Emerson EPRO PR6424/010-110 16mm Eddy Current Sensor

Emerson EPRO PR6424/010-110 - Professional 16mm Eddy Current Proximity Sensor

The Emerson EPRO PR6424/010-110 is a precision-engineered 16mm eddy current proximity sensor designed for non-contact displacement and vibration measurement in rotating machinery applications. Optimized for shafts ≥80mm diameter, this sensor delivers API 670-compliant performance with 4 V/mm sensitivity and exceptional long-term stability, making it the preferred choice for turbomachinery monitoring, compressor protection, and predictive maintenance programs worldwide.

Precision Measurement Technology

At the heart of the PR6424/010-110 is a carefully tuned electromagnetic coil system that generates a stable high-frequency field. When positioned near a conductive target, eddy currents induced in the target material create a measurable impedance change proportional to the gap distance. This non-contact measurement principle eliminates wear, requires no lubrication, and provides maintenance-free operation for decades.

Key Performance Metrics:

• Measurement Sensitivity: 4 V/mm (101.6 mV/mil) with ±1.5% maximum linearity deviation
• Static Measurement Range: ±2.0 mm (±79 mils) from nominal air gap
• Dynamic Measurement Range: 0 to 1,000 μm (0 to 39 mils) peak-to-peak
• Nominal Air Gap: 2.7 mm (106 mils) - optimized operating point
• Long-Term Drift: <0.3% ensures calibration stability over multi-year service intervals
• Target Material: Calibrated for ferromagnetic steel (42CrMo4 / AISI 4140 standard)

Industrial-Grade Construction

The PR6424/010-110 features a precision-machined stainless steel sleeve that provides both mechanical protection and electromagnetic shielding. The M18x1.5 metric threading (or optional 3/4"-16 UNF) ensures secure mounting in bearing housings, machinery casings, and custom mounting brackets with proper torque retention under vibration.

Environmental Resilience:

• Operating Temperature: -35°C to 150°C (-31°F to 302°F) continuous
• Temperature Error: <4% per 100K meets API 670 machinery protection requirements
• Pressure Rating: 10,000 hPa (145 psi) at sensor head - suitable for pressurized housings
• Vibration Tolerance: 5g @ 60 Hz - can be mounted on vibrating structures
• Cable Insulation: PTFE (Teflon) rated to 150°C with excellent chemical resistance
• Sensor Weight: ~200 grams (7.05 oz) with 1m cable - minimal mounting load

Application-Specific Deployment Strategies

Compressor Shaft Monitoring: In centrifugal and axial compressors, the PR6424/010-110 monitors radial shaft position to detect bearing wear, rotor unbalance, and alignment issues before they escalate to failures. Install sensors in X-Y pairs at each bearing location to capture full orbital motion. The sensor's 2,500 m/s maximum surface speed capability accommodates high-speed compressor applications without measurement degradation.

Pump Reliability Programs: Critical process pumps benefit from continuous vibration monitoring that detects cavitation, impeller damage, and seal wear. The PR6424's ±2mm static range captures both normal operating vibration and abnormal excursions during startup, shutdown, and upset conditions. The sensor's pressure resistance allows installation in pump bearing housings without additional sealing.

Motor and Generator Monitoring: Large electric motors and generators require precise air gap monitoring between rotor and stator. The PR6424/010-110 provides the measurement range and stability needed to detect rotor eccentricity, thermal growth, and magnetic center shifts. Temperature compensation ensures accuracy as machine temperatures vary from cold startup to full-load operation.

Fan and Blower Applications: Industrial fans and blowers operate in harsh environments with temperature extremes, dust, and vibration. The PR6424's rugged construction and sealed design provide reliable measurement in these challenging conditions. The sensor's fast response captures blade-passing frequencies and detects bearing degradation before catastrophic failure.

System Integration Considerations

The PR6424/010-110 sensor requires a compatible signal converter (proximitor) to generate the excitation signal and condition the sensor output for monitoring systems. The sensor is fully compatible with Emerson EPRO CON021, CON031, and CON041 converter families, as well as legacy proximitor systems.

Signal Converter Selection Guide:

• CON021: Standard 4mm range, -24V supply, 0-20kHz bandwidth - most common choice
• CON021/914-060: Extended 6mm range for high-vibration applications
• CON021/914-080: Extended 8mm range for large displacement monitoring
• CON041: Legacy system compatibility with -24V supply

Installation Best Practices

Proper sensor installation is critical for measurement accuracy and long-term reliability. The PR6424/010-110 should be installed perpendicular to the shaft surface with the sensor tip positioned at the nominal 2.7mm air gap. Use precision shims or adjustable mounting brackets to achieve the correct gap during installation.

Installation Guidelines:

• Ensure target surface is clean, smooth, and free from coatings or platings
• Verify minimum shaft diameter of 80mm to avoid curvature effects
• Route sensor cable away from high-voltage cables and electromagnetic interference sources
• Secure cable with strain relief to prevent mechanical stress on sensor connection
• Use armored cable option in high-vibration or mechanically harsh environments
• Verify proper grounding of sensor sleeve to minimize electrical noise

Configuration Flexibility

The PR6424/010-110 model designation indicates specific configuration options:

• PR6424: 16mm sensor diameter platform
• 010: 3/4"-16 UNF threading (use 000 for M18x1.5 metric)
• 110: 110mm total sensor length with adapter plug, 10m cable, Lemo connector

Additional configurations are available with different sensor lengths (40mm to 290mm), cable lengths (4m to 10m), threading options, and connector types to match specific installation requirements.

Maintenance and Lifecycle Management

Eddy current sensors are inherently maintenance-free due to their non-contact operation. However, periodic inspection of the sensor tip and target surface is recommended to detect contamination, corrosion, or mechanical damage. The PR6424's robust construction typically provides 15-20 years of service life in properly maintained installations.

Troubleshooting Common Issues:

• Erratic readings: Check for target surface contamination or runout
• Reduced sensitivity: Verify air gap is within specified range
• Noisy signal: Inspect cable routing and grounding connections
• Temperature drift: Confirm operating temperature is within -35°C to 150°C range

API 670 Compliance and Standards

The PR6424/010-110 meets the performance requirements of API Standard 670 "Machinery Protection Systems" 5th Edition, including specifications for temperature error, linearity, and long-term stability. This compliance makes the sensor suitable for use in safety-critical machinery protection applications in petroleum, chemical, and power generation industries.

Complete Your Monitoring System

Build a comprehensive vibration monitoring solution with these compatible components:

• Emerson EPRO PR6424/003-030+CON021 16mm Eddy Current System - Factory-matched sensor and converter package
• Emerson EPRO PR6426/010-110 32mm Eddy Current Sensor - Larger sensor for 200mm+ shaft applications

Replacement and Retrofit Applications

The PR6424/010-110 is a direct replacement for aging Bently Nevada 3300 series sensors and other legacy eddy current probes in many installations. When retrofitting existing systems, verify mechanical compatibility (thread size, sensor length) and electrical compatibility with existing proximitor systems. Our technical team can assist with cross-reference verification and system integration planning.

Technical Support and Application Engineering

Selecting the optimal sensor configuration requires consideration of shaft diameter, operating speed, temperature environment, measurement range requirements, and mounting constraints. Our application engineering team provides expert guidance on sensor selection, installation design, and system integration to ensure successful deployment.

Why Choose Industrial Control Hub?

As a specialized supplier of Emerson EPRO vibration monitoring components, we maintain extensive inventory of sensors, signal converters, and accessories for immediate shipment. Our technical team brings decades of experience in machinery monitoring system design, installation, and troubleshooting across power generation, oil & gas, chemical processing, and manufacturing industries.

Same-Day Shipping | Genuine EPRO Components | Technical Application Support | Competitive Pricing

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