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- PR6424/103-100
- 16 mm Eddy Current Sensor
- Germany
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Product Overview
The Epro PR6424/103-100 16 mm Eddy Current Sensor is a non-contact displacement measurement device designed for monitoring the operating condition of rotating machinery. It belongs to the PR6424 sensor family developed for machinery protection and condition monitoring applications, particularly in industrial environments where accurate shaft movement measurements are important.
Manufactured under the EPRO product line associated with Emerson, the PR6424 series is used in applications involving steam turbines, gas turbines, hydro turbines, compressors, pumps, and fans. Its primary purpose is to measure changes in the distance between the sensor tip and a suitable metallic target. These measurements can be used to evaluate shaft vibration, radial and axial displacement, shaft position, eccentricity, and speed-related characteristics.
Unlike contact-based measurement devices, an eddy current sensor does not need to physically touch the rotating shaft. This non-contact operating principle makes it suitable for continuous monitoring of high-speed rotating equipment, where mechanical contact could cause wear or interfere with the measurement.
The PR6424/103-100 has a nominal sensor head diameter of 16 mm. Its compact sensing head allows installation in appropriately designed machinery monitoring arrangements. The sensor is typically used with a compatible signal converter and the required extension or connection components to form a complete measurement chain.
The PR6424 family is specified with a sensitivity of 4 V/mm and a static measurement range of ±2.0 mm. Its dynamic measurement range is 0 to 1,000 μm peak-to-peak. These characteristics allow the sensor system to detect relatively small changes in shaft position and vibration.
For industrial maintenance teams, the PR6424/103-100 can serve as a replacement component in existing machinery monitoring systems, provided that its electrical characteristics, cable arrangement, connector, mounting dimensions, and converter compatibility match the installed equipment.
Technical Specifications
| Parameter | Specification |
|---|---|
| Brand | Epro / EPRO |
| Manufacturer | Emerson |
| Model | PR6424/103-100 |
| Product Series | PR6424 |
| Product Type | Eddy Current Sensor |
| Measurement Principle | Non-contact eddy current |
| Sensor Head Diameter | 16 mm |
| Sensitivity | 4 V/mm |
| Sensitivity 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% |
| Standard Target Material | Ferromagnetic steel, 42CrMo4 |
| Recommended Shaft Diameter | ≥80 mm |
| Sensor Sleeve Material | Stainless steel |
| Cable Material | PTFE |
| Operating Temperature | Depends on the applicable sensor specification and exact configuration |
| Sensor Weight | Approximately 0.2 kg |
| Sensor Head Diameter Classification | 16 mm |
| Typical Applications | Turbines, compressors, pumps, fans, and rotating machinery |
Note: The technical performance values describe the PR6424 sensor family. Exact cable length, connector type, armor, thread configuration, and temperature rating should be verified for the PR6424/103-100 variant before installation.
Function and Working Principle
The PR6424/103-100 operates using the eddy current measurement principle. It generates an electromagnetic field near the sensor tip and detects changes caused by the movement of a conductive metallic target.
This approach allows the sensor to measure shaft movement without physical contact.
1. Electromagnetic Field Generation
The sensing element inside the probe produces an alternating electromagnetic field. When the sensor is positioned near a conductive metallic surface, the field induces small electrical currents known as eddy currents within the target.
The strength and distribution of these currents depend on the distance between the sensor and the metallic surface.
2. Displacement Detection
When a rotating shaft moves closer to or farther away from the sensor, the electromagnetic interaction changes. The sensor system detects this change and produces a corresponding electrical response.
The resulting signal can be processed by a compatible signal converter to provide a measurement proportional to the distance between the sensor and the target.
This measurement principle makes the PR6424 suitable for monitoring small shaft movements that may indicate changes in machinery operating conditions.
3. Shaft Vibration Measurement
Shaft vibration is an important indicator of rotating machinery condition. Excessive vibration can be associated with imbalance, misalignment, looseness, bearing-related problems, or other mechanical abnormalities.
When installed in an appropriate position, the PR6424 can detect dynamic shaft displacement. The measurement can then be used by a machinery monitoring system to evaluate vibration trends and identify abnormal changes.
4. Shaft Position Measurement
The sensor can also measure static shaft position within its specified measuring range. This is useful for monitoring shaft movement in the radial or axial direction.
Changes in shaft position may be relevant to the evaluation of clearances, thermal expansion, mechanical movement, and other operating conditions.
5. Signal Conversion and Monitoring
The sensor is normally part of a complete measurement chain rather than a standalone monitoring instrument. A compatible converter conditions the probe signal and provides an output suitable for machinery monitoring equipment.
The complete system may include:
- PR6424 eddy current sensor.
- Compatible extension cable.
- Signal converter.
- Machinery protection or monitoring equipment.
- Control-room monitoring and alarm interfaces.
The exact components depend on the installed EPRO measurement system and the required measurement function.
Role in Industrial Machinery Protection Systems
The PR6424/103-100 can contribute to a machinery protection arrangement by providing non-contact shaft measurements to monitoring equipment.
Rotating machinery often operates continuously and may involve high mechanical loads, temperature changes, and demanding operating conditions. Monitoring shaft behavior can help maintenance teams identify developing problems before they lead to equipment failure.
Turbine Monitoring
Steam, gas, and hydro turbines contain rotating shafts that must operate within defined mechanical limits. Shaft displacement and vibration measurements provide useful information about rotor behavior.
A correctly installed PR6424 measurement chain can contribute to monitoring radial and axial shaft movement in compatible turbine applications.
Compressor Monitoring
Industrial compressors often operate continuously in production and utility systems. Shaft vibration and position measurements can help maintenance personnel assess the condition of rotating components.
The sensor can be installed at suitable measurement locations to provide data for machinery monitoring systems.
Pump Monitoring
Large industrial pumps may experience changes in shaft movement due to operating conditions, mechanical wear, or installation issues.
Non-contact displacement measurement can provide useful information about pump shaft behavior, particularly in critical process applications.
Fan Monitoring
Large fans used in industrial ventilation and process systems can develop vibration problems due to imbalance, mechanical looseness, or changes in operating conditions.
The PR6424 sensor family can be used in suitable rotating machinery monitoring arrangements where shaft displacement measurement is required.
Industrial Applications
1. Steam Turbine Shaft Monitoring
Steam turbines are important components in power generation and industrial energy systems. Their rotating shafts operate under demanding mechanical and thermal conditions.
The PR6424 can be used as part of a monitoring arrangement to measure shaft vibration and displacement. Continuous measurement helps operators observe changes in rotor behavior during normal operation and changing load conditions.
2. Gas Turbine Condition Monitoring
Gas turbines are used in power generation, industrial processing, and mechanical drive applications. Their high-speed rotating assemblies require reliable condition monitoring.
A compatible PR6424 measurement chain can provide shaft displacement information for machinery protection and diagnostic purposes.
3. Hydro Turbine Monitoring
Hydro turbines operate in power generation environments where shaft position and vibration are important operating parameters.
Non-contact displacement measurement can help identify changes in rotor behavior and support long-term machinery condition assessment.
4. Industrial Compressor Protection
Compressors are widely used in petrochemical plants, refineries, gas processing facilities, and manufacturing operations.
Shaft vibration monitoring can provide early indications of mechanical changes. The PR6424 sensor can be incorporated into suitable monitoring systems to measure dynamic shaft movement.
5. Critical Pump Monitoring
Critical pumps are commonly installed in power stations, chemical plants, water treatment facilities, and process industries.
Where the machinery monitoring design requires shaft displacement measurement, the PR6424 family can provide non-contact sensing for compatible pump installations.
6. Large Industrial Fan Monitoring
Large fans are used in ventilation systems, combustion equipment, cooling installations, and process air systems.
Monitoring shaft vibration can help maintenance teams identify abnormal mechanical behavior and plan inspections.
Installation and System Integration
Correct installation is essential for obtaining reliable measurements from the PR6424/103-100.
The sensor must be positioned and connected according to the applicable system documentation. Incorrect mounting, cable installation, or converter selection can affect measurement accuracy.
1. Verify the Sensor Configuration
Before installation, confirm the complete model number and the configuration of the supplied unit.
Important details include:
- Sensor head diameter.
- Thread and mounting arrangement.
- Cable length.
- Cable armor or non-armored construction.
- Connector type.
- Compatible signal converter.
- Applicable temperature and environmental ratings.
Do not assume that every PR6424 probe uses the same cable or connector arrangement.
2. Prepare the Mounting Location
The sensor should be installed at the specified measurement position, with the sensing tip facing the appropriate metallic target.
The mounting surface must provide adequate mechanical stability. The installation should also preserve the required clearance between the probe and surrounding metallic structures.
For the PR6424 family, the standard target material is ferromagnetic steel, with 42CrMo4 used as the reference material. Target material differences can influence measurement performance and should be considered during system design.
3. Set the Initial Air Gap
The sensor must operate within its specified measurement range. The initial air gap should be adjusted according to the manufacturer’s installation procedure and the compatible converter’s requirements.
The PR6424 family has an approximate nominal center air gap of 2.7 mm. This value is a family-level specification and should be applied according to the relevant measurement-chain documentation.
Incorrect gap adjustment can reduce measurement range or cause the output to operate outside its intended linear region.
4. Route the Sensor Cable
Cable routing is an important part of sensor installation. Avoid excessive bending, mechanical tension, crushing, and unnecessary exposure to heat or moving machinery.
Maintain the minimum bending radius specified for the actual cable construction. Keep sensor wiring away from sources of strong electrical interference where required by the system design.
5. Connect the Compatible Signal Converter
The sensor must be paired with a compatible signal converter. The converter should match the probe’s electrical characteristics and cable configuration.
Check the connector, extension cable, calibration requirements, and converter model before making the connection.
Mixing components from different measurement configurations without verification can produce inaccurate measurements or prevent the system from operating correctly.
6. Perform Calibration and Functional Checks
After installation, verify the complete measurement chain. Check the initial gap, signal output, sensor response, and monitoring-system indication.
Where possible, compare the measurement with an appropriate reference or commissioning procedure. Confirm that alarm and trip settings are consistent with the machinery protection design.
Compatible System Components
The PR6424/103-100 is normally integrated into a complete machinery measurement system.
| Component | Function | Integration Considerations |
|---|---|---|
| PR6424 sensor | Detects shaft displacement without contact | Verify exact probe variant and mounting configuration |
| Extension cable | Connects the probe to the converter | Confirm electrical and mechanical compatibility |
| Signal converter | Conditions the sensor signal | Must match the PR6424 probe configuration |
| Machinery monitoring system | Processes displacement and vibration signals | Verify input type and measurement configuration |
| Shaft or metallic target | Provides the conductive measurement surface | Confirm suitable ferromagnetic target material |
| Sensor mounting bracket | Holds the probe in the required position | Maintain mechanical stability and correct alignment |
| Control-room monitoring interface | Displays measurement values and alarms | Depends on the installed monitoring architecture |
| Machinery protection equipment | Provides alarm and protection functions | Configure according to the machinery protection design |
These components are not necessarily included with the sensor. Confirm the supplied package and existing system configuration before purchasing replacement parts.
Alternative Models and Replacement Considerations
The PR6424 is part of a broader EPRO eddy current sensor family. Other models may have similar measurement principles but different sensing ranges, probe dimensions, temperature capabilities, or connection configurations.
| Alternative Model or Component | Main Consideration |
|---|---|
| Epro PR6424 sensor variants | Same general 16 mm sensor family; verify cable, connector, thread, and converter compatibility |
| Epro PR6423 | 8 mm eddy current sensor family with a different measuring range and sensitivity |
| Epro PR6425 | 16 mm sensor family designed for higher-temperature measurement applications |
| Epro PR6426 | Different measurement range and sensitivity; not a direct substitute without engineering review |
| Compatible PR6424 extension cable | Must match the probe and signal converter configuration |
| Compatible EPRO signal converter | Required for proper signal conditioning and measurement-chain operation |
Before replacing the PR6424/103-100, check the following:
- Complete sensor model number.
- Sensor head diameter.
- Thread and mounting dimensions.
- Cable length and construction.
- Connector and adaptor arrangement.
- Signal converter compatibility.
- Measurement range and sensitivity.
- Target material.
- Operating temperature requirements.
- Machinery monitoring system input configuration.
A sensor from the same product family is not automatically a direct replacement. The complete measurement chain must be checked to ensure that the replacement provides the required measurement performance.
Key Advantages
Non-Contact Measurement
The eddy current principle allows shaft displacement to be measured without direct mechanical contact. This reduces sensor-tip wear and makes the technology suitable for continuous rotating machinery monitoring.
16 mm Sensing Head
The 16 mm sensor head is designed for installations requiring this probe size and corresponding measurement arrangement.
Static and Dynamic Measurement
The PR6424 family supports both static shaft-position measurement and dynamic displacement measurement, allowing it to contribute to different machinery monitoring functions.
High Measurement Sensitivity
The specified sensitivity of 4 V/mm and linearity of up to ±1.5% support accurate displacement measurement when the complete system is installed and calibrated correctly.
Long-Term Measurement Stability
The family specification lists long-term drift below 0.3%, supporting stable measurement in appropriately designed monitoring installations.
Industrial Machinery Applications
The PR6424 family is intended for critical rotating equipment, including turbines, compressors, pumps, and fans.
Compact Mechanical Design
The 16 mm sensor head and threaded mounting arrangement allow installation in suitable machinery measurement locations.
Technical FAQs
1. What is the Epro PR6424/103-100?
The Epro PR6424/103-100 is a 16 mm eddy current sensor designed for non-contact measurement of shaft displacement and vibration in rotating machinery.
2. What is the measurement principle of the PR6424 sensor?
It uses the eddy current principle. An electromagnetic field interacts with a conductive metallic target, and changes in the distance between the sensor and target produce a measurable electrical response.
3. What is the sensor head diameter?
The sensor head diameter is 16 mm.
4. What is the sensitivity of the PR6424 family?
The published sensitivity is 4 V/mm, with linearity of up to ±1.5% under the specified measurement conditions.
5. What is the static measurement range?
The PR6424 family has a 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.
7. What type of target material is required?
The standard target material is ferromagnetic steel, with 42CrMo4 used as the reference material. Other target materials should be evaluated according to the applicable calibration and installation requirements.
8. Which machines can use the PR6424 sensor?
Typical applications include steam turbines, gas turbines, hydro turbines, compressors, pumps, and industrial fans.
9. Does the PR6424/103-100 work without a signal converter?
The sensor is normally used as part of a complete measurement chain with a compatible signal converter. The converter conditions the sensor signal for use by machinery monitoring equipment.
10. What should be checked before replacing the PR6424/103-100?
Verify the complete model number, sensor diameter, thread, cable length, connector, signal converter compatibility, target material, and measurement requirements. These details are important for maintaining the performance of the existing machinery monitoring system.
Procurement and Maintenance Recommendations
When purchasing the Epro PR6424/103-100, confirm the complete product designation and the physical configuration of the supplied sensor. Particular attention should be given to cable length, connector type, cable armor, mounting thread, and compatibility with the existing signal converter.
For replacement projects, compare the new sensor with the installed probe before removing the original component. Differences in cable arrangement or converter compatibility can affect the entire measurement chain.
For used or surplus products, inspect the sensor head, threaded sleeve, cable insulation, connector, and identification label. Check for mechanical damage, corrosion, cable deformation, or signs of improper storage.
During maintenance, inspect the probe mounting and cable routing periodically. Ensure that the sensor remains securely positioned and that its sensing tip has not been damaged by contact with the rotating target.
Keep records of the installed model, converter configuration, initial gap, calibration information, and monitoring-system settings. These records help maintenance personnel identify compatible replacement parts and troubleshoot measurement problems.
Conclusion
The Epro PR6424/103-100 16 mm Eddy Current Sensor is designed for non-contact measurement of shaft displacement and vibration in critical rotating machinery. Its 16 mm sensing head, 4 V/mm sensitivity, ±2.0 mm static measurement range, and 0–1,000 μm dynamic measurement range make the PR6424 family suitable for a range of industrial machinery monitoring applications.
Used with a compatible signal converter and correctly installed measurement chain, the sensor can provide important information about shaft movement in turbines, compressors, pumps, and fans. For maintenance and replacement work, verifying the exact probe configuration, cable arrangement, and converter compatibility is essential to maintaining reliable machinery monitoring.