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- 16 mm Eddy Current Sensor
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Product Overview
The Epro PR6424/105-000 16 mm Eddy Current Sensor is a non-contact displacement sensor designed for monitoring the condition and operating behavior of rotating machinery. Part of the EPRO PR6424 sensor family from Emerson, it is used in machinery protection and condition-monitoring systems where accurate measurement of shaft movement, vibration, and position is important.
Unlike contact-type measurement devices, an eddy current sensor operates without physically touching the rotating shaft. It generates an electromagnetic field at the probe tip and detects changes in that field when a conductive target approaches or moves away from the sensing surface. This allows the system to monitor shaft movement without introducing mechanical contact between the sensor and the rotating component.
The PR6424 series is commonly used in steam turbines, gas turbines, hydro turbines, compressors, pumps, and industrial fans. These machines often operate continuously and may experience changes in shaft position or vibration as operating conditions change. Continuous measurement helps operators and maintenance teams identify abnormal mechanical behavior and evaluate equipment condition.
The PR6424 sensor has a nominal sensing-head diameter of 16 mm. Its published series specifications include a sensitivity of 4 V/mm, static measurement range of ±2.0 mm, and dynamic measurement range of 0–1,000 μm. These characteristics make it suitable for applications requiring the measurement of both relatively slow shaft-position changes and dynamic shaft vibration.
The sensor is generally used as part of a complete measurement system consisting of a probe, extension cable, and compatible signal converter. The converter processes the probe signal and provides an output suitable for monitoring equipment or machinery protection systems.
For the PR6424/105-000, the exact cable length, connector arrangement, mounting configuration, and converter compatibility should be confirmed against the complete product identification before installation or replacement.
Technical Specifications
| Parameter | Specification |
|---|---|
| Brand | Epro / EPRO |
| Manufacturer | Emerson |
| Model | PR6424/105-000 |
| 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 |
| 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 |
| Recommended Shaft Diameter | ≥80 mm |
| Sensor Sleeve Material | Stainless steel |
| Cable Material | PTFE |
| Reference Operating Temperature | Refer to the exact probe 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 |
| Dimensions | 16 mm sensor head diameter |
| Weight | 0.2 kg |
| Typical Applications | Turbines, compressors, pumps, fans, and rotating machinery |
Note: Electrical and measurement values above are published PR6424 family specifications. Confirm the complete PR6424/105-000 ordering details for its exact cable, connector, thread, and temperature configuration.
Function and Working Principle
The PR6424/105-000 uses eddy current technology to measure the distance between the sensor tip and a conductive metallic target. In rotating machinery, the target is typically the surface of a shaft or another suitable ferromagnetic component.
1. Electromagnetic Field Generation
An excitation signal inside the measurement system energizes the sensor coil. This creates an electromagnetic field around the probe tip.
When a conductive metallic target is positioned within the sensing field, electrical currents known as eddy currents are induced in the target material. These currents influence the electromagnetic behavior of the sensor coil.
2. Displacement Detection
As the distance between the sensor tip and the shaft changes, the strength and characteristics of the induced eddy currents also change.
The measurement system detects this change and converts it into a signal related to the distance between the probe and the target.
This allows the sensor to detect small movements of a rotating shaft without direct mechanical contact.
3. Static Position Measurement
Static measurement is used to identify the relative position of a shaft or other target surface.
The PR6424 family has a published static measurement range of ±2.0 mm. This capability is useful for monitoring shaft position, axial movement, and changes in the mechanical relationship between rotating and stationary components.
Position measurements can help engineers evaluate shaft alignment, bearing behavior, and other mechanical conditions.
4. Dynamic Vibration Measurement
When a shaft rotates, it may move slightly because of imbalance, misalignment, bearing conditions, or changing mechanical loads.
The sensor detects these movements as changes in the distance between the probe tip and the shaft surface.
The PR6424 series supports dynamic measurement from 0 to 1,000 μm. When connected to a compatible signal converter and monitoring system, the resulting signal can be used to evaluate shaft vibration and identify abnormal operating patterns.
5. Signal Conversion and Monitoring
The probe is normally connected to an appropriate extension cable and signal converter. The converter processes the sensor response and produces an electrical output suitable for the monitoring equipment.
A complete system may provide information about shaft displacement, vibration, position, eccentricity, and speed-related events, depending on the sensor configuration and monitoring architecture.
The probe should not be treated as a standalone controller or display device. Its measurement performance depends on the correct combination of probe, cable, converter, and monitoring equipment.
Role in Industrial Machinery Protection Systems
The PR6424/105-000 can be incorporated into machinery condition-monitoring and protection systems. Its primary role is to provide non-contact shaft measurement data that helps operators and maintenance personnel understand the mechanical condition of critical rotating equipment.
Shaft Vibration Monitoring
Shaft vibration is an important indicator of rotating machinery condition. Excessive vibration may be associated with imbalance, misalignment, bearing deterioration, looseness, or other mechanical problems.
A properly installed PR6424 measurement system can provide continuous shaft movement data for vibration monitoring equipment.
Axial and Radial Displacement Measurement
The sensor can be used in measurement arrangements designed to monitor radial or axial shaft movement.
Radial measurement helps identify movement perpendicular to the shaft axis, while axial measurement evaluates movement along the shaft’s longitudinal direction.
The probe orientation and mounting arrangement must be selected according to the specific measurement objective.
Machinery Condition Assessment
Changes in shaft vibration and position may provide useful information about equipment condition.
Maintenance teams can compare measurement trends with established operating baselines to identify changes that may require inspection. This can support condition-based maintenance and help prioritize maintenance activities.
Integration with Monitoring Equipment
The sensor operates as part of a larger measurement chain. A compatible converter processes its signal, while monitoring equipment evaluates the resulting measurement.
The exact interface and signal characteristics depend on the converter and monitoring hardware selected for the installation.
Industrial Applications
The PR6424 16 mm Eddy Current Sensor is designed for critical rotating machinery applications. It is particularly relevant where continuous shaft displacement and vibration monitoring are required.
1. Steam Turbines
Steam turbines operate at high rotational speeds and require reliable monitoring of shaft behavior.
The PR6424 series can be used to measure shaft vibration and position in suitable turbine monitoring arrangements. Measurement data can help maintenance teams identify changes in mechanical operating conditions and investigate abnormal vibration trends.
2. Gas Turbines
Gas turbines are used in power generation and industrial energy systems. Their rotating assemblies require continuous monitoring because changes in shaft movement may affect reliability and equipment availability.
A properly configured eddy current measurement system can provide shaft displacement information for turbine protection and condition monitoring.
3. Hydro Turbines
Hydro turbines operate under changing hydraulic and mechanical loads. Shaft movement and vibration can vary according to operating conditions, bearing behavior, and equipment condition.
Non-contact displacement measurement can support the monitoring of radial and axial shaft behavior in suitable hydroelectric installations.
4. Industrial Compressors
Large compressors are commonly used in chemical processing, petrochemical facilities, gas transportation, and industrial manufacturing.
Shaft vibration monitoring is important for evaluating compressor operating conditions. The PR6424 series can be incorporated into appropriate monitoring systems to measure dynamic shaft displacement.
5. Industrial Pumps
Pumps used in continuous industrial processes may operate under changing flow rates and pressure conditions.
A suitable shaft measurement arrangement can help detect changes in vibration and mechanical movement. This information can support maintenance assessments and help identify developing mechanical problems.
6. Industrial Fans
Large fans and ventilation systems often operate for extended periods. Changes in rotor balance, bearing condition, and mechanical alignment may influence shaft vibration.
The sensor can be used in suitable fan-monitoring installations where non-contact shaft measurement is required.
Installation and System Integration
Correct installation is essential for obtaining reliable measurement results from the PR6424/105-000.
1. Verify the Complete Sensor Configuration
Before installation, confirm the complete model number and identify the supplied cable and connector arrangement.
PR6424 sensors are available with different cable lengths, connection arrangements, and mounting configurations. The extension cable and signal converter must be compatible with the selected probe.
Do not assume that all PR6424 probes are interchangeable simply because they share the same sensor-head diameter.
2. Check the Mounting Thread
PR6424 family documentation identifies M18 × 1.5 and 3/4-16 UNF mounting-thread options, depending on the configuration.
The mounting thread must match the intended sensor holder or machine installation point. Verify the actual probe before machining or modifying the mounting arrangement.
3. Maintain the Correct Air Gap
The distance between the sensor tip and the target surface is an important factor in measurement performance.
The PR6424 series specifies a nominal center air gap of approximately 2.7 mm. The actual installation gap should be established according to the applicable probe and converter documentation.
An incorrect gap can cause inaccurate measurements or move the sensor outside its intended linear operating range.
4. Verify Target Material
The PR6424 series is designed for measurement against suitable ferromagnetic steel targets. The published reference material is 42CrMo4 steel.
Target material and surface characteristics influence eddy current behavior. If the shaft material differs from the reference material, the measurement system may require appropriate calibration or verification.
5. Route the Sensor Cable Correctly
The sensor cable should be routed away from high-power conductors and sources of electrical interference where possible.
Avoid sharp bends, excessive pulling force, and mechanical damage. The PR6424 family documentation identifies different minimum bending radii for armored and non-armored cable configurations. Follow the value applicable to the actual cable supplied.
6. Connect to a Compatible Signal Converter
The probe must be paired with a compatible converter and extension cable.
The converter is responsible for processing the sensor response and providing a usable output signal. Confirm the complete measurement-chain compatibility before connecting the sensor to machinery monitoring equipment.
7. Commission the Measurement System
After installation, verify the mechanical mounting, air gap, cable connections, and converter configuration.
Check the output signal under stationary conditions before evaluating measurements during normal machine operation. Record baseline values and compare them with the machine’s established operating limits.
Compatible System Components
The PR6424/105-000 is generally used with other components that form a complete eddy current measurement system.
| Component | Function | Compatibility Considerations |
|---|---|---|
| PR6424 Eddy Current Sensor | Detects shaft displacement without contact | Confirm exact probe variant and mounting configuration |
| Extension Cable | Connects the sensor to the converter | Cable type and length must match the system requirements |
| Signal Converter | Processes the probe response | Must be compatible with the PR6424 probe and cable |
| Machinery Monitoring System | Displays and evaluates measurement signals | Verify input type and measurement configuration |
| Shaft or Target Surface | Provides the metallic measurement target | Target material and geometry affect measurement performance |
| Sensor Mounting Bracket | Holds the probe in the required position | Ensure mechanical stability and correct alignment |
| Machinery Protection System | Evaluates measurements for protection functions | Confirm signal compatibility and alarm configuration |
| Control Room Monitoring Interface | Presents equipment condition information | Depends on the monitoring system architecture |
A complete measurement installation should be engineered as a matched system. The sensor alone does not provide the full monitoring and protection functions.
Alternative Models and Replacement Considerations
The PR6424 belongs to the EPRO 16 mm eddy current sensor family. Other models may have similar measurement functions, but they should not be treated as automatic replacements.
| Alternative Model or Series | General Description | Replacement Considerations |
|---|---|---|
| Epro PR6424/000 Series | PR6424 16 mm eddy current sensor variants | Compare cable, connector, thread, and converter compatibility |
| Epro PR6424/005 Series | 16 mm sensor configurations | Confirm exact electrical and mechanical variant |
| Epro PR6424/006 Series | 16 mm sensor configurations with variant-specific cable arrangements | Check cable length and connection details |
| Epro PR6425 Series | Eddy current sensor family for higher-temperature applications | Different sensor design and temperature capability; not a direct substitute |
| Epro PR6423 Series | Smaller-diameter eddy current sensor family | Different probe dimensions and measurement characteristics |
Before replacing the PR6424/105-000, verify:
- Complete probe model and suffix.
- Sensor-head diameter.
- Mounting thread and mechanical dimensions.
- Cable length and cable construction.
- Connector type and pin arrangement.
- Compatible extension cable.
- Signal converter compatibility.
- Measurement sensitivity and linear range.
- Target material and shaft dimensions.
- Operating temperature and environmental requirements.
A replacement probe should be tested with the existing measurement chain before the equipment is returned to normal operation.
Key Advantages
Non-Contact Measurement
The sensor measures shaft movement without physical contact, avoiding direct mechanical wear between the probe and the rotating target.
High Measurement Sensitivity
The PR6424 family has a published sensitivity of 4 V/mm, supporting the detection of small changes in the distance between the probe and the target.
Static and Dynamic Measurement
The sensor family supports both static position measurement and dynamic displacement measurement, making it useful for different machinery-monitoring requirements.
Compact 16 mm Sensing Head
The 16 mm sensor-head diameter supports installation in suitable machinery mounting arrangements where available space is limited.
Industrial Machinery Applications
The PR6424 series is designed for use with critical rotating machinery, including turbines, compressors, pumps, and fans.
Integration with Monitoring Systems
When paired with a compatible cable and signal converter, the sensor can provide measurement signals for industrial machinery monitoring and protection systems.
Suitable for Continuous Condition Monitoring
Its non-contact measurement principle allows the sensor to remain installed near the rotating shaft during normal equipment operation, supporting continuous monitoring.
Technical FAQs
1. What is the Epro PR6424/105-000?
The PR6424/105-000 is a 16 mm eddy current sensor from the EPRO PR6424 series. It is designed for non-contact measurement of shaft displacement and vibration in rotating machinery.
2. What is the main function of this sensor?
Its main function is to measure the distance between the sensor tip and a metallic target. In rotating machinery, this allows the monitoring system to evaluate shaft position and dynamic movement.
3. What is the sensor-head diameter?
The PR6424 series uses a 16 mm sensor head. This dimension is suitable for installations designed around the corresponding probe mounting arrangement.
4. What is the measurement sensitivity?
The published PR6424 series sensitivity is 4 V/mm, with linearity of approximately ±1.5% or better under the specified conditions.
5. What is the static measurement range?
The published static measurement range is ±2.0 mm. The actual usable measurement range depends on the specified operating gap and the complete measurement configuration.
6. Can it measure shaft vibration?
Yes. When connected to a compatible extension cable, signal converter, and monitoring system, the sensor can provide dynamic displacement information used for shaft vibration monitoring.
7. Does the sensor need to touch the rotating shaft?
No. It uses an electromagnetic eddy current measurement principle and operates without physical contact with the target surface.
8. What material can it measure?
The PR6424 family is specified for suitable ferromagnetic steel targets, with 42CrMo4 steel used as the reference material in published specifications.
9. Can the PR6424/105-000 connect directly to a PLC?
The probe normally requires a compatible signal converter before its measurement signal can be integrated into a monitoring or control system. The converter’s output type must match the receiving equipment.
10. What should be checked before replacing this sensor?
Verify the complete model number, sensor-head diameter, mounting thread, cable length, connector, converter compatibility, target material, and measurement range. Matching only the 16 mm diameter is not sufficient to establish full compatibility.
Procurement and Maintenance Recommendations
When purchasing the Epro PR6424/105-000, verify the complete model number and inspect the sensor’s physical condition. Pay particular attention to the sensing tip, threaded sleeve, cable insulation, connector, and identification label.
The supplied weight is 0.2 kg. The PR6424 specification sheet gives an approximate reference weight of 200 grams for the sensor with a 1 m cable and without armor. Actual weight may vary with cable length and construction.
For replacement projects, check the existing extension cable and signal converter before ordering. A probe that appears mechanically compatible may not provide the correct electrical performance if its cable or converter configuration differs.
During installation and maintenance, protect the sensor tip from impact and contamination. Avoid bending or pulling the cable beyond its specified limits, and inspect the mounting arrangement for looseness or mechanical movement.
It is also useful to maintain records of the initial air gap, measurement baseline, converter settings, and probe identification. These records can help maintenance teams compare future measurements and identify changes in the machinery’s operating condition.
Conclusion
The Epro PR6424/105-000 16 mm Eddy Current Sensor is a non-contact measurement device designed for shaft displacement and vibration monitoring in industrial rotating machinery. Its 16 mm sensing head, 4 V/mm sensitivity, and published ±2.0 mm static measurement range make it suitable for integration into appropriately configured machinery monitoring systems.
Used with a compatible extension cable and signal converter, the sensor can support condition monitoring for turbines, compressors, pumps, and industrial fans. Accurate model verification, correct air-gap adjustment, and proper measurement-chain compatibility are essential for reliable operation.