Industrial Debris Detection

No. The NZMS debris sensor product family does not collect or detect non-ferrous debris such as aluminum, brass, ceramics, or dirt. Only ferrous metallic particles are detected.

No. All NZMS debris sensors are completely axially symmetric and can operate reliably in any orientation. Performance is unaffected by mounting direction, allowing flexible installation across a wide variety of systems.

In applications where the sensor is positioned away from nearby ferrous materials, no calibration is required. Non-ferrous metals such as aluminum, annealed stainless steel, magnesium, brass, copper, zinc, and titanium have absolutely no effect on sensor readings and are invisible to the sensor.

In installations with close proximity to ferrous materials, calibration must be handled on the integration side by recording the analog output at baseline and adjusting PLC or SCADA thresholds accordingly. There is no calibration button or on-sensor procedure. See the installation guidelines for your specific product series for more information.

Yes. All NZMS debris sensors are designed to respond to a wide range of particle sizes, from fine metallic dust indicating early-stage wear to larger chips or fragments that typically signal more severe mechanical damage. The sensor does not differentiate particle size, the output signal reflects the total accumulated ferrous mass on the sensor face, regardless of whether it comes from many small particles or a single larger piece.

Debris sensors can be connected via analog, digital, IO-Link, Modbus RTU, or CAN bus outputs depending on the sensor order code configuration. On the 1030 series, output styles A (0 to 10 V), B (0 to 5 V) and C (0 to 3.3 V) are available now, each with a spare digital output. The 18D1000 is built with output A (0 to 10 V) only. Styles E (IO-Link), F (Modbus RTU) and G (CANbus) are in development. See the product family data sheet for ordering code information.

Yes. Both the 1020 and 1030 product families are designed for direct integration into larger systems. Multiple mounting configurations are available, and both series are rated to withstand elevated pressures and temperatures. The 1030 series, with its single-piece 6061-T6 aluminum housing and mil-spec connector, is particularly suited for demanding environments where structural integrity is critical.

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

NZMS debris sensors are highly reliable due to their lack of moving parts. Service life is influenced by factors such as vibration, thermal cycling, maximum operating temperature, and chemical compatibility with the monitored fluid. Housing durability and seal integrity also play a role.

The 1030 series, machined from a single piece of 6061-T6 aluminum and rated to 125°C, is specifically designed for extended service in harsh or high-temperature environments. The 1020 series, with its Ultem polymer housing rated to 85°C, is well suited for standard industrial applications. When installed and maintained according to specifications, both series are designed for long-term, dependable operation.

NZMS sensing technology works by detecting disturbances in a magnetic field. Nearby ferrous materials, such as steel or cold-worked stainless steel, can alter the ambient field and produce a signal. These effects can be minimized through careful mechanical design and post-installation threshold calibration. Magnetic field strength drops off with the cube of the distance, so even modest separation from ferrous structures significantly reduces interference. A practical rule of thumb is to consider the attraction force between the sensor and any nearby object. The weaker the attraction force feels, the less influence it will have.

Transient magnetic fields generated by high-voltage wiring, motors, pumps, or strong electromagnets can influence sensor readings if the sensor is mounted too close. Where possible, position the sensor away from significant electromagnetic noise sources.

In high-EMI environments, a ferrous guard around the sensor may improve stability and reduce interference. In most cases, the sensor's internal safe guards prevent EMI interference.

Yes, but only to a limited extent. Rust is weakly magnetic, and detectability depends on the type present. Magnetite (Fe₃O₄) is more magnetic and easier to detect, while hematite (Fe₂O₃) is less magnetic and produces a weaker response. Because rust composition varies significantly, KasperAero recommends independent testing to confirm performance in rust detection applications.

The underlying NZMS sensing technology is capable of extremely high sensitivity. Internal electronics take analog measurements of the magnetic field and scale them such that the ADC resolution of the host PLC is never the limiting factor. The practical sensitivity limit is determined by signal noise - setting a debris threshold too low, or failing to apply adequate hysteresis, will cause the sensor to operate unreliably.

For the "A" output configuration (0.25V-10V analog), with a sensitivity of approximately 1V per 0.020 grams, typical PLC threshold values for a large gear train lubrication system might be set as follows:

1V = low-level alarm  |  2V = medium-level alarm  |  3V = high-level alarm

See the output-specific installation guidelines for more information.

NZMS debris sensors are intentionally designed with a slight response delay, typically under three seconds, to reduce false positives and ensure highly reliable data. This filtering helps suppress transient noise and minimizes nuisance trips in real-world operating environments.

Often, yes. We build in small batches, so changes are practical here that would not be on a mass-produced part. The ones that come up most:

• Serial output instead of analog. On the 1030, pin B (the spare digital output) can be configured as a 3.3 V UART, so a microcontroller reads the measurement directly with no analog-to-digital converter in between. That usually makes the whole measurement chain simpler and more accurate.
• 3.3 V supply. We can build a sensor to run from a 3.3 V rail. It trades away some of the onboard circuit protection, so we would rather discuss it than just ship it.
• Port and thread changes beyond the published options.

These are build-time changes, quoted per application. We are not going to design your system for you over email, but we will tell you honestly whether a change is worth doing, and we would rather say "that will not help" than sell you something that does not fit.

Tell us what the sensor is talking to and what you are trying to measure: request a quote or contact us.

Everything in the catalogue. The 18D1000, all six 1030 series sensors and the 1030XM9 harness are all available for checkout, with published pricing and lead times. Above the checkout ceiling shown on each product page the button becomes Request a quote, so we can confirm the schedule before taking money.

It is shown on each product page. The 18D1000 has a minimum of 5 units; the 1030 series and the harnesses have no minimum. Below a minimum, ask us - sometimes we can help with samples for a qualified evaluation.

This choice applies to the 1030 series; the 18D1000 is built with the 0 to 10 V output only. Match it to what your controller already reads. All three carry the same information and cost the same.

• 0 to 10 V (output A) - the default. Best noise margin over a long cable run, and what most PLC analog input cards expect.
• 0 to 5 V (output B) - for 5 V input ranges.
• 0 to 3.3 V (output C) - for microcontroller ADCs running on a 3.3 V rail, with no divider needed.

It depends on the port already in your machine, not on preference.

• NPT (1030AM101, 102, 103 and 601) - a tapered thread that seals on the thread itself. It drops straight into an existing NPT boss with no port machining and no separate seal. This is the usual choice for industrial equipment.
• AS4395 straight thread (1030AM501 and 502) - seals with an O-ring in a matching AS5202 port rather than on the thread. The 37 degree flare is removed and the sensor ships with the fluorocarbon O-ring that seal needs. Choose this where the fitting will be broken and remade repeatedly, because the seal does not depend on thread interference and so does not degrade with each cycle.

The 1030AM601 is the 1/2 in NPT part in a shortened body, for installations without enough clearance behind the port for the standard length.

Because we build them. The quantity pricing table shows the lead time against each break so you can see the trade-off before you order rather than after. The estimated ship date shown at checkout is the one we will acknowledge in writing.

Above the checkout ceiling the button becomes Request a quote. That is not a brush-off: larger quantities get better pricing than the published ladder and we want to confirm the schedule with you before taking money.

Yes, but not through the store. Checkout cannot take a carrier account. Contact us with your carrier, account number and service level and we will take the order directly and invoice it without freight. Note that once the shipment is on your account, risk of loss in transit passes to you at our dock.

Request a quote and send your exemption certificate rather than ordering through checkout. Checkout applies tax automatically based on the ship-to address and we would rather not charge you tax and refund it afterwards.

Not through the store. Checkout is US delivery only, because we quote international freight and documentation per order rather than guessing at it.

We do sell internationally. It works like this: tell us the part, the quantity and the destination, we send a quotation covering goods, freight and paperwork, you raise a purchase order against it, and we ship once payment has cleared. Payment in advance on international orders, without exception.

Every product is classified EAR99, which keeps the paperwork light, but embargoed destinations, denied parties and prohibited end uses still apply and we screen every order. See the export notice.

Straight through the store, no paperwork:

• Bank transfer (ACH) - no fee. Takes about four business days to clear, and we start the build once it does.
• Debit card - no fee. Paid immediately.
• Credit card - a 3% processing fee is added. Paid immediately.

By purchase order, invoiced:

• Check
• Wire transfer

Check and wire go through a purchase order rather than the store. Request a quote and we will invoice you.

That is normal for industrial buyers and we are set up for it. It does not go through the store checkout. Send us a quote request with the part numbers and quantities. We reply with a formal quotation you can raise a PO against, then invoice you with our bank details for a wire or our remittance address for a check. Unless we have agreed credit terms in writing, we ship once payment clears.

Our Terms and Conditions of Sale govern the transaction, and our order acknowledgement says so. If your procurement process needs specific flowdown clauses, raise them before you order so we can agree them in writing rather than discover them after the fact.

You get a receipt from Stripe immediately, and a formal order acknowledgement from us within one business day confirming the part number, quantity, pricing and promised ship date. When it ships you get tracking plus the packing slip and test paperwork.

Yes. Test data is recorded per serial number. Tell us at order time if your PO requires a C of C or a calibration certificate and it ships in the box and by email.

Contact us for an RMA number before returning anything. See the returns and RMA policy.

KasperAero debris sensors are designed to deliver high performance at a price that supports broad industrial deployment. They should be viewed as affordable insurance against costly downtime, warranty claims, unplanned service visits, and potential contract penalties.

The 1020 series offers the most cost-effective entry point. Costs can be reduced by ordering the default configuration (1020AW101), or reduced further by ordering the base unit without a mounting adapter (1020AW000). The 1030 series carries a higher price point reflecting its single-piece aluminum construction and mil-spec connector, and is intended for applications where ruggedness and high-temperature performance justify the investment.

For volume pricing on either series, 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.