a conductive target without physically touching the rotating surface. This makes it suitable for continuous monitoring in machinery where direct contact could introduce wear or interfere with normal operation.

The PR6424/010-120 is the 16 mm sensing probe, while CON010 identifies the associated converter configuration supplied with the product listing. Together, the components form part of a measurement chain that detects shaft movement and converts the sensor response into an electrical signal for compatible monitoring equipment.

The PR6424 series is designed for demanding rotating-machinery applications. Its measurement characteristics support shaft vibration monitoring, axial and radial displacement measurement, eccentricity monitoring, and other machinery-condition assessment tasks.

The 16 mm probe diameter is an important identification feature when selecting a replacement. The probe’s thread, cable arrangement, connector, calibration characteristics, and converter compatibility should also be checked before installation.

Technical Specifications

Note: The technical values above describe the PR6424 sensor family. Confirm the complete PR6424/010-120 and CON010 configuration, cable length, connector, and converter specifications before replacement or system commissioning. The supplied weight of 0.32 kg is retained as the product listing value.

Function and Working Principle

The Epro PR6424/010-120 uses eddy current technology to measure the distance between the probe and a conductive target. When installed near a rotating shaft, the probe generates an electromagnetic field. The conductive shaft influences this field, and changes in the distance between the probe and the target affect the sensor’s electrical response.

The associated converter processes the sensor signal so that the measurement can be used by compatible machinery-monitoring equipment.

1. Non-Contact Displacement Measurement

The probe is installed near the surface of a rotating shaft without making physical contact. As the shaft moves toward or away from the probe, the distance changes.

The sensor detects these variations and produces a measurement response corresponding to the relative shaft position.

This arrangement is useful for monitoring shaft movement in turbines, compressors, and other rotating machines where continuous measurement is required.

2. Eddy Current Measurement Principle

The sensor operates by generating a high-frequency electromagnetic field near the conductive target. This field induces eddy currents in the target material.

The induced currents affect the electromagnetic characteristics of the probe. As the distance between the probe and the shaft changes, the electrical response also changes.

The associated signal-processing equipment converts these changes into a usable measurement signal.

The measurement depends on the target material and surface characteristics. For reliable results, the probe must be calibrated for the specified target material and installed with the correct initial gap.

3. Shaft Vibration Monitoring

During normal operation, a rotating shaft may move slightly due to mechanical vibration, bearing clearance, load changes, and other operating conditions.

The PR6424 sensor can detect these relative movements without contacting the shaft. Its dynamic measurement capability allows monitoring equipment to analyze shaft vibration and identify changes in vibration behavior.

This information can support machinery condition assessment and maintenance planning.

4. Axial and Radial Displacement Measurement

The probe can be used in suitable installation arrangements to monitor different directions of shaft movement.

• Radial displacement: Measures movement of the shaft relative to the probe in a radial direction.
• Axial displacement: Measures movement along the shaft’s longitudinal axis when installed in an appropriate position.
• Eccentricity: Helps identify changes in the shaft’s geometric position during rotation.

The measurement direction depends on probe placement and the mechanical arrangement of the monitored equipment.

5. Signal Conversion

The PR6424 probe is part of a measurement system that requires suitable signal-conditioning or conversion equipment.

The CON010 designation in this product combination should be verified against the actual converter label and documentation. The probe and converter must have matching electrical characteristics, calibration, and connection arrangements.

The final output must be compatible with the connected machinery-monitoring system. A converter should not be substituted solely because it has a similar connector or product appearance.

Role in Industrial Machinery Monitoring Systems

The PR6424/010-120 + CON010 assembly can form part of a machinery protection and condition-monitoring arrangement. It supplies measurement information that helps operators and maintenance engineers evaluate the condition of critical rotating equipment.

Turbine Monitoring

Steam, gas, and hydro turbines contain rotating shafts operating under demanding mechanical and thermal conditions. Shaft vibration and displacement monitoring help maintenance teams observe changes that may indicate mechanical imbalance, bearing problems, misalignment, or abnormal operating conditions.

A properly installed eddy current sensor can provide continuous shaft-position measurements for compatible turbine-monitoring equipment.

Compressor Protection

Industrial compressors are widely used in petrochemical plants, gas processing facilities, refineries, and manufacturing systems.

Shaft vibration and displacement measurements are important for monitoring compressor mechanical condition. The PR6424 sensor can be installed at suitable measurement points to monitor shaft movement and provide information for machinery protection systems.

Pump Monitoring

Large industrial pumps may operate continuously and are often essential to production processes. Abnormal shaft movement can be associated with bearing wear, alignment problems, hydraulic conditions, or mechanical damage.

Non-contact displacement measurement can help maintenance personnel identify changes in pump operating behavior.

PLC and DCS Integration

The sensor itself is not a PLC or DCS input module. It operates as part of a measurement chain that includes the probe, compatible converter or signal-conditioning equipment, and a monitoring interface.

Depending on the installed system, processed signals may be connected to machinery-monitoring modules or other compatible control and monitoring equipment.

Before integration, verify the signal type, electrical range, terminal arrangement, and input requirements of the receiving device.

Industrial Applications

1. Steam Turbines

Steam turbines are used in power generation and industrial energy systems. Continuous monitoring of shaft vibration and displacement can help identify changes in mechanical operating conditions.

The PR6424 series is designed for critical turbomachinery applications and can be used in suitable turbine-monitoring arrangements.

2. Gas Turbines

Gas turbines operate at high rotational speeds and require reliable monitoring of mechanical behavior. Shaft displacement and vibration measurements can provide information about rotor movement and machine condition.

Correct probe positioning, target material, and calibration are essential for reliable readings.

3. Hydro Turbines

Hydroelectric generating equipment uses large rotating assemblies that may experience mechanical movement under changing operating conditions.

Non-contact displacement sensors can be used to monitor shaft behavior and support condition-based maintenance programs.

4. Industrial Compressors

Centrifugal and other industrial compressors require machinery monitoring to help maintain reliable operation.

The PR6424 sensor can be used in suitable configurations to measure shaft displacement and vibration. Monitoring data may help identify changes associated with bearing wear, rotor imbalance, or mechanical misalignment.

5. Industrial Pumps

Large pumps used in water treatment, power plants, and process industries may require continuous shaft-condition monitoring.

A properly installed sensor can provide relative shaft movement measurements to a compatible monitoring system.

6. Industrial Fans

Large industrial fans are used in ventilation, cooling, combustion-air, and material-handling applications. Shaft vibration monitoring can help identify mechanical changes that may affect fan reliability.

The sensor may be used where the shaft geometry, target material, and measurement arrangement meet the PR6424 application requirements.

Installation and System Integration

Correct installation is essential for accurate measurement and reliable machinery monitoring.

1. Verify Probe Identification

Before installation, confirm the complete model number:

• PR6424/010-120
• Associated converter designation: CON010
• Sensor head diameter: 16 mm

Also verify the probe thread, overall length, cable length, connector, and any supplied mounting accessories.

The 16 mm head diameter alone is not sufficient to establish full mechanical and electrical compatibility.

2. Select the Correct Mounting Position

The probe should be installed at the measurement point specified by the machinery-monitoring design.

The mounting arrangement must maintain a stable distance between the probe and the target surface. Avoid positions where the probe may contact the rotating shaft during operation or where mechanical vibration could loosen the mounting assembly.

For shaft vibration measurement, probe orientation and mounting stiffness are important factors.

3. Set the Initial Air Gap

The initial air gap must be established according to the manufacturer’s installation procedure and the applicable measurement range.

The PR6424 series has a nominal center air gap of approximately 2.7 mm. The actual setup should be confirmed using the correct converter, calibration data, and measurement procedure.

Incorrect probe spacing can reduce the usable measurement range or cause inaccurate readings.

4. Check the Target Material

The PR6424 sensor is designed for use with conductive ferromagnetic targets, with specified performance based on a standard steel target material.

Differences in target material, surface condition, shaft geometry, and dimensions can affect measurement characteristics.

Verify the target material and calibration requirements before commissioning.

5. Cable Routing and Connection

Route the probe cable according to the manufacturer’s recommendations. Avoid unnecessary bending, mechanical tension, and contact with hot or moving equipment.

Keep sensor wiring away from high-power cables and sources of electromagnetic interference where possible.

Check connector condition and cable continuity before energizing the measurement system.

6. Verify Converter Compatibility

The associated CON010 component must be checked against the exact PR6424 probe configuration.

Confirm:

• Probe and converter model compatibility.
• Supply voltage and polarity.
• Connector type and pin arrangement.
• Output signal characteristics.
• Calibration and scaling information.
• Receiving monitoring-module requirements.

Do not assume that different EPRO converter models are interchangeable.

7. Commissioning and Functional Testing

After installation, verify the mechanical mounting, electrical connections, initial air gap, and measurement output.

Compare the sensor reading with the expected shaft position. Check for abnormal signal fluctuations, unstable output, or wiring faults.

Record the installation gap and final measurement settings for future maintenance.

Compatible System Components

The PR6424/010-120 + CON010 is part of a broader machinery-monitoring measurement chain.

The table describes typical components of a measurement installation. It does not mean that all components are included in the supplied product package.

Alternative Models and Replacement Considerations

The EPRO PR6424 family includes different probe configurations and cable arrangements. Replacement selection should be based on the complete model designation and measurement requirements.

When selecting an alternative, compare:

• Sensor head diameter.
• Probe length and mounting thread.
• Cable length and cable protection.
• Connector type.
• Probe and converter calibration.
• Sensitivity and linearity.
• Static and dynamic measurement ranges.
• Target material and shaft dimensions.
• Operating temperature requirements.
• Monitoring-system input compatibility.

A probe with the same nominal diameter may still have a different cable, connector, or calibration. Always verify the complete part number before ordering.

Key Advantages

Non-Contact Measurement

The eddy current operating principle allows shaft displacement to be measured without physical contact between the probe and the rotating target.

Suitable for Critical Rotating Machinery

The PR6424 series is designed for machinery such as turbines, compressors, pumps, and fans where shaft-condition monitoring is important.

Dynamic Displacement Measurement

The sensor supports dynamic measurement of shaft movement, making it useful for vibration-monitoring applications.

High Measurement Sensitivity

The published PR6424 series sensitivity is 4 V/mm, with linearity of up to ±1.5% under the specified measurement conditions.

Industrial Construction

The stainless-steel sleeve and PTFE cable construction are intended for demanding industrial measurement environments.

Integration with Machinery Monitoring

When paired with the correct converter and monitoring equipment, the probe can provide measurement information for machinery condition assessment and protection.

Support for Predictive Maintenance

Continuous shaft-displacement measurements can help maintenance teams identify changes in operating behavior and plan inspections before mechanical problems cause extended downtime.

Technical FAQs

1. What is the Epro PR6424/010-120 + CON010?

It is an EPRO eddy current sensor combination consisting of a PR6424/010-120 probe and an associated CON010 component. It is intended for non-contact measurement of shaft displacement and vibration in rotating machinery.

2. What is the sensor head diameter?

The specified sensor head diameter is 16 mm.

3. What is the measurement principle?

The sensor uses eddy current technology. An electromagnetic field interacts with the conductive target, and changes in the probe-to-target distance affect the electrical response.

4. What is the sensitivity of the PR6424 sensor?

The published PR6424 series sensitivity is 4 V/mm, with a linearity specification of no more than ±1.5% under the specified conditions.

5. What is the measurement range?

The published static range is ±2.0 mm, while the dynamic measurement range is 0–1000 μm.

6. What equipment can use this sensor?

It is designed for suitable rotating machinery, including steam turbines, gas turbines, hydro turbines, compressors, pumps, and fans. The complete measurement chain must be compatible with the installed monitoring system.

7. Can the sensor connect directly to a PLC?

The probe should not be treated as a standard PLC input device. It requires compatible signal-conversion and monitoring equipment. The processed output may then be connected to a suitable PLC or DCS interface.

8. Is the CON010 component interchangeable with other EPRO converters?

Interchangeability should not be assumed. Confirm the exact converter model, probe compatibility, supply requirements, connector, and calibration characteristics.

9. What should be checked before purchasing a replacement?

Check the full part number, sensor head diameter, probe length, thread, cable length, connector, converter model, and calibration requirements. Confirm the unit’s physical condition and packaging contents.

10. What is the supplied weight?

The supplied product listing weight is 0.32 kg. Confirm whether this represents the complete probe-and-converter package or a particular shipping configuration before calculating freight.

Procurement and Maintenance Recommendations

When purchasing the Epro PR6424/010-120 + CON010, verify the full identification details rather than relying only on the PR6424 series name. Probe length, cable configuration, connector, converter type, and calibration are all important to system compatibility.

For replacement projects, compare the existing sensor’s nameplate and installation documentation with the proposed unit. Confirm the mechanical mounting arrangement, target material, operating temperature, cable routing, and monitoring-system input requirements.

For used or refurbished equipment, request clear photographs of the probe, cable, connector, and associated converter. Check for damaged cable insulation, bent or worn connectors, corrosion, and visible mechanical damage. Where possible, request functional test information and confirm the supplier’s warranty and return conditions.

During maintenance, inspect the probe mounting and cable condition regularly. Ensure that the probe remains securely installed and that the initial air gap has not changed. Review measurement trends for unexpected shifts, unstable readings, or abnormal vibration patterns.

Maintain records of probe position, calibration, cable configuration, and converter identification. These details make future replacement and troubleshooting more efficient.

Conclusion

The Epro PR6424/010-120 + CON010 16 mm Eddy Current Sensor is designed for non-contact shaft displacement and vibration measurement in critical rotating machinery. Its applications include turbines, compressors, pumps, and industrial fans.

The PR6424 series provides a published sensitivity of 4 V/mm, linearity of up to ±1.5%, a static measurement range of ±2.0 mm, and a dynamic range of 0–1000 μm under specified conditions.

For industrial maintenance and machinery protection projects, correct probe installation, target material, converter compatibility, and calibration are essential. Verifying the complete PR6424/010-120 + CON010 configuration helps ensure that a replacement sensor can operate correctly within the existing monitoring system.