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ROSS Fluid Power Products for Pneumatic Solutions

ROSS 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.

General Information: Provides ordering information and additional literature references.

Product Specifications: Details various valve types, including base-mounted and line-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 products like control reliable valves, L-O-X® valves for energy isolation, and safety clamping devices, ensuring compliance with global safety standards.

Revolutionizing Fluid Power: Discusses ROSS's history and commitment to innovation in fluid power, emphasizing customer-driven development and global reach.

Important Notes: Readers are advised to review cautions and warnings thoroughly, especially regarding safety products.

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. The design includes a micro-thin air bearing for reduced friction and wear.

Specifications: ROSS provides detailed specifications for various valve sizes and types, including flow capacity, materials of construction, operating pressure, and certification standards. The valves are compatible with various electrical connections and are designed for high cycle rates and long service life.

Standard Specifications: The document outlines the specifications for ISO (5599/I) Spool and Sleeve Valves, Series W60. The ambient/media temperature range is 40° to 175°F (4° to 80°C), and the flow media is filtered air with a 5-micron recommendation. Inlet pressure ranges from vacuum to 150 psig (10 bar), with pilot pressure requirements varying by model size.

Valve Types and Models: The document details various valve types, including 5/3 Valves (Double Pressure Controlled), 5/2 Valves (Single Pressure Controlled, Spring Return), and 5/2 Valves (Double Pressure Controlled, Detented). Each valve type is associated with specific model numbers, dimensions, and weights.

EnergySaver® Valves: The ENERGYSAVER® valves are designed to reduce compressed air consumption by up to 30%. They operate by supplying full line pressure to port 4 and reduced pressure to port 2, allowing for full cylinder force while reducing return pressure.

Valve Operation: The operation of the ENERGYSAVER® valve is explained, highlighting the energy-saving mode where the valve functions as a fixed spring regulator, maintaining cylinder return pressure at approximately 30 psig (2 bar).

Accessories and Options: The document lists available accessories and options for manifolds, including blank station kits, blocking discs, and pressure plates. It also provides details on sub-base and manifold dimensions for different ISO sizes.

Electrical Connectors: Connectors for use with DROPCORDS (DIN 43650, Form A) are described, including wired connectors with abrasion-resistant insulation and flying solenoid leads with spade connectors.

Overview: This document provides detailed specifications and components for pneumatic systems, focusing on manifold stations, valves, and related accessories. It includes information on blank station kits, transition plates, flow controls, pressure plates, and various valve configurations.

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. Interposed pressure regulators, available in single and double configurations, allow for independent pressure settings at outlet ports.

Valve Specifications: The document details various valve models, including solenoid and pressure-controlled valves, with specifications on solenoid ratings, power consumption, temperature ranges, and pressure requirements.

Sub-Bases and Manifolds: Information on side and bottom-ported sub-bases and manifolds is provided, including dimensions and part numbers for different ISO sizes.

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

Overview: The document provides technical specifications and operational details for various valve models and accessories used in controlling the speed of a cylinder's extend and retract motions. It includes information on solenoid and pressure-controlled valves, transition plates, and sub-bases.

Specifications: The valves are designed for high cycle rates and long life, featuring a micro-thin air bearing between the spool and sleeve for quick response. They are suitable for vacuum service and do not have seals that wear out. The document specifies standard voltages, power consumption, ambient and media temperature ranges, flow media requirements, and inlet and pilot pressures.

Valve Models: The document lists various valve models with their corresponding ANSI port sizes, model numbers, average CV (flow coefficient), dimensions, and weights. It includes models for single and double solenoid pilot-controlled valves, as well as pressure-controlled valves.

Transition Plates and Regulators: Transition plates are used to bank different manifold sizes together. The document also describes single and double interposed regulators, which can reverse output ports and potentially cause unexpected cylinder movement.

Sub-Bases: Sub-base model numbers are provided, specifying pressure ports with NPT threads and electrical openings. The document includes dimensions and CV ratings for various sub-base configurations.

Warnings and Notes: The document contains important notes and warnings regarding the operation and installation of the valves, emphasizing the need to read all cautions and warnings thoroughly.

Overview: The document provides detailed specifications and assembly instructions for ROSS manifold stations and valves, including solenoid and pressure-controlled types. It includes model numbers, dimensions, and configurations for various valve types and sizes.

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.

Assembly and Integration:

Manifold stations can be assembled by ROSS to precise specifications and are ready for system integration.
Single and double interposed regulators are available for valves with CV ratings up to 4.2, allowing for independent pressure settings at outlet ports.

Manual Overrides and Accessories:

Flush flexible manual overrides are standard on solenoid pilot-controlled valves with CV ratings of 2.0 or larger.
Locking and non-locking metal override buttons are available, with specific kit numbers provided for ordering.

Valve Models and Configurations:

Various valve models are listed with corresponding CV ratings and dimensions.
Specific configurations for single and double solenoid pilot valves are detailed, including wiring options and connector types.

Important Notes:

CV values are intended for use with ROSS performance charts and should not be compared with other manufacturers.
External pilot supply conversion instructions are provided for solenoid pilot valves.

Overview: The document provides detailed specifications and options for solenoid and poppet valves, focusing on Series 21 and 27. It includes information on indicator lights, manual override kits, and valve configurations for different temperature services.

Specifications: The valves are available in various port sizes and configurations, including 2/2, 3/2, and 4/2 types. They are designed for both high and low-temperature services, with specific seals and materials to ensure performance under different conditions. The document specifies standard voltages (24 volts DC and 110-120 volts AC) and power consumption details.

Valve Models and Dimensions: The document lists multiple valve models with their corresponding port sizes, average CV (flow coefficient), dimensions, and weight. It provides detailed tables for easy reference.

Manual Override Kits: Options include flush and extended buttons, with locking and non-locking types available. Kit numbers are provided for ordering.

Temperature Specifications: Type H valves are suitable for high temperatures up to 300°F (150°C), while Type O valves are designed for low temperatures down to -40°F (-40°C). Media temperature ranges are also specified.

Vacuum Service Valves: These valves are suitable for applications like lifting, holding, and leak testing. They are designed to tolerate particles entering the valve due to the absence of filters in vacuum applications.

Important Notes: The document emphasizes reading all cautions and warnings thoroughly. It also highlights the need to specify voltage when ordering and provides contact information for further technical support.

Overview: The document provides detailed technical specifications and guidelines for explosion-proof solenoid pilot-controlled valves, specifically the Series 27 and Dale Series from 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" and are suitable for both AC and DC power. Standard voltages include 24 volts DC and 110-120 volts AC. The power consumption is specified as 4.6 watts for standard models and 87 VA inrush, 30 VA holding for others. The ambient temperature range is 40° to 120°F, and media temperature ranges from 40° to 175°F. The valves are designed to handle inlet pressures from 15 to 150 psig depending on the port size.

Features: Key features include solenoid pilot control, poppet construction for minimal leakage, high dirt tolerance, self-cleaning, and wear compensation. The valves are also noted for their repeatability and ability to be field-converted to explosion-proof models using conversion kits.

Applicable Standards: The valves comply with several CSA standards for use in hazardous locations, including C22.2 No. 0-10, CSA C22.2 No. 25-1966, and CAN/CSA E79-0-95, among others.

Applications: These valves are suitable for a wide range of industries, including power generation, food and beverage, petrochemical, wastewater treatment, and more. They are particularly useful in environments with flammable gases, vapors, liquids, combustible dust, or ignitable fibers.

Additional Options: The document mentions options such as indicator light kits and manual override kits for enhanced functionality and ease of use. The valves can be mounted in line or on a manifold, with various configurations available for different applications.

Technical Drawings: The document includes technical drawings and dimensions for various valve models, providing detailed installation and configuration information.

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. Ambient temperature ranges from 39° to 122°F (4° to 50°C), and media temperature ranges from 39° to 175°F (4° to 80°C).
Features: Includes a "duck-bill" protected exhaust port to limit fluid entry and contamination, corrosion-resistant epoxy powder coat, and patented ball-poppet internals for near-zero internal leakage.
Applications: Suitable for washdown applications, food and beverage industries, and process industries in hot, cold, or wet environments.

Pendant Control Valves:

Specifications: Designed for manual control of devices such as air hoists and motors. Available in single, dual, and triple configurations with various lever and handle options.
Features: Spring-return rubber poppet internals for dependable shifting and long life. Twin Pacer® inserts for reliability and dirt tolerance.

Pushbutton and Toggle Lever Valves:

Specifications: Ambient/media temperature ranges from 40° to 175°F (4° to 80°C). Inlet pressure ranges from 5 to 150 psig (0.3 to 10 bar).
Features: Self-cleaning poppet design tolerates dirty air. Available in 2/2 and 3/2 configurations with pushbutton or toggle lever actuation.

Cam Valves:

Specifications: Similar temperature and pressure specifications as pushbutton valves. Available in roller and plunger types.
Features: Designed for mechanical/manual control with self-cleaning poppet design.

Flow Control Valves:

Specifications: Used to control air flow from air cylinders, allowing free flow in one direction and adjustable flow in the other.
Features: Adjustment options include screwdriver slot or knurled knob, depending on the model.

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

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 configurations, including stainless steel options for environments where corrosion is a concern.

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 fluorocarbon slipper seals for reliability.

Key Features:

Effectiveness: Isolates equipment by shutting off air supply and exhausting stored air immediately.
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: Designed for long-term use with special seals.
Efficiency: Large exhaust ports for rapid air release.
User Confidence: Three-way valve design ensures any leakage is exhausted quickly.

EEZ-ON® Operation: 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 particularly useful for safely moving cylinders or other work elements into position before full pressure is applied.

Applications: The stainless steel version is suitable for industries such as food and beverage, pharmaceuticals, pulp and paper, chemical processing, oil and gas, and offshore industries.

Compliance and Safety: The valves comply with various standards, including OSHA 29 CFR 1910.147, and are designed to be padlocked in the closed position to prevent accidental operation during maintenance. They are not intended as emergency stop devices.

Additional Features: The valves include a pressure sensing port for verification of pressure release, and options for visual or electronic pressure indicators are available.

Conclusion: ROSS Controls' Manual L-O-X® valves provide a reliable and efficient solution for pneumatic energy isolation, with features that enhance safety and ease of use in industrial applications.

Specifications:
The document provides detailed specifications for various pneumatic components, including visual indicators, pressure switches, silencers, and valves. Key materials used include stainless steel and nickel plating, with components designed for wash-down areas and industrial environments. The document specifies NPT port threads, with options for BSPP threads.

Procedures:
Instructions are provided for the operation of L-O-X® valves, including manual and solenoid pilot controls. The document describes the valve operation in both open and closed states, emphasizing the importance of quick shut-off capabilities and the ability to padlock the valve in the closed position for safety.

Standards and Recommendations:
The document highlights the importance of energy isolation devices, specifying that these are not to be used as emergency stop devices. It recommends the use of filtered air and provides temperature and pressure ranges for optimal operation. The document also notes the availability of explosion-proof solenoid pilots and the importance of monitoring safety switch status for diagnostic coverage.

Key Data from Tables:
The tables provide dimensions, weight, and flow coefficients (CV) for various valve models, indicating their suitability for different applications. The tables also specify the construction materials and port sizes, offering a comprehensive overview of the product range.

Critical Information:
Emphasis is placed on the correct installation and operation of the components to ensure safety and reliability. The document advises consulting ROSS for specific voltage requirements and other thread types, and it provides contact information for further inquiries.

Overview: This document provides detailed specifications and operational guidelines for various types of valves, including EEZ-ON® valves, L-O-X® valves, and solenoid pilot-controlled valves. It includes information on valve models, dimensions, weight, and operational procedures.

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 valves.
Temperature Range: Ambient and media temperatures range from 40° to 175°F (4° 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 are available in various port sizes and are identified by model numbers such as 2773B2037 and 2773B3037. They feature adjustable needle valves for gradual pressure buildup.
Internal Pressure Controlled Valves: Similar to solenoid valves but operate based on internal pressure changes. Models include 2783C2037 and 2783C3037.
EEZ-ON® Valves: Designed for gradual air pressure application to prevent rapid equipment movement. They include features like exhaust ports and are available with L-O-X® adapters.
L-O-X® Valves: These valves provide lockout and exhaust capabilities, ensuring safety during maintenance. They are available in manual and modular versions.

Operational Procedures:

EEZ-ON® Function: Gradually applies air pressure downstream, preventing rapid movement at startup.
Valve Operation: Describes the sequence of operations for solenoid and internal pressure-controlled valves, including pilot energization and de-energization.
Adjusting Needle: Used to control the rate of pressure buildup in the system.

Additional Features:

Indicator Lights: Optional feature for solenoid pilot-controlled valves.
Sensing Ports: Integrated into L-O-X® valves for pressure verification.
Safety Compliance: Valves are designed as energy isolation devices, not emergency stop devices.

Important Notes: Users are advised to read all cautions and warnings thoroughly to ensure safe and effective use of the valves.

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.

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 kit.

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

Specifications:
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 and control systems for industrial applications, particularly focusing on lockout/tagout (LOTO) procedures and control reliability.

Valve Types and Specifications:
The document lists various valve types, including solenoid pilot and pressure-controlled valves, with specifications on length and number of cables. It also details the DM1 and DM2 series valves, highlighting features such as dynamic monitoring, dirt tolerance, and high flow capacity. The valves are designed for rapid response and include status indicators for operational feedback.

Dynamic Monitoring and Safety Features:
Dynamic monitoring is integrated into the valve systems for Category 3 and 4 applications, ensuring that any asynchronous movement results in a lockout condition. The valves are equipped with status indicators that provide feedback on whether the valve is in a ready-to-run or lockout state. The document emphasizes the importance of integrating these indicators into the electrical safety control system.

Operational Procedures:
The document describes the operation of the valves, including the de-actuated (ready-to-run) and actuated states. It explains the process of energizing and de-energizing the pilot solenoids, which control the movement of internal parts to manage air flow and pressure. The document also outlines the conditions under which asynchronous operation can occur and the resulting safety implications.

Installation and Maintenance:
The valves are designed for inline mounting with BSPP or NPT pipe threads, providing flexibility in piping configurations. The document includes specifications for power consumption, ambient and media temperature ranges, and pressure ratings. It also notes the importance of reading all cautions and warnings thoroughly to ensure safe operation.

Key Data and Certifications:
The valves are CE marked and certified for various safety standards, including BG, CSA/UL, and TSSA. Functional safety data is provided, including performance levels (PL d and PL e), B10d values, and mean time to dangerous failure (MTTFd). The document also mentions the availability of Sistema library data for further safety analysis.

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 done 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.

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 for pilot solenoids, standard voltages, power consumption, and enclosure ratings.

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, requiring a reset signal to return to normal operation.

Design Features: The valves include features such as dynamic monitoring with memory, dirt-tolerant poppet design, and optional status indicators. They are base-mounted with flexible piping options and include high-flow silencers.

Safety and Certifications: The valves are designed for safety applications, with certifications including CE Marking and compliance with ISO 13849-1:2006 Category 4 PL e applications. They are not designed for controlling clutch/brake mechanisms on mechanical power presses.

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 to flow through the system. 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 ensures all components change state with each valve cycle. In the event of asynchronous operation, the valve locks out and prevents further operation until manually reset. This system retains fault information even if air or electrical supply changes, requiring a defined procedure for reset.

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 specifications. It also includes detailed dimensions and weight information 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 port. In case of a malfunction, the system defaults to a fail-safe condition, exhausting air to prevent hazardous situations.

Lockout and Reset Mechanism: The valves feature a lockout mechanism that activates if the valve elements operate asynchronously. A remote or manual reset is required to return the valve to normal operation, ensuring that the system does not automatically reset and potentially cause unsafe conditions.

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 that the valve defaults to a de-energized position upon fault detection.

Specifications: The document outlines specifications for various valve sizes, including pilot solenoid ratings, power consumption, temperature ranges, and pressure requirements. It also details the functional safety data, certifications, and vibration/impact resistance standards.

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

Product Variants: The document lists different models and configurations of the Series 35 Serpar® valves, including options with internal and external monitoring, various port sizes, and reset mechanisms.

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 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, and the flow media is filtered air.

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 standards 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 valve sizes and configurations. Voltage codes are used to specify the required voltage for each model.

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

Pre-Installation or Service
Before servicing any pneumatic component, ensure all energy sources are turned off and locked out. Only trained personnel should install or service ROSS products. Regular maintenance checks are necessary to ensure safety and functionality. Overhauled or serviced valves must be tested before use.

Filtration and Lubrication
Install a filter with a 5-micron rating to prevent contaminants from affecting equipment performance. Use only compatible lubricants, typically petroleum-based oils with specific properties, to avoid damage to components.

Avoid Intake/Exhaust Restriction
Do not restrict air flow in supply lines or exhaust ports, as this can cause erratic valve operation. Use exhaust silencers that match or exceed the valve's exhaust capacity to prevent back pressure.

Power Presses
For machinery with pneumatically controlled clutches and brakes, use a press control double valve with a monitoring device to ensure safety. A monitoring system should inhibit operation if a valve failure occurs.

Energy Isolation/Emergency Stop
ROSS L-O-X® products are defined as energy isolation devices and should not be used as emergency stop devices.

Standard Warranty
ROSS products are warranted for one year, except for Filters, Regulators, and Lubricators, which have a seven-year warranty. The warranty covers defects in material and workmanship but excludes misuse or improper maintenance.

Global Reach
ROSS distributors are available worldwide to assist with product selection and support. Contact information for various regional offices is provided for customer service and technical support.

Catalog excerpts

ROSS Fluid Power Products for Pneumatic Solutions-1

DIGEST CATALOG

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ROSS 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 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 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 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 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 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 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 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 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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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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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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