Industrial Debris Detection

Continous Ferrous Debris Monitoring
Reduces Unplanned Downtime
Straightforward Installation and Implementation
Robust for Harsh Environments

Continous Ferrous Debris Monitoring
Reduces Unplanned Downtime
Straightforward Installation and Implementation
Robust for Harsh Environments

Home / Industrial Debris Detection

The KasperAero NZMS debris sensor is designed for industrial applications where reliability and integration matter. Proven in demanding environments, the NZMS detects ferrous debris at the earliest stages of machine failure and can be deployed in gearboxes, hydraulics, fuel, and other fluid systems. It connects seamlessly with PLCs and plant monitoring systems, providing real-time data that supports predictive maintenance and reduces unplanned downtime.

Key Features

Real-time, continuous condition monitoring
Detects and quantifies both fine and coarse ferrous wear debris
Proven to reduce unplanned downtime and maintenance costs
Compatible with PLC and SCADA systems for seamless integration
Standard industrial output options (analog and digital)
Robust construction for harsh environments
Compact form factor for easy installation in existing systems

Typical Applications

Steel Mill Rolling Equipment
Industrial Hydraulic Power Units
Industrial Air Compressor Gear Trains
Canning Equipment Recirculatory Oil Systems
Wind Turbine Final Drive
Injection Molding Machine Hydraulic Systems
Industrial Air Compressor Gear Trains
Pulp & Paper Processing Equipment
Hydroelectric Turbine Gearbox Systems
Oil & Gas Drilling Rig Top Drives

Product Overview

Performance Advantages

The KasperAero NZMS debris sensor brings proven oil debris monitoring technology to industrial applications with off the shelf solutions developed for a wide range of applications. The flagship 1020 product line provides the earliest warning of component failure by detecting debris in oil and other fluid systems. It can be applied in gearboxes, fuel systems, and hydraulics, coolants, and other liquids. The 1020 series is designed to be easily integrated into systems with the large range of mounting adapters and output signal varieties.

Product Features:

Senses Fine Ferrous Dust
Extremely Compact
Low Cost
Low Power Draw
Low Noise (EMI/EMR)
Rugged design for harsh environments
No Moving Parts
No Microcontrollers
No Temperature Compensation
No Calibration
No Electrodes Exposed to Fluid Environment

Flexible Installations

In high-demand industrial environments such as steel mills, production lines, and transportation systems, unplanned downtime can cost tens of thousands of dollars per hour. A custom debris sensor provides measurable cost savings by detecting wear and contamination early, preventing catastrophic failures before they occur. By integrating directly into existing equipment without requiring additional hardware or major cabinet modifications, installation costs remain low while maximizing uptime. Early detection reduces emergency repairs, extends the service life of critical machinery, and lowers maintenance expenses. Across operations, the sensor can improve overall equipment efficiency, reduce lost production hours, and protect against costly warranty claims or component replacements. When evaluated over the life of the machinery, the investment in a debris sensor can quickly pay for itself, delivering a strong ROI while also enhancing system reliability and safety.

Core Capabilities

Continuous ferrous debris detection
Real-time oil condition monitoring
Compact form factor for embedded systems
Rugged design for harsh environments
Zero-maintenance solid-state construction

Strategic Benefits

Prevent unplanned downtime
Lower total cost of ownership
Enable predictive maintenance

Frequently Asked Questions

No, the 1020 series of sensors does not collect or detect non-ferrous debris such as aluminum, brass, ceramics, or dirt.

No, all 1020 sensors are completely axially symmetric and can operate reliably in any orientation. Its performance is unaffected by how it is mounted, allowing flexible installation in a wide variety of systems.

In applications where the sensor is positioned away from nearby ferrous materials, the 1020 product line does not require calibration. Because it detects disturbances in magnetic fields, non-ferrous metals such as aluminum, annealed stainless steel, magnesium, brass, lead, copper, zinc, and titanium have absolutely no effect on its readings. These materials are invisible to the sensor and allows for straightforward installation without the need for adjustment.

For applications, with close proximity to ferrous materials, calibration must be done on the implementation side by recording the analog output and adjusting the PLC or SCADA thresholds accordingly. There is no calibration button or procedure for KasperAero Industrial debris sensors. See installation guidelines for more information.

Yes. All our industrial debris sensors are designed to respond to a wide range of particle sizes, from fine metallic dust that may point to early-stage wear, to larger chips or fragments that typically signal more severe mechanical damage. While our sensors can detect both, it does not differentiate particle size. The signal is influenced by the overall mass of metallic material accumulated on the sensor rather than whether that mass comes from many tiny particles or a single larger chip.

Debris sensors can be connected via analog, digital, IO Link, or Modbus (RTU), and CANbus outputs, depending on the sensor order code configuration (Ex. 1020_). Currently, only order code “A” has been developed. Order code A specifies a 0.25V - 10V analog output as well as a spare digital output. See the 1020 Product Family Data Sheet for sensor ordering code information.

Yes. The NZMS sensor is designed with a wide range of mounting options, and its ability to withstand high pressures and temperatures makes it easy to integrate directly into larger systems.

Whether or not to clean the sensor face depends on your specific application. Some systems may allow periodic cleaning, similar to a magnetic drain plug, while others may recommend leaving the sensor untouched. Always follow your maintenance guidelines to determine if and when cleaning is appropriate during the sensor’s operational life.

The 1020 product line is highly reliable due to its lack of moving parts. Its service life can be influenced by factors such as vibration, thermal cycles and thermal shocks, maximum operating temperature, and chemical compatibility with the monitored fluid. The durability of the housing and the sensor’s seals (O-rings) also play a role. When installed and maintained according to specifications, the sensor is designed to provide long-term, dependable operation.

The NZMS sensing technology, that is the backbone of the 1020 product line, works by detecting disturbances in a magnetic field. Nearby ferrous materials such as steel or even cold-worked stainless steel can alter the field and be picked up by the sensor. These effects can be minimized through careful design and post-installation calibration. For best results, the sensor should be positioned away from other ferrous objects. Fortunately, magnetic strength decreases rapidly with distance (dropping off with the cube of the distance), so objects farther away have little influence. A good rule of thumb is to imagine the attraction force between the object in question and the sensor.

Transient magnetic fields (such as those generated by high-voltage wiring, motors, pumps, or strong electromagnets) can influence sensor readings if the sensor is mounted too close. To minimize these effects, position the sensor away from electromagnetic noise if possible.

For best performance in noisy EMI environments ferrous guarding around the sensor may improve performance and sensor stability.

Yes, but only to a limited extent. Rust is weakly magnetic, and its detectability depends on the type present. Magnetite (Fe3O4) is more magnetic and easier to detect, while hematite (Fe3O3) is less magnetic and produces a weaker response. Because rust composition can vary significantly, KasperAero recommends independent testing to confirm performance in rust detection applications.

The underlying NZMS sensing technology is capable of extremely high sensitivity. The internal electronics take analog measurements of the magnetic field and scale them. The internal scaling amplifies the measurement in such a way that the ADC of the PLC system is never the limiting factor. The limiting factor in debris measurement is the noise of the signal. This means that setting a debris threshold too low, or not allowing for proper hysteresis, will cause the sensor to be operate improperly.

For the 1020A sensor configuration, with a sensitivity of 1V per 0.040 grams, a typical installation using a PLC to monitor the sensor, with the sensor installed in a lubrication system for a large gear train, typical PLC threshold values might be set at 1-volt increments such as shown below.

1V = low level alarm, 2V = medium level alarm, 3V = high level alarm

See the output specific installation guidelines for more information.

The 1020 series is intentionally designed to have a delayed reaction (typically under three seconds) to reduce false positives and ensure highly reliable data. This helps filter out noise and increases reliability by reducing nuisance trips.

The 1020 product line delivers high performance at a price that supports wide industrial deployment. It should be viewed as affordable insurance that helps prevent costly downtime, warranty claims, service visits, and potential contract penalties.

Cost can be reduced by ordering the default configuration (1020AW101). Costs can be reduced further by buying the base unit with no mounting adapter (1020AW000).

For large volume price breaks on industrial sensors, please contact our team. For mass market applications, please review our custom debris sensor options.

KasperAero provides comprehensive support for all product lines. Our team can assist with installation guidance, system integration, calibration questions, and troubleshooting. We also offer support for interpreting sensor data and optimizing sensor placement. Support is available via email, phone, or virtual consultation, and we aim to respond promptly to all inquiries.

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Important Notice Regarding CAD Models:

The threads on the CAD models provided here are intended solely for reference purposes.