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- 16 mm Eddy Current Sensor
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Product Overview
The Epro PR6424/013-121 16 mm Eddy Current Sensor is a non-contact displacement measurement sensor designed for monitoring the operating condition of critical rotating machinery. It belongs to the PR6424 series developed by EPRO, part of Emerson’s machinery health monitoring product portfolio.
The sensor uses eddy current technology to measure the distance between its sensing tip and a conductive target, typically a ferromagnetic steel shaft. It can provide measurement information related to shaft vibration, radial and axial displacement, shaft position, eccentricity, and rotational speed when used with a compatible signal converter and monitoring system.
The PR6424 series is commonly applied to steam turbines, gas turbines, hydro turbines, compressors, pumps, and industrial fans. These machines contain rotating components that must operate within defined mechanical tolerances. Continuous measurement of shaft movement helps operators and maintenance engineers identify abnormal conditions before they develop into more serious equipment problems.
The PR6424/013-121 has a nominal sensor head diameter of 16 mm. Its compact sensing head and threaded mounting arrangement allow installation near an appropriate rotating shaft surface. The sensor is designed to operate as part of a complete measurement chain, which generally includes the probe, an extension cable where required, and a compatible signal converter.
With a typical sensitivity of 4 V/mm and a static measuring range of ±2.0 mm, the PR6424 family supports precise monitoring of shaft position and dynamic movement. Its non-contact operating principle avoids direct mechanical contact with the rotating shaft during normal measurement.
For industrial maintenance and replacement projects, the complete model number should be checked carefully. Cable length, connector type, probe construction, and converter compatibility can differ between PR6424 variants.
Technical Specifications
| Parameter | Specification |
|---|---|
| Brand | Epro / EPRO |
| Manufacturer | Emerson |
| Model | PR6424/013-121 |
| Product Series | PR6424 |
| Product Type | Eddy Current Displacement Sensor |
| Sensor Technology | Non-contact eddy current |
| Sensor Head Diameter | 16 mm |
| Static Measuring Range | ±2.0 mm |
| Dynamic Measuring Range | 0–1,000 μm peak-to-peak |
| Sensitivity | 4 V/mm |
| Linearity | ≤ ±1.5% |
| Nominal Center Air Gap | Approximately 2.7 mm |
| Long-Term Drift | Less than 0.3% |
| Target Material | Ferromagnetic steel |
| Standard Target Material | 42CrMo4 steel |
| Recommended Shaft Diameter | ≥80 mm |
| Sensor Sleeve Material | Stainless steel |
| Cable Material | PTFE |
| Operating Temperature | Typically -35°C to +180°C for the PR6424 sensor specification |
| Temperature Error | Less than 4% per 100 K |
| Sensor Head Pressure Resistance | 10,000 hPa (145 psi) |
| Shock and Vibration Resistance | 5 g at 60 Hz and 25°C |
| Weight | 0.2 kg |
| Typical Applications | Turbines, compressors, pumps, fans, and rotating machinery |
Note: The technical values above describe the PR6424 sensor family. Exact cable, connector, armored construction, and configuration details for the PR6424/013-121 should be confirmed against the complete product label and applicable configuration documentation.
Function and Working Principle
The PR6424/013-121 operates using the eddy current measurement principle. It generates a high-frequency electromagnetic field at the sensor tip and detects changes in that field caused by the distance between the probe and a conductive target.
This measurement method is suitable for rotating machinery because the sensor can monitor shaft movement without physically touching the rotating component.
1. Electromagnetic Field Generation
The sensor contains an internal coil that generates an electromagnetic field when supplied by a compatible signal converter. The field extends from the sensing tip toward the target surface.
When a conductive metal target approaches the sensor, electrical currents known as eddy currents are induced in the target material. These currents affect the electromagnetic characteristics of the sensor coil.
2. Distance Measurement
The electrical response of the sensing coil changes according to the distance between the probe tip and the target surface.
A compatible converter processes this change and produces an electrical output proportional to the measured gap. The resulting signal can be supplied to a machinery protection or monitoring system.
The relationship between output and distance depends on the sensor’s calibration, target material, converter configuration, and installation gap.
3. Shaft Vibration Measurement
When installed near a rotating shaft, the sensor can detect small changes in the shaft-to-probe distance.
As the shaft moves during rotation, the measured gap changes. The resulting signal provides information about shaft vibration and displacement.
This information can help maintenance teams identify abnormal vibration patterns, mechanical imbalance, shaft misalignment, bearing deterioration, and other potential machinery problems.
4. Shaft Position Monitoring
The PR6424 series also supports static displacement measurement. This is important for monitoring the relative position of a shaft and identifying changes in its mechanical location.
In suitable turbine installations, axial and radial displacement measurements can provide information about shaft movement relative to the machine structure.
5. Speed and Key Measurement
With an appropriate target arrangement and monitoring configuration, the sensor can also be used for rotational speed or keyphasor-related measurements.
Speed information is useful for correlating vibration signals with machine operating conditions. It can help engineers distinguish between vibration components associated with rotational frequency and other mechanical or process-related disturbances.
Role in Industrial Machinery Protection Systems
The PR6424/013-121 is a sensing component rather than a complete machinery protection system. Its measurement signal must be processed by compatible signal-conditioning equipment and connected to an appropriate monitoring or control platform.
1. Turbine Shaft Monitoring
Steam and gas turbines operate at high rotational speeds and require continuous monitoring of mechanical behavior.
Eddy current sensors installed near the shaft can provide information about vibration and displacement. Monitoring systems use this information to identify changes in shaft movement and support equipment protection strategies.
2. Compressor Condition Monitoring
Industrial compressors are widely used in petrochemical plants, refineries, gas processing facilities, and other process industries.
Shaft vibration and displacement measurements help operators evaluate compressor operating conditions. Abnormal movement may indicate mechanical wear, rotor imbalance, misalignment, or changes in bearing performance.
3. Pump Monitoring
Large process pumps often operate continuously and may be exposed to changing flow rates, pressure conditions, and mechanical loads.
A properly installed PR6424 sensor can provide shaft movement information for machinery monitoring systems. This data can support maintenance decisions and help identify developing mechanical problems.
4. Integration with Machinery Monitoring Platforms
The PR6424 sensor can be integrated into an appropriate monitoring arrangement through a compatible converter.
Depending on the selected converter and monitoring equipment, measurement signals may be used for:
- Shaft vibration monitoring.
- Radial displacement measurement.
- Axial position monitoring.
- Eccentricity measurement.
- Speed and phase-reference applications.
- Machinery alarm and protection functions.
The complete measurement chain must be checked for compatibility. A sensor should not be connected directly to a PLC analog input unless the signal-conditioning arrangement provides the required electrical output.
Industrial Applications
The Epro PR6424/013-121 is intended for non-contact measurement in industrial rotating machinery. Its applications are particularly relevant where shaft vibration and position measurements are important for equipment reliability.
1. Steam Turbines
Steam turbines are used in power generation, industrial energy systems, and large process facilities.
Shaft vibration and displacement monitoring provide information about rotor movement during normal operation, startup, shutdown, and changing load conditions.
The PR6424 series can be used as part of an appropriate turbine monitoring system to measure radial and axial shaft movement.
2. Gas Turbines
Gas turbines operate under demanding mechanical and thermal conditions. Continuous monitoring of rotating components is important for maintaining stable operation.
Non-contact displacement sensors can provide shaft movement information that helps identify abnormal vibration and changes in rotor position.
3. Hydro Turbines
Hydroelectric generating equipment contains large rotating assemblies that require mechanical condition monitoring.
Eddy current sensors can be used to monitor shaft displacement and vibration when installed with a suitable target arrangement and compatible monitoring equipment.
4. Industrial Compressors
Centrifugal and other high-speed compressors are important components in gas processing, refining, chemical manufacturing, and industrial utility systems.
Shaft vibration monitoring helps maintenance teams evaluate rotor behavior and detect potential mechanical deterioration.
5. Industrial Pumps
Large pumps used in water treatment, chemical processing, and power plants may require continuous condition monitoring.
The PR6424 sensor can provide non-contact shaft displacement information for suitable pump installations.
6. Industrial Fans
Large industrial fans and blowers may operate continuously in ventilation, combustion-air, and process-gas applications.
Monitoring shaft movement can help maintenance personnel identify developing mechanical problems and plan inspections.
Installation and System Integration
Correct installation is essential for obtaining reliable measurement results. The sensor must be mounted with the appropriate mechanical clearance, target material, cable arrangement, and converter configuration.
1. Verify the Sensor Configuration
Before installation, confirm the complete model number, probe dimensions, cable arrangement, connector type, and intended converter.
The /013-121 suffix identifies a specific configuration. Do not assume that all PR6424 sensors have identical cable lengths or connector arrangements.
2. Select the Correct Mounting Position
Install the probe near the shaft surface according to the machinery manufacturer’s recommendations and the sensor installation instructions.
The sensing tip must face a suitable target area. Ensure that the mounting arrangement provides sufficient mechanical clearance and prevents accidental contact between the sensor and the rotating shaft.
3. Set the Initial Air Gap
The PR6424 family has a nominal center air gap of approximately 2.7 mm under its specified measurement arrangement.
The actual installation gap must be established using the correct sensor and converter calibration procedure. Incorrect initial spacing can reduce the usable measurement range or cause the output to operate outside its intended linear region.
4. Check Target Material
The PR6424 sensor is calibrated for a specified ferromagnetic steel target, with 42CrMo4 used as the standard reference material.
Different shaft materials or surface characteristics can affect sensor response. Confirm that the target material matches the sensor calibration requirements.
5. Install the Cable Correctly
Route the sensor cable away from high-power conductors and sources of electromagnetic interference where practical.
Avoid sharp bends, excessive pulling force, abrasion, and unnecessary mechanical stress. Observe the cable’s specified minimum bending radius and temperature limits.
Cable length and connector configuration must also match the signal converter requirements.
6. Connect the Signal Converter
The sensor must be paired with a compatible converter designed for the PR6424 series.
The converter processes the probe’s electrical response and provides an output suitable for monitoring equipment. Confirm the correct sensor-converter combination before connecting the measurement chain.
7. Perform Calibration and Functional Testing
After installation, verify the sensor gap, converter configuration, output response, and measurement polarity.
Check that the signal changes correctly as the target distance changes. Confirm that the monitoring system receives stable measurement values before returning the machinery to normal operation.
Compatible System Components
The PR6424/013-121 normally operates as part of a complete eddy current measurement chain.
| Component | Function | Compatibility Considerations |
|---|---|---|
| PR6424 sensor | Detects shaft displacement and vibration | Verify exact model and configuration |
| Extension cable | Connects the sensor to the converter | Match cable type, length, and connector |
| Signal converter | Converts the probe response into a usable electrical signal | Must support the PR6424 sensor |
| Machinery monitoring module | Processes vibration or position measurements | Confirm input characteristics and channel configuration |
| PLC or DCS | Receives process or machinery status information | Requires a suitable conditioned output or interface |
| Machinery protection system | Monitors equipment condition and supports protection functions | Verify sensor-converter-system compatibility |
| Sensor mounting bracket | Provides mechanical support and positioning | Must maintain the correct probe alignment and air gap |
| Rotating shaft target | Provides the conductive measurement surface | Material and surface condition must match calibration requirements |
A complete installation may use additional cables, adapters, terminal assemblies, and monitoring modules. These items should be selected according to the actual system design rather than assumed to be included with the sensor.
Alternative Models and Replacement Considerations
The PR6424 family includes different probe configurations. Although models may share a 16 mm sensing diameter and similar measurement characteristics, their mechanical and electrical arrangements can differ.
| Alternative Model or Component | Description | Replacement Considerations |
|---|---|---|
| Epro PR6424 series | 16 mm eddy current sensor family | Compare the full model number and cable configuration |
| Epro PR6423 series | 8 mm eddy current sensor family | Different probe diameter and measurement range |
| Epro PR6425 series | High-temperature eddy current sensor family | Designed for different temperature requirements |
| Epro CON011 | Signal converter option | Confirm compatibility with the specific probe |
| Epro CON021 | Signal converter option | Verify sensor configuration and electrical interface |
| Epro CON031 | Signal converter option | Check the supported sensor and system arrangement |
| Epro CON041 | Signal converter option | Confirm exact compatibility before replacement |
Before selecting a replacement, compare:
- Sensor head diameter.
- Complete probe model number.
- Measurement range and sensitivity.
- Thread size and mounting dimensions.
- Cable length and construction.
- Armored or non-armored cable configuration.
- Connector type.
- Target material and calibration.
- Operating temperature range.
- Compatible signal converter.
- Monitoring-system input requirements.
A sensor with the same 16 mm diameter is not necessarily a direct replacement. The full measurement chain must be evaluated to ensure accurate readings and reliable machinery protection.
Key Advantages
Non-Contact Measurement
The sensor measures shaft movement without physical contact with the rotating surface. This makes it suitable for continuous monitoring of high-speed machinery.
High Measurement Sensitivity
The PR6424 series provides a nominal sensitivity of 4 V/mm, supporting the detection of small changes in shaft-to-probe distance.
Static and Dynamic Measurement
The sensor supports both static displacement and dynamic movement measurement, allowing it to be used for shaft position and vibration monitoring.
Industrial Machinery Applications
The PR6424 family is designed for critical rotating equipment, including turbines, compressors, pumps, and fans.
Stainless Steel Sensor Sleeve
The stainless steel sleeve provides a robust mechanical structure for industrial probe installation.
PTFE Cable Construction
The specified cable material supports the temperature requirements of the PR6424 sensor design. Exact cable configuration should be confirmed for the individual model.
Integration with Monitoring Systems
When paired with a compatible converter, the sensor can provide measurement signals for machinery monitoring and protection equipment.
Technical FAQs
1. What is the Epro PR6424/013-121?
It is a 16 mm eddy current displacement sensor designed for non-contact monitoring of shaft vibration, displacement, position, and eccentricity in rotating machinery.
2. What is the measuring principle?
The sensor uses electromagnetic induction. Its sensing coil generates an electromagnetic field, and the presence of a conductive target changes the coil’s electrical response according to the distance between the probe and target.
3. What is the sensor head diameter?
The nominal sensor head diameter is 16 mm.
4. What is the measuring range of the PR6424 series?
The typical static measurement range is ±2.0 mm. The recommended dynamic measurement range is 0–1,000 μm peak-to-peak.
5. What is the sensitivity?
The nominal sensitivity is 4 V/mm, with specified linearity of up to ±1.5% under the applicable standard measurement conditions.
6. Which machines can use this sensor?
Typical applications include steam turbines, gas turbines, hydro turbines, compressors, pumps, and industrial fans.
7. Does the sensor require a signal converter?
Yes. The PR6424 is normally used with a compatible signal converter that supplies the required excitation and processes the sensor response into a usable measurement output.
8. Can the PR6424/013-121 connect directly to a PLC?
It should not be treated as a direct PLC analog-input device. A compatible signal converter or interface is normally required to provide the appropriate output signal.
9. What target material is used for calibration?
The PR6424 family uses ferromagnetic steel as its standard target material, with 42CrMo4 steel specified as the reference material.
10. What is the weight of the PR6424/013-121?
The supplied product listing weight is 0.2 kg. The PR6424 specification sheet gives an approximate weight of 200 grams for the sensor with a 1-meter cable without armor. Actual weight can vary with cable length and construction.
11. What should be checked before ordering a replacement?
Confirm the full model number, probe diameter, mounting thread, cable length, connector, cable construction, and compatible signal converter. These details are essential for avoiding measurement-chain compatibility problems.
Procurement and Maintenance Recommendations
When purchasing the Epro PR6424/013-121, verify the complete model number and compare it with the sensor installed on the machine. The suffix should not be omitted because it may identify important differences in cable and connection configuration.
For replacement projects, request clear photographs of the product label, sensing tip, mounting thread, cable, and connector. Confirm whether the product is supplied as a sensor-only item or as part of a larger measurement assembly.
During installation, protect the sensing tip from impact and contamination. Avoid damaging the cable and connector, and maintain the recommended mounting gap. The probe should be installed securely so that vibration from the machine structure does not create unwanted measurement errors.
For ongoing maintenance, inspect the cable, mounting hardware, connector, and signal stability during scheduled equipment inspections. Compare sensor readings with historical operating data to identify changes in shaft movement or vibration.
If abnormal readings occur, check the sensor installation gap, target surface condition, cable connections, converter compatibility, and monitoring-system configuration before concluding that the probe itself has failed.
Conclusion
The Epro PR6424/013-121 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, and ±2.0 mm static measurement range make it suitable for integration into appropriately configured machinery monitoring systems.
Used with a compatible signal converter, the sensor can provide important information about shaft movement, position, eccentricity, and vibration in turbines, compressors, pumps, and fans.
For industrial replacement and procurement projects, verifying the complete model number, cable configuration, connector, target material, and converter compatibility is essential to maintaining reliable measurement performance.