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- PR6424/101-000
- 16 mm Eddy Current Sensor
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Product Overview
The Epro PR6424/101-000 16 mm Eddy Current Sensor is a non-contact displacement sensor designed for monitoring the movement and position of rotating machinery components. It belongs to the PR6424 series developed for machinery condition monitoring in demanding industrial environments.
Manufactured under the EPRO product line, now part of Emerson, the PR6424 sensor is commonly used in applications involving turbines, compressors, pumps, fans, and other critical rotating equipment. Its primary function is to measure the distance between the sensor probe and a conductive target, typically a ferromagnetic steel shaft. Changes in this distance can be used to monitor shaft vibration, axial or radial displacement, position, and other dynamic operating characteristics.
The sensor uses eddy-current technology to perform measurements without physical contact with the rotating shaft. This is particularly important in high-speed machinery, where conventional contact measurement methods may introduce mechanical wear or interfere with equipment operation.
The PR6424/101-000 has a nominal sensor head diameter of 16 mm. Its compact sensing head supports installation in machinery monitoring arrangements where accurate shaft measurements are required and mounting space must be considered.
When connected to a compatible signal converter and monitoring system, the sensor provides measurement information that can be used for equipment condition assessment, alarm generation, and machinery protection. The complete sensor configuration, including cable length, connector type, mounting thread, and converter compatibility, should be confirmed before installation or replacement.
Technical Specifications
| Parameter | Specification |
|---|---|
| Brand | Epro / EPRO |
| Manufacturer Group | Emerson |
| Model | PR6424/101-000 |
| Product Series | PR6424 |
| Product Type | Eddy Current Sensor |
| Measurement Principle | Non-contact eddy-current technology |
| Sensor Head Diameter | 16 mm |
| Typical Sensitivity | 4 V/mm |
| Sensitivity Linearity | ≤ ±1.5% |
| Static Measurement Range | ±2.0 mm |
| Dynamic Measurement Range | 0–1,000 μm |
| Nominal Center Air Gap | Approximately 2.7 mm |
| Long-Term Drift | Less than 0.3% |
| Target Material | Ferromagnetic steel |
| Reference Target Material | 42CrMo4 steel |
| Reference Minimum Shaft Diameter | 80 mm |
| Sensor Sleeve Material | Stainless steel |
| Cable Material | PTFE |
| Sensor Weight Provided | 0.2 kg |
| Typical Application | Turbine, compressor, pump, fan, and rotating machinery monitoring |
Note: The performance values above describe the PR6424 sensor family. Cable length, connector arrangement, mounting details, and other variant-specific features should be verified against the complete PR6424/101-000 product documentation and nameplate.
Function and Working Principle
The PR6424/101-000 operates using the eddy-current measurement principle. It generates an electromagnetic field at the sensor tip and detects changes in that field when a conductive target moves closer to or farther away from the probe.
This allows the sensor to measure shaft movement without making physical contact with the rotating component.
1. Electromagnetic Field Generation
The sensor contains a coil inside its probe assembly. When connected to a compatible converter, the coil is energized and generates a high-frequency electromagnetic field around the sensing tip.
The field extends toward the metallic target surface. The sensor must be installed with an appropriate clearance so that it can operate within its specified measurement range.
2. Eddy Current Formation
When the electromagnetic field interacts with a conductive metal target, electrical currents known as eddy currents are induced in the target surface.
These currents affect the electromagnetic characteristics of the sensor coil. The degree of change depends on the distance between the probe and the target.
As the shaft moves, the gap changes and the sensor detects the corresponding variation.
3. Displacement Measurement
A compatible signal converter processes the sensor’s electrical characteristics and produces a measurement signal related to the probe-to-target distance.
The PR6424 family has a typical sensitivity of 4 V/mm and a static measurement range of ±2.0 mm. These values describe the specified sensor system under the appropriate calibration and target conditions.
The resulting measurement can represent shaft position or dynamic movement, depending on the monitoring arrangement.
4. Vibration Monitoring
When a rotating shaft moves repeatedly during operation, the sensor detects the changing gap between the shaft and probe.
The resulting signal can be analyzed to identify vibration amplitude, frequency, and changes in shaft movement. This information helps maintenance teams assess rotor condition and identify developing mechanical problems.
5. Signal Processing and Monitoring
The sensor normally operates as part of a complete measurement chain that includes a compatible converter and machinery monitoring equipment.
The monitoring system can process the measurement signal, display operating values, and generate alarms when configured limits are exceeded. The sensor itself is the measurement element; it does not independently perform all monitoring, alarm, or protection functions.
Role in Industrial Machinery Monitoring Systems
The PR6424/101-000 can be used as part of a machinery condition monitoring system. Its measurements provide information about the mechanical behavior of rotating shafts and support the assessment of equipment operating conditions.
Shaft Displacement Measurement
Shaft displacement is an important parameter in rotating machinery. Excessive movement may be associated with bearing wear, alignment problems, changes in rotor position, or other mechanical conditions.
The sensor measures the distance between its sensing tip and the shaft surface. The monitoring system can use this information to track changes in shaft position.
Radial Vibration Monitoring
Radial vibration refers to movement of a shaft perpendicular to its rotational axis. The PR6424 series is designed for radial and axial dynamic displacement measurements in suitable machinery applications.
By monitoring shaft movement continuously, engineers can identify changes in vibration behavior and investigate possible mechanical issues.
Axial Position Monitoring
Axial displacement describes movement along the shaft’s rotational axis. Monitoring axial position can help identify changes in rotor location and support the assessment of thrust-bearing conditions.
The sensor’s installation direction and measurement arrangement must be selected according to the machinery design.
Integration with Machinery Protection Equipment
The PR6424 sensor can be connected to compatible signal converters and monitoring equipment used in machinery protection systems.
Depending on the system architecture, processed signals may be provided to monitoring racks, control systems, or plant-level supervisory equipment. Compatibility must be confirmed for the sensor, converter, extension cable, and monitoring input as a complete system.
Industrial Applications
The PR6424 16 mm eddy-current sensor family is intended for critical rotating machinery applications. Its non-contact measurement principle is useful where continuous shaft monitoring is required.
1. Steam Turbines
Steam turbines operate at high rotational speeds and under demanding mechanical and thermal conditions. Monitoring shaft vibration and displacement helps engineers evaluate rotor behavior during normal operation and changing load conditions.
The PR6424 sensor can be used in suitable turbine monitoring arrangements to measure shaft movement and provide information for machinery condition assessment.
2. Gas Turbines
Gas turbines are important components in power generation and industrial energy systems. Their rotating assemblies require reliable monitoring to identify changes in mechanical behavior.
A compatible eddy-current measurement system can monitor shaft displacement and vibration, supporting maintenance planning and machinery protection strategies.
3. Hydro Turbines
Hydro turbines operate with large rotating assemblies and may experience changes in mechanical loading during operation.
Non-contact displacement measurement can provide useful information about shaft movement and help operators assess the condition of the rotating equipment.
4. Industrial Compressors
Centrifugal and other high-speed compressors rely on stable rotor operation. Changes in vibration or shaft position may indicate mechanical conditions that require investigation.
The PR6424 sensor family can be used in suitable compressor monitoring systems to measure radial and axial shaft movement.
5. Industrial Pumps
Large process pumps and high-speed pumps may require continuous monitoring of shaft displacement and vibration.
A properly installed sensor system can provide information about rotating equipment behavior and help maintenance teams identify abnormal changes.
6. Industrial Fans
Large fans used in power plants, processing facilities, and industrial ventilation systems may require vibration monitoring to support reliable operation.
The sensor can be considered for suitable fan applications where the shaft geometry, target material, and measurement requirements match the PR6424 specifications.
Installation and System Integration
Correct installation is essential for obtaining stable and reliable measurement results. The sensor must be matched with the target material, mounting arrangement, cable configuration, and signal converter.
1. Confirm the Sensor Variant
Before installation, verify the complete model number, PR6424/101-000. Different PR6424 variants may have different cable lengths, connector arrangements, armor options, and mechanical configurations.
Do not assume that two sensors with the same 16 mm head diameter are mechanically interchangeable.
2. Check the Target Surface
The PR6424 family is designed for measurement against ferromagnetic steel targets, with 42CrMo4 identified as the standard reference material.
Target material and surface characteristics affect measurement performance. Confirm that the actual shaft material and surface condition are suitable for the intended measurement system.
3. Set the Correct Air Gap
The nominal center air gap for the PR6424 family is approximately 2.7 mm.
During installation, the probe must be positioned within the required measurement range. The final gap should be established according to the manufacturer’s installation procedure and the connected converter’s calibration requirements.
Incorrect positioning may reduce the usable measurement range or cause inaccurate readings.
4. Secure the Sensor Mechanically
Install the sensor using the correct mounting arrangement for the specific variant. Confirm the thread, mounting length, available clearance, and required locking method from the product documentation.
The probe should be secured against unwanted movement. Mechanical instability can introduce measurement errors that may be mistaken for actual shaft vibration.
5. Protect the Cable
The PR6424 family uses PTFE cable material. Cable routing should follow the applicable installation instructions.
Avoid excessive bending, pulling, crushing, and contact with sharp edges. Keep the cable away from sources of electrical interference where required, and confirm the correct connector arrangement before connecting it to the converter.
6. Connect a Compatible Converter
The sensor requires a compatible signal converter to process the measurement characteristics and provide a usable output signal.
The converter must match the sensor’s electrical and mechanical configuration. Check the complete sensor-converter combination rather than selecting a converter based only on the PR6424 series name.
7. Calibrate and Verify the Measurement
After installation, verify the air gap and calibrate the measurement chain according to the manufacturer’s procedure.
Check the signal response over the expected operating range and confirm that the monitoring system displays reasonable values. Record the installation position and calibration information for future maintenance.
Compatible System Components
The PR6424/101-000 should be considered as one component of a complete machinery monitoring arrangement.
| Component | Function | Integration Considerations |
|---|---|---|
| Compatible signal converter | Processes the sensor’s electrical response | Must match the exact sensor variant and cable arrangement |
| Extension cable | Connects the sensor to the converter | Confirm cable type, length, and connector compatibility |
| Machinery monitoring module | Processes and evaluates measurement signals | Verify input type and supported sensor system |
| Monitoring rack | Provides centralized machinery monitoring | Confirm channel configuration and system compatibility |
| PLC or DCS | Uses available monitoring information for plant control and alarms | Integration depends on the monitoring system’s output interface |
| Operator monitoring system | Displays measurement values and alarms | Configure according to the plant’s monitoring architecture |
| Sensor mounting hardware | Secures the probe in the required position | Match thread, dimensions, and mounting requirements |
| Rotating shaft | Provides the conductive target surface | Confirm target material, surface condition, and shaft geometry |
The table lists typical system components, not items necessarily supplied with the sensor.
Alternative Models and Replacement Considerations
The PR6424 family includes different 16 mm sensor configurations. A replacement must match the original electrical and mechanical requirements.
| Alternative or Related Model | Description | Replacement Considerations |
|---|---|---|
| Epro PR6424/xxx-xxx | Other PR6424 16 mm sensor variants | Compare cable length, connector, armor, thread, and measurement configuration |
| Epro PR6425 | High-temperature eddy-current sensor family | Designed for different temperature requirements; not a direct substitute |
| Epro PR6423 | Related eddy-current sensor family | Uses a different sensor configuration and measurement arrangement |
| Bently Nevada 3300 XL series | Alternative machinery proximity measurement system | Requires a complete system-level compatibility assessment |
Before replacing a PR6424/101-000, verify:
- Full sensor model and ordering code.
- Sensor head diameter.
- Mounting thread and mechanical dimensions.
- Cable length and cable protection.
- Connector type and pin arrangement.
- Compatible signal converter.
- Measurement range and sensitivity.
- Target material and shaft dimensions.
- Temperature and environmental requirements.
- Monitoring system input compatibility.
A sensor from another manufacturer may perform a similar measurement function but should not be treated as a direct replacement without reviewing the complete measurement chain.
Key Advantages
Non-Contact Measurement
The sensor measures shaft movement without physical contact, avoiding mechanical contact between the probe and rotating target during normal operation.
Suitable for Critical Rotating Machinery
The PR6424 family is designed for applications involving turbines, compressors, pumps, and fans where shaft displacement and vibration measurements are important.
16 mm Sensor Head
The 16 mm sensing head provides a defined mechanical format for suitable machinery monitoring installations.
Static and Dynamic Measurement
The sensor family supports static position measurement and dynamic displacement monitoring, allowing the same measurement system to provide information about shaft position and vibration.
Stable Measurement Characteristics
Published family specifications include 4 V/mm sensitivity, linearity within ±1.5%, and long-term drift below 0.3% under the specified conditions.
Industrial Environmental Design
The sensor uses a stainless-steel sleeve and PTFE cable. These materials are intended for industrial measurement environments, subject to the stated temperature and installation limitations.
Integration with Machinery 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 PR6424/101-000?
The PR6424/101-000 is a 16 mm eddy-current sensor designed for non-contact measurement of shaft displacement and vibration in rotating machinery.
2. What is the sensor head diameter?
The nominal sensor head diameter is 16 mm.
3. What measurement principle does it use?
It uses eddy-current technology. The sensor generates an electromagnetic field, and changes in the distance to a conductive target affect the sensor’s electrical characteristics.
4. What is the typical sensitivity of the PR6424 series?
The published family sensitivity is 4 V/mm, with linearity specified at no more than ±1.5% under the applicable measurement conditions.
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 connected to a compatible converter and monitoring system, it can measure dynamic shaft displacement used for vibration monitoring.
7. What material should the sensor measure?
The PR6424 family is specified for ferromagnetic steel targets, with 42CrMo4 steel used as the standard reference material.
8. Does the sensor work without a signal converter?
The sensor is normally used with a compatible signal converter. The converter processes the sensor’s electrical response and provides a usable measurement signal to the monitoring system.
9. What is the weight of the PR6424/101-000?
The supplied product listing weight is 0.2 kg. The manufacturer’s family specification gives approximately 200 grams for the sensor with a 1 m cable and without armor. Actual weight may vary with cable length and configuration.
10. Can another PR6424 variant replace the PR6424/101-000?
Not automatically. Cable length, connector type, armor, mounting details, and converter compatibility may differ. Compare the complete ordering codes and installation requirements before replacement.
Procurement and Maintenance Recommendations
When purchasing the Epro PR6424/101-000, verify the complete model number and inspect the sensor’s physical configuration. The 16 mm sensor head diameter alone is not sufficient to establish interchangeability with other PR6424 variants.
Ask the supplier to confirm the cable length, connector arrangement, mounting thread, and whether the cable is armored. These details are important when replacing a sensor in an existing machinery monitoring installation.
For critical turbine, compressor, or pump applications, compatibility should be checked across the sensor, extension cable, signal converter, and monitoring system. A replacement probe should also be calibrated according to the applicable installation procedure.
During maintenance, inspect the sensing tip, threaded sleeve, cable insulation, and connector for physical damage. Check that the probe remains securely mounted and that the cable has not been exposed to excessive bending or mechanical stress.
Keep a record of the installed sensor model, mounting position, air gap, converter configuration, and calibration information. This documentation helps reduce errors during future maintenance and replacement work.
Conclusion
The Epro PR6424/101-000 16 mm Eddy Current Sensor is designed for non-contact shaft displacement and vibration measurement in critical rotating machinery. Its eddy-current measurement principle allows it to monitor shaft movement without physical contact, making it suitable for properly configured turbine, compressor, pump, and fan monitoring systems.
With a 16 mm sensor head and published PR6424 family performance characteristics including 4 V/mm sensitivity and a ±2.0 mm static measurement range, the sensor can support machinery condition monitoring when paired with compatible signal conversion and monitoring equipment.
For maintenance and procurement projects, confirming the exact sensor variant, cable configuration, mounting requirements, and converter compatibility is essential for reliable replacement and continued operation.