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ROSS CONTROLS FLUID POWER PRODUCTS FOR PNEUMATIC SOLUTIONS

ROSS CONTROLS FLUID POWER PRODUCTS FOR PNEUMATIC SOLUTIONS

Product catalog summary

Overview: This document is a comprehensive catalog of ROSS Controls' product line, focusing on fluid power solutions. It includes specifications, industry solutions, and safety products.

Key Sections:

General Information: Provides ordering information and additional literature references.
Product Specifications: Details various valve types, including line-mounted and base-mounted valves, with specific series and applications.
Industry Solutions: Highlights tailored solutions for industries such as glass container manufacturing, steel processing, and metal forming, emphasizing efficiency and reduced maintenance.
Safety Products: Lists safety-related solutions, including control reliable valves and energy isolation products, meeting global safety standards.
Historical Context: Describes the origins of ROSS Controls and its evolution into a global leader in pneumatic control systems.

Critical Information:

ROSS emphasizes customer-driven innovation through its ROSS/FLEX® process.
The company is ISO 9000 certified and operates globally with a network of distributors.
Safety products are designed to meet or exceed global safety requirements.

Conclusion: ROSS Controls is committed to providing innovative and reliable pneumatic solutions, with a strong focus on customer needs and safety standards.

Industry Solutions: ROSS Controls offers a wide range of general automation products including line-mounted valves, ISO, ANSI, SAE base mounted valves, and various specialized valves such as ENERGYSAVER®, flow control, check, and manual L-O-X® valves. Additional products include filters, regulators, lubricators, silencers, and mechanical valves.

ROSS/FLEX® Process: The ROSS/FLEX® process is a customer-centric manufacturing approach aimed at reducing costs and enhancing the value of pneumatic systems. It allows for custom-designed products tailored to specific functional and financial needs, eliminating traditional costs associated with custom manufacturing.

ROSS Integrated Systems: ROSS provides engineering services including systems and controls engineering, custom fabrication, and installation assistance. They offer custom design and manufacturing of valve systems, including enclosed system panels for harsh environments and flexible valve stands.

ROSS Poppet Valves: ROSS poppet valves are designed for high speed, repeatability, and strong shifting forces. They feature self-compensating wear, self-cleaning capabilities, and positive sealing, making them suitable for high-speed machines and dirty air environments.

Stainless Steel Spool & Sleeve Valves: These valves offer low shifting forces, balanced design, and minimal maintenance. They are suitable for high-speed machines and environments with dirty air, providing long service life and fast response.

Specifications: ROSS provides detailed specifications for their ISO valves, including flow capacity, materials of construction, operating pressure, and certification standards. The valves are designed for high cycle rates and long life, with options for various electrical connections and solenoid configurations.

Standard Specifications:

Ambient/Media Temperature: 40° to 175°F (4° to 80°C).
Flow Media: Filtered air; 5 micron recommended.
Inlet Pressure: Vacuum to 150 psig (10 bar).
Pilot Pressure: Size 1 models require at least 30 psig (2 bar), Size 2 & 3 models require at least 15 psig (1 bar).
Solenoids: AC or DC power with standard voltages of 24 volts DC; 110-120 volts AC, 50/60 Hz.
Power Consumption: Each solenoid uses 8.5 VA inrush, 6 VA holding on 50 or 60 Hz; 6 watts on DC.
Manual Override: Flush; metal, non-locking.
Options: Indicator Light available in electrical connector.

Valve Types and Models:

5/3 Valves: Double Pressure Controlled with Closed Center, Open Center, and Power Center configurations.
5/2 Valves: Single Pressure Controlled, Spring Return; Double Pressure Controlled, Detented; Single Solenoid Pilot Controlled, Spring Return; Double Solenoid Pilot Controlled, Detented.
EnergySaver® Valves: Reduces compressed air consumption up to 30% by reducing cylinder retract pressure.

Valve Operation:

The ENERGYSAVER® valve operates by directing full line pressure to port 4 and reduced pressure to port 2, providing full cylinder force to move the load while reducing air consumption during retraction.
Solenoid Energized: Directs supply pressure from the inlet port to port 4, extending the cylinder at full pressure.
Solenoid De-energized: The spool shifts back to a normal position, directing inlet air to the rod end of the cylinder and exhausting the cap end.

Dimensions and Weights:

ISO Port Valve Models are available in sizes 1/8 - 3/8, 3/8 - 1/2, and 1/2 - 3/4 with varying dimensions and weights.
Sub-base and electrical connectors are not included and must be ordered separately.

Accessories and Options:

Manifolds and sub-bases are available for different ISO sizes with specific dimensions.
Connectors for use with DROPCORDS (DIN 43650, Form A) are available, allowing cord orientation in multiple directions.

Important Notes:

Carefully read all CAUTIONS and WARNINGS provided in the documentation.
Specify voltage when ordering valves.

Overview: This document provides detailed specifications and descriptions of various components and accessories used in pneumatic systems, specifically focusing on manifold stations, valves, and related accessories. It includes information on blank station kits, transition plates, flow controls, pressure plates, and more.

Blank Station Kits: These kits are used to cover unused manifold stations. Each kit includes a metal plate, gasket, and mounting bolts.

Transition Plates: These allow different size ISO valves to be used within the same manifold installation by connecting the inlet and exhaust ports of different size manifold stations.

Interposed Flow Controls: These units regulate the exhaust flow of air from pneumatic cylinders, controlling extension and retraction speeds. They are available for Series W60 valves and require no additional piping.

Independent Pressure Plates: These plates allow a valve to operate at a different pressure than the manifold by isolating the valve from the manifold inlet pressure and providing an independent supply.

Blocking Disks and Interposed Pressure Regulators: Blocking disks close ports between manifold stations, while pressure regulators (single and double) allow for independent pressure settings at outlet ports.

Valve Specifications: The document details specifications for various valve types, including solenoid and pressure-controlled valves. It includes information on standard voltages, power consumption, temperature ranges, and certifications.

Sub-Bases and Manifolds: Dimensions and specifications for side and bottom-ported sub-bases and manifolds are provided, including details on mounting and port sizes.

Flow Control Kits: These kits allow for independent adjustment of flow control, enhancing the flexibility and efficiency of pneumatic systems.

Important Notes: The document emphasizes reading all cautions and warnings thoroughly, which are located on the inside back cover.

Overview: The document provides detailed specifications and assembly instructions for ROSS manifold stations and valves, including solenoid and pressure-controlled variants. It includes model numbers, dimensions, and configurations for various valve types, along with guidelines for assembly and integration into systems.

Specifications:

Manifold stations are equipped with NPT threads for pressure ports and electrical openings. Indicator lights are available for smaller manifold sizes.
Solenoid and pressure-controlled manifolds have different port positions and cannot be mixed in the same installation.
Standard voltages for solenoids are 24 volts DC and 110-120 volts AC, 50/60 Hz.
Valves are rated for continuous duty with specific power consumption values for different models.
Operating temperature ranges from 5° to 120°F for ambient and 5° to 175°F for media.

Procedures:

Manifold stations are assembled by ROSS and ready for system integration. Consult ROSS distributors for detailed assembly information.
Interposed pressure regulators can be used with valves having CV ratings up to 4.2, allowing for independent pressure settings at outlet ports.
Manual override kits are available for solenoid pilot-controlled valves, with options for locking and non-locking buttons.

Recommendations:

Use only manifold stations for solenoid-controlled valves if both solenoid and pressure-controlled valves are required in the same installation.
For temperatures below 40°F, ensure air is free of water vapor to prevent ice formation.
Specify voltage when ordering valves and accessories.

Tables and Charts: The document includes tables listing model numbers, dimensions, and CV ratings for various valve types. It also provides wiring diagrams and conversion instructions for external pilot supply configurations.

Warnings:

Read all cautions and warnings thoroughly, especially regarding the potential for unexpected cylinder movement with double interposed regulators.
CV values are specific to ROSS performance charts and should not be used for comparison with other manufacturers.

Overview: This document provides detailed specifications and configurations for various types of valves and adaptors used in industrial applications. It includes information on dimensions, port sizes, model numbers, and additional features such as manual overrides and adaptors for specific functionalities.

Specifications: The document outlines standard specifications for solenoids, including power consumption, standard voltages (24 volts DC; 110-120 volts AC, 50/60 Hz), and temperature ranges (ambient: 40° to 120°F, media: 40° to 175°F). It also specifies inlet and pilot pressures, port threads (NPT, BSPP), and options for manual overrides and indicator lights.

Valve Configurations: The document lists various valve models with their respective port sizes, average CV (flow coefficient), dimensions, and weights. It covers different types of valves such as 2/2, 3/2, and 4/2 valves, with configurations for normally open (NO) and normally closed (NC) operations.

Adaptors and Accessories: Several adaptors are described, including the Timed Sequence Adaptor, "PB" Adaptor, Air Index Adaptor, and "Q" Adaptor, each providing specific control functions like delayed actuation or increased actuating force. The document also mentions optional manual override kits and indicator light kits for enhanced functionality.

Model Numbers and Port Sizes: The document provides tables listing model numbers alongside their corresponding port sizes for different sub-bases and stations, indicating compatibility with NPT threads and the option to consult ROSS for SAE threads.

Additional Features: Features such as poppet construction for near-zero leakage, self-cleaning, wear compensation, and repeatability are highlighted for Series 27 poppet valves. The document also notes the availability of explosion-proof solenoid pilots and the option for field conversion between internal and external pilot supplies.

Important Notes: The document emphasizes reading all cautions and warnings thoroughly, as indicated on the inside back cover, to ensure safe and proper use of the valves and accessories.

Overview: The document provides detailed specifications and options for various valve models, including solenoid and poppet valves, designed for different temperature services and applications such as vacuum service. It includes information on indicator lights, manual override kits, and specific valve configurations.

Specifications: The valves are available in different series (21 and 27) and are designed for both high and low-temperature services. The document specifies the use of fluorocarbon seals for high temperatures and Buna-N seals for low temperatures. Standard voltages for solenoids are 24 volts DC and 110-120 volts AC, with power consumption details provided.

Valve Models and Configurations: The document lists various valve models with their respective port sizes, average CV (flow coefficient), dimensions, and weight. It includes configurations for 2/2, 3/2, and 4/2 valves, with options for normally open (NO) and normally closed (NC) states.

Manual Override and Indicator Light Kits: Manual override kits are available in flush and extended button types, with locking and non-locking options. Indicator light kits are available for specific solenoid models, and users must specify the voltage when ordering.

Applications and Features: The valves are suitable for applications such as lifting, holding, vacuum packaging, and leak testing. They are designed for high dirt tolerance, self-cleaning, and wear compensation, ensuring repeatability throughout their lifespan.

Important Notes: Users are advised to read all cautions and warnings thoroughly. The document emphasizes the need for filtered air as the flow media and specifies inlet and pilot pressure requirements.

Overview: The document provides detailed technical specifications and guidelines for explosion-proof solenoid pilot-controlled valves, specifically the Series 27 and Dale Series by ROSS Controls. These valves are designed for use in hazardous environments where safety from electrical ignition is crucial.

Specifications: The valves are available in various port sizes ranging from 1/4" to 2½". They are designed to handle inlet pressures from 15 to 150 psig, depending on the port size. The standard solenoids operate on 24 volts DC or 110-120 volts AC, with power consumption varying between 4.6 watts and 87 VA.

Features: Key features include solenoid pilot control, poppet construction for minimal leakage, high dirt tolerance, and self-cleaning capabilities. The valves are also wear-compensating and maintain repeatability throughout their lifespan. They are CSA approved for use in various hazardous locations.

Applications: These valves are suitable for industries such as power generation, food and beverage, petrochemical, wastewater treatment, and more. They are particularly useful in environments with flammable gases, vapors, liquids, or combustible dust.

Conversion Kits: The document mentions conversion kits that allow standard valves to be converted into explosion-proof models, ensuring flexibility and adaptability in various applications.

Technical Drawings and Dimensions: The document includes detailed technical drawings and dimensions for different valve models, providing essential information for installation and integration into existing systems.

Additional Options: Options such as indicator light kits and manual override kits are available to enhance functionality and ease of use. The document also highlights the availability of manifold mounting options for compact and efficient system integration.

Compliance and Standards: The valves comply with several CSA standards, ensuring they meet safety and performance requirements for use in explosive atmospheres.

Overview: This document provides detailed specifications and descriptions of various solenoid and manual control valves manufactured by ROSS CONTROLS®. It includes information on solenoid pilot-controlled valves, pendant control valves, pushbutton and toggle lever valves, cam valves, and flow control valves.

Solenoid Valves:

Specifications: Rated for continuous duty with standard voltages of 24 volts DC and 110-120 volts AC, 50/60 Hz. Power consumption is 0.03 VA holding on 50/60 Hz and 0.8 watts on DC.
Temperature Range: Ambient temperature is 39° to 122°F (4° to 50°C), and media temperature is 39° to 175°F (4° to 80°C).
Flow Media: Filtered air with inlet pressure ranging from 30 to 150 psig (2 to 10 bar).
Certification: Certified by CSA according to UL 429 and CSA 22.2-139.
Features: Includes a patented ball-poppet design for near-zero internal leakage and faster operation than spool valves.

Pendant Control Valves:

Applications: Suitable for manual control of devices like air hoists and motors, ideal for material handling devices.
Specifications: Ambient temperature is 40° to 120°F (4° to 50°C), media temperature is 40° to 175°F (4° to 50°C), and inlet pressure is 0 to 150 psig (0 to 10 bar).
Design: Features spring-return rubber poppet internals for dependable shifting and long life.

Pushbutton and Toggle Lever Valves:

Specifications: Ambient/media temperature is 40° to 175°F (4° to 80°C), with inlet pressure ranging from 5 to 150 psig (0.3 to 10 bar).
Design: Includes self-cleaning poppet design that tolerates dirty air.

Cam Valves:

Specifications: Similar temperature and pressure specifications as pushbutton and toggle lever valves.
Design: Available in roller and plunger types, with self-cleaning poppet design.

Flow Control Valves:

Function: Used to control air flow from air cylinders, allowing free flow in one direction and adjustable flow in the other.
Design: Adjustment is made via a screwdriver slot or a knurled knob, depending on the model.

Important Notes: The document emphasizes reading all cautions and warnings thoroughly, especially those on the inside back cover.

Overview: The document provides detailed information on ROSS Controls' Manual L-O-X® (Lockout and Exhaust) valves, which are used for energy isolation in pneumatic systems. These valves are designed to control air flow with a simple push/pull mechanism and are available in various sizes and materials, including stainless steel for corrosion resistance.

Specifications: The valves operate within an ambient/media temperature range of 40° to 175°F (4° to 80°C) and are suitable for filtered air. They support inlet pressures from 15 to 300 psig (1 to 20 bar) depending on the port size. The valves are identified by a yellow body with a red handle and feature large exhaust ports for rapid air release.

Key Features:

Effectiveness: Isolates equipment by shutting off air supply and immediately exhausting stored air.
Ease of Use: Simple push/pull operation with a large red handle.
Locking Protection: Can be padlocked in the closed position to prevent accidental operation.
Reliability: PTFE seals ensure functionality even after long periods of inactivity.
Efficiency: Large exhaust ports for quick air release, compatible with silencers or remote exhaust lines.
User Confidence: Three-way valve design ensures any leakage is exhausted faster than it can build up.

Additional Options: The manual L-O-X® valve with EEZ-ON® operation combines lockout functionality with gradual start-up capability, allowing for a controlled buildup of downstream air pressure. This feature is adjustable and enhances safety by allowing equipment to move slowly into position before full pressure is applied.

Applications: The stainless steel version is suitable for environments where corrosion and contaminants are a concern, such as food and beverage, pharmaceutical, pulp and paper, chemical processing, oil and gas, and offshore industries.

Compliance and Safety: The valves comply with various standards, including OSHA, and are designed to be padlocked in the closed position to prevent accidental operation during maintenance. They are not intended as emergency stop devices.

Energy Release Verification: Options include a visual pop-up indicator or an electronic pressure switch to verify the release of downstream pressure, ensuring safety during maintenance operations.

Overview: This document provides technical specifications and operational details for various pneumatic control devices, including visual indicators, pressure switches, silencers, and L-O-X® valves. It is intended for use in industrial environments, particularly those requiring wash-down capabilities and energy isolation.

Specifications:

Visual Indicator: Model 1155H30 with dimensions 2.33 inches (59.3 mm) and weight 0.22 lbs (0.1 kg).
Pressure Switch: Model 1162A30 with dimensions 8.50 inches (215.9 mm) and weight 0.23 lbs (0.01 kg). Features a 316 stainless steel body and nitrile seals.
Silencers: Available in port sizes 1/4 to 2 inches, constructed from stainless steel or nickel-plated bodies with stainless internals.
L-O-X® Valves: Manual and solenoid pilot controlled options available, designed for lockout/tagout applications. Various models with different port sizes and configurations.

Procedures:

Valve Operation: Describes the operation of L-O-X® valves, including opening and closing mechanisms, and the role of the red handle for quick shut-off.
Pressure Control: Details on pressure-controlled and solenoid pilot-controlled operations, including inlet and exhaust port functions.

Standards and Recommendations:

Products are defined as energy isolation devices, not emergency stop devices.
Machine design should include methods for verifying energy release after lockout.
Electrical life of switches rated in excess of 15 million cycles.

Key Features:

Stainless steel construction for wash-down applications.
Visual indicators with 360° visibility and redundant verification features.
Pressure switches integrated into safety monitoring systems.

Contact Information: For more information, contact ROSS’ Global Safety Team at [email protected].

Overview: The document provides detailed specifications and operational guidelines for various types of valves, including EEZ-ON® valves, solenoid pilot-controlled valves, and manual L-O-X® valves with EEZ-ON® operation. These valves are used in pneumatic systems to control air pressure and flow, ensuring gradual pressure buildup and safe operation.

Specifications:

Flow Media: Filtered air with a 5-micron recommendation.
Inlet Pressure: Ranges from 15 to 150 psig (1 to 10 bar) for standard valves, and up to 200 psig (13.8 bar) for modular L-O-X® valves.
Temperature Range: Ambient and media temperatures range from 40°F to 175°F (4°C to 80°C).
Port Threads: Available in NPT and BSPP.
Body Paint: Gold for standard valves, yellow for L-O-X® valves.

Valve Types and Models:

Solenoid Pilot Controlled Valves: These valves use AC or DC power solenoids and are available in various port sizes with specific model numbers. They feature adjustable needle valves for controlling pressure buildup.
Internal Pressure Controlled Valves: Similar to solenoid-controlled valves but operate based on internal pressure changes.
EEZ-ON® Valves: Designed for gradual air pressure application to prevent rapid equipment movement. They include features like exhaust ports and adjustable pressure settings.
Manual L-O-X® Valves with EEZ-ON® Operation: These combine shut-off capabilities with gradual pressurization, featuring a blue handle for easy identification and operation.

Operational Guidelines:

EEZ-ON® valves allow for gradual downstream air pressure buildup, adjustable via a needle valve.
Solenoid and internal pressure-controlled valves shift to full open positions when downstream pressure reaches a certain percentage of inlet pressure.
Manual L-O-X® valves can be locked in the off position for safety and feature a large exhaust port for rapid pressure release.

Additional Features:

Optional indicator lights for solenoid pilot-controlled valves.
Integrated sensing ports for pressure verification in L-O-X® valves.
Compatibility with MUFFL-AIR® silencers for noise reduction.

Important Notes:

These valves are defined as energy isolation devices and not as emergency stop devices.
Special attention should be given to the CAUTIONS and WARNINGS provided in the document.

Overview: The document provides detailed specifications and operational guidelines for the Modular L-O-X® Lockout Valve with Integrated Filter/Regulator, designed for pneumatic energy isolation and air entry applications. It includes information on various components, configurations, and accessories.

Specifications:

Drain Options: Automatic, manual, or float drain (metal bowl only).
Filter Element: 5-micron polyethylene, optional 40-micron.
Pressure Ratings: Inlet pressure minimum 15 psig with automatic drain; plastic bowl up to 150 psig, metal bowl up to 200 psig. Outlet pressure adjustable up to 150 psig.
Materials: Nitrile seals, brass valve, acetal slide.
Ports: Available in 1/4, 3/8, 1/2 sizes with NPT and BSPP threads.

Features:

Integrated filter and regulator in a compact design.
Modular mounting for easy servicing.
Reverse flow, self-relieving piston-type regulator.
Lockable only in the off position for safety.
Optional EEZ-ON® operation for ease of use.

Flow Characteristics: The document includes flow characteristics for different port sizes, indicating the differential pressure across the valve at various flow rates.

Valve Operation:

Closed Position: Blocks supply air, allows downstream air to exhaust, must be padlocked during maintenance.
Open Position: Allows free flow from inlet to outlet, exhaust port blocked, handle detented in open position.

Accessories:

Extra port block for auxiliary ports.
MUFFL-AIR® silencers for noise reduction.
Clamps and mounting brackets for module connections.
Male and female end ports for easy module removal.

Sensing Valves (Series SV27):

Combines poppet technology with position and state sensing.
Provides electrical feedback via a safety-rated DPST switch.
Available in 2/2 and 3/2 normally closed functions.
Enhanced safety with optional visual pressure indicator or pressure switch.

Applications: Suitable for packaging, material handling, conveyor panels, and all air entry points.

Specifications and Standards:
The document references several standards including CSA Z460-05, ISO 13849-1, ISO 14118:2000, EN 1037, ANSI/ASSE Z244.1-2003 (R2008), and ANSI/PMMI B155.1-2011. These standards relate to safety requirements for machinery and control systems, particularly focusing on lockout/tagout (LOTO) procedures and control reliability.

Valve Types and Specifications:
The document lists various valve types such as Solenoid Pilot and Pressure Controlled valves, with specifications on length and number of cables. For example, the Solenoid Pilot valve is available in lengths of 4 meters (13.1 feet) and 10 meters (32.8 feet), each with two cables.

Dynamic Monitoring and Valve Functionality:
The document describes dynamic monitoring features integrated into valve elements for Category 3 and 4 applications. These valves exhaust downstream air if asynchronous movement occurs, ensuring safety by maintaining a residual outlet pressure of less than 1% of supply. The valves are designed to reset automatically without memory of abnormal behavior, except in certain series where an intentional reset is required.

Valve Operation and Safety Features:
The valves feature a 3/2 Normally Closed Valve Function with dirt-tolerant, wear-compensating poppet design for quick response and high flow capacity. They include status indicators with pressure switches to provide feedback on valve conditions. The valves are equipped with silencers and are inline mounted with flexible piping options.

Technical Specifications:
The document provides detailed technical specifications for the valves, including power consumption, standard voltages, ambient and media temperature ranges, inlet pressure, and functional safety data. The valves are CE marked and tested for vibration/impact resistance.

Valve Operation Overview:
The operation of the valves is explained, detailing the flow of inlet air pressure, the actuation and de-actuation process, and the handling of asynchronous operations. The document emphasizes the importance of integrating the status indicator switch into the electrical safety control system to prevent hazardous situations.

Valve Reset and Lockout Mechanism: The valve remains in a locked-out position even if the inlet air supply is removed and re-applied. A reset signal must be intentionally applied to reset the valve. Resetting is achieved by energizing the reset solenoid, which applies inlet air pressure to reset pistons, pushing the main valve elements to their de-actuated position. The reset anti-tie-down feature prevents the valve from being reset if the main solenoids are energized while the reset solenoid is active.

Status Indicator: A pressure switch indicates the valve's status, actuating when the valve operates normally and de-actuating when in a locked-out position or when inlet pressure is removed. This indicator is not part of the lockout function but reports the valve's status.

Valve Specifications: The document provides detailed specifications for various valve models, including port sizes, average CV, dimensions, and weight. It also specifies the electrical requirements, enclosure ratings, and temperature ranges for operation.

Valve Operation: The valve operates by energizing pilot valves, which apply pressure to pistons, moving internal parts to an open position. The valve locks out if asynchronous movement occurs during actuation or de-actuation, requiring a reset signal to return to normal operation.

Safety and Monitoring Features: The valve includes a dynamic monitoring system with memory, preventing unintentional resets. It is designed for safety applications with features like an electrical reset valve and a status indicator switch.

Technical Data and Certifications: The document includes technical data such as functional safety data, certifications, and vibration/impact resistance. It also provides information on mounting orientation and port threads.

Overview: The document provides detailed specifications and operational guidelines for various pneumatic valves and wiring kits offered by ROSS CONTROLS. It includes information on model numbers, port sizes, average CV, dimensions, and additional features such as explosion-proof solenoids and pressure switches.

Specifications: The valves are designed for continuous duty with standard voltages of 24 volts DC and 110-120 volts AC. They operate within an ambient temperature range of 40° to 120°F and a media temperature range of 40° to 175°F. The flow media is filtered air with a recommended 5-micron filter. Inlet pressure ranges from 40 to 150 psig.

Functional Safety: The valves comply with ISO 13849-1:2006 Category 4 PL e applications, featuring a self-contained dynamic monitoring system. They are CE marked and tested for vibration and impact resistance.

Applications: These valves are suitable for small pneumatic cylinder-operated presses, safety latches, pinch point applications, and more. They are not designed for controlling clutch/brake mechanisms on mechanical power presses.

Wiring Kits: The document details various wiring kits, including DM1 and DM2 Series, with options for DIN and M12 connectors. Kits include cables for solenoids and status indicators, available in different lengths.

Operation and Safety: The valves require simultaneous pressurization of pilot supply ports for operation. They feature a safety function that defaults to a safe state if asynchronous operation is detected. Pressure switches provide feedback on valve status.

Service Kits: Service kits are available for valve maintenance, including seal and gasket kits, valve body service kits, and pressure switch service kits.

Overview: The document provides detailed technical specifications and operational guidelines for the ROSS DM2® Series D Double Valves, which are designed for use in pneumatically controlled clutch and brake applications, particularly in the mechanical press industry. These valves incorporate advanced safety features, including dynamic monitoring and memory, to ensure reliable operation and compliance with industry standards.

Specifications: The DM2® Series D valves are available in sizes 2, 4, 8, 12, and 30, with various inlet and outlet port configurations. They are designed to operate with a 3/2 normally closed air flow pattern and include features such as dirt-tolerant poppet design, high flow capacity, and integrated silencers. The valves are compatible with both lubricated and unlubricated air and can operate within a temperature range of 15° to 120°F (-10° to 50°C).

Valve Operation: The valves function by using two solenoid pilots to control two independent valve elements. When the pilots are energized, the valve elements open, allowing air flow. If the elements do not operate synchronously, the valve enters a faulted condition, exhausting downstream air and maintaining a residual outlet pressure of less than 1% of the inlet supply.

Safety Features: The DM2® Series D valves include a patented dynamic monitoring system that changes state with each valve cycle. In the event of asynchronous operation, the valve locks out and prevents further operation until manually reset. This ensures that any faults are retained in memory and cannot be reset by simply cycling power or air supply.

Standards and Compliance: The valves meet various safety standards, including Category 4 PL e, and are CE marked. They are designed to comply with regulations requiring self-contained monitoring devices for pneumatically controlled systems.

Ordering Information: The document provides a model configurator for selecting the appropriate valve based on size, voltage, reset type, and other options. It also includes detailed dimensions and weight specifications for each valve size.

Overview: The document provides a detailed technical description of ROSS Controls' double valves, specifically the DM2® Series D Valve and Series 35 Serpar® valves. These valves are designed for pneumatic control systems, ensuring safety and reliability through redundant internal elements and monitoring systems.

Valve Operation: The valves operate as 3/2 normally closed valves, requiring both internal elements to function correctly to supply pressure to the outlet. In case of a malfunction, the system defaults to a fail-safe condition, exhausting air to prevent hazardous situations.

Lockout Mechanism: The valves feature a lockout position that activates when elements operate asynchronously. This position ensures one crossover is exhausted while the other is pressurized, preventing unintended operation. Resetting requires a manual or remote signal to pressurize the reset port.

Monitoring and Safety Features: The valves include internal and external monitoring options. Internal monitoring automatically locks out the valve upon detecting a malfunction, while external monitoring provides feedback signals for system checks. Both systems ensure the valve defaults to a de-energized position upon fault detection.

Specifications: The document lists specifications for various valve sizes, including pilot solenoid ratings, power consumption, temperature ranges, and pressure requirements. It also details the functional safety data and certifications, emphasizing the valves' compliance with safety regulations.

Applications: Originally designed for clutch/brake mechanisms in stamping presses, these valves are now used in various safety-critical applications, including energy isolation systems and load-holding systems in pneumatic circuits.

Product Variants: The document describes different models and sizes of the Series 35 Serpar® valves, including options with internal and external monitoring, and various port sizes. It also provides model numbers and ordering information for specific configurations.

Valve Operation Overview:
In normal operation, energizing both solenoids actuates the pilots, causing valve elements A and B to shift, connecting inlet 1 to outlet 2 via crossflow passages C and D, while closing exhaust 3. Monitoring pressure signals equalize to inlet pressure.

Completion of Normal Cycle:
De-energizing both solenoids returns the valve to its initial state, where inlet 1 is closed to outlet 2, and outlet 2 is open to exhaust 3.

Malfunction Detection:
A malfunction may cause one valve element to remain open while the other closes, leading to pressure imbalance. This triggers a switch (SW) that breaks the electrical circuit to the pilot solenoids, returning valve element A to the closed position.

Lock-out Mechanism:
In a lock-out state, monitoring air pressure is exhausted, and the electrical circuit remains broken. To reset, a reset solenoid must be briefly energized, ensuring pilot solenoids are de-energized to prevent hazardous cycling.

Specifications:
Pilot solenoids are rated for continuous duty with standard voltages of 24 volts DC or 110-120 volts AC. The E-P reset solenoid is rated for intermittent duty. The valves operate within an ambient temperature range of 40° to 120°F and a media temperature range of 40° to 175°F. The pressure range is 30 to 125 psig.

Functional Safety and Certifications:
The valves are certified with CE Mark, BG, CSA/UL, and tested for vibration/impact resistance. They meet functional safety data requirements with a Category 4 PL e rating.

Wiring and Model Information:
Single and dual input wiring diagrams are provided, with model numbers specified for different configurations and sizes. Voltage codes "W" for 24 volts DC and "Z" for 110-120 volts AC are used in model numbers.

Important Notes:
Valves without pressure switches should not be used for controlling clutch/brake mechanisms on press machinery. External monitoring systems are required for compliance with safety standards.

Introduction
This document provides guidelines and safety measures for the installation and maintenance of pneumatic controls by ROSS CONTROLS, a manufacturer of premium pneumatic controls since 1921. It includes cautions, warnings, and warranty information.

Pre-Installation and Service Guidelines
1. Ensure all energy sources are turned off and locked out before servicing pneumatic components (OSHA 1910.147, EN 1037).
2. Only trained personnel should install or service ROSS products. Regular checks and maintenance are necessary.
3. Follow all instructions to prevent harm to persons or equipment. Test overhauled or serviced valves before use.
4. Use ROSS parts for repairs and adhere to specification limits.

Filtration and Lubrication
5. Install a 5-micron filter to clean air supply and prevent contaminants.
6. Use metal bowl guards for polycarbonate plastic bowls to prevent high-pressure fragmentation. Avoid exposure to certain fluids.
7. Use compatible lubricants, typically petroleum-based oils with specific properties, to avoid valve failure.

Avoid Intake/Exhaust Restriction
8. Do not restrict air flow in supply lines to prevent pressure drops.
9. Ensure exhaust silencers are clog-resistant and have adequate flow capacity.

Power Presses
10. Use a press control double valve with a monitoring device for hazardous machinery. Ensure monitoring systems inhibit operation in case of valve failure.

Energy Isolation/Emergency Stop
11. ROSS L-O-X® products are energy isolation devices, not emergency stop devices.

Standard Warranty
ROSS products are warranted for one year (seven years for FRLs) against defects. The warranty covers repair, replacement, or refund at ROSS's discretion. Misuse or improper maintenance voids the warranty.

Global Reach
ROSS distributors are available worldwide to assist with product selection and support. Contact information for various regions is provided.

Catalog excerpts

ROSS CONTROLS FLUID POWER PRODUCTS FOR PNEUMATIC SOLUTIONS-1

DIGEST CATALOG

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ROSS CONTROLS FLUID POWER PRODUCTS FOR PNEUMATIC SOLUTIONS-2

This catalog represents an overview of ROSS’ extensive product line. If you need products or specications not shown within this catalog, please contact ROSS for more information or visit ROSS website at www.rosscontrols.com.

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ROSS CONTROLS FLUID POWER PRODUCTS FOR PNEUMATIC SOLUTIONS-3

Revolutionizing Fluid Power Chevrolet engine tappets, springs, and retainers were the ingredients that Charlie Ross used to make the rst poppet valve after a re destroyed Detroit Seamless Steel Tube Company in 1917. Charlie, a master mechanic, needed to resume production in a hurry and could not wait for shipments of replacement valves from Europe. Soon after, he led his rst patent and in 1921, Charlie Ross, StClair Cameron and four others incorporated the Ross Operating Valve Company. Today, ROSS CONTROLS® proudly continues as a private company owned by the Cameron family and the ROSS spirit...

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ROSS CONTROLS FLUID POWER PRODUCTS FOR PNEUMATIC SOLUTIONS-4

Industry Solutions Visit the ROSS web site at www.rosscontrols.com to fully explore the premium pneumatic and electronic controls systems, services, and distributor channels. ROSS is dedicated to developing matchless pneumatic, electronic, and/or hydraulic system industry solutions to improve the safety and effectiveness of customers’ equipment and operations. Glass Container Machines • • • • • • • • • • • • • • Valves designed for repeatability Counterblow vacuum valves Hi/low pressure valves Plunger up/down & cooling valves Blowhead on/off valve including kickoff Mold open/close valves Pusher...

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ROSS CONTROLS FLUID POWER PRODUCTS FOR PNEUMATIC SOLUTIONS-5

Industry Solutions Safety Products • • • • • • • • • • • • • • • Control Reliable 3/2 and 5/2 pneumatic valves with BG certication Pneumatic internally monitored double valves for safety applications Control Reliable double valves Manual and solenoid L-O-X® valves for energy isolation EEZ-ON® valves for gradual start-up Manual L-O-X® valves with EEZ-ON® operation Modular L-O-X® air entry combination Stainless Steel L-O-X® valves for energy isolation Sensing valves Category 2 In-line valves Pilot operated check valves (single/double channel sensing available) Check valves Safety Clamping Devices...

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ROSS CONTROLS FLUID POWER PRODUCTS FOR PNEUMATIC SOLUTIONS-6

ROSS/FLEX® Process For Innovative Solutions ROSS/FLEX® Is Not a Product Line The ROSS/FLEX® process is a manufacturing culture. Its goal is to help you reduce costs while increasing the practical value of your air controls and pneumatic systems. It puts the power back where it belongs: In the hands of the customer! As a customer, we believe you have every right to receive a product that is precisely suited to your needs - both functional and nancial. If you’re building a machine that requires six different air controls, and the design could be improved by having a single, six-function control...

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ROSS CONTROLS FLUID POWER PRODUCTS FOR PNEUMATIC SOLUTIONS-7

ROSS Integrated Systems ROSS Offers Custom Design, Manufacturing and Support of Complete Valve Systems ROSS – Providing more than just components ROSS offers engineering and construction of Valve Stands, Wall Mounted Plates or Enclosed System Panels to allow quick and easy installation at the job site. Services Provided: Systems Engineering Controls Engineering Custom Fabrication Installation Assistance Integrated ROSS Components into a Engineered System Solution Valve Stands Wall or Plate Mounted Systems Free standing valve stands provides a exible way to isolate and position a group of valves...

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ROSS CONTROLS FLUID POWER PRODUCTS FOR PNEUMATIC SOLUTIONS-8

The ROSS Poppet Valve . . . A ROSS Speciality from the Beginning Positive Sealing Self-Cleaning and Dirt Tolerant Inlet air pressure forces the inlet poppet upward, pushing the poppet seal rmly against the seat. The higher the inlet pressure, the greater the sealing force. Note that the seal is engaged perpendicular to the seat; there is no sliding action to damage and wear the seal, or to cause erratic friction. The ow velocity for a given volume of air is dependent upon the area through which it is owing. The smaller the area, the greater the velocity. In poppet valves, the smallest ow-through...

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ROSS CONTROLS FLUID POWER PRODUCTS FOR PNEUMATIC SOLUTIONS-9

Choose the Type of Base Mounted Valve Construction that Best Meets Your Needs Poppet- ISO W64, ANSI W74, SAE 84 Series Poppet surfaces face-seal against at poppet seats. FEATURES • Large pilot pistons • Mechanical detents • Self-cleaning • Short stroke • Fluorocarbon seal option available • Wear-compensating design BENEFITS • Very dependable • Tolerant of dirty air • Positive seating • Fast response • Long service life • Low maintenance • Repeatability Where there is no lubricated air Where the air is dirty (steel mills, glass plants, foundries, and aluminum smelters) High-speed machines High-temperature...

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ROSS CONTROLS FLUID POWER PRODUCTS FOR PNEUMATIC SOLUTIONS-10

ISO Valves and Serial Bus Communication from ROSS CONTROLS For more information please refer to Please visit the ROSS web site to view the complete Bulletin 600 (Form #A10309) and Bulletin 600T (Form A10309T) at www.rosscontrols.com. © 2013, 5266 CONTROLS®. All Rights Reserved.

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ROSS CONTROLS FLUID POWER PRODUCTS FOR PNEUMATIC SOLUTIONS-11

ISO (15407-1 & 2) Size 00 & 0 Valves Series W66 Specications Flow Capacity: Size 00, Series W66: 0.55 Cv (18 mm) Size 0, Series W66: 1.1 Cv (26 mm) End Caps: PBT (Polybutylene Terephthalate) Fasteners: Zinc Plated Steel Valve Body: Aluminum Coils: Thermoset Plastic Operating Pressure: • Vacuum to 145 psi (10 bar) • Minimum Operating Pressure Size 00 (18 mm) Single Solenoid (5/2) Series W66 (15407-1) • Terminal Block Wiring (Series W66, Size 0 Only) • Collective Wiring – 25-Pin, D-Sub – 19-Pin Round – 16 Point Terminal Strip – M23, 12-Pin – Serial Bus Field Bus Solenoids: • Surge Suppression (Standard)...

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ROSS CONTROLS FLUID POWER PRODUCTS FOR PNEUMATIC SOLUTIONS-12

ISO (5599/I) Spool and Sleeve Valves Series W60 Solenoid Pilot Controlled • Micro-thin air bearing between spool and sleeve assures quick valve response • Designed for high cycle rates, long life • No seals to wear out • Suitable for vacuum service (with external pilot supply) 4 2 5/2 Valves – Single Solenoid Pilot Controlled, Spring Return Port Size Valve Model Avg. Number* CV * Sub-base and electrical connector not included. See pages 17-19 for sub-bases, manifolds and accessories. 4 2 5/2 Valves – Double Solenoid Pilot Controlled, Detented Port Size Valve Model Avg. Number* CV * Sub-base and...

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