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- 16 mm Eddy Current Sensor
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Product Overview
The Epro PR6424/101-100 16 mm Eddy Current Sensor is a non-contact displacement and proximity sensor designed for monitoring the operating condition of rotating industrial machinery. It belongs to the PR6424 sensor family developed for machinery protection and condition monitoring applications, particularly in environments where accurate shaft movement measurements are important for equipment reliability.
Manufactured under the EPRO product line associated with Emerson, the PR6424 series is widely used in monitoring systems for steam turbines, gas turbines, hydro turbines, compressors, pumps, fans, and other rotating equipment. Its primary function is to detect changes in the distance between the sensor tip and a suitable metallic target without requiring physical contact.
The sensor uses eddy current technology to measure shaft displacement and vibration. When positioned near a ferromagnetic target, the sensor generates an electromagnetic field. Changes in the distance between the sensor and the target affect the electrical characteristics of the sensing element. A compatible signal converter processes these changes and produces a measurement signal for machinery monitoring equipment.
The PR6424/101-100 has a nominal sensor head diameter of 16 mm and a supplied weight of approximately 0.2 kg. Its compact sensing head and threaded mounting arrangement make it suitable for installation near rotating shafts where mechanical clearance and measurement accuracy must be considered.
In industrial machinery protection systems, the sensor can provide important information about shaft vibration, axial or radial displacement, operating position, and other mechanical conditions. This information helps maintenance personnel identify abnormal changes before they develop into more serious equipment problems.
The exact cable length, connector arrangement, mounting configuration, and temperature rating should be verified against the specific /101-100 product identification and applicable documentation before installation or replacement.
Technical Specifications
| Parameter | Specification |
|---|---|
| Brand | Epro |
| Manufacturer / Product Group | Emerson EPRO |
| Model | PR6424/101-100 |
| 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 |
| Nominal Center Air Gap | Approximately 2.7 mm |
| Long-Term Drift | Less than 0.3% |
| Target Material | Ferromagnetic steel |
| Reference Shaft Diameter | ≥80 mm |
| Sleeve Material | Stainless steel |
| Cable Material | PTFE |
| Operating Temperature | Refer to exact sensor configuration |
| Sensor Head Pressure Resistance | 10,000 hPa (145 psi), PR6424 family specification |
| Shock and Vibration Reference | 5 g at 60 Hz at 25°C |
| Dimensions | 16 mm sensor head diameter |
| Weight | 0.2 kg |
| Typical Applications | Turbines, compressors, pumps, fans, and rotating machinery |
Note: Performance figures above describe the PR6424 sensor family. Confirm the exact electrical, mechanical, cable, connector, and environmental configuration of PR6424/101-100 before installation.
Function and Working Principle
The PR6424/101-100 uses eddy current technology to measure the distance between its sensing tip and a conductive metallic target. It provides non-contact measurements that can be used for machinery condition monitoring and protection.
1. Eddy Current Measurement Principle
The sensor generates an alternating electromagnetic field at its sensing tip. When a suitable metallic target approaches the sensor, the electromagnetic field induces eddy currents in the target surface.
These eddy currents affect the electrical characteristics of the sensor coil. The resulting change is related to the distance between the sensor and the target.
A compatible signal converter interprets this change and converts it into an electrical measurement signal. The signal can then be used by a machinery monitoring system to calculate shaft displacement or vibration.
Because the measurement is non-contact, the sensor can monitor high-speed rotating shafts without physically touching them.
2. Shaft Displacement Measurement
One important application of the PR6424 sensor is measuring shaft displacement.
In rotating machinery, shaft movement can result from operating loads, bearing conditions, thermal expansion, mechanical imbalance, or changes in alignment. Monitoring the distance between the shaft and a fixed sensor provides information about these movements.
The PR6424 family supports static position measurement within a specified range of ±2.0 mm. This capability is useful for monitoring shaft position and identifying changes in mechanical alignment or operating conditions.
3. Vibration Monitoring
The sensor can also measure dynamic shaft movement associated with vibration.
When a rotating shaft moves relative to the sensor, the sensor-to-target distance changes continuously. The resulting signal represents the dynamic displacement of the shaft.
A machinery monitoring system can use this information to identify changes in vibration amplitude and operating behavior. Engineers can compare measurements with established operating limits and investigate abnormal trends.
4. Position and Eccentricity Detection
In addition to vibration measurement, the PR6424 series can be used for shaft position and eccentricity monitoring.
Eccentricity refers to the deviation between the geometric center of a rotating shaft and its actual rotational axis. Excessive eccentricity may indicate mechanical deformation, uneven thermal expansion, installation problems, or other abnormal conditions.
Monitoring these parameters can help operators evaluate machine behavior during startup, shutdown, and normal operation.
5. Speed and Key Reference Applications
The PR6424 sensor family also supports speed and key-related measurements in suitable monitoring arrangements.
A metallic target or reference feature passing the sensor changes the measured distance and produces a corresponding signal. With suitable signal processing and system configuration, this information can support rotational speed or reference-position monitoring.
The exact measurement function depends on the target arrangement, sensor installation, converter configuration, and monitoring equipment.
Role in Industrial Machinery Monitoring Systems
The PR6424/101-100 is normally used as part of a complete machinery monitoring arrangement rather than as an independent measurement system.
A typical installation includes the sensor, extension or connection cable where required, compatible signal converter, monitoring module, and supervisory control or protection equipment.
Turbine Protection Systems
Steam, gas, and hydro turbines operate under demanding mechanical conditions. Shaft vibration and displacement measurements are important for evaluating rotor behavior and protecting critical rotating components.
The PR6424 sensor can provide shaft movement information to a compatible monitoring system. Operators can use this information to assess changes in vibration, shaft position, and machine operating conditions.
Compressor Monitoring
Industrial compressors operate at high rotational speeds and may experience changing loads during normal production.
Non-contact shaft displacement measurement can help identify abnormal vibration patterns, changes in rotor movement, and possible mechanical problems.
The sensor is suitable for applications where the specified measurement range, target material, mounting arrangement, and operating temperature meet the installation requirements.
Pump Monitoring
Large industrial pumps may operate continuously in power plants, chemical processing facilities, water treatment plants, and other industrial environments.
Monitoring shaft movement can provide useful information about bearing conditions, mechanical alignment, and rotating assembly behavior.
The PR6424 sensor can be incorporated into a compatible pump monitoring arrangement to provide non-contact displacement measurements.
PLC and DCS Integration
A compatible signal converter or machinery monitoring module processes the sensor signal before the measurement is passed to the wider automation system.
Depending on the system architecture, measurement information may be made available to a PLC, distributed control system, machinery protection platform, or plant supervisory system.
Engineers should confirm signal compatibility and the required converter configuration before connecting the sensor to monitoring equipment.
Industrial Applications
1. Steam Turbines
Steam turbines operate at high rotational speeds and require continuous monitoring of shaft movement and vibration. Changes in rotor behavior may indicate mechanical imbalance, bearing wear, thermal expansion, or alignment problems.
The PR6424/101-100 can be used in a suitable turbine monitoring arrangement to provide non-contact shaft displacement measurements.
2. Gas Turbines
Gas turbines operate under high temperatures and demanding mechanical conditions. Monitoring shaft displacement and vibration helps maintenance teams evaluate rotor behavior and identify unusual operating trends.
The sensor’s exact temperature capability must be checked against the selected configuration and the actual installation environment.
3. Hydro Turbines and Generators
Hydro turbines and generator assemblies contain rotating components that require reliable mechanical monitoring.
Non-contact displacement sensors can measure shaft movement and help detect changes in rotor alignment or vibration behavior.
The PR6424 series is designed for large rotating machinery applications, including turbine and generator installations.
4. Industrial Compressors
Compressors used in petrochemical plants, refineries, gas processing facilities, and manufacturing operations often require continuous condition monitoring.
The sensor can measure shaft displacement without physical contact, allowing monitoring systems to evaluate changes in rotor movement during operation.
5. Industrial Pumps
Large pumps may experience mechanical vibration caused by changing hydraulic conditions, bearing wear, misalignment, or rotor imbalance.
A correctly installed eddy current sensor can provide displacement information that supports equipment condition assessment and preventive maintenance.
6. Industrial Fans and Blowers
Large fans and blowers are commonly used in power generation, ventilation, and industrial process systems.
Monitoring shaft vibration can help maintenance teams identify mechanical abnormalities and plan inspections before unexpected equipment failure occurs.
Installation and System Integration
Correct installation is essential for obtaining stable measurements from the PR6424/101-100. Sensor positioning, target material, mounting clearance, and cable routing can all influence measurement performance.
1. Confirm the Sensor Configuration
Before installation, verify the complete model number, sensor head diameter, cable arrangement, connector type, and mounting configuration.
The PR6424 family includes different cable lengths and mechanical configurations. A sensor with the same head diameter may not have an identical cable or connection arrangement.
Confirm the exact /101-100 variant against the product label and the corresponding technical documentation.
2. Select a Suitable Mounting Position
The sensor should be mounted securely near the monitored shaft, with the sensing tip facing the intended metallic target.
The mounting arrangement must maintain the required mechanical clearance and avoid interference with nearby metallic components. Unwanted metallic material near the sensing area can affect the electromagnetic measurement field.
The recommended target surface material for the PR6424 family is ferromagnetic steel, with 42CrMo4 identified as the standard reference material.
3. Set the Correct Air Gap
The PR6424 family specifies a nominal center air gap of approximately 2.7 mm.
The actual installation gap must be established according to the applicable sensor and converter documentation. Incorrect spacing may cause inaccurate measurements or reduce the available linear measurement range.
During commissioning, technicians should verify the gap using the manufacturer’s recommended procedure and suitable measuring equipment.
4. Connect a Compatible Signal Converter
The sensor requires a compatible signal converter to process its measurement characteristics.
The converter should match the PR6424 sensor configuration and the intended measurement function. Different converter models may support different signal arrangements and monitoring applications.
Check the converter model, electrical connections, cable compatibility, and calibration requirements before commissioning.
5. Route and Protect the Cable
The sensor cable should be routed carefully to avoid excessive bending, mechanical damage, and interference from nearby power conductors.
Observe the minimum bending radius specified for the exact cable construction. Where the cable is exposed to vibration or mechanical hazards, provide suitable support and protection.
Do not assume that every PR6424 cable configuration has the same bending-radius or temperature limits.
6. Calibrate and Test the Measurement System
After installation, verify the sensor-to-target gap and confirm that the signal converter produces a stable measurement output.
Check the sensor response across the intended operating range and confirm that the monitoring system displays reasonable position and vibration values.
Record the initial operating measurements as a reference for future condition monitoring.
Compatible System Components
The PR6424/101-100 is normally integrated with other machinery monitoring components. The exact compatible hardware should be selected according to the sensor’s electrical and mechanical configuration.
| Component | Function | Integration Considerations |
|---|---|---|
| Compatible PR6424 signal converter | Converts sensor impedance changes into a measurement signal | Must match the sensor variant and electrical characteristics |
| Sensor extension cable | Connects the sensor to the converter where required | Confirm cable type, length, connector, and total system configuration |
| Machinery monitoring module | Processes vibration and displacement information | Verify supported sensor and converter combination |
| Shaft or rotor target | Provides the metallic measurement surface | Use a suitable ferromagnetic target surface |
| Turbine protection system | Monitors machine operating conditions | Confirm measurement input compatibility and alarm configuration |
| PLC | Coordinates plant automation functions | Use an appropriate signal interface or monitoring-system output |
| DCS | Provides plant-wide monitoring and control | Confirm available measurement signals and communication interfaces |
| Mounting hardware | Secures the sensor in the correct position | Verify thread, dimensions, and mechanical clearance |
| Cable protection accessories | Protect cable routing in industrial environments | Select according to vibration, temperature, and installation conditions |
The components listed above are examples of equipment used in a complete monitoring arrangement. They are not necessarily included with the sensor.
Alternative Models and Replacement Considerations
The PR6424 series includes different sensor configurations designed for various mounting, cable, and connection requirements. A replacement should be selected according to the original installation rather than the 16 mm head diameter alone.
| Alternative or Related Model | Description | Replacement Considerations |
|---|---|---|
| Epro PR6424/000 Series | 16 mm eddy current sensor configurations | Verify cable and connector arrangement |
| Epro PR6424/005 Series | 16 mm eddy current sensor variants | Confirm exact mechanical and electrical configuration |
| Epro PR6424/006 Series | 16 mm sensor variants | Check cable length and mounting details |
| Epro PR6424/007 Series | 16 mm sensor variants | Verify the full catalog number before substitution |
| Epro PR6424/008 Series | 16 mm sensor variants | Confirm converter compatibility and measurement requirements |
| Epro PR6425 Series | Related eddy current sensor family | Designed for different temperature and measurement conditions; not automatically interchangeable |
Before selecting an alternative, compare:
- Sensor head diameter and mechanical dimensions.
- Thread size and mounting arrangement.
- Cable length and cable construction.
- Connector type and pin configuration.
- Sensitivity and linear measurement characteristics.
- Static and dynamic measurement ranges.
- Target material and required air gap.
- Operating temperature and environmental limits.
- Compatible signal converter.
- Monitoring system input requirements.
A sensor with the same nominal diameter may still produce different results if its electrical characteristics or converter compatibility differ. Always verify the complete sensor system before replacement.
Key Advantages
Non-Contact Measurement
The PR6424/101-100 measures shaft displacement without physical contact. This makes it suitable for monitoring rotating machinery where conventional contact measurement methods are impractical.
Compact 16 mm Sensing Head
The 16 mm sensor head supports installation in machinery monitoring locations where mounting space is limited.
High Measurement Sensitivity
The PR6424 family specifies a sensitivity of 4 V/mm, supporting the measurement of relatively small changes in the sensor-to-target distance.
Static and Dynamic Measurement
The sensor family supports both static position measurement and dynamic displacement measurement, allowing it to be used for different machinery monitoring functions.
Industrial Machinery Applications
The PR6424 series is designed for critical rotating machinery, including turbines, compressors, pumps, and fans.
Stainless Steel Sensor Sleeve
The stainless steel sleeve provides a robust mechanical structure for industrial sensor installation.
PTFE Cable Material
The specified PR6424 family construction uses PTFE cable material, supporting applications where suitable thermal and mechanical cable characteristics are required.
Condition Monitoring Support
By providing shaft displacement information, the sensor can contribute to machinery condition monitoring and maintenance planning.
Technical FAQs
1. What is the Epro PR6424/101-100?
The PR6424/101-100 is a 16 mm non-contact eddy current sensor used for measuring shaft displacement and vibration in industrial rotating machinery.
2. What is the sensor head diameter?
The nominal sensor head diameter is 16 mm.
3. What measurement principle does the sensor use?
It uses eddy current technology. The sensor generates an electromagnetic field, and changes in the distance to a suitable metallic target affect the sensor’s electrical characteristics.
4. What is the sensitivity of the PR6424 sensor family?
The published sensitivity is 4 V/mm, equivalent to approximately 101.6 mV/mil, with a specified linearity of up to ±1.5%.
5. What is the static measurement range?
The PR6424 family specifies a static measurement range of ±2.0 mm.
6. What is the dynamic measurement range?
The published dynamic measurement range is 0–1,000 μm. Actual measurement performance depends on the complete sensor and converter arrangement.
7. What materials can the sensor measure?
The PR6424 family is specified for ferromagnetic steel targets, with 42CrMo4 identified as the standard reference material.
8. Does the sensor require a signal converter?
Yes. A compatible signal converter is required to process the sensor’s electrical response and provide a usable measurement signal for the machinery monitoring system.
9. Where is the PR6424/101-100 commonly used?
Typical applications include steam turbines, gas turbines, hydro turbines, compressors, industrial pumps, fans, and other rotating machinery.
10. What is the weight of the PR6424/101-100?
The supplied product weight is approximately 0.2 kg. The actual shipping weight may vary depending on cable length, packaging, and included accessories.
Procurement and Maintenance Recommendations
When purchasing the Epro PR6424/101-100, verify the complete model number and inspect the sensor label before confirming an order. Different PR6424 configurations may have similar appearances but different cable lengths, connectors, and mounting arrangements.
For replacement projects, compare the original sensor’s dimensions, thread, cable configuration, converter compatibility, and measurement characteristics. Replacing a sensor based only on its 16 mm diameter may result in an incompatible monitoring arrangement.
For used or surplus units, request clear photographs of the sensor head, threaded sleeve, cable, connector, and identification label. Check for damaged insulation, bent mounting components, corrosion, and signs of mechanical impact.
During maintenance, inspect the cable routing and mounting hardware regularly. Ensure that the sensor remains securely positioned and that the sensing tip is not exposed to mechanical contact or contamination that could affect the measurement.
It is also useful to record baseline shaft displacement and vibration readings after commissioning. Comparing future readings with these reference values can help maintenance teams identify changes in machine condition.
Conclusion
The Epro PR6424/101-100 16 mm Eddy Current Sensor is a non-contact measurement component designed for industrial rotating machinery monitoring. Its eddy current operating principle allows it to measure shaft displacement and dynamic movement without physical contact.
With a nominal 16 mm sensor head, a supplied weight of approximately 0.2 kg, and PR6424 family performance specifications including 4 V/mm sensitivity and a ±2.0 mm static measurement range, it can support machinery condition monitoring applications in turbines, compressors, pumps, and fans.
For installation and replacement projects, engineers should verify the exact sensor variant, cable and connector configuration, signal converter compatibility, and mounting requirements. Correct system matching and installation are essential for reliable measurement performance.