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- 16 mm Eddy Current Sensor
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Product Overview
The Epro PR6424/102-100 16 mm Eddy Current Sensor is a non-contact displacement sensor designed for monitoring the operating condition of rotating machinery. Belonging to the EPRO PR6424 sensor family from Emerson, it is used in machinery protection and condition-monitoring applications where accurate measurement of shaft movement, vibration, position, and eccentricity is important.
Unlike contact-based measurement devices, an eddy current sensor measures the distance between its sensing tip and a conductive metallic target without requiring physical contact. This operating principle makes it suitable for continuous monitoring of rotating shafts in turbines, compressors, pumps, fans, and other critical industrial equipment.
The PR6424 family uses a 16 mm sensing head and is designed for applications involving relatively large rotating shafts. Its typical sensitivity is 4 V/mm, with a static measurement range of ±2.0 mm and a dynamic measurement range of 0 to 1,000 μm peak-to-peak. The nominal center air gap is approximately 2.7 mm under the specified measurement conditions.
The sensor generates a measurement signal that can be processed by a compatible EPRO signal converter and monitoring system. The resulting measurement can be used to evaluate shaft vibration, displacement, axial position, eccentricity, and other operating characteristics.
In industrial installations, the PR6424/102-100 can form part of a machinery monitoring arrangement that helps operators identify abnormal shaft movement and investigate potential mechanical problems before they develop into more serious equipment failures.
The exact cable, connector, mounting, and certification configuration should be checked against the complete product identification before installation or replacement. Different PR6424 variants may share the same basic sensing technology while having different mechanical and connection details.
Technical Specifications
| Parameter | Specification |
|---|---|
| Brand | Epro / EPRO |
| Manufacturer | Emerson |
| Model | PR6424/102-100 |
| Product Series | PR6424 |
| Product Type | Eddy Current Sensor |
| Measurement Principle | Non-contact eddy current |
| Sensor Head Diameter | 16 mm |
| Typical Sensitivity | 4 V/mm |
| Linearity | ≤ ±1.5% |
| Static Measurement Range | ±2.0 mm |
| Dynamic Measurement Range | 0–1,000 μm peak-to-peak |
| Nominal Center Air Gap | Approximately 2.7 mm |
| Long-Term Drift | Less than 0.3% |
| Reference Target Material | Ferromagnetic steel, 42CrMo4 standard |
| Reference Shaft Diameter | ≥80 mm |
| Operating Temperature | -35°C to +150°C, according to the current PR6424 specification sheet |
| Sensor Head Pressure Resistance | 10,000 hPa (145 psi) |
| Shock and Vibration Reference | 5 g at 60 Hz and 25°C |
| Sleeve Material | Stainless steel |
| Cable Material | PTFE |
| Weight Provided | 0.2 kg |
| Typical Applications | Turbines, compressors, pumps, fans, and rotating machinery |
Note: The performance values above are PR6424 family specifications. Confirm the exact /102-100 variant’s cable, connector, mounting thread, temperature limits, and certification details before ordering or installation.
Function and Working Principle
The PR6424/102-100 operates using the eddy current measurement principle. It detects changes in the distance between the sensor head and a suitable conductive target, such as a ferromagnetic steel shaft.
The measurement process is based on electromagnetic interaction rather than physical contact. This makes the sensor useful for monitoring rotating components that move continuously during machine operation.
1. Non-Contact Displacement Measurement
An alternating electrical signal in the sensor creates an electromagnetic field around the sensing head. When a conductive metallic target approaches the sensor, eddy currents are induced in the target surface.
These currents affect the electromagnetic field and change the electrical characteristics of the sensor system. A compatible converter processes this response and produces an output related to the distance between the probe and the target.
As the shaft moves closer to or farther away from the sensor, the measured signal changes accordingly. This allows the monitoring system to identify shaft displacement without mechanical contact.
2. Shaft Vibration Monitoring
During normal operation, rotating shafts may experience small radial movements caused by imbalance, misalignment, bearing conditions, or changing mechanical loads.
The PR6424 measures these movements as changes in the probe-to-shaft distance. When installed as part of a suitable measurement system, the resulting signal can be used to calculate shaft vibration.
Continuous vibration monitoring helps maintenance personnel observe changes in machine behavior and identify conditions that may require further inspection.
3. Axial Position Measurement
The sensor can also be used in suitable arrangements to monitor axial shaft displacement. Axial movement is particularly important in turbines and compressors, where rotor position must remain within the permitted mechanical limits.
By monitoring changes in the distance between the probe and the target surface, the system can provide information about rotor movement along the shaft axis.
The installation geometry and monitoring configuration must be designed for the required measurement direction.
4. Eccentricity and Position Detection
Shaft eccentricity describes the deviation between the shaft’s geometric center and its rotational axis. Excessive eccentricity can contribute to vibration, uneven loading, and abnormal mechanical behavior.
The PR6424 measurement system can provide displacement information that helps identify eccentricity and changes in shaft position.
Accurate results depend on correct probe installation, suitable target material, mechanical alignment, and appropriate converter calibration.
5. Signal Conversion and Monitoring
The sensor is normally used with a compatible signal converter rather than as an independent measurement display device.
The converter supplies the required excitation and processes the sensor response. Its output can then be connected to a machinery protection or condition-monitoring system.
The complete measurement chain must be compatible. Probe type, extension cable, connector, converter, calibration, and target material all affect measurement performance.
Role in Industrial Machinery Protection Systems
The Epro PR6424/102-100 is intended for use in machinery monitoring applications where shaft movement provides important information about equipment condition.
Turbine Monitoring
Steam, gas, and hydro turbines operate with high-speed rotating assemblies. Monitoring shaft vibration and displacement helps operators assess rotor behavior and identify abnormal operating conditions.
A PR6424 sensor can be installed at an appropriate measurement location to monitor radial or axial shaft movement, depending on the mechanical arrangement.
Compressor Condition Monitoring
Industrial compressors operate under changing pressure, temperature, and load conditions. Changes in rotor behavior can indicate developing mechanical problems.
Non-contact shaft measurement provides useful information for evaluating vibration and position in critical compressor installations.
Pump and Fan Monitoring
Large pumps and industrial fans may experience vibration changes caused by imbalance, bearing wear, coupling problems, or hydraulic and aerodynamic operating conditions.
A shaft displacement sensor can provide measurement data for machinery monitoring systems that support condition-based maintenance.
Integration with Monitoring Equipment
The sensor’s output is processed by a compatible converter and monitoring equipment. The monitoring system may provide vibration values, shaft position information, alarms, and trip functions according to the overall protection design.
The PR6424 probe itself is only one part of the measurement chain. Correct converter selection and system configuration are essential for reliable operation.
Industrial Applications
1. Steam Turbines
Steam turbines require continuous monitoring of rotor movement and vibration. Abnormal shaft displacement may be associated with rotor imbalance, bearing problems, thermal changes, or mechanical contact.
The PR6424 sensor can be used in suitable turbine monitoring arrangements to provide non-contact shaft displacement measurements.
2. Gas Turbines
Gas turbines operate under demanding mechanical and thermal conditions. Rotor monitoring is important for evaluating machine stability and identifying changes in vibration behavior.
A compatible eddy current measurement system can help monitor shaft movement at selected measurement locations.
3. Hydro Turbines
Hydro turbine installations contain large rotating assemblies that may require continuous shaft-position and vibration monitoring.
The PR6424 family is designed for applications involving large shafts and can be considered for appropriate hydro turbine measurement arrangements.
4. Centrifugal Compressors
Centrifugal compressors are widely used in petrochemical facilities, natural gas processing plants, refineries, and industrial gas systems.
Shaft vibration and displacement measurements can help maintenance teams assess rotor behavior and investigate abnormal machine conditions.
5. Industrial Pumps
Large process pumps often operate continuously and are important to production reliability. Monitoring shaft movement can help identify mechanical changes that may affect pump operation.
The sensor can be used as part of a suitable pump monitoring arrangement when its measurement range and mechanical configuration match the installation.
6. Industrial Fans and Blowers
Large fans and blowers may experience changing vibration levels as operating conditions vary. Non-contact displacement monitoring can provide useful information for evaluating shaft movement in suitable equipment.
Installation and System Integration
Correct installation is essential for achieving reliable measurements from an eddy current sensor.
1. Verify the Sensor Configuration
Before installation, check the complete model number, sensor head diameter, cable arrangement, connector type, mounting thread, and required converter.
Do not assume that all PR6424 probes are interchangeable simply because they share the same 16 mm sensing-head diameter.
The extension cable and converter must be compatible with the selected sensor configuration.
2. Confirm the Target Material
The PR6424 family specifications use ferromagnetic steel, with 42CrMo4 as the standard reference target material.
Different shaft materials can affect sensor calibration and measurement performance. If the actual target material differs from the standard reference material, verify whether the measurement chain requires material-specific calibration.
The target surface should also be suitable for stable measurement. Surface irregularities, contamination, and mechanical damage can influence the measurement signal.
3. Establish the Correct Air Gap
The nominal center air gap for the PR6424 family is approximately 2.7 mm.
The final installation gap must follow the applicable sensor and converter documentation. An incorrect gap can reduce measurement range or cause the system to operate outside its intended linear region.
Use the specified setup procedure and appropriate measurement equipment when adjusting the probe position.
4. Secure the Sensor Mechanically
Install the sensor using the correct mounting hardware and thread arrangement for the exact variant.
The probe should be secured against vibration and mechanical movement. Its sensing tip must be aligned with the intended target surface and positioned to avoid accidental contact during shaft movement.
Do not apply excessive mechanical force to the sensor body or cable connection.
5. Route and Protect the Cable
The cable should be routed away from excessive mechanical stress, sharp edges, high-temperature surfaces, and sources of electrical interference.
Maintain the minimum bending radius specified for the actual cable construction. Avoid pulling, twisting, or sharply bending the cable near the sensor or connector.
The exact cable length and connector arrangement should be confirmed before designing the installation.
6. Connect the Compatible Converter
Connect the sensor to the designated EPRO converter using the specified cable and connector arrangement.
A mismatched converter, extension cable, or probe configuration may cause incorrect readings or prevent the system from operating correctly.
Check the complete measurement chain before commissioning.
7. Perform Calibration and Functional Testing
After installation, verify the air gap, target material, signal response, and converter configuration.
Check that the measurement output changes consistently as the target distance changes. Confirm that the monitoring system displays plausible shaft-position and vibration values.
Record the final installation settings and measurement-chain configuration for future maintenance.
Compatible System Components
The PR6424/102-100 should be treated as part of a complete machinery measurement chain. The following components describe typical system roles; exact part-number compatibility must be confirmed before ordering.
| Component | Function | Compatibility Considerations |
|---|---|---|
| EPRO signal converter | Excites the probe and processes its measurement response | Must match the PR6424 sensor configuration |
| Extension cable | Connects the probe to the converter | Verify cable type, length, connector, and electrical compatibility |
| Machinery protection system | Processes vibration and position measurements | Confirm supported signal input and monitoring configuration |
| Shaft or target surface | Provides the metallic measurement target | Material and surface condition affect calibration |
| Probe mounting bracket | Holds the sensor in the correct position | Must provide secure mounting and adjustment |
| Monitoring display | Presents measurement values and alarms | Depends on the connected monitoring system |
| PLC or DCS | Uses suitable measurement signals for process monitoring | Signal conditioning and interface requirements must be checked |
| Grounding and cable accessories | Support reliable installation and signal integrity | Follow the system wiring and installation instructions |
Alternative Models and Replacement Considerations
The PR6424 family includes different probe configurations. Although some models share the same basic 16 mm sensing technology, their cable, connector, mounting, and ordering details may differ.
| Related Model or Option | Replacement Considerations |
|---|---|
| EPRO PR6424 series variants | Compare complete model numbers, cable construction, connector, mounting, and calibration |
| EPRO PR6425 series | A related 16 mm sensor family designed for higher-temperature applications; not automatically interchangeable |
| EPRO PR6423 series | Uses a different sensing-head size and measurement range; requires a separate compatibility assessment |
| Compatible CON-series converters | Must be selected according to the sensor and complete measurement-chain configuration |
| Complete replacement measurement chain | May be required when the original probe, cable, and converter configuration cannot be matched |
Before selecting a replacement, compare:
- Sensor model and complete ordering code.
- Sensing-head diameter.
- Static and dynamic measurement ranges.
- Sensitivity and linearity.
- Target material and shaft diameter.
- Operating temperature requirements.
- Mounting thread and mechanical dimensions.
- Cable type, length, and connector.
- Converter compatibility.
- Required certifications and hazardous-area approvals.
A sensor with the same nominal diameter is not necessarily a direct replacement. The complete measurement chain must be evaluated to preserve calibration and measurement accuracy.
Key Advantages
Non-Contact Measurement
The eddy current principle allows the sensor to monitor shaft displacement without physical contact, making it suitable for continuously rotating machinery.
16 mm Sensing Head
The 16 mm probe design is intended for applications involving relatively large rotating shafts and critical turbomachinery.
Shaft Vibration and Position Monitoring
The PR6424 family supports measurement of radial and axial displacement, position, eccentricity, and related shaft movement.
Stable Measurement Characteristics
The published family specifications include a typical sensitivity of 4 V/mm, linearity of ≤ ±1.5%, and long-term drift below 0.3%.
Industrial Temperature Capability
The current PR6424 specification sheet lists an operating temperature range of -35°C to +150°C. The exact limit for the selected sensor configuration should be confirmed before installation.
Integration with Machinery Monitoring Systems
When connected to a compatible converter, the sensor can provide measurement information to machinery protection and condition-monitoring equipment.
Support for Predictive Maintenance
Continuous shaft measurement can help maintenance teams observe changes in machine behavior and investigate developing mechanical problems.
Technical FAQs
1. What is the Epro PR6424/102-100?
The Epro PR6424/102-100 is identified as a 16 mm eddy current sensor in the PR6424 family. It is designed for non-contact measurement of shaft displacement and vibration in rotating machinery.
2. What is the sensor head diameter?
The sensor head diameter is 16 mm.
3. What is the measurement principle?
It uses the eddy current principle. The sensor generates an electromagnetic field, and changes in the distance to a conductive target affect the sensor response. A compatible converter processes this response into a measurement signal.
4. What is the typical sensitivity of the PR6424 family?
The published typical sensitivity is 4 V/mm, equivalent to approximately 101.6 mV/mil, with a stated linearity of ≤ ±1.5%.
5. What is the static measurement range?
The PR6424 family has a published static measurement range of ±2.0 mm.
6. What is the dynamic measurement range?
The published dynamic measurement range is 0 to 1,000 μm peak-to-peak. The actual usable range depends on the complete measurement configuration and installation conditions.
7. What material should be used as the measurement target?
The standard reference target material is ferromagnetic steel, specifically 42CrMo4. Different target materials may affect calibration and should be checked against the applicable documentation.
8. Can the sensor be used for turbine vibration monitoring?
Yes. The PR6424 family is designed for critical turbomachinery applications, including steam, gas, and hydro turbines, as well as compressors, pumps, and fans.
9. Does the sensor work without a signal converter?
The PR6424 is normally used as part of a measurement chain with a compatible EPRO signal converter. The converter provides the required excitation and processes the sensor response.
10. Can the PR6424/102-100 replace another PR6424 model?
Not automatically. The complete model number, cable, connector, mounting configuration, calibration, and converter compatibility should be checked before replacement.
Procurement and Maintenance Recommendations
When purchasing the Epro PR6424/102-100, verify the complete model number and inspect the probe, cable, connector, and mounting components. Since the PR6424 family includes multiple mechanical and electrical configurations, matching only the 16 mm sensing-head diameter is insufficient for a reliable replacement.
For critical machinery applications, confirm the sensor’s compatibility with the existing converter and monitoring system. Check the target material, measurement range, air gap, and required operating temperature before installation.
During maintenance, inspect the sensor body and cable for mechanical damage, contamination, and signs of overheating. Check the mounting arrangement and verify that the probe has not moved from its commissioned position.
Where abnormal readings occur, inspect the complete measurement chain rather than replacing the sensor immediately. Cable damage, incorrect air gap, target-surface condition, converter mismatch, or calibration problems can all affect measurement performance.
Keep a record of the sensor model, converter model, cable configuration, installation gap, target material, and commissioning measurements. This information can simplify future troubleshooting and help ensure that replacement parts match the original system.
Conclusion
The Epro PR6424/102-100 16 mm Eddy Current Sensor is intended for non-contact shaft displacement and vibration measurement in critical rotating machinery. The PR6424 family provides a typical sensitivity of 4 V/mm, a static measurement range of ±2.0 mm, and a dynamic measurement range of 0 to 1,000 μm peak-to-peak.
Its measurement capabilities make it suitable for appropriately configured monitoring systems used with turbines, compressors, pumps, fans, and other industrial rotating equipment. For maintenance and replacement projects, the complete sensor configuration and compatibility with the signal converter should always be verified to maintain reliable measurement performance.