Bray 54 Series User manual
SERIES
PROXIMITY SENSORS
Installation Operation and Maintenance Manual
BRAY.COM THE HIGH PERFORMANCE COMPANY
SERIES 54 PROXIMITY SENSORS
Installation, Operation, and Maintenance Manual
1 of 28© 2022 BRAY INTERNATIONAL, INC. ALL RIGHTS RESERVED. BRAY.COM The Information
contained herein shall not be copied, transferred, conveyed, or displayed in any manner that would
violate its proprietary nature without the express written permission of Bray International, Inc.
TABLE OF CONTENTS
Definition of Terms
Introduction
Hazard-Free Use
Qualified Personnel
Pre-installed storage
Adjustment
Connections (Operation)
Sensor Part Numbers
Required Tools
Numbering
Operation Overview
Activators
SERIES 54 PROXIMITY SENSORS
Installation, Operation, and Maintenance Manual
2 of 28© 2022 BRAY INTERNATIONAL, INC. ALL RIGHTS RESERVED. BRAY.COM The Information
contained herein shall not be copied, transferred, conveyed, or displayed in any manner that would
violate its proprietary nature without the express written permission of Bray International, Inc.
DEFINITION OF TERMS
All information within this manual is relevant to the safe operation
and proper care of your Bray product Please understand the
following examples of information used throughout this manual
DANGER
Indicates a potentially hazardous situation which if not avoided
will result in death or serious injury
WARNING
Indicates a potentially hazardous situation which if not avoided
could result in death or serious injury
CAUTION
Indicates a potentially hazardous situation which if not avoided
could result in minor or moderate injury
NOTICE
Used without the safety alert symbol indicates a potential
situation which if not avoided may result in an undesirable result
or state including property damage
READ AND FOLLOW THESE INSTRUCTIONS CAREFULLY
SAVE THIS MANUAL FOR FUTURE USE
SERIES 54 PROXIMITY SENSORS
Installation, Operation, and Maintenance Manual
3 of 28© 2022 BRAY INTERNATIONAL, INC. ALL RIGHTS RESERVED. BRAY.COM The Information
contained herein shall not be copied, transferred, conveyed, or displayed in any manner that would
violate its proprietary nature without the express written permission of Bray International, Inc.
INTRODUCTION
All information within this manual is relevant to the safe operation
and proper care of your Bray product Please understand the
following examples of information used throughout this manual
The Series Proximity Sensor has been designed to provide
valve position indication utilizing various signal types Each of
these configurations will be covered in more detail on the pages
that follow
All Bray S Proximity Sensors utilize solid state switches
Although the solid state switch performs the same function as a
conventional mechanical switch there are dierences in the way
solid state switches operate
NOTICE
It is very important for the user to pay close attention to the
exact specifications of their sensor in order to avoid damaging
the unit
Solid state switches have current restrictions imposed by the
semi conducting materials used to form the sensor These
current limitations have to be accounted for during setup
Unlike mechanical switches which can normally handle several
amperes of current flowing through them solid state switches are
generally rated for half an ampere or less
NOTICE
The electrical characteristics of the S must be compatible with
the application
When working with the S several parameters must be
considered A few of which (with significant importance) are
listed here
> operating voltage
> maximum switching current
> output voltage drop
> residual current.
Using an S outside of these parameter limits can cause damage
to the unit and void factory warranty
Operating voltage is the amount of voltage necessary for the
sensor to operate The maximum switching current is the largest
amount of current that the sensor’s solid state electronics can
have flowing through them in the on-state (when the target is in
proximity of the sensor) During commissioning it is up to the
user to correctly apply the sensor to their control system in order
to limit the current flowing through the device All the necessary
information can be found in the technical manual
SERIES 54 PROXIMITY SENSORS
Installation, Operation, and Maintenance Manual
4 of 28© 2022 BRAY INTERNATIONAL, INC. ALL RIGHTS RESERVED. BRAY.COM The Information
contained herein shall not be copied, transferred, conveyed, or displayed in any manner that would
violate its proprietary nature without the express written permission of Bray International, Inc.
Introduction continued
Output voltage drop is defined as the amount of voltage that
will drop across the solid state switch This voltage drop will
often vary with the amount of current flowing through the sensor
and the load This drop in voltage becomes paramount when
connecting several proximity sensors in series each unit will have
a voltage drop across it – adding each subsequent drop and
subtracting from the supply voltage yields the resulting voltage
at the end of the series connection The user needs to ensure that
the supply voltage is large enough so that the resulting voltage
after all the drops is above the minimum operating voltage of
the last S in the series connection Sensors located a great
distance from the load require consideration as well as a general
rule every ft of wire will have a resistance of (see
electrical code references for the resistance value of specific wire
sizes) It is important for the customer to ensure that the distance
between the S and the control panel is not long enough to
cause the voltage drop to fall below the minimum operating
voltage of the sensor
Residual current is often referred to as leakage current In the
“o” state (target is NOT in proximity of the sensor) the sensor
draws a small amount of current in order to power the device’s
electronics This is necessary for the device to sense the target
at any point in time when the supply voltage is applied It is
important that this residual current is below the maximum o-
state current rating of the control system
SERIES 54 PROXIMITY SENSORS
Installation, Operation, and Maintenance Manual
5 of 28© 2022 BRAY INTERNATIONAL, INC. ALL RIGHTS RESERVED. BRAY.COM The Information
contained herein shall not be copied, transferred, conveyed, or displayed in any manner that would
violate its proprietary nature without the express written permission of Bray International, Inc.
HAZARD-FREE USE
This device left the factory in proper condition to be safely
installed and operated in a hazard-free manner The notes and
warnings in this document must be observed by the user if this
safe condition is to be maintained and hazard-free operation of
the device assured
Take all necessary precautions to prevent damage due to rough
handling impact or improper storage Do not use abrasive
compounds to clean or scrape its surfaces with any objects
Configuration and calibration procedures are described in this
document Proper configuration and calibration is required for
the safe operation of this product
The control system in which the unit is installed must have
proper safeguards to prevent injury to personnel or damage to
equipment should failure of system components occur
This document does not cover every detail about every version
of the product described It cannot take into account every
potential occurrence in installation operation maintenance and
use
If situations transpire that are not documented in sucient detail
please request the required information from the Bray Distributor
or Representative responsible for your area
SERIES 54 PROXIMITY SENSORS
Installation, Operation, and Maintenance Manual
6 of 28© 2022 BRAY INTERNATIONAL, INC. ALL RIGHTS RESERVED. BRAY.COM The Information
contained herein shall not be copied, transferred, conveyed, or displayed in any manner that would
violate its proprietary nature without the express written permission of Bray International, Inc.
QUALIFIED PERSONNEL
A qualified person in terms of this document is one who is
familiar with the installation commissioning and operation of the
product and who has appropriate qualifications such as
> Is trained in the operation and maintenance of pneumatic
pressure equipment and systems in accordance with
established safety practices.
> Is trained or authorized to energize, de-energize, ground, tag
and lock electrical circuits and equipment in accordance with
established safety practices.
> Is trained in the proper use and care of personal protective
equipment (PPE) in accordance with established safety
practices.
> Is trained in first aid.
> In cases where the device is installed in a potentially
explosive (hazardous) location – is trained in the operation,
commissioning, and maintenance of equipment in hazardous
locations.
SERIES 54 PROXIMITY SENSORS
Installation, Operation, and Maintenance Manual
7 of 28© 2022 BRAY INTERNATIONAL, INC. ALL RIGHTS RESERVED. BRAY.COM The Information
contained herein shall not be copied, transferred, conveyed, or displayed in any manner that would
violate its proprietary nature without the express written permission of Bray International, Inc.
PRE-INSTALLED STORAGE
Bray Series Proximity Sensors are not weatherproof until
the unit is properly installed or all conduits and applicable port
connections are sealed o and prepared for storage The units
may be shipped with temporary covers to prevent foreign matter
from entering through the conduit openings however the user is
responsible for replacing with the proper sealing plugs to support
its NEMAIP ratings
To prevent condensation from forming inside the unit maintain
a near constant external temperature and store indoors in a well
ventilated clean dry room The temperature shall be between
F (C) and F (C) with a relative humidity less than
Store units away from vibration and direct sunlight exposure
and place units on a shelf or wooden pallet in order to protect
against dampness Keep units covered to protect against dust
and dirt if storing for long term placing the unit inside a plastic
sealed bag may be preferred
Bray cannot accept responsibility for deterioration caused on-site
once the cover is removed or due to improper storage
SERIES 54 PROXIMITY SENSORS
Installation, Operation, and Maintenance Manual
8 of 28© 2022 BRAY INTERNATIONAL, INC. ALL RIGHTS RESERVED. BRAY.COM The Information
contained herein shall not be copied, transferred, conveyed, or displayed in any manner that would
violate its proprietary nature without the express written permission of Bray International, Inc.
1
1
ADJUSTMENT
Adjusting the Activator
Adjustable activators are for customers that want the flexibility
to position their indication limits outside of the standard zero to
ninety degrees The three pieces of the adjustable activator can
be rotated in five degree increments To adjust follow the steps
below
1. Loosen the allen head bolt which holds the three pieces of the
activator on the pinion.
2. Rotate the relevant piece until the desired amount of travel is
achieved.
a Use the incremental degree marks on the activator for
reference
3. Ensure the yellow indicator is set to match the valve disc
position.
4. Tighten the allen head bolt.
Adjusting the High Visibility Activator
1. Remove the two activator cover bolts.
2. Remove activator cover by pulling up and away from the
actuator.
3. Loosen center allen head bolt holding the activator to the
pinion.
4. Rotate the relevant piece of the activator until the desired
amount of rotation is achieved.
a Insure that the open and close activator is visible when
the cover shield is installed
5. Re-tighten the center allen head bolt locking the activator to
the pinion.
6. Install the cover and mounting bolts.
SERIES 54 PROXIMITY SENSORS
Installation, Operation, and Maintenance Manual
9 of 28© 2022 BRAY INTERNATIONAL, INC. ALL RIGHTS RESERVED. BRAY.COM The Information
contained herein shall not be copied, transferred, conveyed, or displayed in any manner that would
violate its proprietary nature without the express written permission of Bray International, Inc.
S-connector
Y-connector
System side
CONNECTIONS (OPERATION)
Bray oers three dierent connections to satisfy the customer’s
application requirements Each sensor’s pin connection is listed
in its respective technical manual Turn o all power and lockout
tag out service panel before installing or modifying any electrical
wiring
Sensor Only
Sensor connection supplies sensor power and signal output
Sensor and Solenoid (Shared)
Y-connectors are used to allow solenoid control on sensors
without dedicated solenoid outputs The system side line carries
both the sensor and solenoid power The system side line splits to
supply power and signal to sensor and solenoid
Sensor and Solenoid (Independent)
Bray also oers sensors with dedicated solenoid outputs In this
set up the sensor signal and solenoid power are transmitted on
the main system side line The solenoid is activated via power
supplied from the sensor through the S-connector S-connector
selection can be found in the sensor technical manual
Cable Gland Connections
M cable gland connections are found on the following sensors
-
-
-
- (included in Kit PN -xx)
In order to field-wire these models follow these guidelines
1. Take the sensor cover o. The cover should be kept on hand
for reference.
2. Wire the sensor as per the wiring diagram on the outside of
the sensor cover or technical specification sheet.
3. Close the cover and securely tighten cover screws
Range of wire size gauge acceptable
(single conductor per terminal)
General: 16 to 28AWG
Industrial: 14 to 22AWG
Hazardous: 14 to 22AWG
SERIES 54 PROXIMITY SENSORS
Installation, Operation, and Maintenance Manual
10 of 28© 2022 BRAY INTERNATIONAL, INC. ALL RIGHTS RESERVED. BRAY.COM The Information
contained herein shall not be copied, transferred, conveyed, or displayed in any manner that would
violate its proprietary nature without the express written permission of Bray International, Inc.
NOTICE
Cable glands used must be certified in accordance with the
application The temperature range of cable glands must
be selected according to application The degree of ingress
protection must not be reduced by cable glands
The cable gland connections must be properly sealed to maintain
the Ingress Protection rating of the S sensor Use a seal that
meet the requirements of the application
If the sensor is mounted on a vertical pipe it is recommended
that the sensor be positioned with the cable glands on the
bottom to prevent condensation from entering the sensor
through its conduits
In all cases the conduit should be positioned to prevent drainage
into the sensor
Ensure adequate drainage of wiring conduit to prevent water
contamination inside sensor
SERIES 54 PROXIMITY SENSORS
Installation, Operation, and Maintenance Manual
11 of 28© 2022 BRAY INTERNATIONAL, INC. ALL RIGHTS RESERVED. BRAY.COM The Information
contained herein shall not be copied, transferred, conveyed, or displayed in any manner that would
violate its proprietary nature without the express written permission of Bray International, Inc.
REQUIRED TOOLS
Hex key wrench
Hex key wrench
Hex key wrench
Screw Driver - Philips
Screw Driver - Flat
SENSOR PART NUMBERS
Bray Part Number Electrical Output
- DC -wire PNP
- Intrinsically Safe
- ACDC
- ASi-Interface Out
- Intrinsically Safe
- ASi-Interface Out
- DC -wire PNP
- DC -wire
- DC -wire
- DC w-wire PNP
-* DC Wire - Hazardous Location Out
*Included in kit PN54010-126XX536
SERIES 54 PROXIMITY SENSORS
Installation, Operation, and Maintenance Manual
12 of 28© 2022 BRAY INTERNATIONAL, INC. ALL RIGHTS RESERVED. BRAY.COM The Information
contained herein shall not be copied, transferred, conveyed, or displayed in any manner that would
violate its proprietary nature without the express written permission of Bray International, Inc.
NUMBERING
Sensor Part Numbering
V
ersion
00: Plastic Base
01: Aluminum Base
Housing
0: Large Housing with Connector
1: Large Housing with Conduit Entry
2: Small Housing with Connector
3: Small Housing with Conduit Entry
4: Large Housing with Rd24 Connection
Electrical Output
1: DC 3 wire PNP
2: DC 2 wir
e Dual Function
3: Intrinsically Safe
4: AC/DC
5: AS-i
Activator Kit Numbering
Smallest
Actuator Size
For S92/93
0:
Imperial
5: Metric
A: Adjustable
B: Non-Adjustable
C: High Visibility
SERIES 54 PROXIMITY SENSORS
Installation, Operation, and Maintenance Manual
13 of 28© 2022 BRAY INTERNATIONAL, INC. ALL RIGHTS RESERVED. BRAY.COM The Information
contained herein shall not be copied, transferred, conveyed, or displayed in any manner that would
violate its proprietary nature without the express written permission of Bray International, Inc.
540022-71104533
5-30V DC / 100mA
DC 2-Wire PNP/NPN
3
4
L+
L-
L+
1
L-
I
II
2
I
II
I II
Made in Czech Republic
R
540022-71104533
5-30V DC / 100mA
DC 2-Wire PNP/NPN
3
4
L+
L-
L+
1
L-
I
II
2
I
II
I II
Made in Czech Republic
R
540022-71104533
5-30V DC / 100mA
DC 2-Wire PNP/NPN
3
4
L+
L-
L+
1
L-
I
II
2
I
II
I II
Made in Czech Republic
R
R
IND.CONT.EQ.
57M3
12
540041-71104533
DC 3-Wire PNP + Out
10-30 V DC / 100 mA
II I
Madein Czech Republic
valve
PWR
4
L-
SII
V-
V+
V+
V-
3
2
1
5
6
4
3
5
I
II
II I
SI
L+
R
IND.CONT.EQ.
57M3
12
540041-71104533
DC 3-Wire PNP + Out
10-30 V DC / 100 mA
II I
Made in Czech Republic
valve
PWR
4
L-
SII
V-
V+
V+
V-
3
2
1
5
6
4
3
5
I
II
II I
SI
L+
OPERATION OVERVIEW
Bray’s inductive sensors use a contactless indication system
designed to monitor the position of rotary devices An activator is
mounted onto the actuator center pinion As the valve is actuated
the open and close positions are measured by the rotation of the
activator The activator contains a metal insert that activates the
corresponding inductive switch in the sensor This activation is
relayed to the end user to validate valve position
Operations
Bray’s S Sensors contain two proximity switches in a
hermetically sealed housing Location of switches are designated
by a “” or roman numerals Iand II
Based on the position of the pinionactivator one of the metal
inserts on the activator will be directly in front of the switch
When the valve is open one of the metal inserts is directly in
front of the sensor This signals the end user of an open signal
and illuminates the corresponding LED When the valve is closed
the other metal insert activates the second switch This signals
the end user a closed signal and illuminates the second LED The
function of each switch can be selected by the end user This can
be done by adjusting the activator to match the actuator position
(see Section ) or by configuring the PLC All activators can
be configured to be used for clockwise or counter-clockwise
valve operation
R
IND.CONT.EQ.
57M3
12
540041-71104533
DC 3-Wire PNP + Out
10-30 V DC / 100 mA
II I
Made in Czech Republic
valve
PWR
4
L-
SII
V-
V+
V+
V-
3
2
1
5
6
4
3
5
I
II
II I
SI
L+
R
IND.CONT.EQ.
57M3
12
540041-71104533
DC 3-Wire PNP + Out
10-30 V DC / 100 mA
II I
Made in Czech Republic
valve
PWR
4
L-
SII
V-
V+
V+
V-
3
2
1
5
6
4
3
5
I
II
II I
SI
L+
R
IND.CONT.EQ.
57M3
12
540041-71104533
DC 3-Wire PNP + Out
10-30 V DC / 100 mA
II I
Made in Czech Republic
valve
PWR
4
L-
SII
V-
V+
V+
V-
3
2
1
5
6
4
3
5
I
II
II I
SI
L+
540022-71104533
5-30V DC / 100mA
DC 2-Wire PNP/NPN
3
4
L+
L-
L+
1
L-
I
II
2
I
II
I II
Made in Czech Republic
R
540022-71104533
5-30V DC / 100mA
DC 2-Wire PNP/NPN
3
4
L+
L-
L+
1
L-
I
II
2
I
II
I II
Made in Czech Republic
R
540022-71104533
5-30V DC / 100mA
DC 2-Wire PNP/NPN
3
4
L+
L-
L+
1
L-
I
II
2
I
II
I II
Made in Czech Republic
R
R
IND.CONT.EQ.
57M3
12
540041-71104533
DC 3-Wire PNP + Out
10-30 V DC / 100 mA
II I
Madein Czech Republic
valve
PWR
4
L-
SII
V-
V+
V+
V-
3
2
1
5
6
4
3
5
I
II
II I
SI
L+
R
IND.CONT.EQ.
57M3
12
540041-71104533
DC 3-Wire PNP + Out
10-30 V DC / 100 mA
II I
Madein Czech Republic
valve
PWR
4
L-
SII
V-
V+
V+
V-
3
2
1
5
6
4
3
5
I
II
II I
SI
L+
540022-71104533
5-30V DC / 100mA
DC 2-Wire PNP/NPN
3
4
L+
L-
L+
1
L-
I
II
2
I
II
I II
Made in Czech Republic
R
540022-71104533
5-30V DC / 100mA
DC 2-Wire PNP/NPN
3
4
L+
L-
L+
1
L-
I
II
2
I
II
I II
Made in Czech Republic
R
540022-71104533
5-30V DC / 100mA
DC 2-Wire PNP/NPN
3
4
L+
L-
L+
1
L-
I
II
2
I
II
I II
Made in Czech Republic
R
SERIES 54 PROXIMITY SENSORS
Installation, Operation, and Maintenance Manual
14 of 28© 2022 BRAY INTERNATIONAL, INC. ALL RIGHTS RESERVED. BRAY.COM The Information
contained herein shall not be copied, transferred, conveyed, or displayed in any manner that would
violate its proprietary nature without the express written permission of Bray International, Inc.
ACTIVATORS
All S sensors are oered with a dedicated activators
Configurations for installation vary based on the
application of the sensor and its mating components
Selection
Activator and sensor combinations reference the following
charts
Non Adjustable Activator
For Sensors PN -
-
-
Thread Type S Size Activator Kit PN
Imperial
- B-
- B-
Metric
- B-
- B-
Note The Series Scotch Yoke actuator will utilize activator
PN B-
Adjustable Activator
For Sensors PN - -
- -
- -
- -
Thread Type S Size Activator Kit PN
Imperial
- A-
- A-
Metric
- A-
- A-
Note The Series Scotch Yoke actuator will utilize
activator PN A-
SERIES 54 PROXIMITY SENSORS
Installation, Operation, and Maintenance Manual
15 of 28© 2022 BRAY INTERNATIONAL, INC. ALL RIGHTS RESERVED. BRAY.COM The Information
contained herein shall not be copied, transferred, conveyed, or displayed in any manner that would
violate its proprietary nature without the express written permission of Bray International, Inc.
High Visibility Activator
For Sensors PN
- -
- -
- -
- -
Thread Type S Size Activator Kit PN
Imperial
- C-
C-
C-
Metric
- C-
C-
- C-
Note The Series Scotch Yoke actuator will utilize
activator PN C-
SERIES 54 PROXIMITY SENSORS
Installation, Operation, and Maintenance Manual
16 of 28© 2022 BRAY INTERNATIONAL, INC. ALL RIGHTS RESERVED. BRAY.COM The Information
contained herein shall not be copied, transferred, conveyed, or displayed in any manner that would
violate its proprietary nature without the express written permission of Bray International, Inc.
Mounting
Mounting will vary based on the application in which it is
used All activators come with the necessary hardware for
sensor and activator mounting Hardware kits fit multiple
actuator sizes therefore some hardware may be left over
after installation
Size to - NAMUR x mm
Kit No B- Thread Type Imperial
Capscrew M mm Long
Capscrew - Long
Kit No B- Thread Type Metric
Capscrew M mm Long
Capscrew M mm Long
Discard Unused Hardware
Non-Adjustable Activator - Rack and Pinion Actuator
Size to - NAMUR x mm
Kit No B- Thread Type Imperial
Capscrew M mm Long
Capscrew - Long
Kit No B- Thread Type Metric
Capscrew M mm Long
Capscrew M mm Long
Discard Unused Hardware
SERIES 54 PROXIMITY SENSORS
Installation, Operation, and Maintenance Manual
17 of 28© 2022 BRAY INTERNATIONAL, INC. ALL RIGHTS RESERVED. BRAY.COM The Information
contained herein shall not be copied, transferred, conveyed, or displayed in any manner that would
violate its proprietary nature without the express written permission of Bray International, Inc.
Size - NAMUR x mm
Kit No B- Thread Type Metric
Capscrew M mm Long
Capscrew - Long
Countersunk screw M mm Long
Discard Unused Hardware
Non-Adjustable Activator - Rack and Pinion Actuator Continued
Size to - NAMUR x mm
Kit No B- Thread Type Imperial
Capscrew M mm Long
Capscrew - Long
Countersunk screw - Long
Kit No B- Thread Type Metric
Capscrew M mm Long
Capscrew - Long
Countersunk screw M mm Long
Discard Unused Hardware
SERIES 54 PROXIMITY SENSORS
Installation, Operation, and Maintenance Manual
18 of 28© 2022 BRAY INTERNATIONAL, INC. ALL RIGHTS RESERVED. BRAY.COM The Information
contained herein shall not be copied, transferred, conveyed, or displayed in any manner that would
violate its proprietary nature without the express written permission of Bray International, Inc.
Size to - NAMUR x mm
Kit No B- Thread Type Imperial
Capscrew M mm Long
Capscrew - Long
Kit No B- Thread Type Metric
Capscrew M mm Long
Capscrew M mm Long
Discard Unused Hardware
Non-Adjustable Activator - Rack and Pinion Actuator Continued
Size to - NAMUR x mm
Kit No B- Thread Type Imperial
Capscrew M mm Long
Capscrew - Long
Kit No B- Thread Type Metric
Capscrew M mm Long
Capscrew M mm Long
Discard Unused Hardware
SERIES 54 PROXIMITY SENSORS
Installation, Operation, and Maintenance Manual
19 of 28© 2022 BRAY INTERNATIONAL, INC. ALL RIGHTS RESERVED. BRAY.COM The Information
contained herein shall not be copied, transferred, conveyed, or displayed in any manner that would
violate its proprietary nature without the express written permission of Bray International, Inc.
Size - NAMUR x mm
Kit No B- Thread Type Metric
Capscrew M mm Long
Capscrew - Long
Countersunk screw M mm Long
Discard Unused Hardware
Non-Adjustable Activator - Rack and Pinion Actuator Continued
Size to - NAMUR x mm
Kit No B- Thread Type Imperial
Capscrew M mm Long
Capscrew - Long
Countersunk screw - ” Long
Kit No B- Thread Type Metric
Capscrew M mm Long
Capscrew - Long
Countersunk screw M mm Long
Discard Unused Hardware
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