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

1020 Product Family

Cost Effective & Flexible

Industrial Debris Sensor Solution Sketch

Two-piece Aluminum and Ultem polymer housing
Connects via rear cord exit or M12 connector
Rated to 85°C (185°F)
Widest selection of mounting options for flexible installation

Explore the 1020 Product Family »

1030 Product Family

Rugged & High Temperature

Single-Piece 6061-T6 aluminum construction
MS3102R14S-2P Mil-Spec connector
Rated to 125°C (257°F)
Designed for applications where ruggedness outweighs mounting flexibility

Explore the 1030 Product Family »

Product Overview

Performance Advantages

The KasperAero NZMS debris sensor product family brings proven aerospace oil debris monitoring technology to industrial and mobile equipment applications through rugged, off-the-shelf solutions designed for easy integration. These sensors provide early warning of mechanical wear by continuously detecting ferrous debris in oil and other fluid systems before catastrophic failures occur.
The product family currently includes two platforms optimized for different operating environments:

1020 Series — Compact, cost-effective sensors designed for general industrial applications where flexibility, ease of integration, and low power consumption are priorities.
1030 Series — Heavy-duty sensors engineered for harsh environments, elevated temperatures, and demanding aerospace or high-reliability applications requiring maximum ruggedness.

Both product families support integration into gearboxes, hydraulics, fuel systems, lubrication circuits, coolants, and other fluid systems, with multiple mounting configurations and industry-standard electrical interfaces available.

Product Features:

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

Flexible Installations

KasperAero debris sensors are designed for straightforward integration into both new and existing systems. Modular mounting options, adaptable port interfaces, and multiple electrical connector configurations allow installation across a wide range of industrial and mobile equipment without requiring major redesigns or external conditioning hardware.

The 1020 Series emphasizes compact size, installation flexibility, and economical deployment across large equipment fleets, while the 1030 Series is optimized for environments involving vibration, contamination, thermal cycling, and extreme operating temperatures.

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

Download FAQ Summary PDF

Frequently Asked Questions

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. Currently, order code "A" has been developed, which specifies a 0.25V–10V analog output along with a spare digital output. 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 dela, 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.

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.

Download FAQ Summary PDF

Important Notice Regarding CAD Models:

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

1020 Series

Style 000 — No Adapter

1020A_000.STEP

Key Features

Typical Applications

1020 Product Family

Cost Effective & Flexible

1030 Product Family

Rugged & High Temperature

Product Overview

Performance Advantages

Product Features:

Flexible Installations

Core Capabilities

Strategic Benefits

Technical Datasheets

1020 Product Family and Part Numbering System

1030 Product Family and Part Numbering System

Industrial Debris Sensor FAQs

Frequently Asked Questions

Do KasperAero debris sensors detect non-ferrous debris?

Are KasperAero debris sensors orientation-specific?

Do KasperAero debris sensors require calibration?

Can NZMS debris sensors detect both fine and coarse particles?

How are debris sensors integrated into a system?

Can KasperAero debris sensors be integrated into larger systems?

There is debris on the sensor face. Should I clean it?

How long is the expected service life?

Why is proximity to ferrous objects important when installing a debris sensor?

How do transient magnetic fields affect sensor performance?

Can NZMS debris sensors detect rust?

What is the maximum sensitivity of the NZMS debris sensors?

How quickly does the sensor respond to debris?

How cost effective are KasperAero debris sensors?

What kind of technical support is available after purchase?

1020 Series

Style 000 — No Adapter

Style 101 — 1/2" NPT

Style 102 — 3/4" NPT

Style 103 — 1" NPT

Style 201 — M20×1.5

Style 202 — M22×1.5

Style 203 — M24×2.0

Style 301 — 1/2" BSPP

Style 401 — 3/4"-16 UNF

Style 501 — AS4395-08

Style 502 — AS4395-12

1030 Series

Style 101 — 1/2" NPT

Style 102 — 3/4" NPT

Style 103 — 1" NPT

Style 501 — AS4395-08

Style 502 — AS4395-12