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- PR6424/105-021
- 16 mm Eddy Current Sensor
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Product Overview
The Epro PR6424/105-021 16 mm Eddy Current Sensor is a non-contact displacement measurement probe designed for monitoring the condition and operating behavior of rotating machinery. It belongs to the PR6424 sensor family from EPRO, part of Emerson’s machinery health monitoring product range.
The sensor uses eddy current technology to measure the distance between its sensing tip and a conductive target, typically a ferromagnetic steel shaft. Changes in the distance between the probe and the target affect the sensor’s electromagnetic field. When used with a compatible signal converter, these changes can be converted into electrical signals representing shaft displacement, vibration, and position.
The PR6424 series is designed for critical rotating equipment, including steam turbines, gas turbines, hydro turbines, compressors, pumps, and industrial fans. These machines often operate continuously and may experience mechanical changes that are difficult to identify through visual inspection alone. Non-contact displacement measurement provides an additional source of information for machinery condition monitoring and protection systems.
The PR6424 family features a nominal 16 mm sensor head, a sensitivity of 4 V/mm, and a static measurement range of ±2.0 mm. Its dynamic measurement capability is specified for vibration measurements up to 1,000 μm peak-to-peak under the applicable system conditions.
The supplied product information identifies the sensor head diameter as 16 mm and the weight as 0.2 kg. Exact cable length, connector arrangement, mounting configuration, and other ordering details should be confirmed against the complete PR6424/105-021 identification before installation or replacement.
Technical Specifications
| Parameter | Specification |
|---|---|
| Brand | Epro / EPRO |
| Manufacturer | Emerson |
| Model | PR6424/105-021 |
| Product Series | PR6424 |
| Product Type | 16 mm Eddy Current Sensor |
| Measurement Principle | Non-contact eddy current |
| Sensor Head Diameter | 16 mm |
| Sensitivity | 4 V/mm (101.6 mV/mil) |
| 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) |
| Reference Shaft Diameter | ≥80 mm |
| Sensor Sleeve Material | Stainless steel |
| Cable Material | PTFE |
| Operating Temperature | Refer to the exact sensor variant specification |
| Sensor Head Pressure Resistance | 10,000 hPa (145 psi), series specification |
| Shock and Vibration Reference | 5 g at 60 Hz at 25°C |
| Sensor Head Diameter | 16 mm |
| Weight Provided | 0.2 kg |
| Typical Applications | Turbines, compressors, pumps, fans, and rotating machinery |
Note: The performance values above describe the PR6424 sensor family. Confirm the exact temperature rating, cable length, connector, thread, and converter compatibility for the PR6424/105-021 variant before ordering or commissioning.
Function and Working Principle
The PR6424/105-021 uses electromagnetic induction to measure the distance between the probe tip and a metallic target. Unlike contact-based measurement devices, the sensor does not need to touch the rotating shaft. This makes it suitable for continuous monitoring of high-speed machinery.
1. Eddy Current Measurement
An excitation signal generates an electromagnetic field around the probe tip. When a conductive target approaches the sensing surface, eddy currents are induced in the target material.
These currents affect the electrical characteristics of the probe. The resulting change can be evaluated by a compatible signal converter to determine the distance between the sensor and the target.
The measurement is influenced by the target material, probe calibration, installation gap, and the condition of the measurement system.
2. Shaft Displacement Measurement
The PR6424 family provides a static measurement range of ±2.0 mm. This allows a properly configured system to monitor changes in the relative position of a shaft.
In rotating machinery, shaft displacement measurements can help identify changes in bearing clearance, axial position, mechanical alignment, or other operating conditions.
The sensor itself provides the measurement signal; interpretation and alarm decisions are handled by the connected monitoring equipment or control system.
3. Vibration Monitoring
When installed near a rotating shaft, the probe can detect changes in the distance between the shaft surface and the sensor during rotation.
These changes form a dynamic measurement signal that can be used to evaluate shaft vibration. The PR6424 family specifies a dynamic measurement range of 0 to 1,000 μm peak-to-peak under the applicable measurement conditions.
Vibration information can help maintenance teams identify developing mechanical problems, including imbalance, misalignment, looseness, and changes in bearing behavior. Accurate diagnosis requires consideration of the machine design and other monitoring measurements.
4. Position and Eccentricity Measurement
The sensor can also be used to monitor shaft position and eccentricity. Eccentricity describes the variation in the radial distance between a rotating shaft surface and a reference point.
Monitoring this behavior can help identify abnormal shaft movement and changes in rotating equipment condition.
5. Signal Conversion
The PR6424 probe is part of a measurement chain rather than a standalone industrial controller. A compatible signal converter is required to condition the probe response and provide a usable output for machinery monitoring equipment.
The converter must be matched to the sensor type and system configuration. Cable length, connector arrangement, calibration, and target material should all be considered when selecting the complete measurement chain.
Role in Industrial Machinery Monitoring Systems
The PR6424/105-021 can form part of a machinery protection and condition monitoring installation. It provides displacement information that can be used by monitoring equipment to evaluate the mechanical condition of critical rotating assets.
Turbine Monitoring
Steam, gas, and hydro turbines operate under demanding mechanical and thermal conditions. Shaft movement and vibration can change as operating speed, temperature, load, and bearing conditions vary.
A non-contact eddy current probe can provide shaft displacement information for a suitable turbine monitoring system. This information supports the evaluation of machine behavior during startup, normal operation, and shutdown.
Compressor Monitoring
Industrial compressors are used in gas processing, petrochemical facilities, manufacturing plants, and other continuous-process environments.
Monitoring shaft vibration and position can help maintenance personnel identify changes in rotor behavior. The PR6424 sensor family is designed for this type of rotating machinery application when the probe and monitoring system are correctly specified.
Pump Monitoring
Large industrial pumps may operate continuously under changing flow and pressure conditions. Shaft displacement measurements can contribute to monitoring the mechanical condition of the pump and its associated rotating assembly.
The sensor can be used as part of a broader monitoring arrangement that includes vibration, temperature, pressure, and process measurements.
Integration with Machinery Protection Equipment
A compatible signal converter and monitoring system process the probe signal and make the measurement available for display, recording, or alarm functions.
The sensor does not independently perform machinery shutdown or safety logic. These functions depend on the connected protection system, its configuration, and the plant’s engineering design.
Industrial Applications
The PR6424 16 mm eddy current sensor family is intended for applications where accurate non-contact shaft measurement is required.
1. Steam Turbines
Steam turbines are commonly used in power generation and industrial energy systems. Their rotating shafts require monitoring to identify changes in vibration and displacement.
The PR6424 family can provide non-contact measurements for suitable turbine monitoring installations. Multiple measurement points may be used to evaluate shaft behavior at different locations.
2. Gas Turbines
Gas turbines operate at high rotational speeds and under demanding temperature and mechanical conditions. Shaft vibration and position monitoring are important parts of maintaining reliable operation.
The sensor can be incorporated into a compatible monitoring arrangement to provide displacement information for rotating machinery analysis.
3. Hydro Turbines and Generators
Hydroelectric generating equipment often operates for extended periods. Shaft movement and vibration measurements can help operators evaluate mechanical stability and identify changes that may require inspection.
The PR6424 family is suitable for relevant hydro-turbine monitoring applications when its mechanical and electrical specifications match the installation.
4. Industrial Compressors
Compressors used in petrochemical, gas transportation, and process industries may contain high-speed rotating components. Non-contact shaft monitoring can provide information about rotor movement and vibration.
The probe can contribute to condition monitoring when paired with a compatible converter and machinery protection system.
5. Industrial Pumps
Large pumps used in water treatment, power generation, and process facilities may require continuous monitoring. Shaft displacement information can help maintenance teams assess mechanical behavior and investigate abnormal vibration.
6. Industrial Fans
Large fans and blowers are used in ventilation, combustion-air systems, cooling systems, and industrial processing. Monitoring shaft movement can help identify changes in mechanical condition.
The probe’s suitability depends on shaft dimensions, target material, mounting arrangement, and operating environment.
Installation and System Integration
Proper installation is essential for obtaining reliable measurements. The probe position, target material, initial air gap, cable arrangement, and signal converter configuration all influence measurement performance.
1. Verify the Exact Sensor Configuration
Before installation, check the complete model number and product label. The PR6424/105-021 designation should be verified against the ordering documentation to confirm the exact cable length, connector, mounting thread, and mechanical arrangement.
Do not assume that every PR6424 variant has identical physical dimensions or cable configuration.
2. Confirm Target Material
The PR6424 family is calibrated for a specified ferromagnetic steel target, with 42CrMo4 used as the standard reference material.
Different target materials can affect sensor response and calibration. If the actual shaft material differs from the reference material, verify whether the measurement chain requires an appropriate calibration arrangement.
3. Set the Initial Air Gap
The PR6424 family has a nominal center air gap of approximately 2.7 mm. The actual installation gap must be set according to the applicable sensor and converter documentation.
An incorrect initial gap may reduce the available measurement range or cause the output to operate outside its intended linear region.
4. Position the Probe Correctly
The probe should be installed in a stable mounting arrangement with sufficient clearance from surrounding components. The sensor tip must face the intended measurement surface without contacting the rotating shaft.
Check the shaft diameter and mounting geometry. The PR6424 family is intended for reference shaft diameters of 80 mm or greater.
5. Connect the Extension Cable and Converter
The probe must be connected to a compatible signal converter using the specified cable and connector arrangement.
Cable routing should avoid excessive bending, mechanical damage, and unnecessary proximity to strong electrical interference sources. Observe the manufacturer’s requirements for cable length and connection integrity.
6. Verify the Measurement Chain
After installation, check the sensor, cable, converter, and monitoring channel as a complete system.
Verify the initial gap, output response, calibration, and measurement direction. Where the system supports it, confirm that the measured shaft position and vibration values are consistent with the expected machine condition.
7. Record Commissioning Information
Document the probe location, sensor identification, converter model, cable configuration, calibration data, and initial operating measurements.
These records help maintenance teams compare future measurements and identify changes in machine behavior.
Compatible System Components
A PR6424 measurement installation generally requires more than the probe itself. The following components may form part of a complete measurement chain.
| Component | Function | Integration Considerations |
|---|---|---|
| PR6424 sensor | Detects shaft displacement using eddy current technology | Confirm exact sensor variant and target compatibility |
| Extension cable | Connects the probe to the signal converter | Verify cable length, connector, and cable type |
| CON011 signal converter | Conditions the sensor signal in a compatible system configuration | Confirm sensor and converter compatibility |
| CON021 signal converter | Provides signal conditioning for supported probe configurations | Check exact calibration and connector requirements |
| CON041 signal converter | Provides a compatible signal-conditioning option | Verify terminal and system configuration |
| Machinery monitoring system | Processes and displays measurement information | Confirm input type and measurement range |
| Machinery protection system | Uses configured measurements for alarms or protection actions | Protection logic must be engineered separately |
| Probe mounting hardware | Holds the sensor in the required position | Confirm thread, mounting geometry, and mechanical stability |
| Industrial control system | Receives relevant monitoring information | Integration depends on the monitoring system’s outputs |
The listed components are examples of equipment used in compatible PR6424 measurement systems. They are not necessarily included with the sensor.
Alternative Models and Replacement Considerations
When replacing a PR6424/105-021, the full model number and measurement-chain configuration should be checked. Sensors that share the PR6424 family name may differ in cable length, connector, mounting arrangement, and other ordering characteristics.
| Alternative or Related Model | Replacement Considerations |
|---|---|
| Epro PR6424/000 series | Check the exact mechanical and cable configuration before substitution |
| Epro PR6424/005 series | Compare probe construction, cable arrangement, and converter compatibility |
| Epro PR6424/006 series | Verify cable length and connector details |
| Epro PR6424/007 series | Confirm the complete ordering configuration and installation requirements |
| Epro PR6424/008 series | Compare mechanical dimensions and measurement-chain compatibility |
| Epro PR6425 series | A related 16 mm sensor family intended for different temperature requirements; not an automatic substitute |
| Bently Nevada 3300 XL probe system | An alternative machinery measurement technology that requires a complete system-level compatibility assessment |
Before selecting a replacement, compare:
- Sensor head diameter and mechanical dimensions.
- Mounting thread and probe length.
- Cable length and cable construction.
- Connector type and termination.
- Sensitivity and linear measurement range.
- Target material and calibration requirements.
- Operating temperature and environmental limits.
- Signal converter compatibility.
- Monitoring channel configuration.
- Installation gap and mounting arrangement.
A replacement probe should not be selected solely because it has the same nominal sensor diameter. The complete measurement chain must be compatible.
Key Advantages
Non-Contact Measurement
The sensor measures shaft displacement without physical contact. This makes it suitable for monitoring rotating machinery where direct mechanical contact would be impractical.
16 mm Sensor Head
The 16 mm sensing head is designed for applications that require a probe of this nominal diameter. The final mounting arrangement must still be checked against the available space and machine design.
High Measurement Sensitivity
The PR6424 family specifies a sensitivity of 4 V/mm, supporting the measurement of relatively small changes in shaft position when used with the appropriate converter.
Static and Dynamic Measurement
The sensor family supports both static shaft-position measurement and dynamic displacement measurement, allowing one measurement technology to contribute to different aspects of machinery monitoring.
Industrial Rotating Machinery Applications
The sensor family is designed for critical equipment such as turbines, compressors, pumps, and fans.
Suitable for Continuous Monitoring Systems
When integrated into a compatible monitoring installation, the probe can provide ongoing shaft measurement information for machinery condition assessment.
Compact Probe Design
The 16 mm sensing head supports installation in suitable machinery measurement locations where the mounting space and shaft geometry meet the required specifications.
Technical FAQs
1. What is the Epro PR6424/105-021?
The PR6424/105-021 is identified as a 16 mm Epro eddy current sensor. It belongs to the PR6424 family, which is designed for non-contact measurement of shaft displacement and vibration in rotating machinery.
2. What is the sensor head diameter?
The supplied product specification identifies the sensor head diameter as 16 mm.
3. What is the measurement principle?
It uses the eddy current principle. An electromagnetic field interacts with a conductive target, and changes in the probe’s electrical response are used to determine the distance between the sensor tip and the target.
4. What is the sensitivity of the PR6424 sensor family?
The published PR6424 family sensitivity is 4 V/mm, equivalent to approximately 101.6 mV/mil, with a specified linearity of up to ±1.5%.
5. What is its static measurement range?
The PR6424 family has a static measurement range of ±2.0 mm.
6. Can it measure shaft vibration?
Yes. When installed with a compatible converter and monitoring system, it can measure dynamic shaft displacement associated with vibration. The family specification gives a dynamic measurement range of 0 to 1,000 μm peak-to-peak under the applicable conditions.
7. Does the sensor operate without a signal converter?
The probe is part of a measurement chain and normally requires a compatible signal converter to condition its response for use by monitoring equipment. The exact converter must match the probe configuration.
8. What machinery can use the PR6424 sensor?
Typical applications include steam turbines, gas turbines, hydro turbines, compressors, pumps, and industrial fans. Suitability depends on the machine geometry, target material, operating conditions, and monitoring-system design.
9. What is the weight of the PR6424/105-021?
The supplied product information lists the weight as 0.2 kg. Confirm whether this value refers to the sensor alone or a sensor-and-cable assembly when calculating shipping weight.
10. Can the PR6424/105-021 replace another PR6424 model?
Not automatically. Different variants may have different cable lengths, connectors, mounting arrangements, or other configuration details. Compare the complete model numbers and verify compatibility with the existing converter and monitoring system before replacement.
Procurement and Maintenance Recommendations
When purchasing the Epro PR6424/105-021, verify the complete model number and confirm that the supplied sensor matches the required installation. Particular attention should be paid to the probe’s mounting arrangement, cable length, connector type, and compatibility with the installed signal converter.
For replacement projects, compare the existing sensor’s label and physical configuration with the proposed unit. A sensor from the same PR6424 family may still require different cable or mounting arrangements.
For used or surplus equipment, request clear photographs of the sensor head, cable, connector, identification label, and any included accessories. Confirm the condition of the cable insulation and connector contacts, since damage to these parts can affect measurement reliability.
During maintenance, inspect the probe mounting, cable routing, connector security, and surrounding mechanical conditions. Avoid bending or pulling the cable beyond the manufacturer’s permitted limits. Check the measurement gap and verify the signal response as part of the machinery monitoring system’s maintenance procedure.
It is also useful to maintain records of sensor locations, converter configurations, calibration information, and baseline measurements. These records support consistent monitoring and make future replacement work more straightforward.
Conclusion
The Epro PR6424/105-021 16 mm Eddy Current Sensor is designed for non-contact measurement of shaft displacement and vibration in industrial rotating machinery. Its PR6424 family specifications include 4 V/mm sensitivity, a ±2.0 mm static measurement range, and a dynamic measurement range of up to 1,000 μm peak-to-peak under applicable conditions.
With a nominal 16 mm sensor head and a supplied weight of 0.2 kg, it is intended for use in suitable machinery monitoring installations involving turbines, compressors, pumps, and fans.
For reliable operation, the probe must be matched with the correct signal converter, cable arrangement, target material, and mounting configuration. Verifying the complete PR6424/105-021 ordering details is essential when purchasing a replacement or integrating the sensor into an existing machinery protection system.