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- PR6424/102-101
- 16 mm Eddy Current Sensor
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Product Overview
The Epro PR6424/102-101 16 mm Eddy Current Sensor is a non-contact displacement sensor designed for monitoring the condition and operating behavior of critical rotating machinery. Part of the EPRO PR6424 sensor family from Emerson, it is used to measure shaft displacement, vibration, position, eccentricity, and rotational speed-related signals.
In industrial plants, rotating equipment such as steam turbines, gas turbines, compressors, pumps, and fans operates under mechanical and thermal loads that can change over time. Shaft movement and vibration provide important information about equipment condition. Continuous monitoring helps operators identify abnormal behavior and assess machinery performance before problems develop into serious equipment failures.
The PR6424 sensor uses the eddy-current measurement principle. It is installed near a suitable conductive target, typically a ferromagnetic steel shaft. As the distance between the probe tip and the target changes, the electrical characteristics of the sensor change accordingly. When connected to a compatible signal converter and monitoring system, these changes can be used to determine shaft displacement and vibration.
The PR6424/102-101 belongs to the 16 mm sensor family. Its nominal sensor head diameter is 16 mm, and the supplied product information lists a weight of 0.2 kg. The sensor family is designed for machinery applications that require stable, high-resolution measurements without physical contact between the probe and the rotating shaft.
The exact cable length, connector arrangement, mounting thread, and associated converter compatibility should be confirmed against the complete ordering specification for the /102-101 variant. These details are important when replacing an existing probe or assembling a complete machinery protection system.
Technical Specifications
| Parameter | Specification |
|---|---|
| Brand | Epro / EPRO |
| Manufacturer | Emerson |
| Model | PR6424/102-101 |
| Product Series | PR6424 |
| Product Type | 16 mm Eddy Current Sensor |
| Measurement Principle | Non-contact eddy-current technology |
| Sensor Head Diameter | 16 mm |
| Sensitivity | 4 V/mm (101.6 mV/mil) |
| Linearity | ≤ ±1.5% |
| Static Measuring Range | ±2.0 mm |
| Dynamic Measuring Range | 0 to 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 the applicable PR6424 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 |
Note: The electrical and measurement values above describe the PR6424 16 mm sensor family. Confirm the exact cable, connector, mounting, and temperature configuration of PR6424/102-101 before installation or replacement.
Function and Working Principle
The PR6424/102-101 operates through electromagnetic induction, commonly referred to as the eddy-current principle. This technology enables displacement measurement without requiring direct mechanical contact with the rotating shaft.
1. Eddy-Current Measurement
The sensor generates an electromagnetic field around its sensing tip. When a conductive target, such as a steel shaft, enters this field, small circulating electrical currents known as eddy currents are induced in the target surface.
These currents influence the electromagnetic characteristics of the sensor. The resulting electrical change is related to the distance between the sensor tip and the target.
As the shaft moves closer to or farther from the probe, the sensor response changes. A compatible signal converter processes this response and produces a measurement signal representing the target displacement.
2. Shaft Displacement Measurement
Shaft displacement is an important parameter in rotating machinery monitoring. Excessive movement may indicate mechanical wear, bearing problems, shaft misalignment, thermal expansion, or other abnormal operating conditions.
The PR6424 family provides a static measurement range of approximately ±2.0 mm under its specified operating conditions. This allows the monitoring system to evaluate the relative position of the shaft within the sensor’s calibrated measurement range.
Correct installation and calibration are essential. The sensor must be positioned at the specified initial gap and used with a compatible target material.
3. Vibration Monitoring
The sensor can also measure dynamic shaft movement. As the shaft rotates, its surface may move slightly relative to the probe because of vibration, imbalance, misalignment, or bearing-related mechanical conditions.
The resulting displacement signal can be processed by a machinery monitoring system to evaluate vibration amplitude and trends.
The PR6424 family has a specified dynamic measurement range of 0 to 1,000 μm. Actual measurement performance depends on the complete sensor system, including the probe, cable, converter, mounting arrangement, and target surface.
4. Signal Conversion
The sensor is normally used as part of a complete measurement chain rather than as an independent display device.
A compatible signal converter supplies the required excitation and processes the sensor response. The resulting output can then be connected to machinery protection or condition-monitoring equipment.
The exact converter model and cable arrangement must be selected according to the sensor’s full ordering configuration. Incorrect combinations can result in measurement errors or an unusable signal.
Role in Industrial Machinery Monitoring Systems
The Epro PR6424/102-101 can serve as a measurement component within a machinery protection and condition-monitoring system. Its role is to provide information about shaft movement and related mechanical behavior.
Turbine Protection
Steam, gas, and hydro turbines operate at high rotational speeds and are often critical to plant operation. Monitoring shaft displacement and vibration helps operators evaluate mechanical stability and identify abnormal changes.
A properly installed PR6424 sensor can provide displacement information for a compatible turbine monitoring system.
Compressor Monitoring
Industrial compressors are used in petrochemical plants, refineries, gas processing facilities, and manufacturing operations. Shaft vibration and displacement measurements help maintenance teams evaluate rotating assembly behavior.
The sensor can be installed at designated measurement locations to monitor shaft movement during normal operation and changing load conditions.
Bearing Condition Assessment
Shaft movement measurements can contribute to the assessment of bearing performance. Changes in shaft position or vibration may be associated with bearing wear, clearance changes, lubrication problems, or mechanical misalignment.
The probe does not independently diagnose bearing failure. Its measurement data must be interpreted together with other monitoring information and operating conditions.
Integration with Monitoring Equipment
A complete installation may include:
- PR6424 eddy-current sensor.
- Compatible extension cable.
- Compatible signal converter.
- Machinery protection or monitoring rack.
- Alarm and trip logic.
- Plant control or supervisory system.
The converter and monitoring equipment must be selected according to the sensor’s electrical characteristics and the required measurement function.
Industrial Applications
The PR6424 16 mm eddy-current sensor family is designed for critical rotating machinery. Its non-contact measurement principle makes it suitable for applications where continuous shaft monitoring is required.
1. Steam Turbines
Steam turbines operate under high thermal and mechanical loads. Shaft displacement and vibration are important parameters for assessing rotor behavior and machinery stability.
The PR6424 can be used at designated monitoring points to measure shaft movement. Monitoring data can help operators identify changes that require further inspection or maintenance.
2. Gas Turbines
Gas turbines are used in power generation and industrial process facilities. Their rotating assemblies operate under demanding temperature, speed, and load conditions.
Non-contact shaft measurement supports machinery monitoring by providing information about relative shaft movement. Correct probe placement and suitable converter configuration are necessary for dependable measurements.
3. Hydro Turbines
Hydro turbines operate under varying hydraulic and mechanical conditions. Shaft movement monitoring can help identify changes in rotor behavior and support maintenance planning.
The sensor can form part of a larger monitoring arrangement designed to observe displacement and vibration at selected locations.
4. Industrial Compressors
Compressors are essential in air separation, gas processing, chemical production, and petrochemical operations. Unexpected shaft movement can affect equipment efficiency and reliability.
The PR6424 can provide non-contact displacement measurements for compatible compressor monitoring systems.
5. Pumps and Fans
Large industrial pumps and fans may operate continuously for extended periods. Monitoring shaft vibration and displacement can help maintenance teams identify abnormal mechanical conditions.
The sensor is suitable for applications where the target material, shaft dimensions, installation clearance, and measurement range meet the PR6424 specifications.
6. Power Generation Equipment
Power plants depend on reliable rotating machinery. Turbines, generators, compressors, and auxiliary equipment may require continuous vibration and displacement monitoring.
The PR6424 can contribute to a machinery protection system by providing measurements used for alarms, condition assessment, and maintenance decisions.
Installation and System Integration
Proper installation is essential for measurement accuracy and long-term reliability. The probe must be installed according to the mechanical and electrical requirements of the complete measurement system.
1. Confirm the Sensor Configuration
Before installation, verify the complete model number PR6424/102-101. Check the cable length, connector type, mounting thread, sensor length, and compatibility with the intended signal converter.
Do not assume that all PR6424 probes have identical cable or connector arrangements. Different ordering variants may require different installation accessories.
2. Prepare the Mounting Location
The sensor should be mounted at the designated measurement point near the shaft. The mounting arrangement must provide mechanical stability and maintain the required clearance between the probe tip and the target surface.
The installation should also provide sufficient space for cable routing and future maintenance.
3. Set the Initial Air Gap
The PR6424 family has a nominal center air gap of approximately 2.7 mm. The actual gap must be established using the applicable installation and calibration procedure.
Incorrect initial positioning can reduce the usable measuring range or cause the sensor to operate outside its calibrated region.
The probe must not contact the rotating shaft during operation.
4. Check the Target Surface
The specified target material is ferromagnetic steel, with 42CrMo4 commonly used as the reference material in the manufacturer’s series specification.
Target material and surface condition influence measurement performance. Where the shaft material differs from the reference material, the measurement system should be checked for suitability and calibration requirements.
5. Route and Protect the Cable
The cable should be routed away from excessive heat, mechanical abrasion, sharp edges, and sources of electrical interference. Avoid tight bends and excessive tension.
The cable type and length must match the selected sensor and converter configuration. Connector connections should be clean, secure, and protected from contamination.
6. Connect the Signal Converter
Connect the sensor to a compatible signal converter using the specified cable and connector arrangement. Confirm the converter’s compatibility before applying power.
The converter processes the sensor signal and provides the measurement output required by the machinery monitoring system.
7. Perform Calibration and Functional Testing
After installation, verify the initial gap, electrical connections, and measurement output. Confirm that the signal changes correctly when the target position changes within the permitted range.
The system should be tested under the procedures specified for the complete machinery monitoring installation. Record the calibration values and installation details for future maintenance.
Compatible System Components
The PR6424/102-101 is generally used as part of a complete eddy-current measurement system. The following components may be required depending on the installation design.
| Component | Function | Integration Considerations |
|---|---|---|
| PR6424/102-101 Sensor | Detects shaft displacement and vibration | Confirm exact probe variant and mechanical configuration |
| Extension Cable | Connects the sensor to the converter | Match cable type, length, and connector arrangement |
| Signal Converter | Processes the sensor response | Must be compatible with the PR6424 sensor configuration |
| Machinery Monitoring Rack | Receives and evaluates measurement signals | Confirm supported signal inputs and monitoring functions |
| Vibration Monitoring Module | Processes dynamic displacement information | Select according to the required monitoring channel |
| Shaft or Target Surface | Provides the measurement target | Verify target material, diameter, and surface condition |
| Mounting Bracket or Holder | Maintains probe position | Ensure mechanical stability and correct initial gap |
| Plant Control System | Uses monitoring information for operational decisions | Integration depends on the monitoring rack’s output interfaces |
These components are not necessarily supplied with the sensor. A complete system should be designed around the exact sensor configuration and monitoring requirements.
Alternative Models and Replacement Considerations
The PR6424 family includes different probe configurations. A replacement should be selected by comparing the complete model number and electrical and mechanical specifications.
| Model or Product Family | Description | Replacement Considerations |
|---|---|---|
| Epro PR6424 Series | 16 mm eddy-current sensor family | Confirm exact variant, cable, connector, and mounting details |
| PR6424/000 Variants | Different basic probe configurations | Check cable and mounting arrangement before substitution |
| PR6424/006 Variants | Probe configurations with specified cable arrangements | Confirm overall cable length and converter compatibility |
| PR6424/010 Variants | Additional probe configurations | Compare mechanical dimensions and electrical specifications |
| Epro PR6425 Series | 16 mm eddy-current sensor family for different temperature requirements | Not automatically interchangeable; verify temperature range and system compatibility |
Before selecting an alternative, compare:
- Sensor head diameter.
- Probe body length and mounting thread.
- Cable length and cable construction.
- Connector type and pin arrangement.
- Sensitivity and linearity.
- Static and dynamic measuring ranges.
- Nominal air gap.
- Target material and shaft dimensions.
- Operating temperature limits.
- Compatible signal converter.
- Monitoring system input requirements.
A probe with the same 16 mm head diameter is not necessarily a direct replacement. Electrical characteristics and mechanical configuration must also match.
Key Advantages
Non-Contact Measurement
The PR6424 uses eddy-current technology to measure shaft displacement without physical contact. This makes it suitable for monitoring rotating machinery where direct mechanical measurement is impractical.
16 mm Sensor Head
The 16 mm sensing head is designed for industrial machinery monitoring applications requiring a specific probe diameter and mounting arrangement.
High Measurement Sensitivity
The PR6424 family specifies a sensitivity of 4 V/mm, supporting detailed displacement measurements when used with a compatible converter and correctly calibrated system.
Static and Dynamic Measurement
The sensor family supports both static shaft-position measurement and dynamic displacement measurement, allowing it to contribute to several machinery monitoring functions.
Industrial Machinery Applications
The PR6424 family is designed for use with critical rotating equipment, including turbines, compressors, pumps, and fans.
Stainless Steel Sleeve
The stainless steel sleeve provides a robust mechanical structure for the sensor assembly in appropriate industrial installation environments.
PTFE Cable Construction
The specified PTFE cable material is intended for industrial sensor connections. The actual cable temperature limits and routing requirements must be checked for the selected variant.
Low Sensor Weight
The supplied weight is 0.2 kg, consistent with the manufacturer’s approximate weight for a PR6424 sensor with 1 m cable and without armor.
Technical FAQs
1. What is the Epro PR6424/102-101?
The PR6424/102-101 is a 16 mm non-contact eddy-current sensor designed for measuring shaft displacement, vibration, position, and related mechanical parameters in rotating machinery.
2. What is the sensor head diameter?
The sensor head diameter is 16 mm, which is the defining physical size of the PR6424 16 mm sensor family.
3. How does the PR6424 measure shaft displacement?
It generates an electromagnetic field at the probe tip. A conductive target entering this field produces eddy currents that influence the sensor’s electrical characteristics. A compatible converter processes the change and produces a signal related to the target distance.
4. What is the sensitivity of the PR6424 sensor family?
The specified sensitivity is 4 V/mm, equivalent to approximately 101.6 mV/mil. The stated linearity is up to ±1.5% under the specified conditions.
5. What is the measuring range?
The PR6424 family has a static measuring range of approximately ±2.0 mm and a dynamic measuring range of 0 to 1,000 μm. Actual performance depends on the complete measurement system and installation conditions.
6. What material should be used as the measurement target?
The reference target material is ferromagnetic steel, with 42CrMo4 used as the standard reference material in the series specification. Target material should be checked when designing or replacing a measurement system.
7. Does the sensor work without a signal converter?
The PR6424 is normally used with a compatible signal converter. The converter provides the required sensor interface and processes the measurement signal for the monitoring system.
8. What machinery can use this sensor?
Typical applications include steam turbines, gas turbines, hydro turbines, compressors, pumps, and fans. The exact installation must meet the sensor’s mechanical and electrical requirements.
9. What is the weight of the PR6424/102-101?
The supplied product weight is 0.2 kg. This is consistent with the manufacturer’s approximate weight for a sensor with 1 m cable and without armor. The actual shipping weight may differ.
10. What should be checked before replacing an existing PR6424 sensor?
Check the complete model number, sensor length, mounting thread, cable length, connector, sensitivity, measuring range, target material, and signal converter compatibility. Matching only the sensor head diameter is not sufficient to confirm interchangeability.
Procurement and Maintenance Recommendations
When purchasing the Epro PR6424/102-101, verify the complete model number and confirm that the supplied sensor matches the configuration required by the existing machinery monitoring system.
Request clear product photographs showing the probe head, threaded sleeve, cable, connector, and model identification. Confirm whether the sensor is supplied with an extension cable or other accessories, as these may be ordered separately depending on the configuration.
For replacement projects, compare the existing sensor with the proposed unit before installation. Pay particular attention to cable length, connector type, mounting dimensions, and converter compatibility. A probe that appears physically similar may have different electrical or mechanical characteristics.
During routine maintenance, inspect the probe mounting, cable routing, connector condition, and surrounding installation environment. Check for loose fittings, damaged insulation, contamination, and signs of mechanical contact with the shaft.
Measurement readings should be reviewed together with other machinery monitoring data. Sudden changes in displacement or vibration may require further investigation, but a single measurement should not be treated as a complete diagnosis of equipment condition.
Maintain records of sensor identification, installation position, initial gap, converter configuration, calibration results, and maintenance history. These records support future replacement work and help maintain consistency across machinery monitoring channels.
Conclusion
The Epro PR6424/102-101 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 and the PR6424 family’s 4 V/mm sensitivity, ±2.0 mm static measuring range, and approximately 2.7 mm nominal center air gap make it suitable for properly configured machinery monitoring applications.
Used with a compatible signal converter and monitoring system, the sensor can provide important information about shaft position and dynamic movement in turbines, compressors, pumps, and fans.
For procurement and replacement, confirming the complete /102-101 configuration is essential. Cable, connector, mounting, and converter compatibility should be checked before installation to ensure reliable measurement performance.