Home

Series 11and 12 Valves Thank You!

Contents

1. Typical Resilient Seal Spool Valve Cross Section Solenoid Coils Replacement coils for solenoid controlled valves can be ordered by part number 306K33 Specify the correct voltage and hertz when ordering Coils not available separately for size 0 valves order complete solenoid pilot assembly below Complete Solenoid Pilot Assemblies These consist of new pilot valve mechanisms plus a new coil Order by part number 851C79 For size 0 valves order part number 1242B79 Specify the correct voltage and hertz Valve to Base Gasket If your valve is removed from its base for any reason a new valve to base gasket must be used to ensure a leak free seal This gasket is already included in valve body service kits If you need additional information or have questions about installation or servicing your valve call ROSS Technical Services at 1 888 TEK ROSS 835 7677 or 706 356 3708 Valve Model Valve Body Pilot Valve to Base Numbers Service Kit Gasket W6356A1411 1584K77 NA 874B11 W6356A1417 1585K77 NA 874B11 W6356B1417 1585K77 NA 874B11 W6356B2411 1641K77 NA 617B11 W6356B2417 1644K77 NA 617B11 W6356B3411 1642K77 NA 618B11 W6356B3417 1645K77 NA 618B11 W6356B4411 1643K77 NA 619B11 W6356B4417 1646K77 NA 619B11 W6357B3411 1281K77 NA 618B11 W6357C3411 2125K77 NA 618B11 W6357B3417 1492K77 NA 618B11 W6357C3417 2126K77 NA 618B11 W6357B4411 1478K77 NA 619B11 W6357B4417 1490K77 NA 619B11 W6376A1401 1584K77
2. Valve Port Monitor Valve Body Gasket Monitor Lockout Reset Adaptor Size Sizes Type Service Kit Seal Kit Service Kit Kit Solenoid Kit 4 3 8 1 2 3 4 L G 541K77 545K77 542K77 E P 429K77 438K77 421K77 422K77 8 1 2 3 4 1 L G 428K77 437K77 416K77 418K77 D S 430K77 439K77 423K77 E P 432K77 441K77 421K77 422K77 422K77 12 3 4 1 114 L G 431K77 440K77 416K77 418K77 422K77 D S 433K77 442K77 423K77 E P 435K77 444K77 421K77 422K77 30 114 1 2 L G 434K77 443K77 416K77 418K77 D S 436K77 445K77 423K77 Valve Body Service Kits These kits contain all parts needed for complete reconditioning of a valve body Included are poppets spindles gaskets seals and instructions for use Gasket and Seal Kits These kits are needed when valve bodies are disassembled for cleaning Included are all necessary gaskets O rings other seals and lubricants These parts are included in the Valve Body Service Kits above Solenoid Pilot Kit This kit contains all parts needed to recondition one pilot valve of size 8 12 and 30 double valves Order kit number 946K87 two kits required for each valve Solenoids Order replacement solenoids or solenoid coils by the following part numbers specify voltage and hertz Size 4 Solenoid coil only 290B33 Sizes 8 12 30 Complete solenoid 411B04 If you have any questions about installing or servicing your valv
3. ROSS SOUTH AMERICA Ltda Brazil TEL 55 11 4335 2200 email vendas ross sulamerica com br ROSS CONTROLS INDIA Pvt Ltd India TEL 91 44 2624 9040 email rossindia airtelbroadband in ROSS CONTROLS CHINA Ltd China TEL 86 21 6915 7951 email alvinzhurong vip 163 com DIMAFLUID s a s France TEL 33 01 49 45 65 65 web site www dimafluid com VALVE MAINTENANCE Pneumatic equipment should be maintained only by persons trained and experienced in the maintenance of such equipment Supply Clean Air Foreign material lodging in valves is a major cause of breakdowns The use of a 5 micron rated air filter located close to the valve is strongly recommended The filter bowl should be drained regularly and if its location makes draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should put a fine oil mist into the air line in direct proportion to the rate of air flow Excessive lubrication can cause puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute is adequate Compatible Lubricants Although this valve does not require air line lubrication it may be used with lubricated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components and so cause the valve to malfunction Avoid oils with phosphate additives e g
4. You have purchased a premium quality ROSS pneumatic valve It is a resilient seal spool valve built to the highest standards With care in its installation and maintenance you can expect it to have a long and economical service life So before you go any further please take a few minutes to look over the information in this folder Then save it for future reference and for the useful service information it contains ROSS Series W63 valves are shown on bases VALVE INSTALLATION Pneumatic equipment should be installed only by persons trained and experienced in such installation Air Lines Before installing a valve in a new or an existing system the air lines must be blown clean of all contaminants It is recommended that an air filter be installed in the inlet line close to the valve Valve Inlet Port 1 Be sure that the supply line is of adequate size and does not restrict the air supply because of a crimp in the line sharp bends or a clogged filter element Valve Outlets Ports 2 amp 4 For faster pressurizing and exhausting of the mechanism being operated by the valve locate the valve as close as possible to the mechanism The lines must be of adequate size and be free of crimps and sharp bends Valve Exhausts Ports 3 amp 5 The exhaust ports of a spool valve may be restricted in order to control cylinder speed Also to reduce noise you may use an efficient silencer ROSS MUFFL AIR silencers reduce im
5. ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and L O X with EEZ ON operation products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective This warranty shall be void
6. Reset Port RESET If your valve is not equipped with a reset solenoid on the base then the RESET port should be supplied externally from a 3 2 normally closed valve The lines must be of adequate size and be free of crimps and sharp bends Reset signals should be momentary Electrical Supply 3 2 CrossMirror double valves get electrical power through plug in connectors The electrical supply must correspond to the voltage and hertz ratings of the solenoids Otherwise the solenoids are subject to early failure If power is supplied by a transformer it must be capable of handling the inrush current without significant voltage drop See Valve Specifications on page 3 for inrush current data Operating Pressures and Temperatures Allowable ranges for pressure and temperatures are given in the Valve Specificationson page 3 Exceeding these values can adversely affect performance and shorten valve life Pipe Installation To install pipe in valve ports engage pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating the valve To install pipe with parallel threads e g SAE ISO 228 G etc do not use sealant Test After installation or repair and prior to normal use the internal lock out feature of the 3 2 CrossMirRor valve must be tested for proper functioning Observe normal press operation safety precautions during these tests to avoid pe
7. in the U S 1 800 GET ROSS 706 356 3708 outside the U S for information If you service the valve yourself be sure to turn off electrical power to the valve shut off the air supply exhaust the air in the system and lock out all power sources before beginning any disassembly operation Listed below are kits for servicing DM2 Series D double valves as well as replacement solenoid information CAUTION Before operating the DM Series D double valve be sure to complete the test procedure TEST on page 1 upon installation and after any maintenance is performed on the valve Failure to do so could result in personal injury or equipment damage Valve Body Service Kits These kits contain all parts needed for complete reconditioning of a valve body Included are poppets spindles gaskets seals and instructions for use SIZO 4 oc hi an 2102K77 S ZE 8 et esos ee 2103K77 SIZE T2 oss ienai 2104K77 Size 30 2105K77 Status Indicator Assembly Service Kit This kit includes all parts needed for complete reconditioning of the status indicator assembly Pressure switch and connector sold separately see below All SiZ S ceee 2151H77 Replacement Pressure Switch This kit includes a replacement pressure switch and electrical connector for the status indicator assembly All SiZe S eeee 1104A30 If you have any questions about installing or servicing your valve call ROSS Technical Services at your neare
8. zinc dithiophosphate and diester oils both types can harm valve components The best oils to use are generally petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Some compatible oils are listed at the right These oils although believed to be compatible could change without notice because manufacturers sometimes reformulate their oils Therefore use oils specifically compounded for air line service If it is a synthetic oil contact the oil manufacturer for compatibility information Cleaning the Valve If the air supplied to the valve has not been well filtered the interior of the valve may accumulate dirt and varnish which can affect the valve s performance COMPATIBLE LUBRICANTS Maker Brand Name AMOGCO 0000 American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Citgo eee Pacemaker 32 EXXON eee Spinesstic 22 Teresstic 32 Mobil 0 Velocite 10 Non Fluid Oil Air Lube 10H NR Shellie eke Turbo T32 SUM adrar Sunvis 11 Sunvis 722 TEXACO Regal R amp O 32 Union 0 Union Turbine Oil A schedule should be established for cleaning all valves the frequency depending on the cleanliness of the air being supplied To clean the valve use any good commercial solvent Do not scrape varnished surfaces Also do not use chlorinated solvents or abrasive materials The former damages seal
9. 87 VA inrush 30 VA holding Temperature Range Ambient 40 F to 120 F 4 C to 50 C Media 40 F to 175 F 4 C to 80 C Flow Media Filtered air 5 micron recommended Inlet Pressure Vacuum to 150 psig 10 bar Pilot Pressure At least 15 psig 1 bar IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 2 ROSS CONTROLS Typical cross section of a ROSS Series 80 spool amp sleeve valve body Spring return model shown VALVE SERVICE ROSS would be happy to service this valve for you at its factory repair center 1 800 438 7677 inside the U S or 706 356 3708 outside the U S However if you choose to service this valve yourself it is strongly recommended that you obtain a free service manual from your local ROSS distributor Distributor information as well as downloadable service manuals are available at www rosscontrols com Valve Model Valve Body Valve to Base Listed below and in the chart at the right are the parts and Number Service Kit Gasket service kits most likely to be needed if your valve requires 8076B3331 1244K77 637B11 service 8076B3332 1247K77 637B11 Valve Body Service Kits These kits listed in the chart at the charg P a i right contain all parts needed for a complete reconditioning 8076B3351 1244K77 637B11 of a valve body Included are a spool and sleeve assembly all 8076B3352 12
10. F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components potentially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the
11. Form SS297 H S R Valve Thank You You have purchased a premium quality ROSS pneumatic valve It is called an HSR valve and is designed to be used in a two hand control system With care in its installation and maintenance you can expect the HSR valve to have a long and reliable service life So before you go any further please take a few minutes to look over the information in this folder Then save it for future reference and for the useful service information it contains The outlet port 2 in the diagram at the right is connected to the equipment to be controlled by the two hand system The inlet ports 1A and 1B are each connected to a 3 2 normally closed hand valve To produce an output signal at port 2 both hand valves must be actuated at the same time Otherwise port 2 will remain closed The HSR valve is designed to produce an output signal only when the two input signals are applied within approximately 0 5 second of one another and the output volume does not exceed 30 cubic inches CAUTION An HSR valve can be used as a part of an anti repeat control see page 3 butis nota single stroke mechanism as defined by OSHA An HSR valve should not be used to initiate an automatic cycle which cannot be interrupted by the operator s release of the hand valves However if the application calls for such use the system designer must provide clear instructions and warnings to the operator as well as barrier guards to prevent
12. P3 to determine if there is a leak Step 8 Exhaust the part under test by deactivating the isolation solenoid Flow Test Follow steps1 through 4 from above Step 5 Monitor flow from port P2 to port P3 P2 connected to flow sensor inlet P3 connected to flow sensor outlet Step 6 Close the inlet pressure by deactivating the fill solenoid Step 7 Exhaust the part under test by deactivating the isolation and exhaust solenoids Differential Pressure Test Follow steps 1 through 5 from above Step 6 Monitor the difference in pressure between ports P2 and P3 P2 reflects test part press P3 reflects ref volume press Step 7 Exhaust the part under test and the reference volume by deactivating the isolation and exhaust solenoids Applications e Pressure Decay Test P1 Blocked P2 Blocked P3 Pressure Sensor Port e Flow Test P1 Blocked P2 Flow Sensor Inlet Port P3 Flow Sensor Outlet Port e Differential Pressure Test P1 Reference Volume Fill Port P2 Pressure Sensor Port 1 P3 Pressure Sensor Port 2 4 4 amp 5 4 Manifolds The 4 4 and 5 4 LT series manifolds provide a complete pneumatic control for applications requiring two supply lines Benefits include high flow zero isolation leakage and elimination of tubing The manifold can be configured for flow tests pressure decay tests and differential pressure tests The manifold consists of four internal hi
13. Permissible voltage range is Solenoids Two rated for continuous duty Voltage and hertz ratings shown on pilot housing Power Consumption Each solenoid Size 4 30 VA inrush 16 VA holding on AC 11 watts on DC Sizes 8 12 30 87 VA inrush 30 VA holding on AC 14 watts on DC Temperature Range Ambient 40 to 120 F 4 to 50 C Media 40 to 175 F 4 to 80 C Flow Media Filtered air 5 micron recommended Inlet Pressure Size 4 30 to 100 psig 2 to 7 bar Sizes 8 12 30 30 to 125 psig 2 to 8 5 bar Pilot Pressure Supplied internally from inlet port marked on the solenoid housing L G MONITOR Reset pressure requirements Size 4 At least 30 psig 2 bar Sizes 8 12 30 At least 60 psig 4 bar D S MONITOR Use voltage andhertzasshownonD S monitor label Power supply must be independent and continuous IMPORTANT NOTE Please read carefully and thoroughly all the WARNINGS on page 1 and the CAUTIONS on page 4 VALVE SERVICE ROSS would be happy to service this specialized valve for you at its factory repair center 1 800 GET ROSS However if you choose to service this valve yourself it is strongly recommended that you obtain its free service manual from ROSS in the U S A at 1 800 GET ROSS Listed below are kits for servicing double valves They contain the parts required to recondition pilots and valve bodies Service kits for monitors are also available consult ROSS
14. SAE Series 500 Model 8476B4331 for example is an SAE Series 250 valve Pressure Controlled Temperature Range 40 to 175 F 4 to 80 C Flow Media Filtered air 5 micron recommended Inlet Pressure 30 to 150 psig 2 to 10 bar Pilot Pressure Must be equal to or greater than inlet pressure Solenoid Pilot Solenoids Rated for continuous duty 115 volts 60 Hz Power Consumption SAE 125 and 250 models 8 VA inrush 6 VA holding SAE 500 models 87 VA inrush 30 VA holding Temperature Range Ambient 40 to 120 F 4 to 50 C Media 40 to175 F 4 to 80 C Flow Media Filtered air 5 micron recommended Inlet Pressure 30 to 150 psig 2 to 10 bar Pilot Pressure Must be equal to or greater than inlet pressure 2 ROSS CONTROLS Typical cross section of a ROSS Series 84 poppet valve body Internal pressure return model shown VALVE SERVICE ROSS would be happy to service this specialized valve for you at its factory repair center 1 800 GET ROSS However if you choose to service this valve yourself it is strongly recommended that you obtain its free service manual from ROSS in the U S A at 1 800 GET ROSS Listed below and in the chart at the right are the parts and service kits most likely to be needed if your valve Valve Model Valve Body Gasket Valve to Base requires service Numb
15. Svs 800 GET ROSS web site www rosscontrols com ROSS EUROPA GmbH Germany TEL 49 6103 7597 0 web site www rosseuropa com ROSS ASIA K K Japan TEL 81 427 78 7251 web site www rossasia co jp ROSS UK Ltd United Kingdom TEL 44 121 559 4900 email sales rossuk co uk ROSS SOUTH AMERICA Ltda Brazil TEL 55 11 4335 2200 email vendas ross sulamerica com br ROSS CONTROLS INDIA Pvt Ltd India TEL 91 44 2624 9040 email rossindia airtelbroadband in ROSS CONTROLS CHINA Ltd China TEL 86 21 6915 7951 email alvinzhurong vip 163 com DIMAFLUID s a s France TEL 33 01 49 45 65 65 web site www dimafluid com VALVE MAINTENANCE Pneumatic equipment should be installed only by persons trained and experienced in such installation Supply Clean Air Foreign material lodging in valves is a major cause of breakdowns The use of a ROSS 5 micron rated air filter is strongly recommended Install the filter upstream of and as close as possible to the directional valve that supplies air to the flow control or check valve The filter bowl should be drained regularly and if the filter s location makes draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A ROSS lubricator should put atomized oil into the air line in direct proportion to the rate of air flow Excessive air line lubrication can cause puddling in valves and lead to malfunctions For most applications an oil flow rate in t
16. United States TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS web site www rosscontrols com ROSS EUROPA GmbH Germany TEL 49 6103 7597 0 web site www rosseuropa com ROSS ASIA K K Japan TEL 81 427 78 7251 web site www rossasia co jp ROSS UK Ltd United Kingdom TEL 44 121 559 4900 email sales rossuk co uk ROSS SOUTH AMERICA Ltda Brazil TEL 55 11 4335 2200 email vendas ross sulamerica com br ROSS CONTROLS INDIA Pvt Ltd India TEL 91 44 2624 9040 email rossindia airtelbroadband in ROSS CONTROLS CHINA Ltd China TEL 86 21 6915 7951 email alvinzhurong vip 163 com DIMAFLUID s a s France TEL 33 01 49 45 65 65 web site www dimafluid com VALVE OPERATION Normal Operation After installation the valve is operated by pressurizing both pilot supply ports S1 and S2 simultaneously This causes both main valve elements to be actuated so that air from inlet port 1 flows to outlet port 4 but not to port 2 Air downstream of port 2 is exhausted through port 3 When the pilot supply ports are de pressurized both valve elements are de actuated and air then flows from inlet port 1 to outlet port 2 but no longer to outlet port 4 Air downstream of port 4 is exhausted through port 5 Safety Function If the two main valve elements are not actuated or de actuated synchronously within 500 milliseconds the valve defaults so that outlet port 2 receives full inlet pressure and outlet port 4 is exhau
17. after preset delay valve is actuated Solenoid de energized after preset delay valve is de actuated NOTE Upper stem assembly is for timed in control lower stem assembly is for timed out control Description Adaptor Number Dual Timed Adaptor 996K87 Timed In Adaptor 490B93 Timed Out Adaptor 489B93 CONVERSION TO EXTERNAL PILOT SUPPLY When a valve is converted to external pilot supply consult ROSS for the converted valve s model number This will allow records and drawings to be changed and prevent errors when ordering future replacements INLINE POPPET VALVES See Figure 1 1 Remove pilot section and adaptor plate from valve body 2 Remove pipe plug from external pilot supply port and reinstall the plug in the internal pilot supply passage 3 Replace adaptor plate and pilot section 4 Attach 1 8 pilot supply line to external pilot supply port X 1 5 External pilot supply pressure must be at least equal to the main supply pressure PILOT EXTERNAL EXHAUST PILOT PORT SUPPLY PORT ADAPTOR a KA PLATE INTERNAL gt PILOT PASSAGE Figure 1 ROSS CONTROLS 4 SERIES 27 VALVE BODIES p 2 2 Normally Closed 3 2 Normally Closed 3 2 Normally Open 4 2 VALVE SERVICE ROSS would be happy to service this valve for you at
18. and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components potentially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically co
19. as close as possible to the mechanism The lines must be of adequate size and be free of crimps and sharp bends Valve Exhaust Port 3 Do not restrict the air flow from the exhaust port as this can adversely affect the operation of the valve The valves are factory equipped with a properly sized silencer ROSS MUFFL AIR silencers reduce impact noise by as much as 25 dB and produce little back pressure Reset Port RESET If your valve is not equipped with a reset solenoid on the valve then the RESET port should be supplied externally from a 3 2 normally closed valve The lines must be of adequate size and be free of crimps and sharp bends Reset signals must be momentary Electrical Supply DM Series S double valves get electrical power through plug in connectors The electrical supply must correspond to the voltage and hertz ratings of the solenoids Otherwise the solenoids are subject to early failure If power is supplied by a transformer it must be capable of handling the inrush current without significant voltage drop See Standard Specifications on page 3 for inrush current data Operating Pressures and Temperatures Allowable ranges for pressure and temperatures are given in the Standard Specifications on page 3 Exceeding these values can adversely affect performance and shorten valve life ROSS CONTROLS United States TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS Pipe Installation To install pipe in base ports
20. engage pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating the valve To install pipe with parallel threads e g SAE ISO 228 G etc do not use sealant After installing pipe into the base ports use compressed air to blow any debris out of the piping then install the valve onto the base Test After installation or repair and prior to normal use the internal lockout feature of the DM Series S valve must be tested for proper functioning Observe normal press operation safety precautions during these tests to avoid personal injury or damage to equipment Note Reset may need to be performed prior to beginning the test procedure Also both pilot solenoids must be de energized prior to reset and must remain de energized until after the reset signal is removed A Electrically energize both pilot solenoids simultaneously then de energize one pilot solenoid This should result in a valve lock out and prevent the valve from operating B Energize both solenoids and the valve should remain in the lockout condition C De energize both pilot solenoids and reset the valve D Electrically energize both pilot solenoids simultaneously again De energize the other pilot solenoid this time Again this should result in a lockout E Energize both pilot solenoids The valve should remain in a lockout condition F De energize both pilot solenoids and t
21. so that there is then sufficient force to shift the valve properly Adaptor Number Body Size Description 3 8 3 4 1 For 2 way valve 168A86 168A86 169A86 For 3 way valve 168A86 168A86 169A86 For 4 way valve 170A86 171A86 172A86 HSR ADAPTOR HSR Adaptor The HSR valve has two inlet ports To produce an output signal two separate but equal input pressure signals must be applied within approximately 0 5 seconds of one another If this allowable time delay is exceeded the HSR valve will shift and prevent any output signal If signalled to actuate within the allowable time delay the HSR valve will shift and pressurize outlet port 2 The output signal will be exhausted if 1 either input signal is removed or 2 the pressure of the output signal is reduced by 25 or more The HSR valve will reset itself when both input signals are removed Coupled to an inline valve body it gives two hand control over a larger volume of outlet air NOTE HSR adaptors are not field serviceable Ifthe assemblies require service they should be replaced or returned to ROSS for rebuilding TIMED SEQUENCE ADAPTORS Dual Timed Adaptor Timed Out Adaptor Timed In Solenoid energized after preset delay valve is actuated Solenoid de energized valve immediately de actuated Timed Out Solenoid energized valve immediately actuated Solenoid de energized after preset delay valve is de actuated Dual Timed Solenoid energized
22. with HSR Pilot PORT SIZES 3 WAY NORMALLY CLOSED VALVES 4 WAY VALVES In Out Exhaust Average Cv Model Number Average Cy Model Number 1 4 1 2 2 8 2753A2006 2 5 2756A2006 3 8 1 2 4 0 2753A3006 3 6 2756A3006 1 2 1 2 3 8 2753A4016 3 7 2756A4016 1 2 1 10 0 2753A4006 9 0 2756A4006 3 4 1 12 0 2753A5006 11 0 2756A5006 1 1 14 0 2753A6016 13 0 2756A6016 1 1 29 2753A6006 23 2756A6006 1 1 31 2753A7006 24 2756A7006 1 1 31 2753A8016 25 2756A8016 www rosscontrols com STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used
23. wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and L O X with EEZ ON operation products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED AB
24. 1242B79 874B11 W6376B1401 1584K77 1242B79 874B11 W6376A1407 1585K77 1242B79 874B11 W6376B1407 1585K77 1242B79 874B11 W6376B2401 1641K77 306K33 617B11 W6376B2403 1641K77 306K33 617B11 W6376B2411 1641K77 306K33 617B11 W6376B2407 1644K77 306K33 617B11 W6376B3401 1642K77 306K33 618B11 W6376B3407 1645K77 306K33 618B11 W6376B4401 1643K77 306K33 619B11 W6376B4411 1643K77 306K33 619B11 W6376B4407 1646K77 306K33 619B11 W6377A1401 1647K77 1242B79 874B11 W6377B1401 1647K77 1242B79 874B11 W6377A1407 1649K77 1242B79 874B11 W6377B1407 1649K77 1242B79 874B11 W6377B2401 1648K77 306K33 617B11 W6377B2407 1650K77 306K33 617B11 W6377B3401 1281K77 306K33 618B11 W6377C3401 2125K77 306K33 618B11 W6377B3407 1492K77 306K33 618B11 W6377C3407 2126K77 306K33 618B11 W6377B4401 1478K77 306K33 619B11 W6377B4407 1490K77 306K33 619B11 www rosscontrols com 3 STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment must
25. 2 For faster pressurizing and exhausting of the mechanism being operated by the valve locate the valve as close as possible to the mechanism The lines must be of adequate size and be free of crimps and sharp bends Valve Exhaust Port 3 Do not restrict air flow from the exhaust port as this can adversely affect valve operation Pilot Solenoid Electrical Supply Size 4 valves get electrical power through plug in connectors All larger valves have an internal terminal strip which must be connected according to the circuit diagram accompanying the valve In either case the electrical supply must correspond to the voltage and hertz ratings of the solenoids Otherwise the solenoids are subject to early ROSS CONTROLS United States TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS failure If power is supplied by a transformer it must be capable of handling the inrush current without significant voltage drop See Valve Specifications for inrush current data Operating Pressures andTemperatures Allowable ranges for pressure and temperature are given in the Valve Specifications on page 3 Exceeding the values shown can adversely affect performance and shorten valve life Pipe Installation To install pipe in valve ports engage pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating the valve Monitor Connect the wiring according to
26. 2 Normally Closed Pin G Not used Pin 4 Normally Open VALVE MAINTENANCE Pneumatic equipment should be maintained only by persons trained and experienced in the maintenance of such equipment Supply Clean Air Foreign material lodging in valves is a major cause of breakdowns The use of a 5 micron rated air filter located close to the valve is strongly recommended The filter bowl should be drained regularly and if its location makes draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should put a fine oil mist into the air line in direct proportion to the rate of air flow Excessive lubrication can cause puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute is adequate Note that the double valve itself does not require air line lubrication Compatible Lubricants Although this valve does not require air line lubrication it may be used with lubricated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components and so cause the valve to malfunction Avoid oils with anti wear or phosphate additives e g zinc dithiophosphate and diester oils these substances can harm valve components The best oils to use are generally petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO
27. 277804904 1086C7916 322K3316 2778C5900 851C79 306K33 2778C5901 976C79 316K33 2778C5902 976C7916 316K3316 2778C5904 1086C7916 322K3316 2778A6900 851C79 306K33 2778A6901 976C79 316K33 2778A6902 976C7916 316K3316 2778A6904 1086C7916 322K3316 Specify the required voltage and hertz when ordering If you need additional information or have any questions about installing or servicing your valve call ROSS Technical Services in the U S A at 1 888 TEK ROSS 835 7677 or 1 706 356 3708 Valve Port Valve Valve Body Blow Down Model Size Type __ Kit Number _Kit Number 2751A2903 1 4 B 1671K77 2751A2908 1 4 A 1267K77 2751A3901 3 8 B 1671K77 2751A3908 3 8 A 1267K77 2751A3922 3 8 F 1952H77 D2751A3922 G 3 8 F 1952H77 2751A4902 1 2 B 1671K77 2751A4905 1 2 B 1679K77 2751A4915 1 2 A 1267K77 2751A4922 1 2 F 1952H77 D2751A4922 G 1 2 F 1952H77 2751A5903 3 4 B 1679K77 2751A5917 3 4 F 1953H77 2751A6901 1 B 1679K77 2751B6904 1 B 1678K77 2751B7901 1 B 1678K77 2751B8902 1 B 1678K77 2768C3900 3 8 1263K77 2768C3901 3 8 D 1263K77 404H77 2768C3904 3 8 D 1263K77 1704H77 2768C4900 1 2 1535H77 2768C4901 1 2 D 1535H77 404H77 2768C4904 1 2 D 1535H77 1704H77 2768C5900 3 4 C 1264K77 2768C5901 3 4 D 1264K77 404H77 2768C5904 3 4 D 1264K77 1704H77 2768A6900 1 Cc 1264K77 2768A6901 1 D 1264K77 404H77 2768A6904 1 D 1264K77 1704H77 2778C3900 3 8 E 1263K77 404H77 2778C3901 3 8 E 1263K77 404H77 2778C
28. 4 inch control line to the threaded port in the air cap at the top of the valve See Valve Specifications on page 2 for required pressures Solenoid Control Pressure for the pilot valve is supplied internally for most valves and requires no special connection However if your valve is designated for external pilot supply a 1 8 inch pilot supply line must be connected to port X 1 in the pilot housing See Valve specifications on page 2 for pressure requirements Pipe Installation To install pipe in valve ports engage pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating the valve ROSS CONTROLS United States TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS web site www rosscontrols com ROSS EUROPA GmbH Germany TEL 49 6103 7597 0 web site www rosseuropa com ROSS ASIA K K Japan TEL 81 427 78 7251 web site www rossasia co jp ROSS UK Ltd United Kingdom TEL 44 121 559 4900 email sales rossuk co uk ROSS SOUTH AMERICA Ltda Brazil TEL 55 11 4335 2200 email vendas ross sulamerica com br ROSS CONTROLS INDIA Pvt Ltd India TEL 91 44 2624 9040 email rossindia airtelbroadband in ROSS CONTROLS CHINA Ltd China TEL 86 21 6915 7951 email alvinzhurong vip 163 com DIMAFLUID s a s France TEL 33 01 49 45 65 65 web site www dimafluid com VALVE MAINTENANCE Pneumati
29. 549B11 349B04 W7016C4331 W742K87 W769A87 958B11 349B04 W7016C4332 W743K87 W769A87 958B11 349B04 W7017A2331 1059K77 553B11 171095 W7017A2332 275K87 553B11 171C95 W7017A3331 279K87 305A87 549B11 349B04 W7017A3332 282K87 305A87 549B11 349B04 W7017C4331 W744K87 W769A87 958B11 349B04 W7017C4332 W745K87 W769A87 958B11 349B04 W7056A2331 708K77 553B11 W7056A2332 553B11 W7056A3331 276K87 305A87 549B11 W7056A3332 277K77 305A87 549B11 W7056B4331 W742K87 W769A87 356B11 W7056B4332 W743K87 W769A87 356B11 W7056A6331 W746K87 W770A87 344B11 W7056A6332 W747K87 W770A87 344B11 W7056A8331 W750K87 W771A87 339C11 W7056A8332 W751K87 W771A87 339C11 EEE W7057A2331 553B11 W7057A2332 275K87 553B11 W7057A3331 279K87 305A87 549B11 _ W7057A3332 282K87 305A87 549B11 W7057B4331 W787K87 W769A87 958B11 W7057B4332 W788K87 W769A87 958B11 W7057A6331 W748K87 W770A87 344B11 W7057A6332 W749K87 W770A87 344B11 W7057A8331 W752K87 W771A87 339011 W7057A8332 W753K87 W771A87 339C11 W7076A2331 708K77 553B11 304B33 W7076A2332 709K77 553B11 304B33 W7076A3331 276K87 305A87 549B11 347B04 W7076A3332 277K87 305A87 549B11 347B04 W7076D4331 W742K87 W769A87 958B11 411B04 W7076D4332 W743K87 W769A87 958B11 411B04 W7076C6331 W746K87 W770A87 344B11 411B04 W7076C6332 W747K87 W770A87 344B11 411B04 W7076C8331 W750K87 W771A87 339011 411B04 W7076C8332 W751K87 W771A87 339011 411B04 W7077A2331 553B11 304B33 W7077A2332 2
30. 936K87 Z cord not included For additional wiring kit accessories please see Form NPS011 available at www rosscontrols com VALVE SERVICE ROSS would be happy to service this specialized double valve for you at its factory repair center Call your local distributor or in the U S 1 800 GET ROSS 706 356 3708 outside the U S for information If you service the valve yourself be sure to turn off electrical power to the valve shut off the air supply exhaust the air in the system and lock out all power sources before beginning any disassembly operation Listed below are kits for servicing DM Series E double valves as well as replacement solenoid information CAUTION Before operating the DM Series E double valve be sure to complete the Test Procedure on page 1 upon installation and after any maintenance is performed on the valve Failure to do so could result in personal injury or equipment damage Valve Body Service Kit This kit is used for complete reconditioning of a valve body and includes poppets spindles gaskets seals and instructions Order kit number 2277K77 Gasket and Seal Kit This kit is used when valve bodies are disassembled for cleaning and includes all the necessary gaskets O rings and other seals Order kit number 2278K77 Status Indicator Assembly Service Kit This kit is used for complete reconditioning of the status indicator assembly Pressure switch and connector sold separately see
31. All Rights Reserved Form SS123 Series 21 Valves Thank You You have purchased a premium quality ROSS pneumatic valve Itis a poppetvalve with metal internals designed for inline mounting and has been built to the highest standards With care in its installation and maintenance you can expect it to have a long and economical service life So before you go any further please take a few minutes to look over the information in this folder Then save it for future reference and for the useful service information it contains A general service manual with more detailed information is available from ROSS upon request Remote Pressure Controlled Valve e E ie Single Solenoid Pilot Valve Double Solenoid Pilot Valve VALVE INSTALLATION Important Note ROSS Series 21 valves are not designed as control valves for air clutch brake mechanisms on mechanical power presses and must not be installed for such use Only double valves conforming to OSHA standards should be used in such applications Pneumatic equipment should be installed only by persons trained and experienced in such installation High and Low Temperature Valves Temperature specifications are given on page 2 Valves non special whose model numbers end with a 001 011 051 or 061 are Type H valves designed for high temperature service Valves non special whose model numbers end with a 002 003 012 013 052 053 062 or 063 are Type O valve
32. CONTROLS CHINA Ltd China TEL 86 21 6915 7951 email alvinzhurong vip 163 com DIMAFLUID s a s France TEL 33 01 49 45 65 65 web site www dimafluid com VALVE MAINTENANCE Pneumatic equipment should be maintained only by persons trained and experienced in the maintenance of such equipment Supply Clean Air Foreign material lodging in valves is a major cause of breakdowns The use of a 5 micron rated air filter located as close to the valve as possible is strongly recommended The filter bowl should be drained regularly If the filter s location makes manual draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should put atomized oil into the air line in direct proportion to the rate of air flow Excessive air line lubrication can cause puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute of air flow is adequate Note that your ROSS valve does not itself require air line lubrication See next column for a partial list of lubricants that are compatible with ROSS valves and are suitable for use in compressed air systems Compatible Lubricants Although this valve does not require air line lubrication it may be used with lubricated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components and thereby cause the valve to malfu
33. DM Series E valves include a memory function and once locked out must be reset by a dedicated reset function in order to operate further The DM Series E valve cannot be reset simply by removing electrical power from both pilot solenoids and or turning off supply air pressure Therefore it may be necessary to perform a reset on the valve prior to normal operation In order to reset the valve make sure that supply pressure is present and both pilot solenoids are de energized and then momentarily energize the reset solenoid for at least 200 milliseconds The overall function of the DM Series E valve is that of a 3 way 2 position 3 2 normally closed solenoid valve When in the normal at rest condition the valve inlet port 1 is closed and the outlet port 2 is open to the exhaust port 3 Normal actuation of the valve opens the valve inlet port 1 to the outlet port 2 and closes the exhaust port 3 De actuation returns the valve to the normal at rest condition However being a double valve there are two solenoid pilots and two sets of valve elements for redundancy That being the case both solenoids must be energized simultaneously in order for the valve to actuate normally to supply air from inlet to outlet Likewise both solenoids should be de energized simultaneously in order to de actuate and return the valve to its normal at rest condition thus shutting off the inlet and dumping downstream air to exhaust If one of the valv
34. FOR A PARTICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the U S A Rev 05 09 2009 ROSS CONTROLS All Rights Reserved Form SS096 Series 31 and 36 Valves Thank You You have purchased a premium quality ROSS pneumatic valve It is a hand or foot operated poppet valve built to the highest standards With care in its installation and maintenance you can expect it to have a long and economical service life So before you go any further please take a few minutes to look over the information in this folder Then save it for future reference and for the useful service information it contains VALVE INSTALLATION Pneumatic equipment should be installed only by persons trained and experienced in such installation Air Lines Before installing a valve in a new or an existing system the air lines must be blown clean of all contaminants It is recommended that an air filter be installed in the inlet line close to the valve Valve Inlet Port 1 Be sure that the supply line is
35. Japan TEL 81 427 78 7251 web site www rossasia co jp ROSS UK Ltd United Kingdom TEL 44 121 559 4900 email sales rossuk co uk ROSS SOUTH AMERICA Ltda Brazil TEL 55 11 4335 2200 email vendas ross sulamerica com br ROSS CONTROLS INDIA Pvt Ltd India TEL 91 44 2624 9040 email rossindia airtelbroadband in ROSS CONTROLS CHINA Ltd China TEL 86 21 6915 7951 email alvinzhurong vip 163 com DIMAFLUID s a s France TEL 33 01 49 45 65 65 web site www dimafluid com VALVE MAINTENANCE Supply Clean Air Foreign material lodging in valves is a major cause of breakdowns The use of a 5 micron rated air filter located as close to the valve as possible is strongly recommended The filter bowl should be drained regularly If the filter s location makes manual draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should put atomized oil into the air line in direct proportion to the rate of air flow Excessive air line lubrication can cause puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute of air flow is adequate Compatible Lubricants This valve may be used with lubricated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components and thereby cause the valve to malfunction The best oils to use are those specif
36. LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakage and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components potentially leading to valve failure and or human injury AVOID IN
37. Oil Contamination If dirt contaminates the HSR valve because of inadequate or ineffective air filtration the valve must be replaced or returned to ROSS for cleaning Field disassembly of the HSR valve is not recommended If you have any questions about installing or servicing your valve callROSS Technical Services at your nearest ROSS location see page 1 or in the U S A at 1 888 TEK ROSS or 1 706 356 3708 VALVE SPECIFICATIONS IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 Temperature Range 40 to 175 F 4 to 80 C Flow Media Filtered air 5 micron recommended Input Signals 30 to 125 psig 2 to 8 5 bar Both signals must be of the same pressure and must be applied within 0 5 second of one another in order to produce an outlet signal Port Markings on HSR Valve Inlet ports 1A and 1B are on the sides of the valve and are both marked IN The outlet port is on the top of the valve and is marked OUT 2 ROSS CONTROLS ANTI REPEAT TWO HAND CONTROL An HSR valve can be used in a circuit designed for anti repeat two hand control i e a circuit in which actuation of the two hand valves causes the machine to go through one and only one work cycle An example of such a circuit is shown atthe right and consists of two hand valves an HSR valve and a dump valve The remainder of the circuit must be designed so that loss of the HSR outlet air prev
38. Plus Electrical Contacts In the electrical circuits associated with the valve solenoids keep all switches or relay contacts in good condition to avoid solenoid malfunctions Replace Worn Components In most cases it is not necessary to remove the valve from its installation for servicing However turn off the electrical power to the valve shut off the air supply exhaust the air in the system and lockout before beginning any disassembly operation Service kits are listed on page 3 2 ROSS CONTROLS STANDARD SPECIFICATIONS Solenoids According to VDE 0580 Enclosure rating according to DIN 400 50 IP 65 Connector socket according to DIN 43650 Form A Two solenoids rated for continuous duty three with solenoid reset option Standard Voltages 110 volts 50 60 Hz 220 volts 50 60 Hz 24 volts DC Pilot Solenoids Power Consumption each solenoid Sizes 4 12 amp 30 6 0 watts on DC 15 8 VA inrush and 10 4 VA holding on AC Size 8 15 watts on DC 36 VA inrush and 24 6 VA holding on AC Reset Solenoid Power Consumption 6 0 watts on DC 15 8 VA inrush and 10 4 VA holding on AC Ambient Temperature 15 to 120 F 10 to 50 C Media Temperature 40 to 175 F 4 to 80 C Flow Media Filtered 5 micron recommended lubricated or unlubricated air mineral oils according to DIN 51519 viscosity classes 32 46 Inlet Pressure 30 to 115 psig 2 to 8 bar Reset Pressure For remote reset option equal to
39. Pressure 50 to145 psi 3 4 to 10 bar Must be equal to or greater than inlet pressure Inlet Pressure 2 to145 psi 0 13 to 10 bar Port Threads NPT standard BSPP VALVE SERVICE ROSS would be happy to service this valve for you at its factory repair center 1 800 GET ROSS However if you choose to service this valve yourself it is strongly recommended that you obtain a free service manual from ROSS in the U S A at 1 800 GET ROSS If you have any questions about installing or servicing your valve call ROSS Technical Services at your nearest ROSS location see page 1 or in the U S A at 1 888 TEK ROSS or 1 706 356 3708 www rosscontrols com 3 STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power syst
40. Size 4 12 30 306K33 306K33 Size gulee 360K33 306K33 Complete Solenoid Pilot Assemblies Available for sizes 4 and 8 these assemblies consist of new pilot valve mechanisms and a new solenoid coil ready to bolt in position on the valve Specify voltage and hertz when ordering Pilot solenoids Reset solenoid Size i 1403H79 0 851079 Size 8B 1404H79 0 00 851079 Sizes 12 amp 30 1391K79 851079 Pilot Booster Service Kits Available for sizes 12 and 30 these kits contain all parts needed for complete reconditioning of a pilot booster Included are poppets gaskets seals and instructions for use Size 12 amp 30 ccc eee 2106K77 IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 www rosscontrols com 3 STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment must
41. VALVE SPECIFICATIONS Solenoids Two rated for continuous duty Voltage and hertz ratings shown on solenoid coil Size 1 Power Consumption Each solenoid 12 VA inrush 9 8 VA max holding on 50 or 60 hertz 7 5 watts max on DC Size 2 Power Consumption Each solenoid 11 VA inrush 8 5 VA max holding on 50 or 60 hertz 6 0 watts max on DC Electrical Connections Must be purchased separately see charts at the right Cord grip connector at each solenoid Temperature Range Ambient 40 to 120 F 4 to 50 C Media 40 to 175 F 4 to 80 C Flow Media Filtered air 5 micron recommended Inlet Pressure 40 to 100 psig 2 8 to 7 bar IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 Size 1 Part Numbers of Electrical Connectors Without With Connector Type Light Light For use with dropcord 266K77 267K77 cord not included Wired with 10 mm cord 372K77 382K77 cord exits upward Specify solenoid voltage Size 2 Part Numbers of Electrical Connectors Without With Connector Type Light Light For use with dropcord 937K87 936K87 Cord not included Wired with 6 mm cord 721K77 720K77 Wired with 10 mm cord 371K77 383K77 For use with threaded conduit 723K77 724K77 Specify solenoid voltage VALVE SERVICE ROSS would be happy to service this specialized double valve for you at its factory repair center Call your loc
42. Valve Body Service Kits These kits contain all parts needed for complete reconditioning of a valve body Included are poppets spindles gaskets seals and instructions for use See chart below for kit numbers Gasket and Seal Kits These kits are needed when valve bodies are disassembled for cleaning They include all necessary gaskets O rings other seals and lubricants These parts are included in the Valve Body Service Kits above See chart below for kit numbers Solenoid Pilot Kit This kit contains all parts needed to recondition one pilot valve of size 8 12 and 30 double valves Order kit number 946K87 Each valve has two pilots therefore two kits required for each valve Solenoids Order replacement pilot solenoids by the following part number 411B04 specify voltage and hertz See chart below for replacement E P Reset Solenoid number specify voltage and hertz Valve Port Valve Body Gasket E P Monitor L G Monitor Lockout E P Reset Size Sizes Service Kit Seal Kit Service Kit Service Kit Kit L G Solenoid 8 1 2 3 4 1 2071K77 2072K77 2079H77 2078H77 2202H77 2069K77 12 3 4 1 1 1 4 2073K77 2074K77 2079H77 2078H77 2202H77 2069K77 30 1 1 4 1 1 2 2075K77 2076K77 2079H77 2078H77 2202H77 2069K77 www rosscontrols com 3 STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted a
43. a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components potentially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitorin
44. air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakage and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components potentially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure
45. and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the even
46. and sleeve assembly Do not use a chlorinated solvent or abrasive materials which can damage seals or do permanent damage to metal parts COMPATIBLE LUBRICANTS Brand Name American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Pacemaker 32 Spinesstic 22 Teresstic 32 Velocite 10 Turbo T32 Sunvis 11 Sunvis 722 Regal R amp O 32 Union Turbine Oil To reassemble the spool and sleeve put one drop of Anderol 735 or equivalent lubricant on each spool land Insert the spool into the sleeve and rotate it several times to ensure even distribution of the lubricant If the valve is used in a non lubricated application do not use a lubricant for reassembly which can dry out and leave a residue Dry assembly of the spool and sleeve is preferable Each spool and sleeve is a matched set so care must be taken not to reverse the position of the spool in the sleeve Before inserting the spool and sleeve into the valve body very lightly lubricate the O rings with a lubricant such as MobilGrease 28 Do not use Anderol it causes the O rings to deteriorate Electrical Contacts In the electrical circuits associated with the valve solenoids keep all switches or relay contacts in good condition to avoid solenoid malfunctions Replace Worn Components After long usage the spool and sleeve may show signs of wear The valve can be completely reconditioned with the use of ROSS service kits See page 3 for information about such kits VA
47. as well as other product information is available at www rosscontrols com Complete Solenoid Pilot Assemblies These assemblies consist of a new pilot valve mechanism and a new solenoid coil ready to bolt in position on the valve Order replacement solenoid pilot assemblies by the following part numbers Specify voltage and hertz when ordering For standard wattage pilots no override 1044H79 For low wattage pilots with override 1296G79 Solenoid Coils Order replacement solenoid coils by the following part numbers Specify voltage and hertz when ordering 306K33 315K33 For standard wattage For low wattage www rosscontrols com Valve Body Service Kits These kits contain all parts needed for complete reconditioning of a valve body Included are ball poppets pistons all required gaskets and seals and instructions for use 3 2 Primary Valves 1817H77 Pressure Select Valves 1818H77 2 2 Normally Closed Valves 1870H77 2 2 Normally Open Valves 1869H77 If you have any questions about installing or servicing your valve callROSS Technical Services at your nearest ROSS location see page 1 or in the U S A at 1 888 TEK ROSS or 1 706 356 3708 STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA
48. at right Order kit number 2151H77 If you have any questions about installing or servicing your valve call ROSS Technical Services at your nearest ROSS location or in the U S A at 1 888 TEK ROSS or 1 706 356 3708 Replacement Pressure Switch and Connector This kit is used to replace the pressure switch and electrical connector of the status indicator assembly Order kit number 1104A30 Solenoid Coils Order replacement solenoid coils by the following part numbers 306K33165 for 24 volts DC 306K33165 for 110 volts AC Complete Solenoid Pilot and Solenoid Reset Assemblies Order replacement solenoid assemblies by the following part numbers 851079165 for 24 volts DC 851079166 for 110 volts AC IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 www rosscontrols com 3 STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipmen
49. be exhausted Operation Actuation of the solenoid will allow air to flow from the INLET port to the TEST and P1 ports Applications e Isolation Valve P1 Gauge or Pressure Sensor Port e Bypass Pre fill P1 Blocked or Gauge Port 3 3 Manifold The 3 3 LT series manifold was designed for pressure decay tests or by pass fill applications currently using 2 way valves Benefits include high flow zero isolation leakage and elimination of tubing Using the manifold with standard industry leak test units allows the user to rapidly pre fill isolate and exhaust the unit under test improving cycle times while still enjoying the benefits of a benchtop leak test unit The manifold consists of two internal high flow poppets which are actuated by two external solenoids The first solenoid controls the supply pressure and the isolation functions while the second solenoid controls the exhaust The manifold s pressure range is from 2 to145 psi and has a Cv of 2 2 making it ideal for improving test times The supply pressure poppet is normally closed and the exhaust poppet is normally open Therefore if power is lost or if a safety stop has cut power the supply pressure will be closed and the unit under test will be evacuated Pilot Pressure Pilot pressure must be maintained at all times and must be equal to or greater than the inlet pressure to prevent valve failure To prevent loss of pilot pressure it is strongly recommended to
50. be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter
51. by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the U S A Rev 05 09 2009 ROSS CONTROLS All Rights Reserved Form SS150 Series 80 Valves ROSS Thank You You have purchased a premium quality ROSS pneumatic valve It is a stainl
52. by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and L O X with EEZ ON operation products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tamper
53. can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and L O X with EEZ ON operation products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limit
54. care of equipment must check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible conditi
55. check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakage
56. combustible condition hazardous leakage and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components potentially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazard
57. completely and save it for future reference pA Ww VALVE INSTALLATION Pneumatic equipment should be installed only by persons trained and experienced in such installation Air Lines Before installing this valve in a new or existing system the air lines must be blown clean of all contaminants It is recommended that a 5 micron rated air filter be installed in the inlet line close to the valve Valve Inlet Port 1 Be sure that the supply line is of adequate size and does not restrict the air supply because of a crimp in the line a sharp bend or a clogged filter element The air supply must not only provide sufficient pressure see Valve Specifications page 3 but must also provide an adequate flow of airon demand Otherwise the valve elements will be momentarily starved for air and the valve may fail to operate Valve Outlet Port 2 For faster pressurizing and exhausting of the mechanism being operated by the valve locate the valve as close as possible to the mechanism The lines must be of adequate size and be free of crimps and sharp bends Valve Exhaust Port 3 Do not restrict the air flow from the exhaust port as this can adversely affect the operation of the valve Size 4 amp 8 valves are factory equipped with a properly sized silencer Size 2 valves however require an optional silencer to reduce exhaust noise ROSS MUFFL AIR silencers reduce impact noise by as much as 25 dB and produce little back pressure
58. contacts in good condition to avoid solenoid malfunctions Replace Worn Components After long usage the poppets may show signs of wear The valve can be reconditioned with the use of ROSS service kits See page 3 for information about such kits VALVE SPECIFICATIONS Valve Sizes The basic size of your valve is indicated by the size digit which is the fourth digit from the end of the valve s model number For example the size digit is 8 in the model number W7476A8331 For the five different sizes of valves the size digit may be 2 3 4 6 or 8 These are arbitrary numbers and are not related to C ratings Pressure Controlled Temperature Range 40 to 175 F 4 to 80 C Media temperature extended to 220 F 105 C for high temperature models Flow Media Filtered air 5 micron recommended Inlet Pressure 30 to 150 psig 2 to 10 bar Pilot Pressure Must be equal to or greater than inlet pressure IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 Solenoid Pilot Solenoids Rated for continuous duty Voltage and hertz ratings printed on solenoid coils Power Consumption Solenoids for models with size digit 2 10 VA inrush 9 VA holding on 50 or 60 Hz 5 watts on DC Solenoids for all other models 87 VA inrush 30 VA holding on 50 or 60 Hz 14 watts on DC Temperature Range Ambient 40 to 120 F 4 to 50 C extended to 175 F 80 C for high temperature models M
59. dedicated reset function in order to be operated further Therefore it may be necessary to perform a reset on the valve prior to beginning the test procedure below In order to reset the valve make sure that supply pressure is present and both pilot solenoids are de energized then momentarily energize the reset solenoid for at least 200 milliseconds A Electrically energize both pilot solenoids simultaneously The valve should supply pressure from inlet port 1 to outlet port 2 There should be no flow to the exhaust port 3 at this time B De energize one of the pilot solenoids The valve should go into a lockout condition such that any downstream pressure in the outlet port 2 will be exhausted to atmosphere through exhaust port 3 There should also be a small but audible flow of air out the exhaust port 3 as long as the valve remains in the lockout condition C Re energize the pilot solenoid that was de energized in step B above The valve must remain in the lockout condition D De energize both pilot solenoids The valve must remain in the lockout condition E Momentarily energize the reset solenoid at least 200 milliseconds to reset the valve The valve should return to the ready to run condition There should be no pressure present at outlet port 2 and there should no longer be any audible flow of air to exhaust port 3 F Energize both pilots simultaneously again As in step A above the valve should supply pres
60. energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the U S A Rev 05 09 2009 ROSS CONTROLS All Rights Reserved Form SS102 Series 84 Valves Thank Y
61. exhaust ports as this can adversely affect the operation of the valve Any flow control requirements should be installed between the actuator and the valve ports 2 amp 4 at the cylinder and not in the valve exhaust ports Signal Ports Ports S1 and S2 The valves supplying air to these ports should be 3 way normally closed valves and must have a Cv rating of not less than 0 3 The pilot valves must have an adequate supply to provide consistent pressure greater than or equal to the main valve supply in Port 1 see Valve Specifications page 3 Ensure that the lines supplying air to the Signal Ports are of equal length and no less than 3 16 5mm inside diameter Operating Pressures and Temperatures Allowable ranges for pressure and temperature are given in the Valve Specifications on page 3 Exceeding the values shown can adversely affect performance and shorten valve life Pipe Installation To install pipe with tapered threads in the ports in the base engage pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating the valve To install pipe with parallel threads e g SAE ISO 228 G etc do not use sealant Pressure Switch If feedback is desired Ross offers a version of the valve with a pressure switch feedback device that can be used to provide feedback to other electrical controls for valve ready to run status ROSS CONTROLS
62. harm Buna N elastomers Some of the available compatible lubricants are listed at the right However oil manufacturers sometimes change the chemistry of their oils The oils listed although believed to be compatible at the time of printing could change without notice Therefore the best oils to use are those specifically compounded for air line lubricator service lf itis a synthetic oil you should contact the oil manufacturer for compatibility information Brand Name American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Pacemaker 32 Spinesstic 22 Teresstic 32 DTE light Velocite 10 Air Lube 10H NR Turbo T 32 Sunvis 11 Sunvis 722 Regal R amp O 32 Union Turbine Oil If you need additional information or have questions about installation or servicing call ROSS Technical Services at 1 888 TEK ROSS 835 7677 or 706 356 3708 www rosscontrols com 3 STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the saf
63. in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the U S A Rev 05 09 2009 ROSS CONTROLS All Rights Reserved Form SS262 Dale Series CP CX LF LX Compact Poppet amp Manifold Valves Thank You You have purchased a premium quality ROSS pneumatic valve It is a poppet valve with metal internals designed for inline mounting and has been built to the highest standards With care in its installation and maintenance you can expect it to have a long and economical service life So before you go any further please take a few minutes to look over the information in this folder Then save it for future reference and for the useful service information it co
64. installed between the valve body and the solenoid pilot or air head Examples of two valves with special function adaptors are illustrated at the right Lubrication Note Valves using these adaptors except L O X and EEZ ON adaptors require air line lubrication 4 Way solenoid pilot valve 3 Way pressure controlled valve with timed in adaptor with air index adaptor plus Q adaptor Q ADAPTOR The Q adaptor is used with the timed sequence adaptors to extend the timing interval up to 60 seconds It also ensures snap action of the valve by keeping pilot pressure off the main valve piston until it has built up high enough to cause prompt valve response All Sizes order model number W421B93 AIR INDEX ADAPTOR a The air index adaptor allows a valve controlled by a single signal source solenoid pilot or remote pressure control to function as an impulse controlled mechanically detented valve Amomentary electrical signal to the solenoid actuates the valve and holds it in the actuated position A second momentary signal from the same source returns the valve to its deactuated position All Sizes order model number W674B93 Air Index Adaptor L O X and EEZ ON ADAPTORS The ROSS valves with EEZ ON adaptors are used in air supply lines to give an adjustable gradual buildup of pressure at startup time ROSS valves with L O X adaptors are used in air supply lines to provide a lockable shut off
65. is designed for standard temperatures If the model number ends with any other group of digits you have ordered a valve with special characteristics Consult ROSS to verify the characteristics of your particular valve Air Lines Before installing a valve in a new or an existing system the air lines must be blown clean of all contaminants It is recommended that an air filter be installed in the inlet line close to the valve Valve Inlet Port 1 Be sure that the supply line is of adequate size and does not restrict the air supply because of a crimp in the line sharp bends or a clogged filter element Valve Outlets Ports 2 amp 4 For faster pressurizing and exhausting of the mechanism being operated by the valve locate the valve as close as possible to the mechanism The lines must be of adequate size and be free of crimps and sharp bends Valve Exhausts Ports 3 amp 5 Exhaust air flow must not be restricted for proper valve performance However any properly sized silencer such as aROSS MUFFL AIR silencer should be used to reduce impact noise without providing excessive back pressure Electrical Supply The voltage and hertz ratings of the valve solenoids if any are shown on the pilot housings Electrical supply must correspond to these ratings Otherwise life of the solenoids will be shortened Electrical power from the valve s base goes to the solenoid s via the plug in connector at the valve base interface If po
66. is not for use in press clutch brake applications ROSS produces the Series DM Series D and a number of other double valve configurations with flow amp exhaust characteristics for press clutch brake VALVE INSTALLATION applications Pneumatic equipment should be installed only by persons trained and experienced in such installation Air Lines Before installing this valve in anew or existing system the air lines must be blown clean of all contaminants It is recommended that a 5 micron rated air filter be installed in the inlet line close to the valve Valve Inlet Port 1 Be sure that the supply line is of adequate size and does not restrict the air supply because of a crimp in the line a sharp bend or a clogged filter element The air supply must not only provide sufficient pressure see Standard Specifications page 3 but must also provide an adequate flow of air on demand Valve Outlet Port 2 For faster pressurizing and exhausting of the mechanism being operated by the valve locate the valve as close as possible to the mechanism The lines must be of adequate size and be free of crimps and sharp bends Valve Exhaust Port 3 Do not restrict the air flow from the exhaust port as this can adversely affect the operation of the valve The valves are factory equipped with a properly sized silencer ROSS MUFFL AIR silencers reduce impact noise by as much as 25 dB with minimum back pressure Reset Solenoid DM Series E
67. its factory repair center 1 800 438 7677 inside the U S or 706 356 3708 outside the U S However if you choose to service this valve yourself it is strongly recommended that you obtain a free service manual from your local ROSS distributor Distributor information as well as downloadable service manuals are available at www rosscontrols com Valve Body Service Kits These kits contain all parts needed for complete reconditioning of a valve body Included are poppets spindle all required gaskets and seals and instructions for use Gasket and Seal Kits These kits are needed when valve bodies are disassembled for cleaning They include all the necessary gaskets O rings and other seals Solenoid Pilot Kits These kits contain all parts needed to recondition the pilot valve Order by the following kit numbers 946K87 273K87 Solenoids Replacement solenoids can be ordered by the part numbers listed below Specify the required voltage and hertz when ordering For single solenoid pilots For double solenoid pilots 411B04 171095 For single solenoid pilots For double solenoid pilots Adapters Some valves have adapters e g time delay PB air index or L O X adapters above the valve body For information on servicing these adapters see pages 3 4 or consult ROSS Timed sequence adapter shown between the solenoid pilot and the valve body E www rosscontrols com Valve Port Valve Body G
68. life Pipe Installation To install pipe in valve or base ports engage pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating the valve Ford Wired 5 pin mini connector all voltages Ford Wired 4 pin micro connector 24 vdc O mr EA hez so Chrysler Wired 5 pin mini connector all voltages LIGHT Chrysler Wired 5 pin micro connector 24 vdc LIGHT Chrysler Wired 5 pin micro connector 120 volts 60 Hz LIGHT web site www rosscontrols com ROSS EUROPA GmbH Germany TEL 49 6103 7597 0 web site www rosseuropa com ROSS ASIA K K Japan TEL 81 427 78 7251 web site www rossasia co jp ROSS UK Ltd United Kingdom TEL 44 121 559 4900 email sales rossuk co uk ROSS SOUTH AMERICA Ltda Brazil TEL 55 11 4335 2200 email vendas ross sulamerica com br ROSS CONTROLS INDIA Pvt Ltd India TEL 91 44 2624 9040 email rossindia airtelbroadband in ROSS CONTROLS CHINA Ltd China TEL 86 21 6915 7951 email alvinzhurong vip 163 com DIMAFLUID s a s France TEL 33 01 49 45 65 65 web site www dimafluid com VALVE MAINTENANCE Pneumatic equipment should be maintained only by persons trained and experienced in the maintenance of such equipment Supply Clean Air Foreign material lodging in valves is a major ca
69. nearest W6077B2407 838K77 617B11 ROSS location see page 1 or in the U S A at W6077B3401 839K77 618B11 1 888 TEK ROSS or 1 706 356 3708 W6077B3407 840K77 618B11 W6077B4401 841K77 619B11 W6077B4407 842K77 619B11 www rosscontrols com STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury FILTRATION and L
70. of the air supply and also exhaust downstream air when shut off The L O X adaptor offers low friction seals which ensure easy shifting even after a long standby period and can be padlocked only in the closed position Series 27 L O X adaptors are not field serviceable rebuilding L O X Adaptor If they require service they should be replaced or returned to ROSS for Xo EEZ ON Adaptor s Adaptors 4 5 Valves Size EEZ ON L O X 2 2 EEZ ON 1 4 to 1 271A86 1to 1 266A86 4 3 2 EEZ ON 1 4 to 1 389A86 1to 1 396A86 3 2 L O X 1 4 to 1 339B86 P ee 1 to 2 409B86 AVE SNOWN WINIDO 3 2 L O X with EEZ ON 1 4to 1 396A86 390B86 L OKEANA EEZ ONT Adaptors operation 1to1 396A86 390B86 www rosscontrols com 3 PB ADAPTORS 4 a gt gt DS lt gt 4 way PB Adaptor 3 way PB Adaptor The PB adaptor increases the actuating force on the valve piston It should be used when inlet and pilot pressures are below the minimums specified for the valve It should also be used when an external pilot supply with a lower pressure than the inlet pressure is used The valve s pilot pressure is applied to a piston in the PB adaptor that has a larger area than the piston in the valve The force on the piston in the adaptor is thereby larger than that which could be produced by the piston in the valve This larger force is applied to the valve s piston directly
71. polyurethane components potentially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifica
72. port 2 to be pressurized If the valve locks out further operation is prevented until the valve has been reset Electrical signals to the solenoids must be off to allow the valve to be reset The DM Series C valve is completely self contained and does not need an external monitoring system VALVE MAINTENANCE Pneumatic equipment should be maintained only by persons trained COMPATIBLE LUBRICANTS and experienced in the maintenance of such equipment Supply Clean Air Foreign material lodging in valves is a major cause of breakdowns The use of a 5 micron rated air filter located close to the valve is strongly recommended The filter bowl should be drained regularly and if its location makes draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should put a fine oil mist into the air line in direct proportion to the rate of air flow Excessive lubrication can cause puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute is adequate Note that the double valve itself does not require air line lubrication Compatible Lubricants Although this valve does not require air line lubrication it may be used with lubricated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components and so cause the valve to malfunction Avoid oils with phosphate addi
73. ratings of the solenoids Otherwise the solenoids are subject to early failure If power is supplied by a transformer it must be capable of handling the inrush current without significant voltage drop See Standard Specifications on page 3 for inrush current data Operating Pressures and Temperatures Allowable ranges for pressure and temperatures are given in the Standard Specifications on page 3 Exceeding these values can adversely ROSS CONTROLS United States TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS affect performance and shorten valve life Pipe Installation To install pipe in base ports engage pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating the valve To install pipe with parallel threads e g SAE ISO 228 G etc do not use sealant After installing pipe into the base ports use compressed air to blow any debris out of the piping then install the valve onto the base Test After installation or repair and prior to normal use the internal lockout feature of the DM Series D valve must be tested for proper functioning Observe normal press operation safety precautions during these tests to avoid personal injury or damage to equipment Note Reset may need to be performed prior to beginning the test procedure Also both pilot solenoids must be de energized prior to reset and must remain de energized until afte
74. reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and L O X with EEZ ON operation products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured
75. sheet Then save it for future reference and for the useful service information it contains A general service manual with more detailed information is available from ROSS upon request Double Solenoid Pilot Valve Pressure Controlled Valve Single Solenoid Pilot Valve VALVE INSTALLATION Pneumatic equipment should be installed only by persons trained and experienced in such installation Air Lines Before installing a valve in a new or an existing system the air lines must be blown clean of all contaminants It is recommended that a 5 micron rated air filter be installed in the inlet line close to the valve Valve Inlet Port 1 Be sure that the supply line is of adequate size and does not restrict the air supply because of a crimp in the line a sharp bend or a clogged filter element An inadequate air supply will adversely affect the performance of your valve Valve Outlets Ports 2 and 4 For faster pressurizing and exhausting of the mechanism being operated by the valve locate the valve as close as possible to the mechanism The lines must be of adequate size and be free of crimps and sharp bends Valve Exhausts Ports 3 and 5 To reduce exhaust noise an efficient silencer may be used ROSS MUFFL AIR silencers reduce impact noise by as much as 25 dB Electrical Supply The voltage and hertz ratings of the valve solenoids if any are shown on the valve The electrical supply must correspond to these
76. should be drained regularly and if its location makes draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should put a fine oil mist into the air line in direct proportion to the rate of air flow Excessive lubrication can cause puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute is adequate Note that this valve itself does not require air line lubrication but some optional adaptors do i e air index etc Compatible Lubricants Although this valve does not require air line lubrication it may be used with lubricated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components and so cause the valve to malfunction Avoid oils with phosphate additives e g zinc dithiophosphate and diester oils both types can harm valve components The best oils to use are generally petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Some compatible oils are listed above at the right These oils although believed to be compatible could change without notice because manufacturers sometimes reformulate their oils Therefore use oils specifically compounded for air line service If it is a synthetic oil contact the oil manufacturer for compatibility information Clean
77. show signs of wear The valve can be reconditioned with the use of ROSS service kits See page 3 for information about such kits VALVE SPECIFICATIONS Pressure Controlled Temperature Ranges Sizes 1 2 amp 3 40 to 175 F 4 to 80 C extended to 220 F 105 C for high temperature models Size 0 23 to 212 F 5 to 100 C Flow Media Filtered air 5 micron recommended Inlet Pressure 30 to150 psig 2 to 10 bar Pilot Pressure Must be equal to or greater than inlet pressure IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 Solenoid Pilot Solenoids Rated for continuous duty Voltage and hertz ratings printed on solenoid coils Power Consumption Sizes 1 2 amp 3 8 VA inrush 6 VA holding on 50 or 60 Hz 6 watts on DC Size 0 1 9 watts on DC Temperature Ranges Sizes 1 2 amp 3 Ambient 40 to 120 F 4 to 50 C extended to 175 F 80 C for high temperature models Media 40 to 175 F 4 to 80 C extended to 220 F 105 C for high temperature models Size 0 Ambient Media 23 to 120 F 5 to 50 C Flow Media Filtered air 5 micron recommended Inlet Pressure 30 to150 psig 2 to 10 bar Pilot Pressure Must be equal to or greater than inlet pressure 2 ROSS CONTROLS VALVE OPERATION 5 2 SINGLE CONTROL VALVES 4 2 4 2 513 513 Pressure Controlled Solenoid Pilot No Signal Applied Inlet 1 connected to ou
78. size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and L O X with EEZ ON operation products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS
79. than inlet pressure 2 ROSS CONTROLS VALVE OPERATION 5 2 MOMENTARY CONTROL VALVES UL Wy Pressure Controlled Solenoid Pilot 5 2 SINGLE CONTROL VALVES i Mii 51 Pressure Controlled 4 2 14 5 1 2 14 ZEN 12 a 13 wo hn D wod lho R 1 wH Solenoid Pilot Signal 12 Applied Momentarily Inlet 1 connected to outlet 2 outlet 4 connected to exhaust 5 exhaust 3 closed No Signal Applied Inlet 1 connected to outlet 2 outlet 4 connected to exhaust 5 exhaust 3 closed Signal 14 Applied Momentarily Inlet 1 connected to outlet 4 Outlet 2 connected to exhaust 3 exhaust 5 closed Signal 14 Applied Inlet 1 connected to outlet 4 outlet 2 connected to exhaust 3 exhaust 5 closed Valve Body Service Kits These kits listed atthe right contain Valve Model Valve Body Valve to Base all parts needed for a complete reconditioning of a valve body Number Service Kit Gasket Included are a spindle all poppets and spacers all required W6456B2411 1017K77 617B11 gaskets and seals detent assemblies for valves using them and instructions for use W6456B2412 1014K77 617B11 W6456B2417 834K77 617B11 W6456B2418 843K7
80. the air lines must be blown clean of all contaminants It is recommended that an air filter be installed in the inlet line close to the valve Valve Ports Your valve is a multipurpose valve and may have any of its ports restricted and or pressurized provided there is sufficient pilot pressure Conventional port usage is identified below Valve Inlet Port 1 Be sure that the supply line is of adequate size and does not restrict the air supply because of a crimp in the line sharp bends or a clogged filter element Valve Outlets Ports 2 amp 4 For faster pressurizing and exhausting of the mechanism being operated by the valve locate the valve as close as possible to the mechanism The lines must be of adequate size and be free of crimps and sharp bends Valve Exhausts Ports 3 amp 5 These ports may be restricted to control cylinder speed To reduce exhaust noise use an efficient silencer ROSS MUFFL AIR silencers reduce impact noise by as much as 25 dB and produce little back pressure Electrical Supply The voltage and hertz ratings for solenoid pilot operated valves can be found on the side of each pilot housing Ensure that the electrical supply used is equal to these ratings to avoid solenoid burnout The electrical connection for these valves is achieved at the base to valve interface by means of mating connectors If power is supplied by a transformer it must be capable of handling the inrush current without significan
81. the circuit diagram supplied with the valve A lockout signal port on valve models with L G monitor canbe connected to a normally closed pressure switch to operate a lockout indicator light After installation the monitor L G E P D S and or external monitor must be tested for proper functioning Take normal press operation safety precautions during these tests to avoid personal injury or damage to equipment Electrically energize both solenoids depress one manual override de energize both solenoids This should result in a valve lockout and prevent the valve from operating Reset the monitor and repeat the test using the second manual override Contact ROSS for testing procedures for valves without manual overrides After satisfying these tests energizing both solenoids simultaneously should result in normal valve operation web site www rosscontrols com ROSS EUROPA GmbH Germany TEL 49 6103 7597 0 web site www rosseuropa com ROSS ASIA K K Japan TEL 81 427 78 7251 web site www rossasia co jp ROSS UK Ltd ROSS SOUTH AMERICA Ltda ROSS CONTROLS INDIA Pvt Ltd ROSS CONTROLS CHINA Ltd DIMAFLUID s a s TEL 44 121 559 4900 TEL 55 11 4335 2200 TEL 91 44 2624 9040 TEL 86 21 6915 7951 TEL 33 01 49 45 65 65 email sales rossuk co uk email vendas ross sulamerica com br email rossindia airtelbroadband in email alvinzhurong vip 163 com web site www dimafluid com United Kingdom Brazil In
82. the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakage and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components potentially leadin
83. the result of a temporary circumstance the valve will be ready to resume normal operation as soon as both solenoids have been de energized Pressure Switch Valves with model numbers ending in the number 1 have a pressure switch to aid in detecting when the main valve elements did not move together Out of step movement of the valve elements causes a pressure signal to close electrical contacts This can be used to complete an electrical circuit in an external monitoring system po Ea l Pressure ZH Pilo Valve Chambers Switch Pilot Valve TER Air Supply Base Status Indicator pressure switch Terminals 1 and 4 are connected when air pressure is present and the valve is Ready to Run If an abnormal operation has occured or pressure is removed from the valve inlet terminals 1 and 2 are connected Note DC voltage pressure switches do not have a ground terminal Pin 1 Common Pin 2 Normally Closed Pin G Not used Pin 4 Normally Open VALVE MAINTENANCE Pneumatic equipment should be maintained only by persons trained and experienced in the maintenance of such equipment Supply Clean Air Foreign material lodging in valves is a major cause of breakdowns The use of a 5 micron rated air filter located close to the valve is strongly recommended The filter bowl should be drained regularly and if its location makes dra
84. the valve To install pipe with parallel threads e g SAE ISO 228 I etc do not use sealant Test After installation or repair and prior to normal use the valve must be tested for proper functioning Observe normal equipment operation safety precautions such as lockout procedures during these tests to avoid personal injury or damage to equipment ROSS CONTROLS DM Series E Testing Procedure NOTE After DM Series E valves do lockout they may not stay in the lockout condition as do the DM Series E and DM Series C valves that remember abnormal function The valves that include memory functions once locked out must be reset by a dedicated reset function in order to be operated again DM Series E valves will operate again as soon as the fault condition has cleared Removing electrical power to both pilot solenoids may clear the lockout condition if the situation that caused the valve internals to not operate simultaneously is no longer in effect This is referred to as automatic reset This may result in momentary lockout going undetected during machine operation without the use of the optional status indicator A Electrically energize both pilot solenoids simultaneously The valve should supply pressure from inlet port 1 to outlet port 2 There should be no flow to the exhaust port 3 at this time B De energize one of the pilot solenoids The valve should go into a lockout condition such that any d
85. use oils specifically compounded for air line service If itis a synthetic oil contact the oil manufacturer for compatibility information Cleaning the Valve If the air supplied to the valve has not been well filtered the interior of the valve may accumulate dirt and varnish which can affect the valve s performance A schedule should be established for cleaning all valves the frequency depending on the cleanliness of the air being supplied COMPATIBLE LUBRICANTS Maker Brand Name AMOCO 0000 American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Citgo eee Pacemaker 32 EXXON cee Spinesstic 22 Teresstic 32 Mobil 0 Velocite 10 Non Fluid Oil Air Lube 10H NR Shelliccceihetka Turbo T32 SUN Sunvis 11 Sunvis 722 TEXACO Regal R amp O 32 Union 6 Union Turbine Oil To clean the valve use any good commercial solvent Do not scrape varnished surfaces Also do not use chlorinated solvents or abrasive materials The former damages seals and abrasives can do permanent damage to metal parts Before reassembling the valve lubricate all sliding surfaces with a grease such as MobilGrease 28 for valve sizes 1 2 amp 3 or NYE 842S for size 0 valves Electrical Contacts In the electrical circuits associated with the valve solenoids keep all switches or relay contacts in good condition to avoid solenoid malfunctions Replace Worn Component After long usage dynamic seals may
86. use the same air supply for both the inlet and pilot pressures Normally Closed The LT is a normally closed 3 way valve The supply pressure on the INLET port is closed and the TEST and P1 ports flow through the EXHAUST port Electrical Power Loss Will cause the valve to return to a normally closed position The inlet pressure will be closed and downstream test pressure will be exhausted Operation Pressure Decay Test Step 1 Close the exhaust by actuating the exhaust solenoid Step 2 Open inlet pressure by actuating the fill solenoid Step 3 Allow time to fill and settle Step 4 Monitor pressure drop on port P1 to determine if there is a leak Applications e Pressure Decay Test P1 Pressure Sensor Port e Bypass Pre fill P1 Blocked or Gauge Port e Vacuum amp Fill P1 Gauge Port Exhaust Vacuum Port Inlet Fill Port ROSS CO NTROLS www rosscontrols com VALVE INSTALLATION 3 4 Manifold The 3 4 LT series manifold was designed for test applications currently using standard 3 way and 2 way valves Benefits include high flow zero isolation leakage and elimination of tubing The manifold can be configured for flow tests pressure decay tests and differential pressure tests The manifold consists of three internal high flow poppets which are actuated by three external solenoids The first solenoid controls the supply pressure the second solenoid controls the isolation and the thi
87. valves are supplied with a 3 2 normally closed solenoid valve for reset purposes Electrical reset signal must be momentary and of correct voltage Electrical Supply DM Series E valves get electrical power through plug in connectors The electrical supply must correspond to the voltage and frequency ratings of the solenoids otherwise the solenoids are subject to early failure If power is supplied by a transformer it must be capable of handling the inrush current without significant voltage drop See Standard Specifications on page 3 for current data Operating Pressures and Temperatures Allowable ranges for pressure and temperatures are given in the Standard Specifications onpage 3 Exceeding these values can adversely affect performance and shorten valve life Pipe Installation To install pipe in ports engage pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating the valve To install pipe with parallel threads e g SAE ISO 228 1 etc do not use sealant Test After installation or repair and prior to normal use the valve must be tested for proper functioning Observe normal equipment operation safety precautions such as lockout procedures during these tests to avoid personal injury or damage to equipment DM Series E Test Procedure NOTE DM Series E valves include a memory function and once locked out must be reset by a
88. vent ports of the valve body or pilot body as this can adversely affect the operation of the valve Electrical Supply The voltage and hertz ratings of the valve solenoids if any are shown on the pilot housing The electrical supply must correspond to these ratings Failure to use an electrical supply of the correct voltage and amperage may result in incorrect operation of the valve See Valve Specifications on page 2 for information on inrush current ROSS CONTROLS United States TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS Operating Pressures and Temperatures Allowable ranges for pressure and temperatures are given in the Valve Specifications on page 2 Exceeding the values shown can shorten valve life Remote Trapped Pressure Relief Pilot operated check valves designated for remote trapped pressure relief function blowdown require a 1 8 inch supply line to be connected to port P or port BP where provided As long as pressure is available at port P or port BP the check valve operates normally Loss of pressure at port P or port BP will cause the check valve to relieve trapped pressure Also see Pilot Supply below for Solenoid Control Pilot Supply Pressure Control Connect a 1 8 inch 1 4 inch on Type B valves control line to the threaded port in the air cap labeled VP on some models at the top of the valve See Valve Specifications on page 2 for required pressures Solenoid Control Pressure for the p
89. volts AC Max Current 50 mA Max 24 volts DC VALVE SERVICE ROSS would be happy to service this specialized valve for you at its factory repair center 1 800 GET ROSS For servicing the valve yourself the needed service kits and components are described below Valve Body Service Kits These kits contain all parts needed for complete reconditioning of a valve body Included are spools gaskets and seals kits and instructions for use Valve Body Gasket Kits These kits are needed when valve bodies are disassembled for cleaning They include all necessary gaskets O rings and other seals Base Service Kits These kits contain the seals and other parts required to recondition the valve s base Pressure Switch Assembly Kits These kits contain the parts necessary to recondition the pressure switch assembly Replacement Pressure Switches and Switch Connectors Part numbers for these components are shown in the chart below Valve Valve Body Valve Body Base Pressure Switch Pressure Pressure Valve Model Seal and Service Service Assembly Switch Switch Size Number Gasket Kit Kit Kit Service Kit Connector 7786A3400 2216K77 2218K77 1694K77 N A N A N A 7786A3401 2216K77 2218K77 1694K77 1696K77 AC 518E30 522E30 DC 798E30 7786A4400 2217K77 2219K77 1695K77 N A N A N A 7786A4401 2217K77 2219K77 1695K77 1696K77 AC 518E30 522E30 DC 798E30 If you need additional information or have any questions about inst
90. within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakage and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an anil
91. 0 to 175 F 4 to 80 C Flow Media Filtered 5 micron recommended lubricated or unlubricated air mineral oils according to DIN 51519 viscosity classes 32 46 Inlet Pressure 30 to 115 psig 2 to 8 bar Reset Pressure For remote reset option equal to inlet pressure Pressure Switch Status Indicator Rating Contacts 5 amps at 250 volts AC or 5 amps at 30 volts DC Solenoid Reset Units with solenoid reset include a 3 2 solenoid valve Energize this solenoid momentarily to reset monitor after lock out condition occurs NOTE Main solenoids must be off when performing reset procedure Remote Reset Remote signal to be supplied by customer s 3 2 valve connect remote signal line to remote RESET port in valve Apply signal momentarily to reset valve after fault condition occurs NOTE Main solenoids must be off when performing reset procedure Electrical Connectors Wired connectors have a 2 meter 6 1 2 ft cord with three 18 gauge conductors Cord is available in either 6 mm or 10 mm diameter and with or without indicator light Specify solenoid voltage for lighted connectors Without Light With Light Wired with 6 mm cord 721K77 720K77 Wired with 10 mm cord 371K77 383K77 For threaded conduit 723K77 724K77 For use with drop cord 937K87 936K87 cord not included VALVE SERVICE ROSS would be happy to service this specialized double valve for you at its factory repair center Call your local distributor or
92. 0 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Some compatible oils are listed above These oils although believed to be compatible could change without notice because manufacturers sometimes reformulate their oils Therefore use oils specifically compounded for air line service If it is a synthetic oil contact the oil manufacturer for compatibility information Cleaning the Valve Replace Worn Components ROSS does not recommend disassembling the Series 15 valves for cleaning or repair Referenced Standards All standards are subject to revision Parties are encouraged to investigate and apply the most recent editions of the standards indicated below OSHA 29 CFR 1910 147 CSA 2142 02 CSA 2460 05 ISO 13849 1 ISO 14118 2000 EN 1037 ANSI ASSE 2244 1 2003 ANSI PMMI B155 1 2006 IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 2 ROSS CONTROLS VALVE OPERATION L O X Valve RED Handle VALVE CLOSED With a short inward push of the red handle the flow of supply air is blocked from the outlet port Downstream air flows from outlet to exhaust port The valve must be padlocked while in this position during maintenance to prevent it from being inadvertently pulled outward and creating the potential for injury to people or machinery VALVE OPEN When the red handle is pulled out supply air flows freely from inlet to ou
93. 05 09 2009 ROSS CONTROLS All Rights Reserved Form SS103 DM Series E Control Reliable Double Valves with Dynamic Monitoring Size 2 Thank You You have purchased a premium quality ROSS pneumatic valve It is a high quality DM Series E Control Reliable double valve with Dynamic Monitoring for Category 3 applications With care in its installation and maintenance you can expect it to have a long and economical service life Before you install this valve read the information in this folder completely and save it for future reference IMPORTANT APPLICATION NOTE Because its characteristics are for Category 3 applications this valve is not for use in press clutch brake applications ROSS produces the DM Series D and a number of other double valve configurations with flow exhaust and lockout characteristics for press clutch brake applications VALVE INSTALLATION Pneumatic equipment should be installed only by persons trained and experienced in such installation Air Lines Before installing this valve in a new or existing system the air lines must be blown clean of all contaminants It is recommended that a 5 micron rated air filter be installed in the inlet line close to the valve Valve Inlet Port 1 Be sure that the supply line is of adequate size and does not restrict the air supply because of a crimp in the line a sharp bend or a clogged filter element The air supply must not only provide sufficient pres
94. 1 6915 7951 email alvinzhurong vip 163 com DIMAFLUID s a s France TEL 33 01 49 45 65 65 web site www dimafluid com VALVE MAINTENANCE Pneumatic equipment should be maintained only by persons trained and experienced in the maintenance of such equipment Supply Clean Air Foreign material lodging in valves is a major cause of breakdowns The use of a 5 micron rated air filter located close to the valve is strongly recommended The filter bowl should be drained regularly and if its location makes draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should put a fine oil mist into the air line in direct proportion to the rate of air flow Excessive lubrication can cause puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute is adequate Compatible Lubricants Although this valve does not require air line lubrication it may be used with lubricated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components and so cause the valve to malfunction Avoid oils with phosphate additives e g zinc dithiophosphate and diester oils both types can harm valve components The best oils to use are generally petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosi
95. 11 Sunvis 722 Regal R amp O 32 Union Turbine Oil To reassemble the spool and sleeve put one drop of Anderol 735 or equivalent lubricant on each spool land Insert the spool into the sleeve and rotate it several times to ensure even distribution of the lubricant If the valve is used in a non lubricated application do not use a lubricant for reassembly which can dry out and leave a residue Dry assembly of the spool and sleeve is preferable Each spool and sleeve is a matched set so care must be taken not to reverse the position of the spool in the sleeve Before inserting the spool and sleeve into the valve body very lightly lubricate the O rings with a compatible lubricant Do not use Anderol it causes the O rings to deteriorate Electrical Contacts In the electrical circuits associated with the valve solenoids keep all switches or relay contacts in good condition to avoid solenoid malfunctions Replace Worn Components In some cases it is not necessary to remove the valve from its installation for servicing However turn off the electrical power to the valve shut off the air supply and exhaust the air in the system before beginning any disassembly operation Service kits for these valves are listed on page 3 VALVE SPECIFICATIONS Valve Sizes The basic size of your valve is indicated by the size digit which is the fourth digit from the end of the valve s model number For example the size digit is 8 in the model numbe
96. 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed
97. 20 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components potentially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machi
98. 32 or lighter viscosity Some compatible oils are listed on page 3 These oils although believed to be compatible could change without notice because manufacturers sometimes reformulate their oils Therefore use oils specifically compounded for air line service If it is a synthetic oil contact the oil manufacturer for compatibility information Cleaning the Valve If the air supplied to the valve has not been well filtered the interior of the valve may accumulate dirt and varnish which can affect the valve s performance by causing sluggish or erratic valve action which can result in the valve defaulting A schedule should be established for cleaning all valves the frequency depending on the cleanliness of the air being supplied To clean the valve use a solvent which will dry without leaving a residue This is especially important for the spool and sleeve assembly Do not use a chlorinated solvent or abrasive materials which can damage seals or metal parts Do notscrape varnished surfaces To reassemble the spool and sleeve put one drop of Anderol 735 or equivalent lubricant on each spool land Insert the spool into the sleeve and rotate it several times to ensure even distribution of the lubricant If the valve is used in a non lubricated application do not use a lubricant for reassembly which can dry out or leave a residue Dry assembly of the spool and sleeve is preferable Each spool and sleeve is a matched set so care must be t
99. 3902 3 8 E 1263K77 404H77 2778C3904 3 8 E 1263K77 404H77 2778C4900 1 2 E 1535H77 404H77 2778C4901 1 2 E 1535H77 404H77 2778C4902 1 2 E 1535H77 404H77 2778C4904 1 2 E 1535H77 404H77 2778C5900 3 4 E 1264K77 404H77 2778C5901 3 4 E 1264K77 404H77 2778C5902 3 4 E 1264K77 404H77 2778C5904 3 4 E 1264K77 404H77 2778A6900 1 E 1264K77 404H77 2778A6901 1 E 1264K77 404H77 2778A6902 1 E 1264K77 404H77 2778A6904 1 E 1264K77 404H77 www rosscontrols com STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In a
100. 47K77 637B11 required gaskets and seals detent assemblies for valves using them and instructions for use 8076B4331 1245K77 677B11 8076B4332 1248K77 677B11 8076B4341 1245K77 677B11 Solenoids Replacement solenoids or solenoid coils can be 8076B4342 1248K77 677B11 ordered by the following part numbers 8076B4351 1245K77 677B11 SAE 125 314B33 Coil only 8076B4352 1248K77 677B11 OAT Bo ey a a LBU SAE 500 411B04 Complete solenoid 8076B6341 1246K77 352B11 Specify the correct voltage and hertz when ordering 8076B6342 1249K77 352B11 8076B6351 1246K77 352B11 Pilot Service The following are available to service the pilot 8076B6352 1249K77 352B11 assemblies 2 each required for double solenoid valves padi peel sel SAR ley ssid E ice MOORE 8077B3341 1250K77 637B11 i 8077B3342 1253K77 637B11 SAE 250 Complete pilot assembly 936C79 8077B3351 1250K77 637B11 Includes solenoid coil 8077B3352 1253K77 637B11 SAE 500 Pilot service kit 946K87 8077B4331 1251K77 677B11 Solenoid not included 8077B4332 1254K77 677B11 Valve to Base Gasket If your valve is removed from its base 8077B4341 1251K77 677B11 for any reason a new valve to base gasket must be used to 8077B4342 1254K77 677B11 ensure a leak free seal This gasket is already included in 8077B4351 1251K77 677B11 valve body service kits 8077B4352 1254K77 677B11 8077B6331 1252K77 352B11 If you have any questions about installing or servicing 8077B6332 1255K77 352B11 your valve call ROSS Technic
101. 5 09 2009 ROSS CONTROLS All Rights Reserved Form SS101
102. 6K87 EA OOT a aiao aapa 1169K77 BAN O7 oie e ie 1701K77 BAOT Z te fsceccdoeetica re Bessel 696K87 AAFO7 ooeec 1701K77 B5007 urrena a 696K87 E500 kaaet 1169K77 ASV OT ormana 1701K77 A5HO7 i deaan a 1701K77 B6007 A T 697K87 EQ OO 7 ccd ET T 1170K77 BOOT Sineme a 696K87 AG107 i rinnan 1702K77 AOTT een merece penne 1701K77 Valve Model Service Kit 1968 A6KO7 uu eee 1702K77 AOKTT ne 1701K77 B7007 Tarran aniio 697K87 EZOO rnanan aoe 1170K77 AT IOT innie ween 1702K77 ATEO eaa e Se 1702K77 B8007 rirun t iS 698K87 B8O4 7 sescsciietviiecctliocdissecns 697K87 ASI O Fitts oth Seana 1703K77 ASAT ceed cod oe 1702K77 ABMO7 noie 1703K77 A8MI7 ooe 1702K77 B9007 noiseen 698K87 BIOI a 698K87 QV OF herinneren ho 1703K77 TAE a AT EE 1703K77 A9NO7 ee 1703K77 2 ROSS CONTROLS COMPATIBLE LUBRICANTS Although air line lubrication is not required for most ROSS valves other mechanisms in the system may need such lubrication When a lubricator is used it should be supplied only with oils which are compatible with the materials used in the valves for seals and poppets Generally speaking these are petroleum base oils with oxidation inhibitors and aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Oils with phosphate type additives such as zinc dithiophosphate must be avoided because they can harm polyurethane valve components Diester oils should be avoided because they
103. 7 617B11 W6456B3411 1018K77 618B11 Gu W6456B3412 1015K77 618B11 W6456B3417 835K77 618B11 W6456B3418 844K77 618B11 W6456B4411 1019K77 619B11 Typical Poppet Valve Cross Section W6456B4412 1016K77 619B11 Solenoid Coils Replacement coils for solenoid controlled W6456B4417 836K77 619B11 valves can be ordered by part number 306K33 Specify the W6456B4418 845K77 619B11 correct voltage and hertz when ordering W6476B2401 1017K77 617B11 Complete Solenoid Pilot Assemblies These consist of new W6476B2402 1014K77 617B11 pilot valve mechanisms plus a new coil Order by part number W6476B2407 834K77 617B11 851C79 and ify th t volt d hert Siew cheetah ese ehcmee renege se ae ete W6476B2408 843K77 617B11 Valve to Base Gasket If your valve is removed from its base W6476B3401 1018K77 618B11 for any reason a new valve to base gasket must be used to W6476B3402 1015K77 618B11 ensure a leak free seal This gasket is already included in valve body service kits W6476B3407 835K77 618B11 W6476B3408 844K77 618B11 If you have any questions about installing or servicing your W6476B4401 1019K77 619B11 valve call ROSS Technical Servicesat your nearest ROSS W6476B4402 1016K77 619B11 location see page 1 or in the U S A at W6476B4407 836K77 619B11 1 888 TEK ROSS or 1 706 356 3708 W6476B4408 845K77 619B11 www rosscontrols com STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all so
104. 75K87 553B11 304B33 W7077A3331 279K87 305A87 549B11 347B04 W7077A3332 282K87 305A87 549B11 347B04 W7077D4331 W744K87 W769A87 958B11 411B04 W7077D4332 W745K87 W769A87 958B11 411B04 W7077C6331 W748K87 W770A87 344B11 411B04 W7077C6332 W749K87 W770A87 344B11 411B04 W7077C8331 W752K87 W771A87 339C11 411B04 W7077C8332 W 753K87 W771A87 339C11 411B04 Solenoid pilot models shown above have internal pilot supply and their model numbers all end in the digits 1 or 2 Corresponding model numbers for external pilot supply end in the digits 3 or 4 and use the same kits as the internal supply models www rosscontrols com 3 STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied w
105. 76B4339 616K77 356B11 411B04 W7476A6331 742K77 344B11 411B04 W7476A6332 743K77 344B11 411B04 W7476A6336 811K77 344B11 411B04 W7476A6337 812K77 344B11 411B04 W7476A8331 744K77 339C11 411B04 W7476A8332 745K77 339C11 411B04 W7476A8336 711K77 339C11 411B04 W7476A8337 711K77 339011 411B04 www rosscontrols com STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affec
106. 8K77 3126A6007 693K87 922K87 379K77 3126A6008 693K87 1072 379K77 3126A6009 693K87 922K87 379K77 3126A6010 693K87 922K87 379K77 3126A601 1 693K87 107212 379K77 3126A6012 693K87 107212 379K77 3126A6013 693K87 922K87 379K77 3126A6014 693K87 107212 379K77 3126A7007 694K87 922K87 380K77 3126A7008 694K87 107212 380K77 3126A7009 694K87 922K87 380K77 3126A7010 694K87 922K87 380K77 3126A7011 694K87 107212 380K77 3126A7012 694K87 107212 380K77 3126A7013 694K87 922K87 380K77 3126A7014 694K87 107212 380K77 3623A2003 683K87 3623A2004 683K87 3623A2005 683K87 3623A2006 683K87 3626A2003 684K87 3626A2004 684K87 3626A2005 684K87 3626A2006 684K87 3643A2001 683K87 3643A2002 683K87 3646A2001 684K87 3646A2002 684K87 www rosscontrols com STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment must check ev
107. ABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN ROSS CONTROLS United States TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS web site www rosscontrols com ROSS EUROPA GmbH ROSS ASIA K K ROSS UK Ltd ROSS SOUTH AMERICA Ltda ROSS CONTROLS INDIA Pvt Ltd ROSS CONTROLS CHINA Ltd DIMAFLUID s a s TEL 49 6103 7597 0 TEL 81 427 78 7251 TEL 44 121 559 4900 TEL 55 11 4335 2200 TEL 91 44 2624 9040 TEL 86 21 6915 7951 TEL 33 01 49 45 65 65 Germany Japan United Kingdom Brazil India China France web site www rosseuropa com web site www rossasia co jp email sales rossuk co uk email vendas ross sulamerica com br email rossindia airtelbroadband in email alvinzhurong vip 163 com web site www dimafluid com Printed in the U S A Rev 06 09 2009 ROSS CONTROLS All Rights Reserved Form SS051 STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including s
108. AKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the U S A Rev 05 09 2009 ROSS CONTROLS All Rights Reserved Form SS104 Series 35 Double Valves Thank You You have purchased a premium quality ROSS pneumatic valve It is a double valve designed to offer added safety to the operation of many pneumatically controlled machines When properly installed it conforms with the OSHA standards for control of air clutch brake mechanisms used on certain mechanical power presses With care in its installation and maintenance you can expect it to have a long and reliable service life Before you go any further please take a few minutes to look over the information in this folder and save it for future reference Service manuals with additional information are available from ROSS upon request With L G Monitor The ROSS Family of SERPAR Double Valves Size 4With amp L G Monitor VALVE INSTALLATION WARNINGS Valves Without Monitor If your valve does not have its own monitor the v
109. ARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the U S A Rev 05 09 2009 ROSS CONTROLS All Rights Reserved Form SS118 Series W70 Valves Thank You You have purchased a premium quality ROSS A pneumatic valve Itis a stainless steel spool and sleeve valve built to the highest standards With care in its installation and maintenance you can expect it to have a long and economical service life So before you go any further please take a few minutes to look over the information in this folder Then save it for future reference and for the useful service information it contains ROSS Series W70 valves and bases sold separately VALVE INSTALLATION Pneumatic equipment should be installed only by persons trained and experienced in such installation Air Lines Before installing a valve in a new or an existing system
110. ATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the USA Rev 05 09 2009 ROSS CONTROLS All Rights Reserved Form SS100 Series W74 Valves Thank You You have purchased a premium quality ROSS pneumatic valve It is a single spindle poppet valve built to the highest standards With care in its installation and maintenance you can expect it to have a long and economical service life So before you go any further please take a few minutes to look over the information in this folder Then save it for future reference and for the useful service information it contains ROSS Series W74 valves and bases sold separately VALVE INSTALLATION Pneumatic equipment should be installed only by persons trained and experienced in such installation Operating Pressures and Temperatures Allowable ranges for pressure and temperatures are given in the Valve Specifications on page 2 Exceeding the values shown can shorten valve life If the model number on your valve ends with 336 337 338 or 339 your valve is designed for high temperature service If the model number on your valve ends with 331 332 333 or 334 your valve
111. BRICANTS Brand Name American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Pacemaker 32 Spinesstic 22 Teresstic 32 Velocite 10 Turbo T32 Sunvis 11 Sunvis 722 Regal R amp O 32 Union Turbine Oil A schedule should be established for cleaning all valves the frequency depending on the cleanliness of the air being supplied To clean the valve use any good commercial solvent Do not scrape varnished surfaces Also do not use chlorinated solvents or abrasive materials The former damages seals and abrasives can do permanent damage to metal parts Before reassembling the valve lubricate all sliding surfaces with a grease such as Dow Corning BR2 Plus Electrical Contacts In the electrical circuits associated with the valve solenoids keep all switches or relay contacts in good condition to avoid solenoid malfunctions Replace Worn Components In some cases it is not necessary to remove the valve from its installation for servicing However turn off the electrical power to the valve shut off the air supply and exhaust the air in the system before beginning any disassembly operation VALVE SPECIFICATIONS Pilot Solenoid DC power Rated for continuous duty Standard Voltages 24 volts DC 120 volts AC 50 Hz Power Consumption Per Solenoid 2 5 watts on DC 3 VA on AC Ambient Media Temperature 40 to 120 F 4 to 50 C Flow Media Filtered air 5 micron recommended Sensor Port 1 8 NPT sensor ports Pilot
112. CONTROLS United States TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS automatically close the outlet port If a larger volume must be supplied use a ROSS Series 27 valve with an HSR valve as its pilot See page 3 for more information Operating Pressures and Temperatures Allowable ranges for pressure and temperatures are given in the Valve Specifications on page 2 Exceeding the values shown can shorten valve life Pipe Installation To install pipe in valve ports engage pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating the valve web site www rosscontrols com ROSS EUROPA GmbH Germany TEL 49 6103 7597 0 web site www rosseuropa com ROSS ASIA K K TEL 81 427 78 7251 web site www rossasia co jp Japan United Kingdom Brazil India China France ROSS UK Ltd ROSS SOUTH AMERICA Ltda ROSS CONTROLS INDIA Pvt Ltd ROSS CONTROLS CHINA Ltd DIMAFLUID s a s TEL 44 121 559 4900 TEL 55 11 4335 2200 TEL 91 44 2624 9040 TEL 86 21 6915 7951 TEL 33 01 49 45 65 65 email sales rossuk co uk email vendas ross sulamerica com br email rossindia airtelbroadband in email alvinzhurong vip 163 com web site www dimafluid com VALVE MAINTENANCE Pneumatic equipment should be maintained only by persons trained and experienced in the maintenance of such equipment S
113. DIA Pvt Ltd India TEL 91 44 2624 9040 email rossindia airtelbroadband in ROSS CONTROLS CHINA Ltd China TEL 86 21 6915 7951 email alvinzhurong vip 163 com DIMAFLUID s a s France TEL 33 01 49 45 65 65 web site www dimafluid com VALVE MAINTENANCE Pneumatic equipment should be maintained only by persons trained and experienced in the maintenance of such equipment Supply Clean Air Foreign material lodging in valves is a major cause of breakdowns The use of a 5 micron rated air filter located in the circuit is strongly recommended The filter bowl should be drained regularly and if its location makes draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should puta fine oil mist into the air line in direct proportion to the rate of air flow Excessive lubrication can cause puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute is adequate Note that this valve itself does not require air line lubrication but some optional adaptors do i e air index etc Compatible Lubricants Although this valve does not require air line lubrication it may be used with lubricated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components and so cause the valve to malfunction Avoid oils with phosphate additives e g zinc dithiophospha
114. E ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the U S A Rev 05 09 2009 ROSS CONTROLS All Rights Reserved Form SS156 Series W64 Valves Thank You You have purchased a premium quality ROSS pneumatic valve It is a single spindle poppet valve built to the highest standards With care in its installation and maintenance you can expect it to have a long and economical service life So before you go any further please take a few minutes to look over the information in this folder Then save it for future reference and for the useful service information it contains ROSS Series W64 valves are shown on bases and with electrical connectors purchased separately VALVE INSTALLATION Pneumatic equipment should be installed only by persons trained and experienced in such installation Air Lines Before installing a valve in a new or an existing system the air lines must be blown clean of all contaminants It is recommended that an air filter be installed in the inlet line c
115. E ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN ROSS CONTROLS United States TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS web site www rosscontrols com ROSS EUROPA GmbH Germany TEL 49 6103 7597 0 web site www rosseuropa com ROSS ASIA K K Japan TEL 81 427 78 7251 web site www rossasia co jp ROSS UK Ltd United Kingdom TEL 44 121 559 4900 email sales rossuk co uk ROSS SOUTH AMERICA Ltda Brazil TEL 55 11 4335 2200 email vendas ross sulamerica com br ROSS CONTROLS INDIA Pvt Ltd ROSS CONTROLS CHINA Ltd India China TEL 86 21 6915 7951 TEL 91 44 2624 9040 email rossindia airtelbroadband in email alvinzhurong vip 163 com DIMAFLUID s a s France TEL 33 01 49 45 65 65 web site www dimafluid com Printed in the U S A Rev 05 09 2009 ROSS CONTROLS All Rights Reserved Form SS302 DM Series C Control Reliable Double Valves Sizes 4 8 12 amp 30 Thank You You have purchased a premium qual
116. E BODIES 2 2 Normally Closed aan 3 2 Normally Open VALVE SERVICE 4 2 ROSS would be happy to service this valve for you at its factory repair center 1 800 GET ROSS However if you choose to service this valve yourself it is strongly recommended that you obtain a free service manual from ROSS in the U S A at 1 800 GET ROSS Valve Port Service Valve Body Gasket amp Type Size Type Kit Seal Kit 1 4 3 8 1 2 H 207K77 198K77 2 2 O 237K77 228K77 Normally 1 2 2 4 1 H 208K77 199K77 Closed O 238K77 229K77 1 114 1 H 209K77 200K77 O 239K77 230K77 1 4 3 8 1 2 H 213K77 198K77 2 2 O 243K77 228K77 Normally 1 2 2 4 1 H 214K77 199K77 Open O 244K77 229K77 1 114 1 H 215K77 200K77 O 245K77 230K77 1 4 3 8 1 2 H 219K77 201K77 3 2 O 249K77 231K77 Normally 1 2 2 4 1 H 220K77 202K77 Closed O 250K77 232K77 1 114 1 H 221K77 203K77 O 251K77 233K77 1 4 3 8 1 2 H 225K77 201K77 3 2 O 255K77 231K77 Normally 1 2 2 4 1 H 226K77 202K77 Open O 256K77 232K77 1 114 1 H 227K77 203K77 O 257K77 233K77 1 4 3 8 1 2 H 260K77 258K77 O 264K77 262K77 4 2 1 2 2 4 1 H 261K77 259K77 O 265K77 263K77 1 114 1 H 278K77 277K77 O 289K77 288K77 Consult ROSS Technical Services for high pressure and vacuum service kits 3 STANDARD CA
117. E P monitors operate independently to lock out the valve so that it cannot be cycled after a discordance in the shifting of the two main valve elements is detected Sometimes only one of the two monitors will lock out and other times both will lock out It is recommended that after a lock out occurs reset signals should be provided to both monitors in accordance with the instructions provided in the paragraphs above before attempting to resume normal operation VALVE MAINTENANCE Pneumatic equipment should be maintained only by persons trained and experienced in the maintenance of such equipment Supply Clean Air Foreign material lodging in valves is a major cause of breakdowns The use of a 5 micron rated air filter located close to the valve is strongly recommended The filter bowl should be drained regularly and if its location makes draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should put a fine oil mist into the air line in direct proportion to the rate of air flow Excessive lubrication can cause puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute is adequate Note that the double valve itself does not require air line lubrication Compatible Lubricants Although this valve does not require air line lubrication it may be used with lubricated air being supplied to other mechanisms So
118. HE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the U S A Rev 05 09 2009 ROSS CONTROLS All Rights Reserved Form SS095 ROSS Select 4400 High Pressure Valves 2 Thank You You have purchased a premium quality ROSS pneumatic valve Itis a ball poppet valve designed for base mounting and has been built to the highest standards With care in its installation and maintenance you can expect it to have a long and economical service life So before you go any further please take a few minutes to look over the information in this folder Then save it for future reference and for the useful service information it contains Primary 3 2 Valve Primary amp Pressure Select Valve 2 2 Valve Pressure Selector Valve with Flow Control Pressure Selector Valve VALVE INSTALLATION Pneumatic equipment should be installed only by persons trained and experienced in such installation Important Note Special care must be taken to prevent injury to humans and or damage to equipment when working with high pressure products Air Lines Before installing a valve in a new or an existing system the air lines must be blown clean of all contaminants It is recommended that an air filter be installed in the inlet line close to the valve Valve Inlet Port 1 Be sure that the supply line is of adequate size and does not res
119. H_EXH rae a ee Po 3e OPTIONAL 3 T i FRESSURE swicues TO EXTERNAL MONITORING DEVICE Model illustrated has two pressure switches Normal Operation After installation the valve is operated by energizing both pilot solenoids simultaneously This applies inlet air pressure to the pistons of both main valve elements and causes them to open so that inlet air port 1 flows to the outlet port 2 At this time the pressure switches have air and contacts 1 amp 4 on the pressure switch should be closed When the solenoids are de energized both main valve elements close Air no longer flows from inlet to outlet and downstream air is exhausted through port 3 At this time air is removed from the pressure switches and contacts 1 amp 2 on the pressure switches should be closed Detecting a Malfunction The valve MUST be connected to an external monitoring system so that if the main valve elements do not both open or close at the same time the monitor will detect this condition and lock the valve out so that it cannot be cycled For further information in the use or connection of the pressure switches call ROSS Technical Service at 1 888 TEK ROSS VALVE MAINTENANCE Pneumatic equipment should be maintained only by persons trained and experienced in the maintenance of such equipment Supply Clean Air Foreign material lodging in
120. IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the U S A Rev 05 09 2009 ROSS CONTROLS All Rights Reserved Form SS280 Series 1 9 Flow Control Valves and Check Valves ROSS Thank You You have purchased a premium quality ROSS pneumatic valve It is designed for in line mounting and has been built to the highest standards With care in its installation and maintenance you can expect it to have a long and economical service life Please take a few minutes to look over the following information and save it for the useful service information it contains vee Check Valve 2 1 Flow Control VALVE INSTALLATION Pneumatic equipment should be installed only by persons trained and experienced in such installation Air Lines Before installing a valve in a new or an existing sys
121. In most cases it is not necessary to remove the valve from its installation for servicing However turn off the electrical power to the valve shut off the air supply and exhaust the air in the system before beginning any disassembly operation Service kits are listed on page 3 2 ROSS CONTROLS VALVE SPECIFICATIONS COMPATIBLE LUBRICANTS Brand Name American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Pacemaker 32 Spinesstic 22 Teresstic 32 Maker Velocite 10 Turbo T32 Sunvis 11 Sunvis 722 Regal R amp O 32 Union Turbine Oil IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 Solenoids Two rated for continuous duty Voltage and hertz ratings shown on pilot housing Power Consumption Each solenoid 18 VA inrush 14 VA holding on AC 6 watts on DC Temperature Range Ambient 40 to 120 F 4 to 50 C Media 40 to 175 F 4 to 80 C Flow Media Filtered air 5 micron recommended Inlet Pressure 40 to 150 psig 2 5 to 10 bar Pilot Pressure Supplied internally from inlet port Pressure Switch Rating Contact 4 amps at 250 volts AC max 250 volts AC VALVE SERVICE Ross would be happy to service this specialized valve for you at its factory repair center 1 800 GET ROSS For servicing the valve yourself the needed service kits and components are described below Valve Body Service Kits These kits contain all parts needed for comp
122. KE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and L O X with EEZ ON operation products are defined as e
123. LVE SPECIFICATIONS Pressure Controlled Temperature Range 40 to 175 F 4 to 80 C Flow Media Filtered air 5 micron recommended Inlet Pressure Vacuum to 150 psig 10 bar 16 bar optional consult ROSS Pilot Pressure At least 30 psig 2 bar IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 Solenoid Pilot Solenoids Rated for continuous duty Voltage and hertz ratings shown on valve Power Consumption Each solenoid 6 5 VA holding on 50 or 60 Hz 3 5 watts on DC Temperature Range Ambient 40 to 120 F 4 to 50 C Media 40 to 175 F 4 to 80 C Flow Media Filtered air 5 micron recommended Inlet Pressure Vacuum to 150 psig 10 bar 235 psig 16 bar also available consult ROSS Pilot Pressure At least 30 psig 2 bar 2 ROSS CONTROLS VALVE OPERATION 5 2 SINGLE CONTROL VALVES 4 2 4 2 513 51413 Pressure Controlled Solenoid Pilot No Signal Applied Inlet 1 connected to outlet 2 outlet 4 connected to exhaust 5 exhaust 3 closed Signal 14 Applied Inlet 1 connected to outlet 4 outlet 2 connected to exhaust 3 exhaust 5 closed 5 2 MOMENTARY CONTROL VALVES 4 2 4 2 14 12 14 12 543 543 Solenoid Pilot Pressure Controlled Signal 12 Applied Momentarily Inlet 1 connected to outlet 2 outlet 4 connected to exhaust 5 exhaust 3 closed Signal 14 Applied Momentarily Inlet 1 connected to outlet 4 Out
124. NTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the U S A Rev 05 09 2009 ROSS CONTROLE All Rights Reserved Form SS110 R Series W60 ENERGYSAVER Valves oO Thank You You have purchased a premium quality ROSS pneumatic valve It is a stainless steel spool and sleeve valve built to the highest standards With care in its installation and maintenance you can expect it to have along and economical service life So before you go any further please take a few minutes to look over the information in this folder Then save it for future reference and for the useful service information it contains VALVE INSTALLATION Pneumatic equipment should be installed only by persons trained and experienced in such installation APPLICATION WARNING When inlet pressure is 45 psig 3 bar or less the double and single solenoid ENeERGySAver valves will pressurize port 2 and exhaust port 4 regardless of applied solenoid signals This f
125. O X and L O X with EEZ ON operation products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the U S A Rev 05 09 2009 ROSS CONTROLS
126. OSS AS SET FORTH HEREIN Printed in the U S A Rev 05 07 2007 2008 ROSS CONTROLS All Rights Reserved Form SS190 Series Tf Sizes 2 and 4 5 2 CrossMirror Pressure Controlled Double Valve Thank You EE You have purchased a premium quality ROSS pneumatic valve It is a control reliable pressure control i 4 way double valve that is controlled by two separate pneumatic signals essentially providing AND oe gate control for the output ports Both air pilot signals must be provided within approximately 500 ess milliseconds of each other to actuate the valve If the valve is not actuated not provided appropriate pneumatic signals within the discordance window or if the valve actuates abnormally inlet pressure ige will only be passed to port 2 Proper actuation shifts output pressure to port 4 gt RS This valve is constructed with precision stainless steel spools as the main valve elements and is lt gt designed to offer added safety to the operation of many pneumatic pneumatically controlled machines IMPORTANT NOTE This Valve is Not Designed for Controlling Clutch Brake Mechanisms a J on Mechanical Power Presses With care in its installation and maintenance you can expect it to have a long and reliable service life Before you go any further please take a few minutes to look over the information in this folder and save it for future reference E ee eee i Pneumatic equipment should be insta
127. OVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the U S A Rev 05 09 2009 ROSS CONTROLS All Rights Reserved Form SS266 Series W60 Valves Thank You You have purchased a premium quality ROSS pneumatic valve It is a stainless steel spool and sleeve valve built to the highest standards With care in its installation and maintenance you can expect itto have along and economical service life So before you go any further please take a few minutes to look over the information in this folder Then save it for future reference and for the useful service information it contains VALVE INSTALLATION Pneumatic equipment should be installed only by persons trained and experienced in such installation Air Lines Before installing a valve in a new or an existing system the air lines mu
128. P1 LF1 eee eae Series CP 3 2 NC 1 2 inlet 1467B79 Closed 1 1 2299H77 Series CP 2 2 NO 1 2 amp 1 inlet 1468B79 2 22 2300H77 Series CP 3 2 NO 1 2 inlet 1468B79 Series CP 2 2 1 amp 2 2 inlet 1404H79 2 2 A L 2 Pead Series LF 2 2 except 3 8 and 1 2 1404H79 Open 1 1 2299H77 Series LF 2 2 3 8 amp 1 2 1469H79 2 2 2300H77 Solenoids Replacement solenoids can be ordered by the part numbers listed below Specify the required voltage and hertz 3 2 GPI 3 8 1 2 2296H77 when ordering Normally 3 4 4 2298H77 Series CP 2 2 NC 1 2 amp 1 inlet 1467B79 Closed Series CP 3 2 NC 1 2 inlet 1467B79 3 2 Series CP 2 2 NO 1 2 amp 1 inlet 1468B79 CP4 3 8 1 2 2296H77 i i Normally Series CP 3 2 NO 1 2 inlet 1468B79 Open 3 4 1 2298H77 Series CP 2 2 1 amp 2 inlet 360K33 Series CP 3 2 1 inlet 360K33 Series LF 2 2 except 3 8 and 1 2 inlet 360K33 Series LF 2 2 3 8 amp 1 2 308K33 If you have any questions about installing or servicing your valve call ROSS Technical Services at your nearest ROSS location see page 1 or in the U S A at 1 888 TEK ROSS or 1 706 356 3708 www rosscontrols com 3 Dale Series LT Leak Test Solenoid Pilot Valve amp Manifolds Thank You You have purchased a premium quality ROSS pneumatic valve It is a leak tight compact solenoid pilot valve designed with metal internals and has been built to the h
129. PRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the U S A Rev 05 09 2009 ROSS CONTROLS All Rights Deserved Form SS105 Series 1 5 and L O X with EEZ ON Operation Valves w Blue handie Manual L O X Valves w Red handie ROSS Thank You You have purchased a premium quality ROSS pneumatic valve It is a high quality energy isolation valve for international standards compliance designed for in line mounting With care in its installation and maintenance you can expect it to have a long and economical service life Before you install this valve read the information in this folder completely and save it for future reference VALVE INSTALLATION IMPORTANT NOTE Per specifications and regulations these valves are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES Pneumatic equipment should be installed only by persons trained and experienced in such installation AL O X or L O X with EEZ ON operation valve can be installed in the main or a branch line of an air system L O X or L O X with EEZ ON Pneumatic System Operation Valve NOTE The L O X and the L O X with EEZ ON operation valves are similar in appearance but different in that the L O X valve has a red handle and the L O X with EEZ ON operation valve has a blue handle The operating functions of the two types of valve differ in the f
130. ROSS Series 1 1 and 1 2 Valves eal Thank You You have purchased a premium quality ROSS pneumatic valve It is a hand or cam operated poppet valve designed for inline mounting and built to the highest standards With care in its installation and maintenance you can expect it to have a long and economical service life Please take a few minutes to look over the accompanying information and save it for future reference VALVE INSTALLATION Pneumatic equipment should be installed only by persons trained and experienced in such installation Cam Valves To operate properly and avoid damage to the valve cam operators must be moved by the operating cam only within the following limits Plunger 0 07 to 0 25 inch Roller 0 10 to 0 29 inch One way roller 0 05 to 0 10 inch Air Lines Before installing the valve in your system the air lines must be blown clean of all contaminants It is recommended that an air filter be installed in the circuit Valve Inlet Port 1 Be sure the inlet line is of adequate size and does not restrict the air supply because of a crimp in the line sharp bends or a clogged filter element Valve Outlet Port 2 For best response and control of the mechanism being operated by the valve locate the valve as close as possible to this mechanism The lines must be of adequate size and free of crimps and sharp bends Valve Exhaust Port 3 Exhaust of 3 way valves is unported Operating Pressur
131. RPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN ROSS CONTROLS United States TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS web site www rosscontrols com ROSS EUROPA GmbH ROSS ASIA K K ROSS UK Ltd ROSS SOUTH AMERICA Ltda ROSS CONTROLS INDIA Pvt Ltd ROSS CONTROLS CHINA Ltd DIMAFLUID s a s TEL 49 6103 7597 0 TEL 81 427 78 7251 TEL 44 121 559 4900 TEL 55 11 4335 2200 TEL 91 44 2624 9040 TEL 86 21 6915 7951 TEL 33 01 49 45 65 65 Germany Japan United Kingdom Brazil India China France web site www rosseuropa com web site www rossasia co jp email sales rossuk co uk email vendas ross sulamerica com br email rossindia airtelbroadband in email alvinzhurong vip 163 com web site www dimafluid com Printed in the U S A Rev 05 09 2009 ROSS CONTROLS All Rights Reserved Form SS303 DM Series S Double Valves Sizes 12 amp 30 Thank You You have purchased a premium quality ROSS pneumatic valve It is a h
132. Regal R amp O 32 UNION Union Turbine Oil To clean the valve use any good commercial solvent Do not scrape varnished surfaces Also do notuse chlorinated solvents or abrasive materials The former damages seals and abrasives can do permanent damage to metal parts Before reassembling the valve lubricate all sliding surfaces with a grease such as MobilGrease 28 Electrical Contacts In the electrical circuits associated with the valve solenoids keep all switches or relay contacts in good condition to avoid solenoid malfunctions Replace Worn Components In most cases it is not necessary to remove the valve from its installation for servicing However turn off the electrical power to the valve shut off the air supply and exhaust the air in the system before beginning any disassembly operation Service kits are listed on page 3 ROSS CONTROLS VALVE SPECIFICATIONS Pilot Solenoid Two rated for continuous duty Electrical Connections Terminal Strip Standard Voltages 100 110 volts 50 Hz Ambient Temperature 40 to 120 F 4 to 50 C 100 120 volts 60 Hz 24 volts DC Media Temperature 40 to 175 F 4 to 80 C Power Consumption Each solenoid 87 VA inrush 30 VA Flow Media Filtered air 5 micron recommended holding on 50 or 60 Hz 14 watts on DC Inlet Pressure 30 to 125 psig 2 to 8 5 bar E P Reset Solenoid Rated for intermittent duty Standard L G Reset Pressure 60 psig 4 bar minimum V
133. S SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the U S A Rev 05 09 2009 ROSS CONTROLS All Rights Reserved Form SS161 Series of Valves amp Adaptors ROSS Thank You You have purchased a premium quality ROSS pneumatic valve It is a poppet valve designed for inline mounting and has been built to the highest standards With care in its installation and maintenance you can expectit to have along and economical service life So before you go any further please take a few minutes to look over the information in this folder Then save it for future reference and for the useful service information it contains A general service manual with more detailed information is available from ROSS upon request For information on Series 27 adaptors see pages 3 amp 4 Double Solenoid Pressure Controlled Valve Valve Single Solenoid Pilot Valve VALVE INSTALLATION Pneumatic equipment should be installed only by persons trained and experienced in such installation Important Note ROSS Series 27 valves are not designed as control valves for air clutch brake mechanisms on mechanical power presses and must not be installed forsuch use Only double valves conforming to OSHA standards shall be used in such applications Air Lines Before installing a valve in a new or an existing system the air lines must be blown clean of all contaminants It is recommended that an air filter b
134. TAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and L O X with EEZ ON operation products are defined as
135. TICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the U S A Rev 05 09 2009 ROSS CONTROLS All Rights Reserved Form SS301 DM2 Series D Double Valves Sizes 4 8 12 amp 30 Thank You You have purchased a premium quality ROSS pneumatic valve It is a high quality DM Series D double valve with dynamic monitoring and inherent lockout capability The valve is designed for base mounting for ease of installation and maintenance With care in its installation and maintenance you can expect it to have a long and economical service life Before you install this valve read the information in this folder completely and save it for future reference Size 12 amp 30 VALVE INSTALLATION Pneumatic equipment should be installed only by persons trained and experienced in such installation Air Lines Before installing this valve in a new or existing system the air lines must be blown clean of all contaminants It is recommended that a 5 micron rated air
136. UBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakage and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components potentially leading to valve failure and or human injury AVOID INTA
137. UTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing
138. Worn Components After long usage the spool and sleeve may show signs of wear as indicated by excessive air leakage between ports The valve can be completely reconditioned with the use of a ROSS valve body service kit See page 3 for information about such kits VALVE SPECIFICATIONS Pressure Controlled Temperature Range 4 to 80 C 40 to 175 F Flow Media Filtered air 5 micron recommended Inlet Pressure Vacuum to 10 bar 150 psig Pilot Pressure Size 1 At least 2 bar 30 psig Sizes 2 and 3 At least 1 bar 15 psig IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 Solenoid Pilot Solenoids Rated for continuous duty Voltage and Hertz ratings printed on solenoid coils Power Consumption 8 VA inrush 6 VA holding on 50 or 60 Hz 6 watts on DC Temperature Ranges Ambient 4 to 50 C 40 to 120 F Media 4 to 80 C 40 to 175 F Flow Media Filtered air 5 micron recommended Inlet Pressure Vacuum to 10 bar 150 psig Pilot Pressure Size 1 At least 2 bar 30 psig Sizes 2 and 3 At least 1 bar 15 psig 2 ROSS CONTROLS Typical cross section of a ROSS Series W60 spool and sleeve valve body Spring return model shown VALVE SERVICE Listed below are the parts and service kits most likely to be needed if your valve requires service Valve M
139. X with EEZ ON operation products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the U S A 05 09 2009 ROSS CONTROLS All Rights Reserved
140. Z cord not included For additional wiring kit accessories please see Form NPS011 available at www rosscontrols com VALVE SERVICE ROSS would be happy to service this specialized double valve for you at its factory repair center Call your local distributor or in the U S 1 800 GET ROSS 706 356 3708 outside the U S for information If you service the valve yourself be sure to turn off electrical power to the valve shut off the air supply exhaust the air in the system and lock out all power sources before beginning any disassembly operation Listed below are kits for servicing DM2 Series E double valves as well as replacement solenoid information CAUTION Before operating the DM Series E double valve be sure to complete the test procedure on page 1 upon installation and after any maintenance is performed on the valve Failure to do so could result in personal injury or equipment damage Valve Body Service Kit This kit is used for complete reconditioning of a valve body and includes poppets spindles gaskets seals and instructions for use Order kit number 2279K77 Gasket and Seal Kit This kit is used when valve bodies are disassembled for cleaning and includes all the necessary gaskets O rings and other seals Order kit number 2280K77 Status Indicator Assembly Service Kit This kit is used for complete reconditioning of the status indicator assembly Pressure switch and connector sold separately se
141. a Filtered air 5 micron recommended Inlet Pressure Solenoid Pilot Vacuum to 145 psig 10 bar vacuum service requires external pilot supply Pressure Controlled Vacuum to 250 psig 17 bar Pilot Pressure Must be equal to or greater than inlet pressure For vacuum service models requiring external pilot supply a pilot pressure of at least 30 psig is required IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 2 ROSS CONTROLS CONVERSION TO EXTERNAL PILOT SUPPLY External pilot supply Your ROSS valve may be converted to external pilot gt port X supply by simply installing a 10 32 or 1 8 air supply to the X 1 port on the base manifold See figure on the right VALVE SERVICE ROSS would be happy to service this valve for you at its factory repair center 1 800 GET ROSS However if you choose to service this valve yourself it is strongly recommended that you obtain a free service manual from ROSS in the U S A at 1 800 GET ROSS Valve Body Service Kits These kits contain all parts needed for complete reconditioning of a valve body Included are poppets spindle all required gaskets and seals and instructions for use Valve Model Port Valve Body Solenoid Pilot Kits These kits contain all parts needed Type Type Size Kit ee the pilot valve Order by the following kit 2 2 3 8 1 2 2295H77 Series CP 2 2 NC 1 2 amp 1 inlet 1467B79 Normally C
142. a clogged filter element The air supply must not only provide sufficient pressure see Standard Specifications page 3 but must also provide an adequate flow of air on demand Otherwise the valve elements will be momentarily starved for air and the valve may fail to operate Valve Outlet Port 2 For faster pressurizing and exhausting of the mechanism being operated by the valve locate the valve as close as possible to the mechanism The lines must be of adequate size and be free of crimps and sharp bends Valve Exhaust Port 3 Do not restrict the air flow from the exhaust port as this can adversely affect the operation of the valve The valves are factory equipped with a properly sized silencer ROSS MUFFL AIR silencers reduce impact noise by as much as 25 dB and produce little back pressure Reset Solenoid DM Series C double valves are supplied with a 3 2 normally closed solenoid valve for reset purposes Electrical reset signal must be momentary and of correct voltage Electrical Supply DM Series C double valves get electrical power through plug in connectors The electrical supply must correspond to the voltage and hertz ratings of the solenoids Otherwise the solenoids are subject to early failure If power is supplied by a transformer it must be capable of handling the inrush current without significant voltage drop See Standard Specifications on page 3 for current data Operating Pressures and Temperatures Allowable r
143. a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and L O X with EEZ ON operation products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS
144. acts 3 on DC versions During normal operation the pressure switch is pressurized Alockout condition depressurizes the switch until the valve is reset Contacts 1 and 2 are closed when the switch is depressurized normally closed and contacts 1 and 4 are closed when an adequate pressure signal is applied to the switch normally open On AC models contact 3 is to be used as a ground connection ROSS CONTROLS United States TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS web site www rosscontrols com ROSS EUROPA GmbH Germany TEL 49 6103 7597 0 web site www rosseuropa com ROSS ASIA K K Japan TEL 81 427 78 7251 web site www rossasia co jp ROSS UK Ltd United Kingdom TEL 44 121 559 4900 email sales rossuk co uk ROSS SOUTH AMERICA Ltda Brazil TEL 55 11 4335 2200 email vendas ross sulamerica com br ROSS CONTROLS INDIA Pvt Ltd India TEL 91 44 2624 9040 email rossindia airtelbroadband in ROSS CONTROLS CHINA Ltd China TEL 86 21 6915 7951 email alvinzhurong vip 163 com DIMAFLUID s a s France TEL 33 01 49 45 65 65 web site www dimafluid com VALVE OPERATION On first operation or after the main air supply has been removed and restored the pilot valve supply circuit and inherent monitoring elements must be reset This reset is accomplished by applying a momentary air signal to the RESET port or by energizing the optional reset solenoid momentarily on the sub base After reset the valv
145. additives that can harm seals or other valve components and so cause the valve to malfunction Avoid oils with phosphate additives e g zinc dithiophosphate and diester oils both types can harm valve components The best oils to use are generally petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Some compatible oils are listed above at the right These oils although believed to be compatible could change without notice because manufacturers sometimes reformulate their oils Therefore use oils specifically compounded for air line service If it is a synthetic oil contact the oil manufacturer for compatibility information Cleaning the Valve If the air supplied to the valve has not been well filtered the interior of the valve may accumulate dirt and varnish which can affect the valve s performance COMPATIBLE LUBRICANTS Brand Name American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Pacemaker 32 Spinesstic 22 Teresstic 32 Velocite 10 Turbo T32 Sunvis 11 Sunvis 722 Regal R amp O 32 Union Turbine Oil A schedule should be established for cleaning all valves the frequency depending on the cleanliness of the air being supplied To clean the valve use any good commercial solvent Do not scrape varnished surfaces Also do not use chlorinated solvents or abrasive materials The former damages seals and abrasives can d
146. after fault condition occurs Electrical Connectors Wired connectors have a 2 meter 6 1 2 ft cord with three 18 gauge conductors Cord is available in either 6 mm or 10 mm diameter and with or without indicator light Specify solenoid voltage for lighted connectors Without Light With Light Wired with 6 mm cord 721K77 720K77 Wired with 10 mm cord 371K77 383K77 For threaded conduit 723K77 724K77 For use with drop cord 937K87 836K87 cord not included VALVE SERVICE ROSS would be happy to service this specialized double valve for you at its factory repair center Call your local distributor or in the U S 1 800 GET ROSS 706 356 3708 outside the U S for information If you service the valve yourself be sure to turn off electrical power to the valve shut off the air supply exhaust the air in the system and lock out before beginning any disassembly operation Listed below are kits for servicing Size 2 4 and 8 CrossMirror double valves as well as replacement solenoid information NOTE Before operating the CrossMirror double valve be sure to complete the test procedure TEST on page 1 upon installation and after any maintenance is performed on the valve Failure to do so could result in personal injury or equipment damage Valve Body Service Kits These kits contain all parts needed for complete reconditioning of a valve body Included are poppets spindles gaskets seals and instructions for use SIZO2 ai is ti
147. age 2 Exceeding the values shown can shorten valve life Pilot Supply Pressure Control For valves with single remote pressure control connect the control line to port 14 in the sub base or manifold For valves with double remote pressure control connect the control lines to ports 12 and 14 in the base See Valve Specifications on page 2 for required pressures Solenoid Control Pressure for the pilot valves is supplied from the inlet port Be sure that port 14 in the base is plugged or pilot air will escape If the valve must operate with an inlet pressure less than the required pilot pressure see Valve Specifications on page 2 an external pilot supply of sufficient pressure must be provided Connect the external pilot supply to port 14 in the base Non Air Service Such applications require an external pilot supply for solenoid valves Connect to port 14 in the base Consult ROSS Technical Services for fluid media other than air Pipe Installation To install pipe in valve or base ports engage pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating the valve web site www rosscontrols com ROSS EUROPA GmbH Germany TEL 49 6103 7597 0 web site www rosseuropa com ROSS ASIA K K Japan TEL 81 427 78 7251 web site www rossasia co jp ROSS UK Ltd United Kingdom TEL 44 121 559 4900 email sales rossuk co uk
148. air the inlet shutoff included in the bases for size 2 valves SiZ6i2 ana ni 2007K77 IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 If you need additional information or have any questions about installing or servicing your valve call ROSS Technical Services in the U S A at 1 888 TEK ROSS 835 7677 or 1 706 356 3708 www rosscontrols com 3 STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS pr
149. aken not to reverse the position of the spool in the sleeve Before inserting the spool and sleeve into the valve body very lightly lubricate the O rings with a lubricant such as those shown above Do not use Anderol it causes the O rings to deteriorate Electrical Contacts In the electrical circuits associated with the valve solenoids keep all switches or relay contacts in good condition to avoid solenoid malfunctions Replace Worn Components In most cases it is not necessary to remove the valve from its installation for servicing However turn off the electrical power to the valve shut off the air supply and exhaust the air in the system before beginning any disassembly operation Service kits are listed on page 3 2 ROSS CONTROLS COMPATIBLE LUBRICANTS Brand Name American Industrial Oil 32 Maker Spindle Oil C Amolite 32 Pacemaker 32 Spinesstic 22 Teresstic 32 Velocite 10 Turbo T32 Sunvis 11 Sunvis 722 Regal R amp O 32 Union Turbine Oil VALVE SPECIFICATIONS IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 Temperature Range Ambient 40 to 120 F 4 to 50 C Media 40 to 175 F 4 to 80 C Flow Media Filtered air 5 micron recommended Inlet Pressure 40 to 100 psig 2 5 to 7 0 bar Pilot Pressure Must be equal or greater than inlet pressure but should not exceed maximum inlet pressure Pressure Switch Rating Max Current 4A Max 250
150. al Services at your nearest 8077B6341 1252K77 352B11 ROSS location see page 1 or in the U S A at 8077B6342 1255K77 352B11 8077B6351 1252K77 352B11 1 888 TEK ROSS or 1 706 356 3708 8077B6352 1255K77 352B11 www rosscontrols com STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury FILTRATION and
151. al distributor or in the U S 1 800 GET ROSS for information If you service the valve yourself be sure to turn off electrical power to the valve shut off the air supply and exhaust the air in the system before beginning any disassembly operation Listed below are kits for servicing Size 1 and 2 Crossflow double valves as well as replacement solenoid information Valve Body Service Kits These kits contain all parts needed for complete reconditioning of a valve body Included are poppets spindles gaskets seals and instructions for use SIZ6AMia sick ccscet ce kee 1579K77 Siza 2s rona laaan A 1581K77 Gasket and Seal Kits These kits are needed when valve bodies are disassembled for cleaning They include all necessary gaskets O rings and other seals These parts are included in the Valve Body Service Kits above SiZ Jii 1580K77 S ZE ct os aA 1652K77 Solenoid Coils Order replacement solenoid coils by the following part numbers Specify voltage and hertz when ordering SIZE 1s niee 308K33 SIZE 2 savtitasscteaesacigte ees 306K33 Complete Solenoid Pilot Assemblies These assemblies consist of new pilot valve mechanisms and a new solenoid coil ready to bolt in position on the valve Specify voltage and hertz when ordering SIZE 1 ideas wei ies 936C79 S Zo weer ea adel 851C79 www rosscontrols com 3 STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component
152. alling or servicing your valve call ROSS Technical Services in the U S A at 1 888 TEK ROSS 835 7677 or 1 706 356 3708 www rosscontrols com 3 STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Alth
153. alve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute is adequate Note that the double valve itself does not require air line lubrication Compatible Lubricants Although this valve does not require air line lubrication it may be used with lubricated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components and so cause the valve to malfunction Avoid oils with phosphate additives e g zinc dithiophosphate and diester oils both types can harm valve components The best oils to use are generally petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Some compatible oils are listed above at the right These oils although believed to be compatible could change without notice because manufacturers sometimes reformulate their oils Therefore use oils specifically compounded for air line service If it is a synthetic oil contact the oil manufacturer for compatibility information Cleaning the Valve If the air supplied to the valve has not been well filtered the interior of the valve may accumulate dirt and varnish which can affect the valve s performance This can cause sluggish or erratic valve action and nuisance lockouts A schedule should be established for cleaning all valves the frequency depending on the cleanliness of the air being
154. alve must be connected to an external monitoring system which ensures that press operation will be inhibited in the event of a malfunction Valves with E P L G or D S Monitor Both solenoids must be de energized before resetting the monitor Otherwise the press or other mechanism can cycle immediately and could result in personal injury and or property damage Valves with E P Monitor This product is a dual input device which requires two separate and distinct inputs Connect inputs only to terminals 1 3 amp 5 Using a single input or connecting an input to a terminal other than 1 3 amp 5 could result in personal injury and or property damage Pneumatic equipment should be installed only by persons trained and experienced in such installation Air Lines Before installing a valve in a new or an existing system the air lines must be blown clean of all contaminants It is recommended that a 5 micron rated air filter be installed in the inlet line close to the valve Valve Inlet Port 1 Be sure that the supply line is of adequate size and does not restrict the air supply because of a crimp in the line a sharp bend or a clogged filter element The air supply must not only provide sufficient pressure see Valve Specifications page 3 but must also provide an adequate flow of air on demand Otherwise the valve elements will be momentarily starved for air and the valve may be locked out by the monitoring system Valve Outlet Port
155. an TEL 81 427 78 7251 web site www rossasia co jp email sales rossuk co uk email vendas ross sulamerica com br email rossindia airtelbroadband in email alvinzhurong vip 163 com web site www dimafluid com TEL 44 121 559 4900 TEL 55 11 4335 2200 TEL 91 44 2624 9040 TEL 86 21 6915 7951 TEL 33 01 49 45 65 65 ROSS UK Ltd ROSS SOUTH AMERICA Ltda ROSS CONTROLS INDIA Pvt Ltd ROSS CONTROLS CHINA Ltd DIMAFLUID s a s United Kingdom Brazil India China France VALVE OPERATION On first operation or after repair the pilot valve supply circuit and inherent monitoring elements may need to be reset This reset is accomplished by applying a momentary air signal to the RESET port or by energizing the optional reset solenoid momentarily on the valve After reset the valve will then be ready for operation The air supply to each pilot valve is controlled by the position of the inlet poppets In the ready for operation position these poppets are held on their seats and maintain pilot air flow During shifting of the valve elements the poppets move off seat and momentarily allow pilot air to escape to exhaust If either valve element fails to operate correctly the pilot supply to the other valve element will remain connected to exhaust causing the valve to lock out The internal monitoring system will lock out the valve if the time difference between both elements shifting fully is longer than app
156. and may need to be serviced VALVE MAINTENANCE Pneumatic equipment should be maintained only by persons trained and experienced in the maintenance of such equipment Supply Clean Air Foreign material lodging in valves is a major cause of breakdowns The use of a 5 micron rated air filter located close to the valve is strongly recommended The filter bowl should be drained regularly and if its location makes draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should put a fine oil mist into the air line in direct proportion to the rate of air flow Excessive lubrication can cause puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute is adequate Note that the double valve itself does not require air line lubrication Compatible Lubricants Although this valve does not require air line lubrication it may be used with lubricated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components and so cause the valve to malfunction Avoid oils with phosphate additives e g zinc dithiophosphate and diester oils both types can harm valve components The best oils to use are generally petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Some compatible oils ar
157. and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components potentially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically controll
158. anges for pressure and temperatures are given in the Standard Specifications on page 3 Exceeding these values can adversely ROSS CONTROLS United States TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS affect performance and shorten valve life Pipe Installation To install pipe in base ports engage pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating the valve To install pipe with parallel threads e g SAE ISO 228 G etc do not use sealant After installing pipe into the base ports use compressed air to blow any debris out of the piping then install the valve onto the base Test After installation or repair and prior to normal use the internal lockout feature of the DM Series C double valve must be tested for proper functioning Observe normal equipment operation safety precautions during these tests to avoid personal injury or damage to equipment NOTE Reset may need to be performed prior to beginning the test procedure Also the valve is designed such that both pilot solenoids must be de energized prior to reset and must remain de energized until after the reset signal is removed Otherwise the valve will not reset A Electrically energize both pilot solenoids simultaneously then de energize one pilot solenoid This should result in a valve lockout and prevent the valve from operating B Energize both solenoid
159. aning the Valve If the air supplied to the valve has not been well filtered the interior of the valve may accumulate dirt and varnish which can affect the valve s performance A schedule should be established for cleaning all valves VALVE SPECIFICATIONS Pressure Controlled Switch Current Voltage Max 2 5 A 120 volts AC Switch Current Voltage Min 20 mA 24 volts DC Temperature Range 40 to 175 F 4 to 80 C Flow Media Filtered air 5 micron recommended Inlet Pressure 40 to 150 psig 2 8 to 10 bar Pilot Pressure Must be equal to or greater than inlet pressure IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 COMPATIBLE LUBRICANTS Brand Name American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Pacemaker 32 Spinesstic 22 Teresstic 32 Velocite 10 Air Lube 10H NR Turbo T32 Sunvis 11 Sunvis 722 Regal R amp O 32 Union Turbine Oil the frequency depending on the cleanliness of the air being supplied To clean the valve use any good commercial solvent Do not scrape varnished surfaces Also do not use chlorinated solvents or abrasive materials The former damages seals and abrasives can do permanent damage to metal parts Before reassembling the valve lubricate all sliding surfaces with a grease such as MobilGrease 28 Electrical Contacts In the electrical circuits associated with the valve solenoids keep all switches or relay contacts in
160. apacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and L O X with EEZ ON operation products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discret
161. asket amp Type Sizes Kit Number Seal Kit 2 2 1 4 3 8 1 2 501K87 513K87 Normally 1 2 3 4 1 502K87 514K87 Closed 1 1 1 503K87 515K87 1 2 2 547H77 2 2 1 4 3 8 1 2 504K87 513K87 Normally 1 2 3 4 1 505K87 514K87 Open 1 114 1 2 506K87 515K87 1 2 2 548H77 E 3 2 1 4 3 8 1 2 495K87 510K87 Normally 1 2 3 4 1 496K87 511K87 Closed 1 114 1 497K87 512K87 1 2 2 814K77 3 2 1 4 3 8 1 2 498K87 510K87 Normally 1 2 3 4 1 499K87 511K87 Open 1 114 1 500K87 512K87 1 2 2 550H77 1 4 3 8 1 2 492K87 507K87 4 2 1 2 3 4 1 493K87 508K87 1 1 1 494K87 509K87 Except EEZ ON adaptors Consult ROSS for information If you have any questions about installing or servicing your valve callROSS Technical Services at your nearest ROSS location see page 1 or in the U S A at 1 888 TEK ROSS or 1 706 356 3708 STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the
162. ated for continuous duty Voltage and hertz ratings shown on pilot housing Power Consumption Single Solenoid 87 VA inrush 30 VA holding on AC 14 watts on DC Double Solenoid Each solenoid 190 VA inrush 40 VA holding on AC 20 watts on DC Ambient Temperature Type H 0 to 250 F 17 to 122 C Type O 40 to 120 F 40 to 50 C Media Temperature Type H 0 to 300 F 17 to 150 C Type O 40 to 175 F 40 to 80 C Flow Media Filtered air 5 micron recommended Inlet Pressure 1 4 to 1 1 2 Port Sizes 15 to 150 psig 1 to 10 bar 1 1 2 to 2 1 2 Port Sizes 30 to 150 psig 2 to 10 bar Pilot Pressure Must be equal to or greater than inlet pressure For vacuum service models requiring external pilot supply a pilot pressure of at least 30 psig is required 2 ROSS CONTROLS CONVERSION TO EXTERNAL PILOT SUPPLY When a valve is converted to external pilot supply consult ROSS for the converted valve s model number This will allow records and drawings to be changed and prevent errors when ordering future replacements INLINE POPPET VALVES See Figure 1 1 Remove pilot section and adaptor plate from valve body 2 Remove pipe plug from external pilot supply port and reinstall the plug in the internal pilot supply passage Replace pilot section 3 4 Attach 1 8 pilot supply line to external plot supply port X 1 5 External pilot supply pressure must be at least equal to t
163. ations and regulations ROSS L O X and L O X with EEZ ON operation products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the U S A Rev
164. ations on page 2 Exceeding the values shown can shorten valve life Pipe Installation To install pipe in valve or base ports engage pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating the valve Ford Wired 5 pin mini connector all voltages Ford Wired 4 pin mini connector 24 vdc Chrysler Wired 5 pin mini connector all voltages Chrysler Wired 5 pin micro connector 24 vdc Chrysler Wired 5 pin micro connector 120 volts 60 Hz TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS LIGHT LIGHT LIGHT LIGHT LIGHT LIGHT LIGHT LIGHT Get B LIGHT ee i 2 Cy ea LIGHT web site www rosscontrols com ROSS EUROPA GmbH Germany TEL 49 6103 7597 0 web site www rosseuropa com ROSS ASIA K K Japan TEL 81 427 78 7251 web site www rossasia co jp ROSS UK Ltd United Kingdom TEL 44 121 559 4900 email sales rossuk co uk ROSS SOUTH AMERICA Ltda Brazil TEL 55 11 4335 2200 email vendas ross sulamerica com br ROSS CONTROLS INDIA Pvt Ltd India TEL 91 44 2624 9040 email rossindia airtelbroadband in ROSS CONTROLS CHINA Ltd China TEL 86 2
165. ay accumulate dirt and varnish which can affect the valve s performance by causing sluggish or erratic valve action which can result in the valve defaulting A schedule should be established for cleaning all valves the frequency depending on the cleanliness of the air being supplied To clean the valve use a solvent which will dry without leaving a residue This is especially important for the spool and sleeve assembly Do not use a chlorinated solvent or abrasive materials which can damage seals or metal parts Do notscrape varnished surfaces To reassemble the spool and sleeve put one drop of Anderol 735 or equivalent lubricant on each spool land Insert the spool into the sleeve and rotate it several times to ensure even distribution of the lubricant If the valve is used in a non lubricated application do not use a lubricant for reassembly which can dry out or leave a residue Dry assembly of the spool and sleeve is preferable Each spool and sleeve is a matched set so care must be taken not to reverse the position of the spool in the sleeve Before inserting the spool and sleeve into the valve body very lightly lubricate the O rings with a lubricant such as those shown above Do not use Anderol it causes the O rings to deteriorate Electrical Contacts In the electrical circuits associated with the valve solenoids keep all switches or relay contacts in good condition to avoid solenoid malfunctions Replace Worn Components
166. be connected to a normally closed pressure switch to operate a lockout indicator light Once the valve is installed the monitoring function of the valve must be tested See TEST PROCEDURE on page 3 IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 ROSS CONTROLS United States TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS web site www rosscontrols com ROSS EUROPA GmbH Germany TEL 49 6103 7597 0 web site www rosseuropa com ROSS ASIA K K Japan TEL 81 427 78 7251 web site www rossasia co jp ROSS UK Ltd United Kingdom TEL 44 121 559 4900 email sales rossuk co uk ROSS SOUTH AMERICA Ltda Brazil TEL 55 11 4335 2200 email vendas ross sulamerica com br ROSS CONTROLS INDIA Pvt Ltd India TEL 91 44 2624 9040 email rossindia airtelbroadband in ROSS CONTROLS CHINA Ltd China TEL 86 21 6915 7951 email alvinzhurong vip 163 com DIMAFLUID s a s France TEL 33 01 49 45 65 65 web site www dimafluid com VALVE OPERATION Normal Operation After installation the valve is operated by energizing both pilot solenoids simultaneously This causes both main valve elements to open so that inlet air port 1 flows to the outlet port 2 When the solenoids are de energized both valve elements close Airno longer flows from inlet to outlet but downstream air is exhausted through port 3 Detecting a Malfunction If both main valve elements do not open or close a
167. be free of crimps and sharp bends Valve Exhaust Port 3 Do not restrict air flow from the exhaust port as this can adversely affect the operation of the valve Pilot Solenoid Electrical Supply Size 1 and 2 double valves get electrical power through plug in connectors The electrical supply must correspond to the voltage and hertz ratings of the solenoids Otherwise the solenoids are subject to early failure If power is supplied by a transformer it must be capable of handling the inrush current without significant voltage drop See Valve Specifications for inrush current data ROSS CONTROLS ROSS EUROPA GmbH United States Germany TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS TEL 49 6103 7597 0 Operating Pressures and Temperatures Allowable ranges for pressure and temperatures are given in the Valve Specifications on page 3 Exceeding the values shown can adversely affect performance and shorten valve life Pipe Installation To install pipe in valve ports engage pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating the valve Monitor These valves do not have their own monitors They must be connected to an external monitoring system that ensures that valve operation will be inhibited should a system malfunction occur If controlling a critical element of machinery affecting safety i e press brake the valves m
168. bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakage and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components potentially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Donot restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibil
169. c equipment should be maintained only by persons trained and experienced in the maintenance of such equipment Supply Clean Air Foreign material lodging in valves is a major cause of breakdowns The use of a 5 micron rated air filter located close to the valve is strongly recommended The filter bowl should be drained regularly and if its location makes draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should put a fine oil mist into the air line in direct proportion to the rate of air flow Excessive lubrication can cause puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute is adequate Note that this valve itself does not require air line lubrication but some optional adaptors do i e air index etc Compatible Lubricants Although this valve does not require air line lubrication it may be used with lubricated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components and so cause the valve to malfunction Avoid oils with phosphate additives e g zinc dithiophosphate and diester oils both types can harm valve components The best oils to use are generally petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Some compatible oils are listed above a
170. cal lever pedal or treadle 3 Ports located on sides of valve 2 Position control detented or spring return 4 2 VALVES Port size 1 4 Horizontal lever vertical lever pedal or treadle 4 Ports located on sides of valve 2 Position control detented or spring return ROSS CONTROLS United States TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS web site www rosscontrols com ROSS EUROPA GmbH Germany TEL 49 6103 7597 0 web site www rosseuropa com ROSS ASIA K K Japan TEL 81 427 78 7251 web site www rossasia co jp ROSS UK Ltd United Kingdom TEL 44 121 559 4900 email sales rossuk co uk ROSS SOUTH AMERICA Ltda Brazil TEL 55 11 4335 2200 email vendas ross sulamerica com br ROSS CONTROLS INDIA Pvt Ltd India TEL 91 44 2624 9040 email rossindia airtelbroadband in ROSS CONTROLS CHINA Ltd China TEL 86 21 6915 7951 email alvinzhurong vip 163 com DIMAFLUID s a s France TEL 33 01 49 45 65 65 web site www dimafluid com VALVE MAINTENANCE Supply Clean Air Foreign material lodging in valves is a major cause of breakdowns The use of a 5 micron rated air filter located close to the valve as possible is strongly recommended The filter bowl should be drained regularly and if the filter s location makes draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should put atomized oil into the air line in dire
171. can expect it to have a long and economical service life So before you go any further please take a few minutes to look over the information in this folder Then save it for future reference and for the useful service information it contains Single PO Check Dual PO Check with Blow Down Dual PO Check with Blow Down and Solenoid Pilot VALVE INSTALLATION Pneumatic equipment should be installed only by persons trained and experienced in such installation Air Lines Before installing a valve in a new or an existing system the air lines must be blown clean of all contaminants It is recommended that an air filter be installed in the inlet line close to the valve Valve Inlet s V1 V2 or VLV Inlet ports some valves have two inlets should be connected to the outlet s of the directional valve typically ports 2 and or 4 Be sure that the supply line is of adequate size and does not restrict the air supply because of a crimp in the line a sharp bend ora clogged filter element Valve Outlet s C1 C2 or CYL Outlet ports some valves have two outlets should be connected to cylinder port s For faster pressurizing and exhausting of the cylinder being operated by the valve locate the check valve as close as possible to the cylinder The connecting lines must be of adequate size and be free of crimps and sharp bends unrestrictive Valve Exhausts and Vents Do not restrict the air flow from the exhaust or
172. ce kits are listed on page 3 2 ROSS CONTROLS VALVE SPECIFICATIONS amp ACCESSORIES STANDARD SPECIFICATIONS Solenoids Two rated for continuous duty 3 with solenoid reset option Standard Voltages 100 110 volts 50 Hz 100 120 volts 60 Hz 24 volts DC Other voltages available Pilot Solenoids Power Consumption Each solenoid 30 VA inrush 16 VA max holding on 50 or 60 Hz 11 watts nominal on DC Reset Solenoid Power Consumption Size 4 12 VA inrush 8 5 VA max holding on 50 or 60 Hz 6 watts nominal on DC Size 2 amp 8 Same as pilot solenoids Ambient Temperature 40 F to 120 F 4 C to 50 Media Temperature 40 F to 175 F 4 C to 80 C Flow Media Filtered air 5 micron recommended Inlet Pressure Size 2 30 to 150 psig 2 to 10 bar Size 4 amp 8 40 to 100 psig 2 8 to 7 bar Reset Pressure Remote reset option requires reset pressure to be greater than or equal to inlet pressure within given range of inlet pressure Pressure Switch Rating Contacts 4 amps at 250 volts AC maximum voltage 250 AC Solenoid Reset Units with solenoid reset include a 3 2 solenoid valve on base Energize this solenoid momentarily to reset monitor after fault condition occurs NOTE Main solenoids must be off when performing reset procedure Remote Reset Remote signal to be supplied by customer s 3 2 valve connect remote signal line to remote RESET port in base Apply signal momentarily to reset monitor
173. check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakage
174. chnical Services at your nearest ROSS location see page 1 or in the U S A at 1 888 TEK ROSS or 1 706 356 3708 Valve Model Valve Body Gasket amp Valve Base Solenoid Number Service Kit Seal Kit Gasket Number W7456A2331 712K77 a 553B11 W7456A2332 712K77 553B11 W7456A2336 854K77 553B11 W7456A2337 856K77 553B11 W7456A3331 696K77 549B11 W7456A3332 699K77 549B11 W7456A3336 713K77 a 549B11 W7456A3337 1085K77 TE 549B11 W7456C4331 615K77 819K77 958B11 W7456C4332 615K77 819K77 958B11 W7456C4336 1065K77 958B11 W7456C4337 616K77 958B11 W7456A6331 742K77 344B11 W7456A6332 743K77 344B11 W7456A6336 811K77 344B11 W7456A6337 812K77 344B11 W7456A8331 744K77 339C11 W7456A8332 745K77 339C11 W7456A8336 711K77 339C11 W7456A8337 711K77 339C11 W7476A2331 712K77 553B11 304B33 W7476A2332 712K77 553B11 304B33 W7476A2336 854K77 553B11 304B33 W7476A2337 856K77 553B11 304B33 W7476A3331 696K77 549B11 347B04 W7476A3332 699K77 549B11 347B04 W7476A3336 713K77 E 549B11 347B04 W7476A3337 1085K77 549B11 347B04 W7476C4331 615K77 819K77 958B11 411B04 W7476C4332 615K77 819K77 958B11 411B04 W7476C4333 615K77 819K77 958B11 411B04 W7476C4334 615K77 819K77 958B11 411B04 W7476C4336 1065K77 958B11 411B04 W7476C4337 616K77 958B11 411B04 W7476C4338 1065K77 958B11 411B04 W74
175. contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakage and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components potentially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this
176. ct or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakage and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components pot
177. ct proportion to the rate of air flow Excessive air line lubrication can cause puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute of air flow is adequate Note that your ROSS valve itself does not require air line lubrication See next column for a partial list of lubricants that are compatible with ROSS valves and are suitable for use in compressed air systems Cleaning Valve If the air supplied to the valve has not been well filtered the interior of the valve may accumulate dirt and varnish which can affect the valve s performance Although ROSS poppet valves are very tolerant of dirty air cleaning may sometimes be needed To clean the valve use any good commercial solvent or kerosene Do not use a chlorinated solvent or abrasive materials The former damages seals and abrasives can do permanent damage to metal parts Before reassembling the valve lubricate all sliding surfaces with a grease equivalent to Mobil Grease 28 lubricant Replace Worn Components After long usage the poppets may show signs of wear The valve can be reconditioned with the use of ROSS service kits See page 3 for information about such kits COMPATIBLE LUBRICANTS Although this valve does not require air line lubrication it may be used with lubricated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components and thereb
178. ct the performance of the product or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakage and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can har
179. ddition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakage and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 2
180. dia China France VALVE OPERATION Normal Operation After installation the valve is operated by energizing both pilot solenoids simultaneously This causes both main valve elements to open so that inlet air port 1 flows to the outlet port 2 When the solenoids are de energized both valve elements close Air no longer flows from inlet to outlet but downstream air is exhausted through port 3 Detecting a Malfunction If the main valve elements do not both open or close at the same time the valve s monitor detects this condition and locks the valve out so that it cannot be cycled Each of the monitors detects a malfunction in somewhat different ways but the end result is the same a malfunction shuts down the valve The valve cannot be operated again until the monitor is reset Resetting a Monitor WARNING E P L G amp D S Monitors Both solenoids must be de energized before resetting the monitor Otherwise the press or other mechanism can cycle immediately and could result in personal injury and or property damage Resetting the L G Monitor Size 4 models have either a manual reset button or a pneumatic reset port All other sizes have a pneumatic reset port only Models with a manual reset button on the side of the monitor housing have the monitor reset simply by pushing the reset button Models with a pneumatic reset port also on the side of the monitor housing must have a line supplying air pr
181. digit in the model For example SV27NA305507PSAA1A is a basic size 5 valve Pressure Verification Port Enhanced safety can be achieved by installing an optional visual pressure indicator 988A30 or pressure switch kit 608A86 into the 1 8 NPT pressure verification port PV located in the sensing valve Wiring Diagrams Below are the wiring diagrams for the DPST switch in the sensing module top and the SPST switch in the optional pressure switch kit 6 08A86 bottom Sensing Module Switch Wiring amp Pilot Wiring Switch Wiring 3 4 2 For Basic Sizes 5 amp 7 Switch is de actuated 1 2 3 1 when valve is in 5 de actuated position Switch Wiring For Basic Size 9 Switch is actuated when valve is in de actuated position Optional Pressure Switch Wiring If you need additional information or have any questions about installing or servicing your valve call ROSS Technical Services in the U S A at 1 888 TEK ROSS 835 7677 or 1 706 356 3708 www rosscontrols com 3 STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and e
182. dy Spring return model shown Listed below and in the chart at the right are the service kits and other parts required to repair or refurbish Series W70 valves Valve Body Service Kits These kits contain all parts needed for a complete reconditioning of a valve body Included are a spool and sleeve assembly all required gaskets and seals detent assemblies for valves requiring them and instructions for use Solenoid Pilot Kits These kits contain all parts needed to recondition the pilot valve Order by the following kit numbers Pilots using solenoid 304B33 Kit 714K77 Pilots using solenoid 347B04 or 411B04 Kit 946K87 Solenoids Replacement solenoids can be ordered by the part numbers given in the chart atthe right Specify the correct voltage and hertz when ordering Valve to Base Gasket If your valve is removed from its base for any reason a new valve to base gasket must be used to ensure a leak free seal This gasket is already included as a part of valve body service kits If you have any questions about installing or servicing your valve call ROSS Technical Services at your nearest ROSS location see page 1 or in the U S A at 1 888 TEK ROSS or 1 706 356 3708 Valve Model Valve Body Gasket amp Valve Base Solenoid Number Service Kit Seal Kit Gasket Number W7016A2331 708K77 553B11 171095 W7016A2332 709K77 553B11 171C95 W7016A3331 276K87 305A87 549B11 349B04 W7016A3332 277K87 305A87
183. e and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components potentially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically cont
184. e call ROSS Technical Services at your nearest ROSS location see page 1 or in the U S A at 1 888 TEK ROSS or 1 706 356 3708 www rosscontrols com 3 STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air syst
185. e any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products
186. e at right Order kit number 2151H77 If you have any questions about installing or servicing your valve call ROSS Technical Services at your nearest ROSS location or in the U S A at 1 888 TEK ROSS or 1 706 356 3708 Replacement Pressure Switch and Connector This kit is used to replace the pressure switch and electrical connector for the status indicator assembly Order kit number 1104A30 Solenoid Coils Order replacement solenoid coils by the following part numbers 306K33165 for 24 volts DC 306K33165 for 110 volts AC Complete Solenoid Pilot and Solenoid Reset Assemblies Order replacement solenoid assemblies by the following part numbers 851079165 for 24 volts DC 851C79166 for 110 volts AC IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 www rosscontrols com STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment mus
187. e elements does not shift fully and in sync with the other within a preset discordance time the valve will go into a lockout condition such that any downstream pressure in the outlet port 2 will be exhausted to atmosphere through exhaust port 3 There should also be a small but audible flow of air out the exhaust port 3 as long as the valve remains in the lockout condition If your valve is supplied with the optional status indicator a lockout condition should be indicated by a change in state of the status indicator pressure switch See Lockout Indication on page 1 In order to reset the valve and return it to the ready to run condition with supply pressure applied and the pilot solenoids de energized momentarily energize the reset solenoid at least 200 milliseconds After resetting the valve the lockout condition should be cleared there should be no pressure present at outlet port 2 and there should no longer be any audible flow of air to exhaust port 3 If momentarily energizing the reset solenoid does not clear the lockout condition the valve may need to be serviced See Valve Maintenance below VALVE MAINTENANCE Pneumatic equipment should be maintained only by persons trained and experienced in the maintenance of such equipment Supply Clean Air Foreign material lodging in valves is a major cause of breakdowns The use of a 5 micron rated air filter located close to the valve is strongly recommended The fil
188. e gasket must be used to ensure a leak free seal This gasket is already included in valve body service kits If you have any questions about installing or servicing your valve callROSS Technical Services at your nearest ROSS location see page 1 or in the U S A at 1 888 TEK ROSS or 1 706 356 3708 www rosscontrols com STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affe
189. e installed in the inlet line close to the valve Valve Inlet Port 1 Be sure that the supply line is of adequate size and does not restrict the air supply because of a crimp in the line a sharp bend or a clogged filter element Valve Outlets Ports 2 and 4 For faster pressurizing and exhausting of the mechanism being operated by the valve locate the valve as close as possible to the mechanism The lines must be of adequate size and be free of crimps and sharp bends Valve Exhausts Port 3 Do not restrict the air flow from the exhaust port of the valve body or pilot body as this can adversely affect the operation of the valve However to reduce exhaust noise an efficient silencer may be used ROSS MUFFL AIR silencers reduce impact noise by as much as 25 dB and produce little back pressure Electrical Supply The voltage and hertz ratings of the valve solenoids if any are shown on the pilot housing The electrical supply must correspond to these ratings Otherwise the solenoids are subject to early failure If power is supplied by a transformer it must be capable of handling the inrush current without significant voltage drop See Valve Specifications on page 2 for information on inrush current Operating Pressures and Temperatures Allowable ranges for pressure and temperatures are given in the Valve Specifications on page 2 Exceeding the values shown can shorten valve life Pilot Supply Pressure Control Connect a 1
190. e listed at the right These oils although believed to be compatible could change without notice because manufacturers sometimes reformulate their oils Therefore use oils specifically compounded for air line service If it is a synthetic oil contact the oil manufacturer for compatibility information Cleaning the Valve It is recommended that the inlet air to the valve should be filtered Disassembly of the valve for cleaning and repair must be done by qualified persons The testing procedures must be done for valves that have been COMPATIBLE LUBRICANTS Brand Name American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Pacemaker 32 Spinesstic 22 Teresstic 32 Velocite 10 Air Lube 10H NR Turbo T32 Sunvis 11 Sunvis 722 Regal R amp O 32 Union Turbine Oil disassembled and repaired Lubrication recommended is Owens Corning BR2 Plus grease It is applied only to the piston seals and bores Do not lubricate the poppet seals Repair kits are available for internal components Valves can be returned to Ross Controls for repair Electrical Contacts In the electrical circuits associated with the valve solenoids keep all switches or relay contacts in good condition to avoid solenoid malfunctions Replace Worn Components In most cases it is not necessary to remove the valve from its installation for servicing However turn off the electrical power to the valve shut off the air supply exhaust the air in the system and loc
191. e pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating the valve Outlet Pressure Verification An auxiliary 1 8 NPT port which is connected to the outlet port 2 is provided in the sensing valve An optional pressure indicator 988A30 or pressure switch kit 608A86 may be installed in this port to sense the presence of pressure in the outlet port 2 web site www rosscontrols com ROSS EUROPA GmbH Germany TEL 49 6103 7597 0 web site www rosseuropa com ROSS ASIA K K Japan TEL 81 427 78 7251 web site www rossasia co jp ROSS UK Ltd United Kingdom TEL 44 121 559 4900 email sales rossuk co uk ROSS SOUTH AMERICA Ltda Brazil TEL 55 11 4335 2200 email vendas ross sulamerica com br ROSS CONTROLS INDIA Pvt Ltd India TEL 91 44 2624 9040 email rossindia airtelbroadband in ROSS CONTROLS CHINA Ltd China TEL 86 21 6915 7951 email alvinzhurong vip 163 com DIMAFLUID s a s France TEL 33 01 49 45 65 65 web site www dimafluid com VALVE MAINTENANCE Pneumatic equipment should be maintained only by persons trained and experienced in the maintenance of such equipment Supply Clean Air Foreign material lodging in valves is a major cause of breakdowns The use of a 5 micron rated air filter located close to the valve is strongly recommended The filter bow
192. e the valve to malfunction The best oils to use are those specifically compounded for air line lubricator service Cleaning Valve If the air supplied to the valve has not been well filtered the interior of the valve may accumulate dirt and varnish which can affect the valve s performance To clean the valve use a solvent which will dry without leaving a residue This is especially important for the spool and sleeve assembly Do not use a chlorinated solvent or abrasive materials which can damage seals or do permanent damage to metal parts To reassemble the spool and sleeve put one drop of Anderol 735 or equivalent lubricant on each spool land Insert the spool into the sleeve and rotate it several times to ensure even distribution of the lubricant If the valve is used in a non lubricated application do not use a lubricant for reassembly which can dry out and leave a residue Dry assembly of the spool and sleeve is preferable Each spool and sleeve is a matched set so care must be taken not to reverse the position of the spool in the sleeve Before inserting the spool and sleeve into the valve body very lightly lubricate the O rings with a lubricant compounded for use on Buna N seals Do not use Anderol it causes the O rings to deteriorate Electrical Contacts In the external electrical circuits associated with the valve solenoids keep all switches or relay contacts in good condition to avoid solenoid malfunctions Replace
193. e to the normal at rest condition However being a double valve there are two solenoid pilots and two sets of valve elements for redundancy That being the case both solenoids must be energized virtually simultaneously in order for the valve to actuate normally to supply air from inlet to outlet Likewise both solenoids de energize simultaneously in order to de actuate and return the valve to its normal at rest condition thus shutting off the inlet and dumping downstream air to exhaust If one of the valve elements does not shift fully within a preset discordance time the valve will go into a condition such that any downstream pressure in the outlet port 2 will be exhausted to atmosphere through exhaust port 3 There should also be a small but audible flow of air out the exhaust port 3 as long as the valve remains in this condition De energizing the main pilot solenoids may clear the abnormal condition if the situation that caused the valve elements to not operate simultaneously is no longer in effect This is referred to as automatic reset Once the abnormal condition is cleared the valve is ready to run again If you equip your valve with the optional status indicator a abnormal condition will be indicated by a change in state of the status indicator pressure switch If de energizing the pilot solenoids and or removing supply air pressure do not cause the abnormal condition to clear the circuit and valve must be exhausted
194. e will then be ready for operation The air supply to each pilot valve is controlled by the position of the inlet poppets In the ready for operation position these poppets are held on their seats and maintain pilot air flow During shifting of the valve elements the poppets move off seat and momentarily allow pilot air to escape to exhaust If either valve element fails to operate correctly the pilot supply to the other valve element will remain connected to exhaust causing the valve to lock out The internal monitoring system will lock out the valve if the time difference between both elements shifting fully is longer than 150 milliseconds on a size 2 valve The time differences for size 4 and size 8 valves are 175 milliseconds and 200 milliseconds respectively This timing is preset by restricting orifices and chambers in the pilot air circuit The main airflow from port 1 to port 2 is via crossflow passages between both main valves so that both valve elements must be fully shifted in order for port 2 to be pressurized If the valve locks out further operation is prevented until the valve has been reset Electrical signals to the solenoids must be off to allow the valve to be reset The CrossMirror valve is completely self contained and does not need an external monitoring system VALVE MAINTENANCE Pneumatic equipment should be maintained only by persons trained and experienced in the maintenance of such equipment Supply Clean A
195. eature which occurs when inlet pressure is below 45 psig 3 bar must be taken into consideration in your application design in order to avoid the potential for personal injury or property damage Air Lines Before installing a valve in a new or an existing system the airlines must be blown clean of all contaminants It is recommended that an air filter be installed in the inlet line close to the valve Valve Inlet Port 1 Be sure that the supply line is of adequate size and does not restrict the air supply because of a crimp in the line sharp bends or a clogged filter element Valve Outlets Ports 2 amp 4 For faster pressurizing and exhausting of the mechanism being operated by the valve locate the valve as close as possible to the mechanism The lines must be of adequate size and be free of crimps and sharp bends Valve Exhausts Ports 3 amp 5 To reduce exhaust noise use an efficient silencer ROSS MUFFL AIR silencers reduce impact noise by as much as 25 dB and produce little back pressure ROSS CONTROLS United States TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS Electrical Supply The voltage and hertz ratings for solenoid pilot operated valves are printed on the side of each solenoid It is important that the electrical supply used to power the valve is equal to these ratings to avoid possible solenoid burnout The electrical connection Manual for such valves is achieved by means Override of a con
196. ecause manufacturers sometimes reformulate their oils Therefore use oils specifically compounded for air line service If it is a synthetic oil contact the oil manufacturer for compatibility information Cleaning the Valve If the air supplied to the valve has not been well filtered the interior of the valve may accumulate dirt and varnish which can affect the valve s performance A schedule should be established for cleaning all valves the frequency depending on the cleanliness of the air being supplied COMPATIBLE LUBRICANTS Brand Name American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Pacemaker 32 Spinesstic 22 Teresstic 32 Velocite 10 Air Lube 10H NR Turbo T32 Sunvis 11 Sunvis 722 Regal R amp O 32 Union Turbine Oil To clean the valve use any good commercial solvent Do not scrape varnished surfaces Also do not use chlorinated solvents or abrasive materials The former damages seals and abrasives can do permanent damage to metal parts Before reassembling the valve lubricate all sliding surfaces with a grease such as Dow Corning BR 2 Plus Electrical Contacts In the electrical circuits associated with the valve solenoids keep all switches or relay contacts in good condition to avoid solenoid malfunctions Replace Worn Components In most cases it is not necessary to remove the valve from its installation for servicing However turn off the electrical power to the valve shut off the air sup
197. ect the operation of the valve However to reduce exhaust noise an efficient silencer may be used ROSS MUFFL AIR silencers reduce impact noise by as much as 25 db and produce little back pressure Electrical Supply The voltage and hertz ratings of the valve solenoids if any are shown on the pilot housing The electrical supply must correspond to these ratings Otherwise the solenoids ROSS CONTROLS United States TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS are subject to early failure If power is supplied by a transformer it must be capable of handling the inrush current without significant voltage drop See Valve Specifications on page 2 for information on inrush current Operating Pressures and Temperatures Allowable ranges for pressure and temperatures are given in the Valve Specifications on page 2 Exceeding the values shown can shorten valve life Pilot Supply Pressure Control Connecta 1 4 inch control line to the threaded portin the air cap at the top of the valve See Valve Specifications on page 2 for required pressures Solenoid Control Pressure for the pilot valve is supplied internally for most valves and requires no special connection However if your valve is designated for external pilot supply a 1 8 inch pilot supply line must be connected to port X 1 in the pilot housing See Valve Specifications on page 2 for pressure requirements Pipe Installation To install pipe in valve ports engag
198. ed clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and L O X with EEZ ON operation products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOS
199. ed to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS such product is found to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the U S A Rev 05 09 2009 ROSS CONTROLS All Rights Reserved Form SS099 Series af Pilot Operated Checks ROSS Thank You You have purchased a premium quality ROSS pneumatic valve It is a pilot operated check valve with poppet internals and has been built to the highest standards With care in its installation and maintenance you
200. edia 40 to 175 F 4 to 80 C extended to 220 F 105 C for high temperature models Flow Media Filtered air 5 micron recommended Inlet Pressure 2 to 10 bar 30 to 150 psig Pilot Pressure Must be equal to or greater than inlet pressure 2 ROSS CONTROLS VALVE SERVICE Typical cross section of a ROSS Series W74 poppet valve body Internal pressure return model shown Listed below and in the chart at the right are the service kits and other parts required to repair or refurbish Series W74 valves Valve Body Service Kits These kits contain all parts needed fora complete reconditioning of a valve body Included are a spindle all poppets and spacers all required gaskets and seals detent assemblies for valves requiring them and instructions for use Solenoid Pilot Kits These kits contain all parts needed to recondition the pilot valve Order by the following kit numbers Pilots using solenoid 304B33 Kit 714K77 Pilots using solenoid 347B04 or 411B04 Kit 946K87 Solenoids Replacement solenoids can be ordered by the part numbers given in the chart at the right Specify the correct voltage and hertz when ordering Valve to Base Gasket If your valve is removed from its base for any reason a new valve to base gasket must be used to ensure a leak free seal This gasket is included as a part of all valve body service kits If you have any questions about installing or servicing your valve call ROSS Te
201. eeds of your application web site www rosscontrols com ROSS EUROPA GmbH Germany TEL 49 6103 7597 0 web site www rosseuropa com ROSS ASIA K K Japan TEL 81 427 78 7251 web site www rossasia co jp ROSS UK Ltd United Kingdom TEL 44 121 559 4900 email sales rossuk co uk ROSS SOUTH AMERICA Ltda Brazil TEL 55 11 4335 2200 email vendas ross sulamerica com br ROSS CONTROLS INDIA Pvt Ltd India TEL 91 44 2624 9040 email rossindia airtelbroadband in ROSS CONTROLS CHINA Ltd China TEL 86 21 6915 7951 email alvinzhurong vip 163 com DIMAFLUID s a s France TEL 33 01 49 45 65 65 web site www dimafluid com VALVE MAINTENANCE Pneumatic equipment should be maintained only by persons trained and experienced in the maintenance of such equipment IMPORTANT NOTE To service downstream equipment the handle of the L O X or L O X with EEZ ON operation valve must be pushed inward to cut off the air supply The valve should then be padlocked in this position to ensure that supply air is not inadvertently turned on Valves Padlocked in Closed Position Follow correct lockout procedure as prescribed by industry or your company s lockout tagout standards Observe the following general guidelines for the care and maintenance of the L O X or L O X with EEZ ON operation valve Supply Clean Air Foreign material lodging in valv
202. em Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakage and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components potentially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do s
203. em in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakage and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use l
204. entially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L
205. ents the machine from being reactuated The dump valve D in the diagram at the right is actuated at the end of a work cycle so that it exhausts the output of the HSR valve Exhausting the HSR output causes the HSR valve to shift and prevent any further output signal whether valves A and B are actuated or not A new work cycle can be initiated only after both hands have been removed from the hand valves A and B thus allowing the HSR valve to reset itself The dump valve D must have a flow rating greater than Cv 0 3 and must be closed at the time of HSR actuation HIGH VOLUME OUTPUT TWO HAND CONTROL Where a volume larger than 30 cubic inches must be supplied the HSR valve alone will not suffice However the HSR valve can be used as a pilot valve on a ROSS higher output Series 27 valve Such valves are available as either 3 way normally closed valves or as 4 way valves Model numbers are shown below TWO HAND CONTROL STATION The ROSS two hand control station is a self contained system ready for mounting on a fixture pedestal or machine It requires only two 1 4 pipe connections The station consists of two 3 2 normally closed hand valves an HSR valve and all connecting lines enclosed in a cast aluminum housing Operation is like that of the two hand control system described on page 1 An anti repeat function can also be incorporated by the addition of a dump valve as described above ROSS Series 27 4 Way Valve
206. epressurizes the switch until the valve is ready to run after power has been removed from both pilot solenoids Contacts 1 and 2 are closed when the switch is depressurized normally closed and contacts 1 and 3 are closed when an adequate pressure signal is applied to the switch normally open www rosscontrols com VALVE OPERATION NOTE DM Series E valves do not lockout like the DM Series E and DM Series C valves that remember abnormal function The valves that include memory functions once locked out must be reset by a dedicated reset function in order to be operated again DM Series E valves are ready to operate again as soon as the abnormal condition has cleared Removing electrical power to both pilot solenoids may clear the abnormal condition if the situation that caused the valve internals to not operate simultaneously is no longer in effect This is referred to as automatic reset This may result in abnormal function going undetected during machine operation without the use of the optional status indicator The overall function of the DM Series E double valve is that of a 3 way 2 position 3 2 normally closed single solenoid valve When in the normal at rest condition the valve inlet port 1 is closed and the outlet port 2 is open to the exhaust port 3 Normal actuation of the valve opens the valve inlet port 1 to the outlet port 2 and closes the exhaust port 3 De actuation returns the valv
207. equate size and be free of crimps and sharp bends Valve Exhaust Port 3 Do not restrict the air flow from the exhaust port as this can adversely affect the speed with which downstream lines and components can be exhausted To reduce exhaust noise an efficient silencer may be used ROSS MUFFL AIR silencers reduce impact noise by as much as 25 dB and produce little back pressure L O X Sensing Port A 1 8 NPT sensing port allows installation of either the Pop Up Indicator model number 988A30 or Pressure Switch option model number 586A86 to verify pressure is released Operating Pressures andTemperatures Allowable ranges for pressure and temperatures are given in the Valve Specifications on page 2 Exceeding these values can shorten valve life Pipe Installation To install pipe in valve ports engage pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating the valve EEZ ON Adjustment If usingaL O X with EEZ ON operation valve with a blue handle push the handle fully inward before applying line pressure to the inlet port Turn the brass adjusting screw in the top of the blue handle clockwise until resistance is felt DO NOT TIGHTEN OR THE SCREW MAY BE DAMAGED Now turn the adjusting screw counterclockwise 1 2 turn This will serve as a preliminary setting for the rate of pressure buildup Further adjustment can then be made to suit the n
208. er ROSS MUFFL AIR silencers reduce impact noise by as much as 25 dB and produce little back pressure Pilot Supply Solenoid Control Pressure for the pilot valves is supplied from the inlet port Be sure that the external pilot supply port X inthe base is plugged or pilot air will escape If the valve must operate with an inlet pressure less than the required pilot pressure see Valve Specifications on page 2 an external pilot supply must be provided Connect to port X in the base Pressure Control Connect the control line s to the ports provided in the valve See Valve Specifications on page 2 for required pressures Non Air Service Such applications require an external pilot supply for solenoid valves Connect to port X in the base Electrical Supply The voltage and hertz ratings of the valve solenoids are shown on the plate on the top of the valve The electrical supply must correspond to these ratings or solenoid life will be shortened ROSS CONTROLS United States TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS Power is supplied via the 5 pin connector or conduit in the top of the valve See connector diagrams below If power is supplied by a transformer it must be capable of handling the inrush current without significant voltage drop Operating Pressures and Temperatures Allowable ranges for pressure and temperatures are given in the Valve Specifications on page 2 Exceeding the values shown can shorten valve
209. er operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and L O X with EEZ ON operation products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS such product is found to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF T
210. er Service Kit amp Seal Gasket Valve Body Service Kits These kits listed in the chart pieced 990K77 1031K77 637B11 at the right contain all parts needed for a complete 8476B333 991K77 1032K77 637B11 reconditioning of a valve body Included are a spindle 8476B3341 990K77 1031K77 637B11 all poppets and spacers all required gaskets and 8476B3342 991K77 1032K77 637B11 seals detent assemblies for valves using them and instructions for use g 8476B3351 990K77 1031K77 637B11 l 8476B3352 991K77 1032K77 637B11 Solenoids Replacement solenoids or solenoid coils can be ordered by the following part numbers 8476B4331 785K77 1029K77 677B11 SAE 125 314B33 Coil only 8476B4332 786K77 1030K77 677B11 i 8476B4341 785K77 1029K77 677B11 SAE 250 308K33 Coil only 8476B4342 786K77 1030K77 677B11 SAE 500 411B04 Complete solenoid 8476B4351 785K77 1029K77 677B11 Specify the correct voltage and hertz when ordering 8476B4352 786K77 1030K77 677B11 8476B6331 992K77 1033K77 352B11 Sipe ae a are available to service 8476B6332 993K77 1034K77 352B11 SAE 125 Pilot service kit 1100K77 8476B6341 992K77 1033K77 352B11 Coil not included 8476B6342 993K77 1034K77 352B11 SAE 250 Complete pilot assembly 936C79 8476B6351 992K77 1033K77 352B11 Includes solenoid coil 8476B6352 993K77 1034K77 352B11 SAE 500 Pilot service kit 145H77 Solenoid not included Valve to Base Gasket If your valve is removed from its base for any reason a new valve to bas
211. er retract pressure The Series ENERGYSaver valve is a 5 port 2 position sub base mounted valve that supplies full line pressure to port 4 and reduced pressure 80 psig 2 bar to port 2 This provides full cylinder force to move the load but returns the cylinder with less pressure thus reducing your compressed air consumption by up to 30 Although reduced the pressure in port 2 is enough for quick return of the cylinder The energy saving function is accomplished by action of the spool and works as quickly as a pressure regulator Single Solenoid Models Energize solenoid 14 to cause the valve to supply line pressure to port 4 This causes the cylinder to extend De energize the solenoid to retract the cylinder The valve switches positions to supply reduced pressure to port 2 in order to retract the cylinder Because the cylinder gets retracted with reduced pressure less energy will be consumed Double Solenoid Models Momentarily energize solenoid 14 to cause the valve to supply line pressure to port 4 This causes the cylinder to extend Now in order to retract the cylinder momentarily energize the other solenoid 12 to supply reduced pressure to port 2 Because the cylinder gets retracted with reduced pressure less energy will be consumed Cross section of a ROSS SeriesW60 EnercySaver valve body BE ft YOPI P po EOL Single solenoid model shown VALVE SERVICE Valve Body Service Kits These kits contain all par
212. erials The former damages seals and abrasives can do permanent damage to metal parts Before reassembling the valve lubricate all sliding surfaces with a grease such as MobilGrease 28 Electrical Contacts In the electrical circuits associated with the valve solenoids keep all switches or relay contacts in good condition to avoid solenoid malfunctions Replace Worn Components In some cases it is not necessary to remove the valve from its installation for servicing However turn off the electrical power to the valve shut off the air supply and exhaust the air in the system before beginning any disassembly operation Service kits for these valves are listed on page 5 Service kits for adaptors are listed on pages 3 and 4 Solenoid Pilot Solenoids Rated for continuous duty Voltage and Hertz ratings shown on pilot housing Power Consumption Single Solenoid 87 VA inrush 30 VA holding on AC 14 watts on DC Double Solenoid Each solenoid 190 VA inrush 40 VA holding on AC 20 watts on DC Temperature Range Ambient 40 to 120 F 4 to 50 C Media 40 to 175 F 4 to 80 C Flow Media Filtered air 5 micron recommended Inlet Pressure 1 4 to 1 1 2 Port Sizes 15 to 150 psig 1 to 10 bar 1 1 2 to 2 1 2 Port Sizes 30 to 150 psig 2 to 10 bar Pilot Pressure Must be equal to or greater than inlet pressure 2 ROSS CONTROLS Series 27 eno si Some Series 27 ROSS valves have special function adaptors
213. ersons trained and experienced in the maintenance of such equipment Supply Clean Air Foreign material lodging in valves is a major cause of breakdowns The use of a 5 micron rated air filter located close to the valve is strongly recommended The filter bowl should be drained regularly and if its location makes draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should put a fine oil mist into the air line in direct proportion to the rate of air flow Excessive lubrication can cause puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute is adequate Note that the double valve itself does not require air line lubrication Compatible Lubricants Although this valve does not require air line lubrication it may be used with lubricated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components which could cause the valve to malfunction Avoid oils with phosphate additives e g zinc dithiophosphate and diester oils both types can harm valve components The best oils to use are generally petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Some compatible oils are listed at the right These oils although believed to be compatible could change without notice b
214. ervice kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal
215. ery installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakage and the p
216. es and Temperatures Allowable ranges are shown under STANDARD SPECIFICATIONS on the reverse side Exceeding these values can shorten valve life Pipe Installation To install pipe or fittings in the valve ports engage the pipe or fitting one turn apply thread sealant tape not recommended and tighten pipe or fitting VALVE DESCRIPTION Series 11 Valves Lo wap Port size 1 4 p mg Operators toggle gt a lever pushbutton b a plunger roller gt ihe one way roller 2 way or 3 way normally closed design 1 Way Roller Dual mounting flanges ea Toggle Lever Plunger Series 12 Valves Por size 1 4 for 2 or 3 way pushbutton 1 8 1 4 for Pushbutton Telegraph lever and 2 or 3 Way 3 way Pushbutton bottom left only Operators Large pushbutton telegraph lever 2 way or 3 way normally closed 3 Way Only Telegraph Lever This procedure will prevent sealant from entering and contaminating the valve 3 Way Only ROSS CONTROLS United States TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS web site www rosscontrols com ROSS EUROPA GmbH Germany TEL 49 6103 7597 0 web site www rosseuropa com ROSS ASIA K K Japan TEL 81 427 78 7251 web site www rossasia co jp ROSS UK Ltd United Kingdom TEL 44 121 559 4900 email sales rossuk co uk ROSS SOUTH AMERICA Ltda Brazil TEL 55 11 4335 2200 email vendas ross sulamerica com br ROSS CONTROLS IN
217. es is a major cause of breakdowns The use of a 5 micron rated air filter located close to the valve is strongly recommended The filter bowl should be drained regularly and if its location makes draining difficult the filter should be equipped with an automatic drain VALVE SPECIFICATIONS Temperature Range 40 to 175 F 4 to 80 C Flow Media Filtered air 5 micron recomended Inlet Pressure L O X 15 to 300 psig 1 to 20 bar L O X with EEZ ON operation 30 to 150 psig 2 to 10 bar If you have any questions about installing or servicing your valve call ROSS Technical Services at your nearest ROSS location see page 1 or in the U S A at 1 888 TEK ROSS or 1 706 356 3708 COMPATIBLE LUBRICANTS Brand Name American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Pacemaker 32 Spinesstic 22 Teresstic 32 Velocite 10 Air Lube 10H NR Turbo T32 Sunvis 11 Sunvis 722 Regal R amp O 32 Union Turbine Oil Compatible Lubricants Although this valve does not require air line lubrication it may be used with lubricated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components and so cause the valve to malfunction Avoid oils with phosphate additives e g zinc dithiophosphate and diester oils both types can harm valve components The best oils to use are generally petroleum base oils with oxidation inhibitors an aniline point between 18
218. ese kits contain all parts needed for complete reconditioning of a pilot booster Included are poppets gaskets seals and instructions for use Size 12 amp 30 ee 2106K77 IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 www rosscontrols com 3 STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the product or result in
219. ess steel spool and sleeve valve built to the highest standards With care in its installation and maintenance you can expect it to have a long and economical service life So before you go any further please take a few minutes to look over the information in this folder Then save it for future reference and for the useful service information it contains SAE 500 ROSS Series 80 valves and bases must be purchased separately VALVE INSTALLATION Pneumatic equipment should be installed only by persons trained and experienced in such installation Air Lines Before installing a valve in a new or an existing system the air lines must be blown clean of all contaminants It is recommended that an air filter be installed in the inlet line close to the valve Valve Ports Your valve is a multipurpose valve and may have any of its ports restricted and or pressurized provided there is sufficient pilot pressure Conventional port usage is identified below Valve Inlet Port P Be sure that the supply line is of adequate size and does not restrict the air supply because of a crimp in the line sharp bends or a clogged filter element Valve Outlets Ports A amp B For faster pressurizing and exhausting of the mechanism being operated by the valve locate the valve as close as possible to the mechanism The lines must be of adequate size and be free of crimps and sharp bends Valve Exhausts Ports EA amp EB These ports may be restric
220. essure attached to the port and a small 3 2 reset valve to control the pressure Size 4 valves require a pressure of at least 30 psig 2 bar and larger sizes require a pressure of at least 60 psig 4 bar Applying pressure to the reset port resets the monitor so that normal operation can be resumed Resetting the E P Monitor The E P monitor is reset electrically A solenoid wired through terminals 8 and 9 resets the monitor when energized Energize the reset solenoid only briefly prolonged energization can burn it out Resetting the D S Monitor An external switch connected to terminals G and H is used to reset the monitor Closing the switch momentarily will reset the monitor after a delay of about two seconds Reset can also be accomplished by momentarily interrupting the power supply to the monitor VALVE MAINTENANCE Pneumatic equipment should be maintained only by persons trained and experienced in the maintenance of such equipment Supply Clean Air Foreign material lodging in valves is a major cause of breakdowns The use of a 5 micron rated air filter located close to the valve is strongly recommended The filter bowl should be drained regularly and if its location makes draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should put a fine oil mist into the air line in direct proportion to the rate of air flow Excessive lubrication can cause puddling in the v
221. ety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a
222. eve is a matched set so care must be taken not to reverse the position of the spool in the sleeve Before inserting the spool and sleeve into the valve body very lightly lubricate the O rings with a compatible lubricant Do not use Anderol it causes the O rings to deteriorate Electrical Contacts In the electrical circuits associated with the valve solenoids keep all switches or relay contacts in good condition to avoid solenoid malfunctions Replace Worn Components In some cases it is not necessary to remove the valve from its installation for servicing However turn off the electrical power to the valve shut off the air supply and exhaust the air in the system before beginning any disassembly operation Service kits for these valves are listed on page 3 VALVE SPECIFICATIONS Valve Sizes Series 80 valves are made in three SAE sizes The SAE size of your valve is indicated by the fourth digit from the end of the valve s model number Digit 3 SAE Series 125 Digit 4 SAE Series 250 Digit 6 SAE Series 500 Model 8076B4331 for example is an SAE Series 250 valve Pressure Controlled Temperature Range 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 At least 15 psig 1 bar Solenoid Pilot Solenoids Rated for continuous duty 115 volts 60 Hz Power Consumption SAE 125 and 250 models 8 VA inrush 6 VA holding SAE 500 models
223. factured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the U S A Rev 05 09 2009 ROSS CONTROLS All Rights Reserved Form SS094 Series 35 Sizes 1 and 2 Double Valves for External Monitor ROSS Thank You You have purchased a pre
224. filter be installed in the inlet line close to the valve Valve Inlet Port 1 Be sure that the supply line is of adequate size and does not restrict the air supply because of a crimp in the line a sharp bend or a clogged filter element The air supply must not only provide sufficient pressure see Standard Specifications page 3 but must also provide an adequate flow of air on demand Otherwise the valve elements will be momentarily starved for air and the valve may fail to operate Valve Outlet Port 2 For faster pressurizing and exhausting of the mechanism being operated by the valve locate the valve as close as possible to the mechanism The lines must be of adequate size and be free of crimps and sharp bends Valve Exhaust Port 3 Do not restrict the air flow from the exhaust port as this can adversely affect the operation of the valve The valves are factory equipped with a properly sized silencer ROSS MUFFL AIR silencers reduce impact noise by as much as 25 dB and produce little back pressure Reset Port RESET If your valve is not equipped with a reset solenoid on the valve then the RESET port should be supplied externally from a 3 2 normally closed valve The lines must be of adequate size and be free of crimps and sharp bends Reset signals must be momentary Electrical Supply DM Series D double valves get electrical power through plug in connectors The electrical supply must correspond to the voltage and hertz
225. for these valves are listed on page 3 VALVE SPECIFICATIONS Pressure Controlled Pilot Operated Check Valves WITHOUT Trapped Pressure Relief Function Temperature Range 40 to 175 F 4 to 80 C Flow Media Filtered air 5 micron recommended Inlet Pressure 15 to 150 psig 1 to 10 bar Signal Pressure Must be equal to or greater than inlet pressure IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 Solenoid Pilot Operated Check Valves WITH Trapped Pressure Relief Function Solenoids Rated for continuous duty Voltage and Hertz ratings shown on pilot housing Power Consumption 8 VA inrush 6 VA holding on AC On DC 4 5 watts with 4 pin Micro connector 6 watts with 3 pin Mini connector Temperature Range Ambient 40 to 120 F 4 to 50 C Media 40 to 175 F 4 to 80 C For Internal Pilot Models Ambient Media range 40 to 175 F 4 to 80 C Flow Media Filtered air 5 micron recommended Inlet Pressure 30 to 150 psig 2 to 10 bar Signal Pressure Must be equal to or greater than inlet pressure 2 ROSS CONTROLS SERIES 27 PO CHECK VALVE BODIES EA ie 5 Z Oi 1J ry a 2 i i 7 Type A Single Type B Sin
226. g device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and L O X with EEZ ON operation products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGUL
227. g to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and L O
228. gh flow poppets which are actuated by four external solenoids Two solenoids control the supply pressure the second solenoid controls the isolation and the third controls the exhaust Independent operation of these functions supports many applications including dual pressure tests vacuum and fill tests or over fill and relieve tests The supply pressure poppets are normally closed and the isolation and exhaust poppets are normally open Therefore if power is lost or if a safety stop has cut power the supply pressure will be closed and the unit under test will be evacuated Applications e Pressure Decay Test P1 Pressure Sensor Port e Flow Test P1 Pressure Sensor Port P2 Flow Sensor Inlet Port P3 Flow Sensor Outlet Port e Differential Pressure Test P1 Pressure Sensor Port 1 P2 Pressure Sensor Port 2 IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 2 ROSS CONTROLS VALVE MAINTENANCE Pneumatic equipment should be maintained only by persons trained and experienced in the maintenance of such equipment Supply Clean Air Foreign material lodging in valves is a major cause of breakdowns The use of a 5 micron rated air filter located close to the valve is strongly recommended The filter bowl should be drained regularly and if its location makes draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should put a fine o
229. gle Type F Single Type C Dual Type D Dual with Type E Dual with with Remote without Blow Down Solenoid amp Blow Down Blow Down Blow Down Remote Blow down DIN connector VALVE SERVICE model shown model shown ROSS would be happy to service this valve for you at its factory repair center 1 800 438 7677 inside the U S or 706 356 3708 outside the U S However if you choose to service this valve yourself it is strongly recommended that you obtain a free service manual from your local ROSS distributor Distributor information as well as downloadable service manuals are available at www rosscontrols com Valve Body Service Kits These kits contain all parts needed for complete reconditioning of a valve body Included are poppets spindle all required gaskets and seals and instructions for use Blow Down Service Kits These kits contain all parts needed for complete reconditioning of a blow down adaptor Included are inserts all required gaskets and seals and instructions for use Replacement Solenoid Pilot Assemblies These kits contain replacement solenoid assemblies See the chart below Solenoid Coils Replacement solenoid coils can be ordered by the part numbers listed in the chart below Valve Solenoid Coil Model Assembly Only 2778C3900 851C79 306K33 2778C3901 976C79 316K33 277803902 976C7916 316K3316 2778C3904 1086C7916 322K3316 2778C4900 851C79 306K33 2778C4901 976C79 316K33 277804902 976C7916 316K3316
230. good condition to avoid solenoid malfunctions Replace Worn Components In some cases it is not necessary to remove the valve from its installation for servicing However turn off the electrical power to the valve shut off the air supply exhaust the air in the system and lock out before beginning any disassembly operation Service kits for these valves are listed on page 3 Solenoid Pilot Solenoid Rated for continuous duty Voltage and Hertz ratings shown on pilot housing Power Consumption Size 5 PO Check 15 8 VA inrush 12 8 VA holding on AC 5 8 watts on DC Size 7 87 VA inrush 30 VA holding on AC 14 watts on DC Switch Current Voltage Max 2 5 A 120 volts AC Switch Current Voltage Min 20 mA 24 volts DC Temperature Range Ambient 40 F to 120 F 4 C to 50 C Media 40 F to 175 F 4 C to 80 C Flow Media Filtered air Inlet Pressure 40 to 150 psig 2 8 to 10 bar Pilot Pressure Must be equal to or greater than inlet pressure Electrical life of switch varies with conditions and voltage rated in excess of 15 million cycles 2 ROSS CONTROLS SERIES SV27 VALVE BODIES 3 2 Normally Closed 2 2 Normally Closed PO Checks 3 2 Normally Closed Basic Body Size 9 side view VALVE SERVICE ROSS would be happy to service this valve for you at its factory repair center 1 800 438 7677 inside the U S or 706 356 3708 outside the U S However if you choo
231. gs and retaining hardware These parts are already included in valve body service kits VALVE BODY CROSS SECTIONS Series 31 models Series 36 3 2 models Series 36 rede 4 2 models iS qe f SERVICE KITS If you have any questions about installing or servicing your valve call ROSS Technical Services at your nearest ROSS location see page 1 or in the U S A at 1 888 TEK ROSS or 1 706 356 3708 Valve Model Valve Body Locking Spring amp Number Service Kit Rocker Kit Retainer Kit 3126A3007 829K77 919K87 376K77 3126A3008 829K77 101212 376K77 3126A3009 829K77 919K87 376K77 3126A3010 690K87 919K87 376K77 3126A3011 690K87 101212 376K77 3126A3012 829K77 101212 376K77 3126A3013 690K87 919K87 376K77 3126A3014 690K87 101212 376K77 3126A4007 830K77 920K87 377K77 3126A4008 830K77 103212 377K77 3126A4009 830K77 920K87 377K77 3126A4010 691K87 920K87 377K77 3126A4011 691K87 103212 377K77 3126A4012 830K77 103212 377K77 3126A4013 691K87 920K87 377K77 3126A4014 691K87 103212 377K77 3126A5007 692K87 921K87 378K77 3126A5008 692K87 105212 378K77 3126A5009 692K87 921K87 378K77 3126A5010 692K87 921K87 378K77 3126A5011 692K87 105212 378K77 3126A5012 692K87 105212 378K77 3126A5013 692K87 921K87 378K77 3126A5014 692K87 105212 37
232. h and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and L O X with EEZ ON operation products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ROSS M
233. h as 25 dB and produce little back pressure ROSS CONTROLS United States TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS Electrical Supply The voltage and hertz ratings of the valve solenoids if any are shown on the pilot housing The electrical supply must correspond to these ratings Otherwise the solenoids are subject to early failure The power supply must be capable of handling the inrush current without significant voltage drop See Valve Specifications on page 2 for information on inrush current Operating Pressures and Temperatures Allowable ranges for pressure and temperatures are given in the Valve Specifications on page 2 Exceeding the values shown can shorten valve life Pilot Supply Solenoid Control Pressure for the pilot valve is supplied internally for most valves and requires no special connection However if your valve is designated for external pilot supply a 10 32 or 1 8 inch pilot supply line must be connected to port X 1 in the manifold See Valve specifications on page 2 for pressure requirements Pipe Installation To install pipe in valve ports engage pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating the valve web site www rosscontrols com ROSS EUROPA GmbH Germany TEL 49 6103 7597 0 web site www rosseuropa com ROSS ASIA K K Japan TEL 81 427 78 7251 web site www
234. hanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and L O X with EEZ ON operation products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF R
235. he lubricator of one drop per minute of air flow is adequate Note that your ROSS valve does notitself require airline lubrication See page 3 for a partial list of lubricants that are compatible with the materials in ROSS valves and are suitable for use in compressed air systems Cleaning Valve If the air supplied to the valve has not been well filtered the interior of the valve may accumulate dirt which can affect the valve s performance and so require cleaning To clean the valve use any good commercial solvent Do not scrape varnished surfaces Also do not use chlorinated solvents or abrasive materials The former can damage seals and abrasives can do permanent damage to metal parts Replace Worn Components After long usage the poppets may show signs of wear The valve can be reconditioned with the use of ROSS service kits See below for information about such kits STANDARD SPECIFICATIONS Ambient Media Temperature 40 to 175 F 4 to 80 C Flow Media Filtered air 5 micron recommended Inlet Pressure 5 to 150 psig 0 3 to 10 bar VALVE SERVICE The service kits listed below contain all of the parts needed for complete reconditioning of the valve Service kits are not available for all flow control and check valves Note that some model numbers may be preceded by D or S Valve Model Service Kit 1968 B2007 sce 695K87 E2007 eann a a 1168K77 B3007 ra ae 695K87 E8008 rovere eian 1168K77 B4007 noen 69
236. he main supply pressure d PILOT EXHAUST EXTERNAL PORT IN A PILOT YRS SUPPLY me PORT ADAPTOR PLATE gim T INTERNAL m _ PILOT 4 SUPPLY ATE PASSAGE BE 4 Figure 1 ws oh b Valve Body Service Kits These kits contain all parts needed for complete reconditioning of a valve body Included are poppets spindle all required gaskets and seals and instructions for use Gasket and Seal Kits These kits are needed when valve bodies are disassembled for cleaning They include all the necessary gaskets O rings and other seals Solenoid Pilot Kits These kits contain all parts needed to recondition the pilot valve Order by the following kit numbers For single solenoid pilots Type H 947K87 Type O 946K87 For double solenoid pilots Type O 273K87 Solenoids Replacement solenoids can be ordered by the part numbers listed below Specify the required voltage and hertz when ordering For single solenoid pilots Type H 257B04 Type O 411B04 For double solenoid pilots Type O 171095 Adapters Some valves have adapters arin e g time delay PB air index or L O X Ei adapters above the valve body A a For information on servicing these ANO adapters please consult ROSS g g If you have any questions about installing or servicing your valve call ROSS Technical Services at your nearest ROSS location see page 1 or in the U S A at 1 888 TEK ROSS or 1 706 356 3708 www rosscontrols com SERIES 21 VALV
237. hen reset the valve After satisfying these tests energizing both pilot solenoids simultaneously should result in normal operation Fault Indication If fault indication is desired ROSS offers a status indicator option that can be used to signal the press controls that a fault has occurred The status indicator utilizes a pressure switch The pressure switch has 4 electrical contacts During normal operation the pressure switch is pressurized A lockout condition depressurizes the switch until the valve is reset Contacts 1 and 2 are closed when the switch is depressurized normally closed and contacts 1 and 3 are closed when an adequate pressure signal is applied to the switch normally open web site www rosscontrols com ROSS EUROPA GmbH Germany TEL 49 6103 7597 0 web site www rosseuropa com ROSS ASIA K K Japan TEL 81 427 78 7251 web site www rossasia co jp ROSS UK Ltd United Kingdom TEL 44 121 559 4900 email sales rossuk co uk ROSS SOUTH AMERICA Ltda Brazil TEL 55 11 4335 2200 email vendas ross sulamerica com br ROSS CONTROLS INDIA Pvt Ltd India TEL 91 44 2624 9040 email rossindia airtelbroadband in ROSS CONTROLS CHINA Ltd China TEL 86 21 6915 7951 email alvinzhurong vip 163 com DIMAFLUID s a s France TEL 33 01 49 45 65 65 web site www dimafluid com VALVE OPERATION On first operation or after repair the pilot valve supply circuit and inherent monitoring ele
238. ically compounded for air line lubricator service These are generally petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Some compatible oils are listed above at the right These oils although believed to be compatible could change without notice because manufacturers sometimes reformulate their oils Therefore use oils specifically compounded for air line service If it is a synthetic oil contact the oil manufacturer for compatibility information Cleaning Valve If the air supplied to the valve has not been well filtered the interior of the valve may accumulate dirt and varnish which can affect the valve s performance Although COMPATIBLE LUBRICANTS Brand Name American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Pacemaker 32 Spinesstic 22 Teresstic 32 Velocite 10 Turbo T32 Sunvis 11 Sunvis 722 Regal R amp O 32 Union Turbine Oil ROSS poppet valves are very tolerant of dirty air cleaning may sometimes be necessary To clean the valve use any good commercial solvent or kerosene Do not use a chlorinated solvent or abrasive materials which can damage seals or do permanent damage to metal parts Before reassembling the valve lubricate all sliding surfaces with a grease equivalent to MobilGrease 28 Electrical Contacts In the external electrical circuits associated with the valve solenoids keep all switches or relay
239. icated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components and so cause the valve to malfunction Avoid oils with phosphate additives e g zinc dithiophosphate and diester oils both types can harm valve components The best oils to use are generally petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Some compatible oils are listed above at the right These oils although believed to be compatible could change without notice because manufacturers sometimes reformulate their oils Therefore use oils specifically compounded for air line service If it is a synthetic oil contact the oil manufacturer for compatibility information Cleaning the Valve If the air supplied to the valve has not been well filtered the interior of the valve may accumulate dirt and varnish which can affect the valve s performance COMPATIBLE LUBRICANTS Brand Name American Industrial Oil 32 Spindle Oil C Amolite 32 Pacemaker 32 Spinesstic 22 Teresstic 32 Velocite 10 Turbo T32 Sunvis 11 Sunvis 722 Regal R amp O 32 Union Turbine Oil A schedule should be established for cleaning all valves the frequency depending on the cleanliness of the air being supplied To clean the valve use any good commercial solvent Do not scrape varnished surfaces Also do not use chlorinated solvents or abra
240. ice If it is a synthetic oil contact the oil manufacturer for compatibility information Cleaning the Valve If the air supplied to the valve has not been well filtered the interior of the valve may accumulate dirt and varnish which can affect the valve s performance COMPATIBLE LUBRICANTS Maker Brand Name American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Pacemaker 32 Spinesstic 22 Teresstic 32 Velocite 10 Turbo T32 Sunvis 11 Sunvis 722 Regal R amp O 32 Union Turbine Oil A schedule should be established for cleaning all valves the frequency depending on the cleanliness of the air being supplied To clean the valve use any good commercial solvent Do not scrape varnished surfaces Also do not use chlorinated solvents or abrasive materials The former damages seals and abrasives can do permanent damage to metal parts Before reassembling the valve lubricate all sliding surfaces with a grease such as MobilGrease 28 Electrical Contacts In the electrical circuits associated with the valve solenoids keep all switches or relay contacts in good condition to avoid solenoid malfunctions Replace Worn Components In most cases it is not necessary to remove the valve from its installation for servicing However turn off the electrical power to the valve shut off the air supply and exhaust the air in the system before beginning any disassembly operation Service kits are listed on page 3 2 ROSS CONTROLS
241. ided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the U S A Rev 05 09 2009 ROSS CONTROLS All Rights Reserved Form SS098 Series W65 Valves ROSS Thank You You have purchased a premium quality ROSS pneumatic valve Itis a precision spool and sleeve valve designed for mounting on a base with an ISO 5599 II interface With care in its installation and maintenance you can expect it to have along and economical service life So before you go any further please take a few minutes to look over the information on this
242. ie 2006K77 Size 4 1791K77 S ZE Bihin 1710K77 Gasket and Seal Kits These kits are needed when valve bodies are disassembled for cleaning They include all necessary gaskets O rings and other seals These parts are also included in the Valve Body Service Kits above SIZE 2 hnn Na an N A SIZE ontana Rs 1790K77 SiZe Goa aani 1711K77 Pressure Switch Assembly Service Kit This kit includes all parts needed for complete reconditioning of the pressure switch assembly SIZE 2an 2008K77 SIZE Akuanei 1792K77 SIZE8 taiii oi N A Replacement Pressure Switches and Switch Connectors Pressure Switch Size Voltage Switch Connector 2 AC or DC 1018A30 N A 4 amp 8 100 120 AC 518E30 522E30 24 DC 798E30 522E30 Pressure switch 1018A30 is supplied with connector Solenoid Coils Order replacement solenoid coils by the following part numbers Specify voltage and hertz when ordering Pilot solenoids Reset solenoid Size 2 306K33 306K33 Size 4 290B33 306K33 SiZO e eee eee 290B33 290B33 Complete Solenoid Pilot Assemblies These assemblies consist of new pilot valve mechanisms and a new solenoid coil ready to bolt in position on the valve Specify voltage and hertz when ordering Pilot solenoids Reset solenoid Size 2 eee 1044H79 000 851079 Size 4 eee 842C79 1044H79 Size 8B eee 842079 842C79 Base Service Kits The base service kit is used to rep
243. igh quality DM Series S double valve with dynamic monitoring and inherent lockout capability The valve is designed for base mounting for ease of installation and maintenance With care in its installation and maintenance you can expect it to have a long and economical service life Before you install this valve read the information in this folder completely and save it for future reference Also refer to the guide Connecting Two DM Series S Valves for Separate Clutch amp Brake with 904J32 A Kits form No A10298 VALVE INSTALLATION Size 12 amp 30 Pneumatic equipment should be installed only by persons trained and experienced in such installation Air Lines Before installing this valve in a new or existing system the air lines must be blown clean of all contaminants It is recommended that a 5 micron rated air filter be installed in the inlet line close to the valve Valve Inlet Port 1 Be sure that the supply line is of adequate size and does not restrict the air supply because of a crimp in the line a sharp bend ora clogged filter element The air supply must not only provide sufficient pressure see Standard Specifications page 3 but must also provide an adequate flow of air on demand Otherwise the valve elements will be momentarily starved for air and the valve may fail to operate Valve Outlet Port 2 For faster pressurizing and exhausting of the mechanism being operated by the valve locate the valve
244. ighest standards With care in its installation and maintenance you can expect it to have a long and economical service life So before you go any further please take a few minutes to look over the information in this folder Then save it for future reference and for the useful service information it contains A general service manual with more detailed information is available from ROSS upon request VALVE INSTALLATION 2 2 Valves The 2 2 LT series valves combines the flexibility of a standard 2 way valve with the added benefits of high flow and zero leakage The valve can be used as a bypass valve or as a zero leak isolation valve for a leak test circuit The manifold has a single internal high flow poppet which is actuated by an external solenoid The valve s pressure range is from 2 to 145 psi and has a Cv of 2 2 The LT valve is normally closed Therefore if power is lost or if a safety stop has cut power the supply pressure will be closed Pilot Pressure Pilot pressure must be maintained at all times and must be equal to or greater than the inlet pressure to prevent valve failure To prevent loss of pilot pressure it is strongly recommended to use the same air supply for both the inlet and pilot pressures Normally Closed The LT is a normally closed 2 way valve The supply pressure on the INLET port is closed Electrical Power Loss Will cause the valve to return to a normally closed position Downstream line pressure will not
245. il mist into the air line in direct proportion to the rate of air flow Excessive lubrication can cause puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute is adequate note that this valve itself does not require air line lubrication but some optional adaptors do i e air index etc Compatible Lubricants Although this valve does not require air line lubrication it may be used with lubricated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components and so cause the valve to malfunction Avoid oils with phosphate additives e g zinc dithiophosphate and diester oils both types can harm valve components The best oils to use are generally petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Some compatible oils are listed above at the right These oils although believed to be compatible could change without notice because manufacturers sometimes reformulate their oils Therefore use oils specifically compounded for air line service If it is a synthetic oil contact the oil manufacturer for compatibility information Cleaning the Valve If the air supplied to the valve has not been well filtered the interior of the valve may accumulate dirt and varnish which can affect the valve s performance COMPATIBLE LU
246. ilot valve is supplied externally and requires a 1 8 inch pilot supply line connected to port P in the valve See Valve specifications on page 2 for pressure requirements Loss of pressure to port P during operation will cause the check valve to relieve trapped pressure Pipe Installation To install pipe in valve ports engage pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating the valve web site www rosscontrols com ROSS EUROPA GmbH ROSS ASIA K K TEL 49 6103 7597 0 TEL 81 427 78 7251 Germany Japan web site www rosseuropa com web site www rossasia co jp ROSS UK Ltd United Kingdom TEL 44 121 559 4900 email sales rossuk co uk ROSS SOUTH AMERICA Ltda Brazil TEL 55 11 4335 2200 email vendas ross sulamerica com br ROSS CONTROLS INDIA Pvt Ltd India TEL 91 44 2624 9040 email rossindia airtelbroadband in ROSS CONTROLS CHINA Ltd China TEL 86 21 6915 7951 email alvinzhurong vip 163 com DIMAFLUID s a s France TEL 33 01 49 45 65 65 web site www dimafluid com VALVE MAINTENANCE Pneumatic equipment should be maintained only by persons trained and experienced in the maintenance of such equipment Supply Clean Air Foreign material lodging in valves is a major cause of breakdowns The use of a 5 micron rated air filter located close to the valve is strongly recommended The filter bowl
247. ine point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components potentially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits furth
248. ing THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the U S A Rev 5 09 2009 ROSS CONTROLS All Rights Reserved Form SS293 DM2 Series E Control Reliable Double Valves with Dynamic Monitoring amp Memory Size 2 Thank You You have purchased a premium quality ROSS pneumatic valve It is a high quality DM Series E Control Reliable double valve with Dynamic Monitoring and Memory for Category 4 applications except press clutch brake applications With care in its installation and maintenance you can expect it to have a long and economical service life Before you install this valve read the information in this folder completely and save it for future reference IMPORTANT APPLICATION NOTE Because of its air flow amp exhausting characteristics this valve
249. ing the Valve If the air supplied to the valve has not been well filtered the interior of the valve may accumulate dirt and varnish which can affect the valve s performance A schedule should be established for cleaning all valves the frequency depending on the cleanliness of the air being supplied COMPATIBLE LUBRICANTS Brand Name American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Pacemaker 32 Spinesstic 22 Teresstic 32 Velocite 10 Air Lube 10H NR Turbo T32 Sunvis 11 Sunvis 722 Regal R amp O 32 Union Turbine Oil To clean the valve use any good commercial solvent Do not scrape varnished surfaces Also do not use chlorinated solvents or abrasive materials The former damages seals and abrasives can do permanent damage to metal parts Before reassembling the valve lubricate all sliding surfaces with a grease such as MobilGrease 28 Electrical Contacts In the electrical circuits associated with the valve solenoids keep all switches or relay contacts in good condition to avoid solenoid malfunctions Replace Worn Components In some cases it is not necessary to remove the valve from its installation for servicing However before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 before beginning any disassembly operation Service kits
250. ining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should put a fine oil mist into the air line in direct proportion to the rate of air flow Excessive lubrication can cause puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute is adequate Note that the double valve itself does not require air line lubrication Compatible Lubricants Although this valve does not require air line lubrication it may be used with lubricated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components and so cause the valve to malfunction Avoid oils with anti wear or phosphate additives e g zinc dithiophosphate and diester oils these substances can harm valve components The best oils to use are generally petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Some compatible oils are listed on page 3 These oils although believed to be compatible could change without notice because manufacturers sometimes reformulate their oils Therefore use oils specifically compounded for air line service If itis a synthetic oil contact the oil manufacturer for compatibility information Cleaning the Valve If the air supplied to the valve has not been well filtered the interior of the valve m
251. injury VALVE INSTALLATION ROSS HSR Valve TYPICAL HSR VALVE INSTALLATION Shown above is a typical two hand control arrangement with a ROSS HSR valve and two hand valves A and B The hand valves must be actuated within approximately 0 5 second of one another in order for the HSR valve to produce a signal to the work station A non repeat function can be added by the addition of a dump valve as shown on page 3 Pneumatic equipment should be installed only by persons trained and experienced in such installation Air Lines Before installing a valve in an existing system the air lines must be blown clean of all contaminants It is Valve Outlet Port 2 For faster pressurizing and exhausting of the mechanism being operated by the valve locate the valve as close as possible to the mechanism The total outlet volume must not exceed 30 cubic inches or the HSR will recommended that a 5 micron rated air filter be installed in the inlet lines close to each of the valves supplying the HSR valve Hand Valves The valves supplying air to the inlets of the HSR valve must have a Cv rating of not less than 0 3 and must be piped to an adequate and consistent supply of air with a pressure in the 30 to 125 psig range Valve Inlets Ports 1A and 1B Be sure that the lines supplying air to the HSR valve do not restrict the flow of air The lines must be of nearly equal length and no less than 3 16 in inside diameter ROSS
252. inlet pressure Pressure Switch Status Indicator Rating Contacts 5 amps at 250 volts AC or 5 amps at 30 volts DC Application clutch brake Solenoid Reset Units with solenoid reset include a 3 2 solenoid valve Energize this solenoid momentarily to reset valve after lock out condition occurs NOTE The valve is designed such that both pilot solenoids must be de energized prior to reset and must remain de energized until after the reset signal is removed Otherwise the valve will not reset Electrical Connectors Wired connectors have a 2 meter 6 ft cord with three 18 gauge conductors Cord is available in either 6 mm or 10 mm diameter and with or without indicator light Specify solenoid voltage for lighted connectors Category 3 amp 4 applications except press Without Light With Light Wired with 6 mm cord 721K77 720K77 Wired with 10 mm cord 371K77 383K77 For threaded conduit 723K77 724K77 For use with drop cord 937K87 936K87 cord not included For additional wiring kit accessories please see Form NPSO11 available at www rosscontrols com VALVE SERVICE ROSS would be happy to service this specialized double valve for you at its factory repair center Call your local distributor or in the U S 1 800 GET ROSS 706 356 3708 outside the U S for information If you service the valve yourself be sure to turn off electrical power to the valve shut off the air supply exhaust the air in the system and lock out al
253. ion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the U S A Rev 05 09 2009 ROSS CONTROLS All Rights Reserved Form SS146 Series 3 SERPAR Double Valves with Dual Monitoring ROSS Thank You You have purchased a premium quality ROSS pneumatic valve It is a Serpar double valve designed to offer added safety to the operation of many pneumatically controlled machines When properly installed it conforms with the OSHA amp CSA standards for control of air clutch brake mechanisms used on ce
254. ir Foreign material lodging in valves is a major cause of breakdowns The use of a 5 micron rated air filter located close to the valve is strongly recommended The filter bowl should be drained regularly and if its location makes draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should put a fine oil mist into the air line in direct proportion to the rate of air flow Excessive lubrication can cause puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute is adequate Note that the double valve itself does not require air line lubrication Compatible Lubricants Although this valve does not require air line lubrication it may be used with lubricated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components and so cause the valve to malfunction Avoid oils with phosphate additives e g zinc dithiophosphate and diester oils both types can harm valve components The best oils to use are generally petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Some compatible oils are listed at the right These oils although believed to be compatible could change without notice because manufacturers sometimes reformulate their oils Therefore use oils specifically co
255. ir to the valve be filtered Disassembly of the valve for cleaning and repair must be done by qualified persons The testing procedures must be done for valves that have been disassembled and repaired Lubrication recommended is Owens Corning BR2 Plus grease COMPATIBLE LUBRICANTS Brand Name American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Pacemaker 32 Spinesstic 22 Teresstic 32 Velocite 10 Air Lube 10H NR Turbo T32 Sunvis 11 Sunvis 722 Regal R amp O 32 Union Turbine Oil It is applied only to the piston seals and bores Do not lubricate the poppet seals Repair kits are available for internal components Valves can be returned to Ross Controls for repair Electrical Contacts In the electrical circuits associated with the valve solenoids keep all switches or relay contacts in good condition to avoid solenoid malfunctions Replace Worn Components In most cases it is not necessary to remove the valve from its installation for servicing However turn off the electrical power to the valve shut off the air supply exhaust the air in the system and lock out before beginning any disassembly operation Service kits are listed on page 3 2 ROSS CONTROLS STANDARD SPECIFICATIONS Solenoids According to VDE 0580 Enclosure rating according to DIN 400 50 IP 65 Connector socket according to DIN 43650 Form A Three solenoids rated for continuous duty Standard Voltages 110 volts AC 50 60 Hz 24 volts DC Pilo
256. iston EXH VALVE OPEN Air through the metering orifice gradually increases the pressure on the spring side of the flyback piston At about 25 psi less than inlet pressure the force on the flyback piston is enough to move it up the main spool Full pressure inlet air then flows freely to the outlet STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the produ
257. ith before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakage and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with
258. ity for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and L O X with EEZ ON operation products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS such product is found to be defective This warranty shall be void in the event that product has been subject
259. ity ROSS pneumatic valve double valve with dynamic monitoring and inherent lockout capability for category 3 and 4 applications except press clutch brake applications The valve is designed for base mounting for ease of installation and maintenance With care in its installation and maintenance you can expect it to have a long and economical service life Before you install this valve read the information in this folder completely and save it for future reference NOTE This valve is expressly not intended for use in press clutch brake applications ROSS produces the DM Series D and a number of other double valve configurations specifically for use VALVE INSTALLATION with press clutch brake applications It is a high quality DM Series C ROSS a a 3 a Size 4 illustrated Pneumatic equipment should be installed only by persons trained and experienced in such installation Application DM Series C double valves are intended for use in category 3 amp 4 applications except press clutch brake applications Air Lines Before installing this valve in a new or existing system the air lines must be blown clean of all contaminants It is recommended that a 5 micron rated air filter be installed in the inlet line close to the valve Valve Inlet Port 1 Be sure that the supply line is of adequate size and does not restrict the air supply because of a crimp in the line a sharp bend or
260. k out before beginning any disassembly operation Service kits are listed on page 3 2 ROSS CONTROLS STANDARD SPECIFICATIONS Solenoids According to VDE 0580 Enclosure rating according to DIN 400 50 IP 65 Connector socket according to DIN 43650 Form A Two solenoids rated for continuous duty Standard Voltages 110 volts AC 50 60 Hz 220 volts AC 50 60 Hz 12 volts DC 24 volts DC Pilot Solenoid Power Consumption each solenoid 6 0 watts on DC and 15 8 VA inrush and 10 4 VA holding on AC Ambient Temperature 15 to 120 F 10 to 50 C Media Temperature 40 to 175 F 4 to 80 C Flow Media Filtered 5 micron recommended lubricated or unlubricated air mineral oils according to DIN 51519 viscosity classes 32 46 Inlet Pressure 30 to 116 psig 2 to 8 bar Pressure Switch Status Indicator Rating Contacts 5 amps at 250 volts AC or 5 amps at 30 volts DC Application Category 3 applications and not press clutch brake applications Electrical Connectors Wired connectors have a 2 meter 6 1 2 ft cord with three 18 gauge conductors Cord is available in either 6 mm or 10 mm diameter and with or without indicator light Specify solenoid voltage for lighted connectors Without Light With Light 24 volts DC With Light 110 volts AC Wired with 6 mm cord 721K77 720K77 W 720K77 Z Wired with 10 mm cord 371K77 383K77 W 383K77 Z For threaded conduit 723K77 724K77 W 724K77 Z For use with drop cord 937K87 936K87 W
261. l and sleeve into the valve body very lightly lubricate the O rings with a lubricant such as those shown below Do not use Anderol it causes the O rings to deteriorate Electrical Contacts In the external electrical circuits associated with the valve solenoids keep all switches or relay contacts in good condition to avoid solenoid malfunctions Replace Worn Components After long usage the spool and sleeve may show signs of wear as indicated by excessive air leakage between ports The valve can be completely reconditioned with the use of a ROSS valve body service kit See page 3 for information about such kits VALVE SPECIFICATIONS IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 Solenoid Pilot Solenoids Rated for continuous duty Voltage and Hertz ratings printed on solenoid coils Standard Voltages 100 110 volts 50 Hz 100 120 volts 60 Hz 200 240 volts 50 60 Hz 24 110 volts DC Temperature Ranges Ambient 40 to 120 F 4 to 50 C Media 40 to 175 F 4 to 80 C Flow Media Filtered air 5 micron recommended Inlet Pressure 60 to 120 psig 4 to 8 bar Manual Override Flush non locking ROSS CONTROLS VALVE OPERATION Traditionally standard valves apply the same pressure for extending and retracting double acting cylinders However this new EnerGySaver valve revolutionizes the way cylinders are controlled by reducing the cylind
262. l power sources before beginning any disassembly operation Listed below are kits for servicing DM Series C double valves as well as replacement solenoid information CAUTION Before operating the DM Series C double valve be sure to complete the test procedure TEST on page 1 upon installation and after any maintenance is performed on the valve Failure to do so could result in personal injury or equipment damage Valve Body Service Kits These kits contain all parts needed for complete reconditioning of a valve body Included are poppets spindles gaskets seals and instructions for use SIZE 4s sccc sdincivenbiaeis 2102K77 SIZE Bien ee 2103K77 Size T2 aia 2104K77 Size 30 2105K77 Status Indicator Assembly Service Kit This kit includes all parts needed for complete reconditioning of the status indicator assembly Pressure switch and connector sold separately see below All SiZ S ccccceee 2151H77 Replacement Pressure Switch This kit includes a replacement pressure switch and electrical connector for the status indicator assembly All Size 1104A30 If you have any questions about installing or servicing your valve call ROSS Technical Services at your nearest ROSS location see page 1 or in the U S A at 1 888 TEK ROSS or 1 706 356 3708 Solenoid Coils Order replacement solenoid coils by the following part numbers Specify voltage and hertz when ordering Pilot solenoids Reset solenoid
263. l should be drained regularly and if its location makes draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should put a fine oil mist into the air line in direct proportion to the rate of air flow Excessive lubrication can cause puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute is adequate Note that this valve itself does not require air line lubrication but some optional adaptors do i e air index etc Compatible Lubricants Although this valve does not require air line lubrication it may be used with lubricated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components and so cause the valve to malfunction Avoid oils with phosphate additives e g zinc dithiophosphate and diester oils both types can harm valve components The best oils to use are generally petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Some compatible oils are listed above at the right These oils although believed to be compatible could change without notice because manufacturers sometimes reformulate their oils Therefore use oils specifically compounded for air line service If it is a synthetic oil contact the oil manufacturer for compatibility information Cle
264. leakage and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components potentially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumaticall
265. let 2 connected to exhaust 3 exhaust 5 closed 5 3 CLOSED CENTER VALVES 4 2 4 2 14 12 14 12 5413 513 Pressure Controlled Solenoid Pilot No Signal Applied All ports closed Signal 12 Applied Inlet 1 connected to outlet 2 outlet 4 connected to exhaust 5 exhaust 3 closed Signal 14 Applied Inlet 1 connected to outlet 4 outlet 2 connected to exhaust 3 exhaust 5 closed 5 3 OPEN CENTER VALVES 14 12 4 2 14 12 51413 5143 Pressure Controlled Solenoid Pilot No Signal Applied Inlet 1 closed outlet 2 connected to exhaust 3 outlet 4 connected to exhaust 5 Signal 12 Applied Inlet 1 connected to outlet 2 outlet 4 connected to exhaust 5 exhaust 3 closed Signal 14 Applied Inlet 1 connected to outlet 4 outlet 2 connected to exhaust 3 exhaust 5 closed VALVE SERVICE ROSS would be happy to service this valve for you at its factory repair center 1 800 GET ROSS However if you choose to service this valve yourself it is strongly recommended that you obtain a free service manual from ROSS in the U S A at 1 800 GET ROSS Listed below are the valve body service kits and solenoid replacement coils for Series W65 valves Valve Body Service Kits These kits contain all parts needed for complete reconditioning of a valve body Included are a spool and sleeve all required gaskets and seals and instructions for use If you need additional information or have questions about installa
266. lete reconditioning of a valve body Included are spools gaskets seals and instructions for use Base Service Kits These kits contain the seals and other parts required to recondition the valve s base Pressure Switch Assembly Kits These kits contain the parts necessary to recondition the pressure switch assembly Replacement Pressure Switches and Switch Connectors Part numbers for these components are shown in the chart below Solenoids Order replacement solenoids or solenoid coils by the following part numbers Be sure to specify voltage and hertz when ordering Solenoid coil only 305K33 Complete pilot assembly 1044H79 SERVICE KITS and COMPONENTS Valve Valve Model Valve Body Valve Pressure Switch Asy Pressure Switch Size Number Gasket Kit Service Kit Service Kit Switch Connector 2 7776A3400 1575K77 1576K77 1696K77 7776A3401 1575K77 1576K77 1696K77 518E30 522E30 4 7776A4400 1577K77 1578K77 1696K77 7776A4401 1577K77 1578K77 1696K77 518E30 522E30 If you need additional information or have any questions about installing or servicing your valve call ROSS Technical Services in the U S A at 1 888 TEK ROSS 835 7677 or 1 706 356 3708 www rosscontrols com 3 STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sou
267. line lubrication it may be used with lubricated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components and so cause the valve to malfunction Avoid oils with phosphate additives e g zinc dithiophosphate and diester oils both types can harm valve components The best oils to use are generally petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Some compatible oils are listed above at the right These oils although believed to be compatible could change without notice because manufacturers sometimes reformulate their oils Therefore use oils specifically compounded for air line service If itis a synthetic oil contact the oil manufacturer for compatibility information Cleaning the Valve If the air supplied to the valve has not been well filtered the interior of the valve may accumulate dirt and varnish which can affect the valve s performance To clean the valve use a solvent which will dry without leaving a residue This is especially important for the spool and sleeve assembly Do not use a chlorinated solvent or abrasive materials The former damages seals and abrasives can do permanent harm to metal parts COMPATIBLE LUBRICANTS Brand Name American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Pacemaker 32 Spinesstic 22 Teresstic 32 Velocite 10 Turbo T32 Sunvis
268. lled only by persons trained and experienced in such installation After installation is complete refer to Valve Operation on page 2 to ensure that the valve is functioning properly Air Lines Before installing a valve in a new or an existing system the air lines must be blown clean of all contaminants It is recommended that a 5 micron rated air filter be installed in the inlet line close to the valve Valve Inlet Port 1 Be sure that the supply line is of adequate size and does not restrict the air supply due to acrimp in the line a sharp bend or a clogged filter element The air supply must not only provide sufficient pressure see Valve Specifications page 3 but must also provide an adequate flow of air on demand Otherwise the valve elements will be momentarily starved for air and the valve may fail to operate Valve Outlet Ports 2 and 4 For faster pressurizing and exhausting of the mechanism being operated by the valve locate the valve as close as possible to the mechanism The lines must be of adequate size and be free of crimps and sharp bends Port 2 is the normally open port pressurized when the valve is de actuated or when the redundant valve elements are not actuated within 500 milliseconds of each other and port 4 is the normally closed port pressurized only when both main valve elements have been actuated within 500 milliseconds of each other Valve Exhaust Ports 3 and 5 Do not restrict air flow from the
269. lose to the valve Valve Inlet Port 1 Be sure that the supply line is of adequate size and does not restrict the air supply because of a crimp in the line sharp bends or a clogged filter element Valve Outlets Ports 2 amp 4 For faster pressurizing and exhausting of the mechanism being operated by the valve locate the valve as close as possible to the mechanism The lines must be of adequate size and be free of crimps and sharp bends Valve Exhausts Ports 3 amp 5 Do not restrict exhaust air flow as this can adversely affect valve performance However to reduce noise you may use an efficient silencer ROSS MUFFL AIR silencers reduce impact noise by as much as 25 dB and produce little back pressure Electrical Supply The voltage and hertz ratings of the valve solenoids if any are printed on the solenoids The electrical supply must correspond to these ratings or the life of the solenoids will be shortened Connections are made with a plug in connector to the prongs as shown in the ROSS CONTROLS United States TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS sketch of the pilot below If power is supplied by a transformer it must be capable of handling the inrush current without significant voltage drop See Valve Specifications on page 2 for information on inrush current Operating Pressures and Temperatures Allowable ranges for pressure and temperatures are given in the Valve Specifications on p
270. lt in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and L O X with EEZ ON operation products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is fo
271. lthough this valve does not require air line lubrication it may be used with lubricated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components and so cause the valve to malfunction Avoid oils with phosphate additives e g zinc dithiophosphate and diester oils both types can harm valve components The best oils to use are generally petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Some compatible oils are listed at the right These oils although believed to be compatible could change without notice because manufacturers sometimes reformulate their oils Therefore use oils specifically compounded for air line service If it is a synthetic oil contact the oil manufacturer for compatibility information Cleaning the Valve If the air supplied to the valve has not been well filtered the interior of the valve may accumulate dirt and varnish which can affect the valve s performance A schedule should be established for cleaning all valves the frequency depending on the cleanliness of the air being supplied Brand Name American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Pacemaker 32 Spinesstic 22 Teresstic 32 Velocite 10 Air Lube 10H NR Turbo T32 Sunvis 11 Sunvis 722 Regal R amp O 32 Union Turbine Oil To clean the valve use any good commercial solvent Do
272. m polyurethane components potentially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specific
273. mail sales rossuk co uk email vendas ross sulamerica com br email rossindia airtelbroadband in email alvinzhurong vip 163 com web site www dimafluid com TEL 55 11 4335 2200 TEL 91 44 2624 9040 TEL 86 21 6915 7951 TEL 33 01 49 45 65 65 Brazil India China France ROSS SOUTH AMERICA Ltda ROSS CONTROLS INDIA Pvt Ltd ROSS CONTROLS CHINA Ltd DIMAFLUID s a s VALVE MAINTENANCE Pneumatic equipment should be maintained only by persons trained and experienced in the maintenance of such equipment Supply Clean Air Foreign material lodging in valves is a major cause of breakdowns The use of a 5 micron rated air filter located close to the valve is strongly recommended The filter bowl should be drained regularly and if its location makes draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should put a fine oil mist into the air line in direct proportion to the rate of air flow Excessive lubrication can cause puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute is adequate note that this valve itself does not require air line lubrication but some optional adaptors do i e air index etc Compatible Lubricants Although this valve does not require air line lubrication it may be used with lubricated air being supplied to other mechanisms Some oils contain
274. me oils contain additives that can harm seals or other valve components and so cause the valve to malfunction Avoid oils with phosphate additives e g zinc dithiophosphate and diester oils both types can harm valve components The best oils to use are generally petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Some compatible oils are listed above at the right These oils although believed to be compatible could change without notice because manufacturers sometimes reformulate their oils Therefore use oils specifically compounded for air line service If it is a synthetic oil contact the oil manufacturer for compatibility information Cleaning the Valve If the air supplied to the valve is not well filtered the interior of the valve may accumulate dirt and varnish which can affect the valve s performance This can cause sluggish or erratic valve action and nuisance lockouts A schedule should be established for cleaning all valves the frequency depending on the cleanliness of the air being supplied 2 COMPATIBLE LUBRICANTS Maker Brand Name AMOCO 0000 American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Citgo ee Pacemaker 32 EXXON eee Spinesstic 22 Teresstic 32 Mobil 00 Velocite 10 Non Fluid Oil Air Lube 10H NR Shell 000000 Turbo T32 S fistinn Sunvis 11 Sunvis 722 TEXACO
275. ments may need to be reset This reset is accomplished by applying a momentary air signal to the RESET port or by energizing the optional reset solenoid momentarily on the valve After reset the valve will then be ready for operation The air supply to each pilot valve is controlled by the position of the inlet poppets In the ready for operation position these poppets are held on their seats and maintain pilot air flow During shifting of the valve elements the poppets move off seat and momentarily allow pilot air to escape to exhaust If either valve element fails to operate correctly the pilot supply to the other valve element will remain connected to exhaust causing the valve to lockout The internal monitoring system will lockout the valve if the time difference between both elements shifting fully is longer than approximately 125 milliseconds This timing is preset by restricting orifices and chambers in the pilot air circuit The main airflow from port 1 to port 2 is via crossflow passages between both main valves so that both valve elements must be fully shifted in order for port 2 to be pressurized If the valve locks out further operation is prevented until the valve has been reset Electrical signals to the solenoids must be off to allow the valve to be reset The DM Series S valve is completely self contained and does not need an external monitoring system VALVE MAINTENANCE Pneumatic equipment should be maintained only by p
276. mium quality ROSS pneumatic valve It is a Crossflow double valve designed for use with a suitable external monitor The external monitor must ensure that the gt operation of the double valve is inhibited should there be a malfunction in the system impacting proper valve functions With care in its installation and maintenance you can expect your valve to have a long and reliable service life Before you go any further please take a few minutes to look over the information in this folder and save it for future reference Size 1 Valve Size 2 Valve VALVE INSTALLATION Pneumatic equipment should be installed only by persons trained and experienced in such installation Air Lines Before installing a valve in a new or an existing system the air lines must be blown clean of all contaminants It is recommended that a 5 micron rated air filter be installed in the inlet line close to the valve Valve Inlet Port 1 Be sure that the supply line is of adequate size and does not restrict the air supply because of a crimp in the line a sharp bend or a clogged filter element The air supply must not only provide sufficient pressure see Valve Specifications page 3 but must also provide an adequate flow of air on demand Valve Outlet Port 2 For faster pressurizing and exhausting of the mechanism being operated by the valve locate the valve as close as possible to the mechanism The lines must be of adequate size and
277. mpounded for air line service If itis a synthetic oil contact the oil manufacturer for compatibility information Cleaning the Valve If the air supplied to the valve has not been well filtered the interior of the valve may accumulate dirt and varnish which can affect the valve s performance A schedule should be established for cleaning all valves the frequency depending on the cleanliness of the air being supplied COMPATIBLE LUBRICANTS Brand Name American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Pacemaker 32 Spinesstic 22 Teresstic 32 Velocite 10 Air Lube 10H NR Turbo T32 Sunvis 11 Sunvis 722 Regal R amp O 32 Union Turbine Oil To clean the valve use any good commercial solvent Do not scrape varnished surfaces Also do not use chlorinated solvents or abrasive materials The former damages seals and abrasives can do permanent damage to metal parts Before reassembling the valve lubricate all sliding surfaces with a grease such as MobilGrease 28 Electrical Contacts In the electrical circuits associated with the valve solenoids keep all switches or relay contacts in good condition to avoid solenoid malfunctions Replace Worn Components In most cases it is not necessary to remove the valve from its installation for servicing However turn off the electrical power to the valve shut off the air supply exhaust the air in the system and lock out before beginning any dissasembly operation Servi
278. n and maintenance you can expect it to have a long and reliable service life Before you go any further please take a few minutes to look over the information in this folder and save it for future reference Pressure Switch and Connector Assembly Model With Pressure Switch Illustrated VALVE INSTALLATION Pneumatic equipment should be installed only by persons trained and experienced in such installation After installation is complete refer to Valve Operation on page 2 to ensure that the valve is functioning properly Air Lines Before installing a valve in a new or an existing system the air lines must be blown clean of all contaminants It is recommended that a 5 micron rated air filter be installed in the inlet line close to the valve Valve Inlet Port 1 Be sure thatthe supply line is of adequate size and does not restrict the air supply because of a crimp in the line a sharp bend or a clogged filter element The air supply must not only provide sufficient pressure see Valve Specifications page 3 but must also provide an adequate flow of air on demand Otherwise the valve elements will be momentarily starved for air and the valve may fail to operate Valve Outlet Ports 2 and 4 For faster pressurizing and exhausting of the mechanism being operated by the valve locate the valve as close as possible to the mechanism The lines must be of adequate size and be free of crimps and sharp bends Port 2 is the no
279. nction The best oils to use are those specifically compounded for air line lubricator service Cleaning Valve If the air supplied to the valve has not been well filtered the interior of the valve may accumulate dirt and varnish which can affect the valve s performance To clean the valve use a solvent which will dry without leaving a residue This is especially important for the spool and sleeve assembly Do not use a chlorinated solvent or abrasive materials which can damage seals or do permanent damage to metal parts To reassemble the spool and sleeve put one drop of Anderol 735 or equivalent lubricant on each spool land Insert the spool into the sleeve and rotate it several times to ensure even distribution of the lubricant COMPATIBLE LUBRICANTS Maker Brand Name AMOGCO 00008 American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Citgo eee Pacemaker 32 EXXON eslent Spinesstic 22 Teresstic 32 Mobil 00 Velocite 10 Non Fluid Oil Air Lube 10H NR Shell 0000 Turbo T32 SUN Sunvis 11 Sunvis 722 TEXACO Regal R amp O 32 UNION Union Turbine Oil If the valve is used in a non lubricated application do not use a lubricant for reassembly which can dry out and leave a residue Dry assembly of the spool and sleeve is preferable Each spool and sleeve is a matched set so care must be taken not to reverse the position of the spool in the sleeve Before inserting the spoo
280. nd all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarb
281. ne in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and L O X EEZ ON products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROS
282. ne to remote RESET port in valve Apply signal momentarily to reset valve after fault condition occurs NOTE Main solenoids must be off when performing reset procedure Electrical Connectors Wired connectors have a 2 meter 6 1 2 ft cord with three 18 gauge conductors Cord is available in either 6 mm or 10 mm diameter and with or without indicator light Specify solenoid voltage for lighted connectors Without Light With Light Wired with 6 mm cord 721K77 720K77 Wired with 10 mm cord 371K77 383K77 For threaded conduit 723K77 724K77 For use with drop cord 937K87 936K87 cord not included For additional wiring kit accessories please see Form NPSO11 available at www rosscontrols com VALVE SERVICE ROSS would be happy to service this specialized double valve for you at its factory repair center Call your local distributor or in the U S 1 800 GET ROSS 706 356 3708 outside the U S for information If you service the valve yourself be sure to turn off electrical power to the valve shut off the air supply exhaust the air in the system and lock out all power sources before beginning any disassembly operation Listed below are kits for servicing DM Series S double valves as well as replacement solenoid information CAUTION Before operating the DM Series S double valve be sure to complete the test procedure TEST on page 1 upon installation and after any maintenance is performed on the valve Failure to do so could re
283. nector whose connections correspond to the prongs pictured in the sketch of a typical solenoid pilot Line AC DC If poweris supplied by a transformer it must be capable of handling the inrush current without significant voltage drop See Valve Specifications on page 2 for information on inrush current Operating Pressures and Temperatures Allowable ranges for pressure and temperatures are given in the Valve Specifications on page 2 Exceeding the values shown can shorten valve life Pilot Supply Solenoid Control Pressure for the pilot valves is supplied from the inlet port Be sure that port 14 in the base is plugged or pilot air will escape Minimum operating pressure for the Series W60 ENERGYSAVER valves is 45 psig 3 bar Pipe Installation To install pipe in valve or base ports engage pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating the valve web site www rosscontrols com ROSS EUROPA GmbH Germany TEL 49 6103 7597 0 web site www rosseuropa com ROSS ASIA K K Japan TEL 81 427 78 7251 web site www rossasia co jp ROSS UK Ltd ROSS SOUTH AMERICA Ltda ROSS CONTROLS INDIA Pvt Ltd United Kingdom Brazil India TEL 44 121 559 4900 TEL 55 11 4335 2200 TEL 91 44 2624 9040 email sales rossuk co uk email vendas ross sulamerica com br email rossindia airtelbroadband in ROSS
284. nents In some cases it is not necessary to remove the valve from its installation for servicing However turn off the electrical power to the valve shut off the air supply and exhaust the air in the system before beginning any disassembly operation Service kits for these valves are listed on page 3 VALVE SPECIFICATIONS Temperature Range 40 to 175 F 4 to 80 C Flow Media Filtered air 5 micron recommended Inlet Pressure 5 to 150 psig 0 3 to 10 bar Models beginning with the numbers 1223 are limited to 125 psig 8 5 bar IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 2 ROSS CONTROLS VALVE SERVICE Parts for servicing your valve can be obtained from ROSS SERVICE KITS Call ROSS Technical Services for assistance see note below FOR SERIES 11 VALVES for phone number Valve Model Valve Body Valve Body Service Kits The service kits listed at right contain Number Service Kit all the internal parts needed to recondition your Series 11 valve 1121A2001 681K87 Included are poppets springs and retainers stem assemblies 1121A2002 681K87 seals and instructions for use Kits are not available for Series 12 1123A2001 682K87 valves 1123A2002 682K87 1131A2001 681K87 a 1131A2002 681K87 If you have any questions about installing or servicing your 413142003 681K87 valve call ROSS Technical Services at your nearest ROSS RENETTE easly locati
285. nergy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the U S A Rev 05 09 2009 ROSS CONTROLS All Rights Reserved Form SS097 Series W63 Valves Thank You
286. ng for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakage and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components potentially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least a
287. nited States TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS web site www rosscontrols com ROSS EUROPA GmbH Germany TEL 49 6103 7597 0 web site www rosseuropa com ROSS ASIA K K Japan TEL 81 427 78 7251 web site www rossasia co jp ROSS UK Ltd United Kingdom TEL 44 121 559 4900 email sales rossuk co uk ROSS SOUTH AMERICA Ltda Brazil TEL 55 11 4335 2200 email vendas ross sulamerica com br ROSS CONTROLS INDIA Pvt Ltd India TEL 91 44 2624 9040 email rossindia airtelbroadband in ROSS CONTROLS CHINA Ltd China TEL 86 21 6915 7951 email alvinzhurong vip 163 com DIMAFLUID s a s France TEL 33 01 49 45 65 65 web site www dimafluid com VALVE OPERATION Normal Operation After installation the valve is operated by energizing both pilot solenoids simultaneously This causes both main valve elements to be actuated so that air from inlet port 1 flows to outlet port 4 but not to port 2 Air downstream of port 2 is exhausted through port 3 When the solenoids are de energized both valve elements are de actuated and air then flows from inlet port 1 to outlet port 2 but no longer to outlet port 4 Air downstream of port 4 is exhausted through port 5 Detecting a Malfunction If the main valve elements are not both actuated or de actuated at the same time the valve defaults so that outlet port 2 receives full inlet pressure and outlet port 4 is exhausted through port 5 If the malfunction was
288. nly by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pres
289. not scrape varnished surfaces Also do not use chlorinated solvents or abrasive materials The former damages seals and abrasives can do permanent damage to metal parts Before reassembling the valve lubricate all sliding surfaces with a grease such as Dow Corning BR 2 Plus Electrical Contacts In the electrical circuits associated with the valve solenoids keep all switches or relay contacts in good condition to avoid solenoid malfunctions Replace Worn Components In most cases it is not necessary to remove the valve from its installation for servicing However turn off the electrical power to the valve shut off the air supply exhaust the air in the system and lock out before beginning any disassembly operation Service kits are listed on page 3 2 ROSS CONTROLS STANDARD SPECIFICATIONS Solenoids According to VDE 0580 Enclosure rating according to DIN 400 50 IP 65 Connector socket according to DIN 43650 Form A Two solenoids rated for continuous duty three with solenoid reset option Standard Voltages 110 volts 50 60 Hz 220 volts 50 60 Hz 24 volts DC Pilot Solenoids Power Consumption each solenoid Sizes 4 12 amp 30 6 0 watts on DC 15 8 VA inrush and 10 4 VA holding on AC Size 8 15 watts on DC 36 VA inrush and 24 6 VA holding on AC Reset Solenoid Power Consumption 6 0 watts on DC 15 8 VA inrush and 10 4 VA holding on AC Ambient Temperature 15 to 120 F 10 to 50 C Media Temperature 4
290. ntains A general service manual with more detailed information is available from ROSS upon request ROSS Series CP LF Valves VALVE INSTALLATION Important Note ROSS Dale Series CP CX LF LX valves are not designed as control valves for air clutch brake mechanisms on mechanical power presses and must not be installed for such use Only double valves conforming to OSHA standards should be used in such applications Pneumatic equipment should be installed only by persons trained and experienced in such installation Air Lines Before installing a valve in a new or an existing system the air lines must be blown clean of all contaminants It is recommended that an air filter be installed in the inlet line close to the valve Valve Inlet Port 1 Be sure that the supply line is of adequate size and does not restrict the air supply because of a crimp in the line a sharp bend or a clogged filter element Valve Outlets Port2 For faster pressurizing and exhausting of the mechanism being operated by the valve locate the valve as close as possible to the mechanism The lines must be of adequate size and be free of crimps and sharp bends Valve Exhausts Port 3 Do not restrict the air flow from the exhaust port of the valve body or pilot body as this can adversely affect the operation of the valve However to reduce exhaust noise an efficient silencer may be used ROSS MUFFL AIR silencers reduce impact noise by as muc
291. ntrolled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and manual L O X with EEZ ON operation products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PAR
292. o could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and L O X with EEZ ON operation products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manu
293. o permanent damage to metal parts Before reassembling the valve lubricate all sliding surfaces with a grease such as MobilGrease 28 Electrical Contacts In the electrical circuits associated with the valve solenoids keep all switches or relay contacts in good condition to avoid solenoid malfunctions Replace Worn Components In some cases it is not necessary to remove the valve from its installation for servicing However turn off the electrical power to the valve shut off the air supply and exhaust the air in the system before beginning any disassembly operation Service kits for these valves are listed on page 3 VALVE SPECIFICATIONS NOTE Type H valves are for high temperature service Type O valves are for low temperature service Pressure Controlled Temperature Range For temperatures below 40 F 4 C air must be free of water vapor to prevent formation of ice Type H 0 to 300 F 17 to 150 C Type O 40 to 175 F 40 to 80 C Flow Media Filtered air 5 micron recommended Inlet Pressure 1 4 to 1 1 2 Port Sizes 15 to 150 psig 1 to 10 bar 1 1 2 to 2 1 2 Port Sizes 30 to 150 psig 2 to 10 bar Pilot Pressure Must be equal to or greater than inlet pressure For vacuum service models requiring external pilot supply a pilot pressure of at least 30 psig is required IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 Solenoid Pilot Solenoids R
294. odel Valve Body Valve to Base Valve Body Service Kits These kits contain all parts Number Service Kit Gasket needed for a complete reconditioning of a valve body W6056B2411 1020K77 617B11 Included are a spool and sleeve assembly all required W6056B2417 831K77 617B11 gaskets and seals detent assemblies for valves requiring W6056B3411 832K77 618B11 them and instructions for use W6056B3417 916K77 618B11 Solenoid Coils Replacement coils for solenoid controlled W6056B4411 833K77 619B11 valves can be ordered by part number 306K33 Specify W6056B4417 917K77 619B11 the correct voltage and hertz when ordering W6057B2411 837K77 617B11 Complete Solenoid Pilot Assemblies These consist of W6057B2417 838K77 617B11 new pilot valve mechanisms and a new coil ready to bolt W6057B3411 839K77 618B11 in position on the valve Order by part number 851C79 W6057B3417 840K77 618B11 and specify the correct voltage and hertz W6057B4411 841K77 619B11 Valve to Base Gasket If your valve is removed from its W6057B4417 842K77 619B11 base for any reason a new valve to base gasket must be W6076B2401 1020K77 617B11 used to ensure a leak free seal This gasket is included W6076B2407 831K77 617B11 as a part of all valve body service kits W6076B3401 832K77 618B11 W6076B3407 916K77 618B11 W6076B4401 833K77 619B11 W6076B4407 917K77 619B11 W6077B2401 837K77 617B11 If you have any questions about installing or servicing your valve call ROSS Technical Services at your
295. oducts Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakage and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter visc
296. of adequate size and does not restrict the air supply because of acrimp in the line sharp bends or a clogged filter element Valve Outlets Ports 2 amp 4 For faster pressurizing and exhausting of the mechanism being operated by the valve locate the valve as close as possible to the mechanism The lines must be of adequate size and be free of crimps and sharp bends Valve Exhaust Port 3 Do not restrict exhaust air flow as this can adversely affect valve performance However to reduce noise use an efficient silencer ROSS MUFFL AIR silencers reduce impact noise by as much as 25 dB and produce little back pressure Operating Pressures and Temperatures Allowable ranges for pressure and temperatures are given in the Valve Specifications on page 2 Exceeding the values shown can shorten valve life Pipe Installation To install pipe in valve or base ports engage pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating the valve SERIES 31 ROSS 4 3 VALVES Port sizes 3 8 to 1 Horizontal or vertical lever 4 Ports located on bottom of valve 3 Position control detented or non detented Center position Outlet ports in models ending in 07 08 09 or 12 are open to exhaust models endingin 10 11 13 or 14 are closed to exhaust SERIES 36 3 2 VALVES Port size 1 4 Horizontal lever verti
297. ollowing ways L O X Valve Pushing the RED handle inward cuts off the supply of air to downstream components and at the same time exhausts the air in the downstream lines to the next obstruction The L O X valve is NOT an emergency stop device but simply an energy isolation device When the red operating handle is pulled outward supply air is again allowed to flow into the downstream lines L O X with EEZ ON Operation Valve When its BLUE operating handle is pushed inward this valve functions like the L O X valve described above In addition when the blue handle is pulled outward the flow of air to the downstream lines is gradual When outlet pressure reaches approximately 25 psi less than inlet pressure the valve will then open fully until the upstream pressure is exhausted or the handle is pushed down Air Lines Before installing this valve in a new or existing system the air lines must be blown clean of all contaminants It is recommended that an air filter be installed in the inlet line close to the valve ROSS CONTROLS United States Port Sizes 1 4 and 3 8 TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS Port Sizes 1 1 2 and 2 Port Sizes 3 8 1 2 3 4 1 1 1 4 ee Valve Inlet Port 1 Be sure that the supply line is of adequate size and does not restrict the air supply Valve Outlet Port 2 For quick pressurizing and exhausting of downstream components the downstream lines must be of ad
298. oltages Same as above for pilot solenoids TEST PROCEDURE Once the valve is installed the monitoring functions of the valve must be tested While testing the monitoring functions take standard press operation safety precautions to avoid personal injury or damage to equipment Step 1 Electrically energize both pilot solenoids Step 2 Depress one of the manual overrides and hold depressed Step 3 De energize both pilot solenoids while continuing to hold the manual override depressed for at least 1 second after de energizing the solenoids Performing steps 1 through 3 should result in a valve lockout and prevent the valve from operating Do not attempt to reset either monitor before performing steps 4 and 5 Step 4 Determine whether or not the L G monitor has locked out Locate the vent on the back of the L G monitor and check for a continuous stream of air exhausting from the vent If air is not exhausting from the vent the L G monitor has not locked out properly Step 5 Determine whether or not the E P monitor has locked out Electrically energize both pilot solenoids and listen for the sound of the solenoids shifting If the solenoids shift the E P monitor has not locked out properly Step 7 De energize both pilot solenoids Next reset both monitors following procedures outlined on page 2 Note that once both monitors are reset the leakage from the back of the L G monitor should stop Step 8 Repeat steps 1 through 7 using the othe
299. on hazardous leakage and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components potentially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using
300. on see page 1 or in the U S A at page 1 1133A2002 682K87 1 888 TEK ROSS or 1 706 356 3708 1133A2003 682K87 VALVE BODY CROSS SECTIONS Series 12 Valve Body used with pushbutton and telegraph lever operators 3 2 design shown Model numbers ending in 5 6 7 or 8 Series 11 Valve Body 3 2 design shown Series 12 Valve Body with pushbutton operator 3 2 design shown Model numbers ending in 1 or 3 Pa www rosscontrols com STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specifica
301. on request amp A Toia lt Q 2 2 Normally Closed Sensing Valve wi a A _ ao _ gt ma ae w d p 1 2 2 Normally Closed PO Checks 3 2 Normally Closed Sensing Valve Category 2 applications not for mechanical stamping presses VALVE INSTALLATION Pneumatic equipment should be installed only by persons trained and experienced in such installation Important Note ROSS Series SV27 valves are not designed as control valves for air clutch brake mechanisms on mechanical power presses and must not be installed for such use Only double valves conforming to localand or international standards shall be used in such applications Air Lines Before installing a valve in a new or an existing system the air lines must be blown clean of all contaminants It is recommended that an air filter be installed in the inlet line close to the valve Valve Inlet Port 1 Be sure that the supply line is of adequate size and does not restrict the air supply because of a crimp in the line a sharp bend or a clogged filter element Valve Outlet Port 2 For faster pressurizing and exhausting of the mechanism being operated by the valve locate the valve as close as possible to the mechanism The lines must be of adequate size and be free of crimps and sharp bends Valve Exhausts Port 3 Do not restrict the air flow from the exhaust port of the valve body or pilot body as this can adversely aff
302. onate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakage and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components potentially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can resu
303. or pressure and temperatures are given in the Valve Specifications on page 2 Exceeding the values shown can shorten valve life Pilot Supply Pressure Control For valves with single remote pressure control connect the control line to port 14 in the sub base or manifold For valves with double remote pressure control connect the control lines to both ports 12 and 14 in the base See Valve Specifications on page 2 for required pressures Solenoid Control Pressure for the pilot valves is supplied from the inlet port Be sure that port 14 in the base is plugged or pilot air will escape If the valve must operate with an inlet pressure less than the required pilot pressure see Valve Specifications on page 2 an external pilot supply of sufficient pressure must be provided Connect the external pilot supply to port 14 in the base Vacuum or Non Air Service Such applications require an external pilot supply for solenoid valves Connect to port 14 in the base Pipe Installation To install pipe in valve or base ports engage pipe one turn apply pipe thread sealant tape not recommended andtighten pipe This procedure will prevent sealant from entering and contaminating the valve ROSS CONTROLS United States TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS web site www rosscontrols com ROSS EUROPA GmbH Germany TEL 49 6103 7597 0 web site www rosseuropa com ROSS ASIA K K Japan TEL 81 427 78 7251 web site ww
304. ort 3 Do not restrict air flow from the exhaust port as this can adversely affect the operation of the valve If you have any questions about installing or servicing your valve call ROSS Technical Services at your nearest ROSS location or in the U S A at 1 888 TEK ROSS or 1 706 356 3708 Electrical Supply Electrical supply for the pilot solenoids and the E P reset solenoid is connected via an internal terminal strip which must be connected according to the circuit diagram accompanying the valve In either case the electrical supply must correspond to the voltage and hertz ratings of the solenoids Otherwise the solenoids are subject to early failure If power is supplied by a transformer the transformer must be capable of handling the inrush current without significant voltage drop See Valve Specifications on page 3 for inrush current data Operating Pressures and Temperatures Allowable ranges for pressure and temperatures are given in the Valve Specifications on page 3 Exceeding the values shown can adversely affect performance and shorten valve life Pipe Installation To install pipe in valve ports engage pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating the valve Monitors Connect the wiring according to the circuit diagram supplied with the valve An L G lockout signal port on same side as reset port can
305. osity Avoid oils with phosphate type additives which can harm polyurethane components potentially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mec
306. otential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components potentially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutc
307. ough some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakage and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components potentially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could
308. oule You You have purchased a premium quality ROSS pneumatic valve Itis a single spindle poppet valve built to the highest standards With care in its installation and maintenance you can expect it to have a long and economical service life So before you go any further please take a few minutes to look over the information in this folder Then save it for future reference and for the useful service information it contains a SAE 250 shown ROSS Series 84 valves and bases must be purchased separately VALVE INSTALLATION Pneumatic equipment should be installed only by persons trained and experienced in such installation Air Lines Before installing a valve in a new or an existing system the air lines must be blown clean of all contaminants It is recommended that an air filter be installed in the inlet line close to the valve Valve Inlet Port P Be sure that the supply line is of adequate size and does not restrict the air supply because of a crimp in the line sharp bends or a clogged filter element Valve Outlets Ports A amp B For faster pressurizing and exhausting of the mechanism being operated by the valve locate the valve as close as possible to the mechanism The lines must be of adequate size and be free of crimps and sharp bends Valve Exhausts Ports EA amp EB Do not restrict exhaust air flow as this can adversely affect valve performance However to reduce noise you may use an efficient silenc
309. ous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and L O X with EEZ ON operation products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHA
310. owl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakage and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components potentially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong
311. ownstream pressure in the outlet port 2 will be exhausted to atmosphere through exhaust port 3 There should also be a small but audible flow of air out the exhaust port 3 as long as the valve remains in the lockout condition C Re energize the pilot solenoid that was de energized in step B above The valve must remain in the lockout condition D De energize both pilot solenoids and the DM Series E valve should return to the ready to run condition There should be no pressure present at outlet port 2 and there should no longer be any audible flow of air to exhaust port 3 E Energize both pilots simultaneously again As in step A above the valve should supply pressure from inlet port 1 to outlet port 2 there should be no flow to the exhaust port 3 F De energize the other pilot solenoid As in step B above the valve should again go into a lockout condition G Re energize the pilot solenoid that was de energized in step F above The valve must remain in the lockout condition H De energize both pilot solenoids andthe DM Series E valve should again return to the ready to run condition as in step D above Fault Indication The status indicator can be used to signal the machine controls that a lockout has occurred The status indicator utilizes a pressure switch The pressure switch has 4 electrical contacts NOTE Contact 4 is a ground During normal operation the pressure switch is pressurized A lockout condition d
312. pact noise by as much as 25 decibels dB and produce little back pressure Electrical Supply The voltage and hertz ratings of the valve solenoids if any 7 Ground are printed on the solenoids Line The electrical supply must AC DC correspond to these ratings or the life of the solenoids will be Manual shortened Connections are Override made with a plug in connector Size 0 to the prongs as shown in the sketch of the pilot at the Sizes right If power is supplied by a 1 2 amp 3 ROSS CONTROLS United States TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS transformer it must be capable of handling the inrush current without significant voltage drop See Valve Specifications on page 2 for information on inrush current Operating Pressures and Temperatures Allowable ranges for pressure and temperatures are given in the Valve Specifications on page 2 Exceeding the values shown can shorten valve life Pilot Supply Pressure Control For valves with single remote pressure control connect the control line to port 14 in the sub base or manifold For valves with double remote pressure control connect the control lines to ports 12 and 14 in the base See Valve Specifications on page 2 for required pressures Solenoid Control Pressure for the pilot valves is supplied from the inlet port Be sure that port 14 in the base is plugged or pilot air will escape If the valve must operate with an inlet
313. ply exhaust the air in the system and lockout before beginning any disassembly operation Service kits are listed on page 3 2 ROSS CONTROLS STANDARD SPECIFICATIONS Solenoids According to VDE 0580 Enclosure rating according to DIN 400 50 IP 65 Connector socket according to DIN 43650 Form A Two solenoids rated for continuous duty three with solenoid reset option Standard Voltages 110 volts 50 60 Hz 220 volts 50 60 Hz 24 volts DC Pilot Solenoids Power Consumption each solenoid Sizes 12 amp 30 6 0 watts on DC 15 8 VA inrush and 10 4 VA holding on AC Reset Solenoid Power Consumption 6 0 watts on DC 15 8 VA inrush and 10 4 VA holding on AC Ambient Temperature 15 to 120 F 10 to 50 C Media Temperature 40 to 175 F 4 to 80 C Flow Media Filtered 5 micron recommended lubricated or unlubricated air mineral oils according to DIN 51519 viscosity classes 32 46 Inlet Pressure 30 to 115 psig 2 to 8 bar Reset Pressure For remote reset option equal to inlet pressure Pressure Switch Status Indicator Rating Contacts 5 amps at 250 volts AC or 5 amps at 30 volts DC Solenoid Reset Units with solenoid reset include a 3 2 solenoid valve Energize this solenoid momentarily to reset monitor after lockout condition occurs NOTE Main solenoids must be off when performing reset procedure Remote Reset Remote signal to be supplied by customers 3 2 valve connect remote signal li
314. pressure less than the required pilot pressure see Valve Specifications on page 2 an external pilot supply of sufficient pressure must be provided Connect the external pilot supply to port 14 in the base The external pilot supply option is not available for the size O valves It is not necessary to plug port 14 in the size 0 bases Non Air Service Such applications require an external pilot supply for solenoid valves Connect to port 14 in the base Consult ROSS Technical Services for fluid media other than air Pipe Installation To install pipe in valve or base ports engage pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating the valve web site www rosscontrols com ROSS EUROPA GmbH Germany TEL 49 6103 7597 0 web site www rosseuropa com ROSS ASIA K K Japan TEL 81 427 78 7251 web site www rossasia co jp email sales rossuk co uk ROSS UK Ltd ROSS SOUTH AMERICA Ltda ROSS CONTROLS INDIA Pvt Ltd ROSS CONTROLS CHINA Ltd DIMAFLUID s a s TEL 44 121 559 4900 TEL 55 11 4335 2200 TEL 91 44 2624 9040 TEL 86 21 6915 7951 TEL 33 01 49 45 65 65 United Kingdom Brazil India China France email vendas ross sulamerica com br email rossindia airtelbroadband in email alvinzhurong vip 163 com web site www dimafluid com VALVE MAINTENANCE Pneumatic equipment should be main
315. r W7076C8331 For the five different sizes of valves the size digit may be 2 3 4 6 or 8 These are arbitrary numbers and are not related to C ratings Pressure Controlled Temperature Range 40 to 175 F 4 to 80 C Flow Media Filtered air 5 micron recomended Inlet Pressure Vacuum to 150 psig 10 bar Pilot Pressure Models with size digit 2 or 8 At least 2 bar 30 psig Models with size digit 3 4 or 6 At least 1 bar 15 psig IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 Solenoid Pilot Solenoids Rated for continuous duty Power Consumption Pilot solenoids for models with size digit 2 10 VA inrush 9 VA holding on 50 or 60 Hz 5 watts on DC Pilot solenoids for all other models 87 VA inrush 30 VA holding on 50 or 60 Hz 14 watts on DC Direct solenoids for models with size digit 2 140 VA inrush 30 VA holding on 50 or 60 Hz 20 watts on DC Direct solenoids for all other models 380 VA inrush 58 VA holding on 50 or 60 Hz Temperature Range Ambient 40 to 120 F 4 to 50 C Media 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 Models with size digit 2 or 8 At least 30 psig 2 bar All other models At least 15 psig 1 bar 2 ROSS CONTROLS VALVE SERVICE Typical cross section of a ROSS Series W70 spool amp sleeve valve bo
316. r installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and L O X with EEZ ON operation products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER W
317. r manual override this time NOTE If your valve is not equipped with manual overrides step 2 should be replaced with remove the input signal from one pilot solenoid Replace step 3 with De energize both pilot solenoids Also step 8 should read Repeat steps 1 through 7 using the other pilot solenoid this time NOTE Occasionally one monitor may lockout the valve before the other monitor has had time to react Contact ROSS Technical Services for further instructions should this occur WARNING Both pilot solenoids must be de energized before resetting the monitors Otherwise the press or other mechanism can cycle immediately and produce a potentially hazardous condition WARNING Do not connect power input signals directly to both terminals 5 and 7 as this could cause the machine being controlled by the valve to immediately cycle and produce a potentially hazardous condition After performing the above tests and obtaining the appropriate results energizing both pilot solenoids simultaneously should result in normal valve operation NOTE The above test procedure checks for proper operation of the valve s overall monitoring function If you have concerns about the operation of either or both of the monitors please contact ROSS Technical Services for further assistance VALVE SERVICE ROSS would be happy to service this valve for you at its factory repair center 1 800 438 7677 inside the U S or 706 356 3708 outside the U S
318. r the reset signal is removed A Electrically energize both pilot solenoids simultaneously then de energize one pilot solenoid This should result in a valve lockout and prevent the valve from operating B Energize both solenoids and the valve should remain in the lockout condition C De energize both pilot solenoids and reset the valve D Electrically energize both pilot solenoids simultaneously again De energize the other pilot solenoid this time Again this should result in a lockout E Energize both pilot solenoids The valve should remain in a lockout condition F De energize both pilot solenoids and then reset the valve After satisfying these tests energizing both pilot solenoids simultaneously should result in normal operation Fault Indication If fault indication is desired ROSS offers a status indicator option that can be used to signal the press controls that a fault has occurred The status indicator utilizes a pressure switch The pressure switch has 4 electrical contacts During normal operation the pressure switch is pressurized A lockout condition depressurizes the switch until the valve is reset Contacts 1 and 2 are closed when the switch is depressurized normally closed and contacts 1 and 3 are closed when an adequate pressure signal is applied to the switch normally open web site www rosscontrols com ROSS EUROPA GmbH Germany TEL 49 6103 7597 0 web site www rosseuropa com ROSS ASIA K K Jap
319. ratings Otherwise the solenoids are subject to early failure If power is supplied by a transformer it must be capable of handling the inrush current without significant voltage drop See Valve Specifications on the reverse side of this sheet for information on inrush current ROSS CONTROLS United States TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS Operating Pressures and Temperatures Allowable ranges for pressure and temperature are given in the Valve Specifications on the reverse side of this sheet Exceeding the values shown can shorten valve life Pilot Supply Pressure Control For valves with single remote pressure control connect the control line to port 14 in the sub base or manifold For valves with double remote pressure control connect the control lines to ports 12 and 14 in the base See Valve Specifications on page 2 for required pressures Solenoid Control Pressure for pilot valves is supplied from the inlet port Be sure that port 14 in the base is plugged or pilot air will escape If the valve must operate with an inlet pressure less than the required pilot pressure see Valve Specifications on page 2 an external pilot supply of sufficient pressure must be provided Connect the external pilot supply to port 14 in the base Non Air Service Such applications require an external pilot supply for solenoid valves Connect to port 14 in the base Consult ROSS for fluid media other than air Pipe Installa
320. rces are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bo
321. rd controls the exhaust Independent operation of these functions provides exceptional flexibility and eliminates the need for two separate valves The supply pressure poppet is normally closed and the exhaust poppet is normally open Therefore if power is lost or if a safety stop has cut power the supply pressure will be closed and the unit under test will be evacuated Pilot Pressure Pilot pressure must be maintained at all times and must be equal to or greater than the inlet pressure to prevent valve failure To prevent loss of pilot pressure it is strongly recommended to use the same air supply for both the inlet and pilot pressures Normally Closed The LT is a normally closed 4 way valve The INLET port is normally closed and the TEST P1 P2 and P3 ports flow through the EXHAUST port Electrical Power Loss Will cause the valve to return to a normally closed position The inlet pressure will be closed and downstream test pressure will be exhausted Operation Pressure Decay Test Step 1 Close the exhaust by actuating the exhaust solenoid Step 2 Open inlet pressure by actuating the fill solenoid Step 3 Allow time to fill and settle Step 4 Close the isolation poppet by actuating the isolation solenoid Step 5 Close the inlet pressure by deactivating the fill solenoid Step 6 Exhaust the valve cavity pressure by deactivating the exhaust solenoid Step 7 Monitor pressure drop on port
322. rmally open port pressurized only when the valve is de actuated and port 4 is the normally closed port pressurized only when both main valve elements have been actuated Valve Exhaust Ports 3 and 5 Do not restrict air flow from the exhaust ports as this can adversely affect the operation of the valve Pilot Solenoid Electrical Supply The valves get electrical power through plug in connectors The electrical supply must correspond to the voltage and hertz ratings of the solenoids Otherwise the solenoids are subject to early failure If power is supplied by a transformer it must be capable of handling the inrush current without significant voltage drop See Valve Specifications on page 3 for inrush current data Operating Pressures and Temperatures Allowable ranges for pressure and temperature are given in the Valve Specifications on page 3 Exceeding the values shown can adversely affect performance and shorten valve life Pipe Installation To install pipe with tapered threads in the ports in the base engage pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating the valve To install pipe with parallel threads e g SAE ISO 228 G etc do not use sealant Pressure Switch If redundant monitoring is desired ROSS offers a pressure switch version that can be used to signal another monitoring device ROSS CONTROLS U
323. rolled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and L O X with EEZ ON operation products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PU
324. rols com ROSS EUROPA GmbH Germany TEL 49 6103 7597 0 web site www rosseuropa com ROSS ASIA K K Japan TEL 81 427 78 7251 web site www rossasia co jp ROSS UK Ltd United Kingdom TEL 44 121 559 4900 email sales rossuk co uk ROSS SOUTH AMERICA Ltda Brazil TEL 55 11 4335 2200 email vendas ross sulamerica com br ROSS CONTROLS INDIA Pvt Ltd India TEL 91 44 2624 9040 email rossindia airtelbroadband in ROSS CONTROLS CHINA Ltd China TEL 86 21 6915 7951 email alvinzhurong vip 163 com DIMAFLUID s a s France TEL 33 01 49 45 65 65 web site www dimafluid com VALVE MAINTENANCE Pneumatic equipment should be maintained only by persons trained and experienced in the maintenance of such equipment Supply Clean Air Foreign material lodging in valves is a major cause of breakdowns The use of a 5 micron rated air filter located close to the valve is strongly recommended The filter bowl should be drained regularly and if its location makes draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should put a fine oil mist into the air line in direct proportion to the rate of air flow Excessive lubrication can cause puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute is adequate Compatible Lubricants Although this valve does not require air
325. rom its base Service kits for these valves are listed on page 3 VALVE SPECIFICATIONS Solenoids Rated for continuous duty Standard Voltage 24 volts DC 100 120 volts 60 Hz 230 volts 50 Hz Other voltages available on request Power Consumption each solenoid 11VA inrush 8 5 VA holding on 50 or 60 Hz 6 watts on DC Low watt coil 2 8 watts on DC Electrical Protection Rating NEMA 4 IP 65 Materials Anodized aluminum stainless steel Ambient Temperature 40 to 120 F 4 to 50 C Media Temperature 40 to 175 F 4 to 80 C Flow Media Filtered dry air 5 micron minimum Inlet Pressure 0 to 600 psig 0 to 40 bar Pilot Supply Pressure 100 to 150 psig 7 to 10 bar Connector Type DIN 43650 Type A Contact ROSS for pressures greater than 600 psi 40 bar Solenoid pilots rated for 230 psi 16 bar available Consult ROSS IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 2 ROSS CONTROLS SELECT 4400 VALVE BODIES 2 2 Normally Closed Valve 2 2 Normally Open Valve VALVE SERVICE ROSS would be happy to service this specialized valve for you at its factory repair center 1 800 GET ROSS However if you choose to service this valve yourself it is strongly recommended that you obtain its free service manual from ROSS in the U S A at 1 800 GET ROSS Listed below are kits for servicing your valve Distributor information
326. rossasia co jp ROSS UK Ltd United Kingdom TEL 44 121 559 4900 email sales rossuk co uk ROSS SOUTH AMERICA Ltda Brazil TEL 55 11 4335 2200 email vendas ross sulamerica com br ROSS CONTROLS INDIA Pvt Ltd India TEL 91 44 2624 9040 email rossindia airtelbroadband in ROSS CONTROLS CHINA Ltd China TEL 86 21 6915 7951 email alvinzhurong vip 163 com DIMAFLUID s a s France TEL 33 01 49 45 65 65 web site www dimafluid com VALVE MAINTENANCE Pneumatic equipment should be maintained only by persons trained and experienced in the maintenance of such equipment Supply Clean Air Foreign material lodging in valves is a major cause of breakdowns The use of a 5 micron rated air filter located close to the valve is strongly recommended The filter bowl should be drained regularly and if its location makes draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should put a fine oil mist into the air line in direct proportion to the rate of air flow Excessive lubrication can cause puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute is adequate note that this valve itself does not require air line lubrication but some optional adaptors do i e air index etc Compatible Lubricants Although this valve does not require air line lubrication it may be used with lubr
327. roximately 125 milliseconds This timing is preset by restricting orifices and chambers in the pilot air circuit The main airflow from port 1 to port 2 is via crossflow passages between both main valves so that both valve elements must be fully shifted in order for port 2 to be pressurized If the valve locks out further operation is prevented until the valve has been reset Electrical signals to the solenoids must be off to allow the valve to be reset The DM Series D double valve is completely self contained and does not need an external monitoring system VALVE MAINTENANCE Pneumatic equipment should be maintained only by persons trained COMPATIBLE LUBRICANTS and experienced in the maintenance of such equipment Supply Clean Air Foreign material lodging in valves is a major cause of breakdowns The use of a 5 micron rated air filter located close to the valve is strongly recommended The filter bowl should be drained regularly and if its location makes draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should put a fine oil mist into the air line in direct proportion to the rate of air flow Excessive lubrication can cause puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute is adequate Note that the double valve itself does not require air line lubrication Compatible Lubricants A
328. rsonal injury or damage to equipment Note Reset must be performed prior to beginning the test procedure Also both pilot solenoids must be de energized prior to reset and must remain de energized until after the reset signal is removed A Electrically energize both pilot solenoids simultaneously then de energize one pilot solenoid This should result in a valve lockout and prevent the valve from operating B Energize both solenoids and the valve should remain in the lock out condition C De energize both pilot solenoids and reset the valve D Electrically energize both pilot solenoids simultaneously again De energize the other pilot solenoid this time Again this should result in a lockout E Energize both pilot solenoids The valve should remain in a lockout condition F De energize both pilot solenoids and then reset the valve After satisfying these tests energizing both pilot solenoids simultaneously should result in normal operation Fault Indication If fault indication is desired ROSS offers a pressure switch option that can be used to signal the press controls that a fault has occurred The pressure switch is only an indicator that the valve elements did not move in step with one another The switch does not lockout the valve Lockout is carried out by the design of the valve whether the pressure switch option is used or not The pressure switch should not be confused with a monitor The pressure switch has 4 electrical cont
329. rtain mechanical power presses With care in its installation and maintenance you can expect the valve to have a long and reliable service life Before you go any further please take a few minutes to look over the information in this folder and save it for future reference Size 8 Dual Monitored Double Valve CSA Z142 Compliant VALVE INSTALLATION Pneumatic equipment should be installed only by persons trained and experienced in such installation Air Lines Before installing a valve in a new or an existing system the air lines must be blown clean of all contaminants It is recommended that a 5 micron rated air filter be installed in the inlet line close to the valve See ROSS Bulletin 420 for available filter products Valve Inlet Port 1 Be sure that the supply line is of adequate size and does not restrict the air supply because of a crimp in the line a sharp bend or a clogged filter element The air supply must not only provide sufficient pressure see Valve Specifications page 3 but must also provide an adequate flow of air on demand Otherwise the valve elements will be momentarily starved for air and the valve may be locked out by the monitoring system Valve Outlet Port 2 For faster pressurizing and exhausting of the mechanism being operated by the valve locate the valve as close as possible to the mechanism The lines must be of adequate size and be free of crimps and sharp bends Valve Exhaust P
330. s and abrasives can do permanent damage to metal parts Before reassembling the valve lubricate all sliding surfaces with a grease such as Dow Corning BR 2 Electrical Contacts In the electrical circuits associated with the valve solenoids keep all switches or relay contacts in good condition to avoid solenoid malfunctions Replace Worn Components After long usage dynamic seals may show signs of wear The valve can be reconditioned with the use of ROSS service kits See page 3 for information about such kits VALVE SPECIFICATIONS Pressure Controlled Temperature Range 40 to 175 F 4 to 80 C extended to 220 F 105 C for high temperature models Flow Media Filtered air 5 micron recommended Inlet Pressure 30 to150 psig 2 to 10 bar Pilot Pressure Must be equal to or greater than inlet pressure IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 Solenoid Pilot Solenoids Rated for continuous duty Voltage and hertz ratings printed on solenoid coils Power Consumption 8 VA inrush 6 VA holding on 50 or 60 Hz 6 watts on DC Temperature Range Ambient 40 to 120 F 4 to 50 C extended to 175 F 80 C for high temperature models Media 40 to 175 F 4 to 80 C extended to 220 F 105 C for high temperature models Flow Media Filtered air 5 micron recommended Inlet Pressure 30 to150 psig 2 to 10 bar Pilot Pressure Must be equal to or greater
331. s Otherwise the solenoids are subject to early failure The power supply must be capable of handling the inrush current without significant voltage drop See Valve Specifications on page 2 for information on inrush current Operating Pressures and Temperatures Allowable ranges for pressure and temperatures are given in the Valve Specifications on page 2 Exceeding the values shown can shorten valve life Pilot Supply Pressure Control Connect a 1 4 inch control line to the threaded port in the air head at the top of the valve See Valve Specifications on page 2 for required pressures Solenoid Control Pressure for the pilot valve is supplied internally for most valves and requires no special connection However if your valve is designated for external pilot supply a 1 8 inch pilot supply line must be connected to port X 1 in the pilot housing See Valve specifications on page 2 for pressure requirements Pipe Installation To install pipe in valve ports engage pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating the valve ROSS CONTROLS United States TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS web site www rosscontrols com ROSS EUROPA GmbH Germany TEL 49 6103 7597 0 web site www rosseuropa com ROSS ASIA K K Japan TEL 81 427 78 7251 web site www rossasia co jp ROSS UK Ltd United Kingdom TEL 44 121 559 4900 e
332. s and the valve should remain in the lockout condition C De energize both pilot solenoids and reset the valve D Electrically energize both pilot solenoids simultaneously again De energize the other pilot solenoid this time Again this should result in a lockout E Energize both pilot solenoids The valve should remain in a lockout condition F De energize both pilot solenoids and then reset the valve After satisfying these tests energizing both pilot solenoids simultaneously should result in normal operation Fault Indication The built in status indicator can be used to signal the machine controls that a fault has occurred The status indicator utilizes a pressure switch The pressure switch has 4 electrical contacts During normal operation the pressure switch is pressurized A lockout condition depressurizes the switch until the valve is reset Contacts 1 and 2 are closed when the switch is depressurized normally closed and contacts 1 and 3 are closed when an adequate pressure signal is applied to the switch normally open web site www rosscontrols com ROSS EUROPA GmbH Germany TEL 49 6103 7597 0 web site www rosseuropa com ROSS ASIA K K Japan TEL 81 427 78 7251 web site www rossasia co jp ROSS UK Ltd United Kingdom TEL 44 121 559 4900 email sales rossuk co uk ROSS SOUTH AMERICA Ltda Brazil TEL 55 11 4335 2200 email vendas ross sulamerica com br ROSS CONTROLS INDIA Pvt L
333. s designed for low temperature service Special Valves If the second digit after the center letter in your valve s model number is an 8 or 9 then your valve has special features e g D2173B3952 You may consult ROSS Technical Services to verify the special features or to obtain high pressure and vacuum service kits Air Lines Before installing a valve in a new or an existing system the air lines must be blown clean of all contaminants It is recommended that an air filter be installed in the inlet line close to the valve Valve Inlet Port 1 Be sure that the supply line is of adequate size and does not restrict the air supply because of a crimp in the line a sharp bend or a clogged filter element Valve Outlets Ports 2 and 4 For faster pressurizing and exhausting of the mechanism being operated by the valve locate the valve as close as possible to the mechanism The lines must be of adequate size and be free of crimps and sharp bends Valve Exhausts Port 3 Do not restrict the air flow from the exhaust port of the valve body or pilot body as this can adversely affect the operation of the valve However to reduce exhaust noise an efficient silencer may be used ROSS MUFFL AIR silencers reduce impact noise by as much as 25 dB and produce little back pressure Electrical Supply The voltage and hertz ratings of the valve solenoids if any are shown on the pilot housing The electrical supply must correspond to these rating
334. s great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and L O X with EEZ ON operation products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and prov
335. se puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute is adequate Compatible Lubricants Although this valve does not require air line lubrication it may be used with lubricated air being supplied to othermechanisms Some oils contain additives that can harm seals or other valve components and so cause the valve to malfunction Avoid oils with phosphate additives e g zinc dithiophosphate and diester oils both types can harm valve components The best oils to use are generally petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Some compatible oils are listed at the right These oils although believed to be compatible could change without notice because manufacturers sometimes reformulate their oils Therefore use oils specifically compounded for air line service If it is a synthetic oil contact the oil manufacturer for compatibility information Cleaning the Valve If the air supplied to the valve has not been well filtered the interior of the valve may accumulate dirt and varnish which can affect the valve s performance A schedule should be established for cleaning all valves the frequency depending on the cleanliness of the air being supplied To clean the valve use a solvent which will dry without leaving a residue This is especially important for the spool
336. se to service this valve yourself it is strongly recommended that you obtain a free service manual from your local ROSS distributor Distributor information as well as downloadable service manuals are available at www rosscontrols com Sensing Module and Valve Body Service Kits These kits contain all parts needed for complete replacement of the sensing module and reconditioning of the main valve body as well Included are sensing module poppets spindle all required gaskets amp seals and instructions for use Valve Basic Sensing Module amp Type Size Valve Body Kit 5 2065H77 2 2 7 2197H77 9 2199H77 57 2062H77 3 2 7 2198H77 9 2200H77 PO 5 2281H77 Check 2282H77 Solenoid Pilot Kits These kits contain all parts needed to recondition the pilot valve Order by the following kit numbers For single solenoid pilots 946K87 For size 5 PO Check 851C79 Solenoids Replacement solenoids can be ordered by the part numbers listed below Specify the required voltage and hertz when ordering For single solenoid pilots 411B04 For size 5 PO Check 306K33 Switch Kit Replacement safety rated switch DPST and wiring harness For A amp B modification basic size s 5 amp 7 2068H77 For C modification basic size s 5 amp 7 2286H77 For basic size 9 2201H77 NOTE Modification letter is designated by the 6th digit in the model For example SV27NA305507PSAA1A Basic size is designated by the 9th
337. sive materials The former damages seals and abrasives can do permanent damage to metal parts Before reassembling the valve lubricate all sliding surfaces with a grease such as MobilGrease 28 Electrical Contacts In the electrical circuits associated with the valve solenoids keep all switches or relay contacts in good condition to avoid solenoid malfunctions Replace Worn Components In some cases it is not necessary to remove the valve from its installation for servicing However turn off the electrical power to the valve shut off the air supply and exhaust the air in the system before beginning any disassembly operation Service kits for these valves are listed on page 3 VALVE SPECIFICATIONS Solenoids AC or DC power Rated for continuous duty Voltage and hertz ratings shown on pilot housing Standard Voltages 120 volts AC 50 60 Hz 24 volts DC Power Consumption Series CP 2 port 2 position 2 2 normally closed NC amp normally open NO 1 2 and 1 inlet Series CP 3 2 NC amp NO 1 2 inlet 3 VA on AC 2 5 watts on DC Series CP 2 port 2 position 1 and 2 inlet Series CP 3 2 NC amp NO 1 inlet Series LF 2 2 except 3 8 and 1 2 inlet 36 VA inrush 23 VA holding on AC 15 watts on DC Series LF 2 port 2 position 3 8 and 1 2 inlet 9 8 VA on AC 7 5 watts on DC Ambient Temperature 40 to 120 F 4 to 50 C Media Temperature 40 to 175 F 4 C to 80 C Flow Medi
338. st ROSS location see page 1 or in the U S A at 1 888 TEK ROSS or 1 706 356 3708 Solenoid Coils Order replacement solenoid coils by the following part numbers Specify voltage and hertz when ordering Pilot solenoids Reset solenoid Size 4 12 30 306K33 306K33 Size 8 0 eee 360K33 306K33 Complete Solenoid Pilot Assemblies Available for sizes 4 and 8 these assemblies consist of new pilot valve mechanisms and a new solenoid coil ready to bolt in position on the valve Specify voltage and hertz when ordering Pilot solenoids Reset solenoid Size 4 1403H79 00 851C79 Size 8 1404H79 0 00 851C79 Sizes 12 amp 30 1391K79 0 851079 Pilot Booster Service Kits Available for sizes 12 and 30 these kits contain all parts needed for complete reconditioning of a pilot booster Included are poppets gaskets seals and instructions for use Size 12 amp 30 eee 2106K77 IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 www rosscontrols com 3 STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced o
339. st be blown clean of all contaminants It is recommended that an air filter be installed in the inlet line close to the valve Valve Inlet Port 1 Be sure that the supply line is of adequate size and does not restrict the air supply because of a crimp in the line sharp bends or a clogged filter element Valve Outlets Ports 2 amp 4 For faster pressurizing and exhausting of the mechanism being operated by the valve locate the valve as close as possible to the mechanism The lines must be of adequate size and be free of crimps and sharp bends Valve Exhausts Ports 3 amp 5 To reduce exhaust noise use an efficient silencer ROSS MUFFL AIR silencers reduce impact noise by as much as 25 dB and produce little back pressure Electrical Supply The voltage and hertz ratings for solenoid pilot operated valves are printed on the side of each solenoid It is important that the electrical supply used to power the valve is equal to these ratings to avoid possible solenoid burnout The electrical connection for such Manual valves is achieved by means of Override a connector whose connections correspond to the prongs pictured in the sketch of a typical solenoid pilot Line AC DC If power is supplied by a transformer it must be capable of handling the inrush current without significant voltage drop See Valve Specifications on page 2 for information on inrush current Operating Pressures and Temperatures Allowable ranges f
340. sted through port 5 If this abnormal operation is the result of a temporary circumstance the valve will be ready to resume normal operation as soon as both pilot signal ports have been de pressurized and both main valve elements have returned to their normal ready to run position Applying pressure to both signal ports simultaneously will resume normal operation If the cause of the abnormal operation is still present the valve will either remain in the default position pressure on port 2 and not port 4 or will again go into this position on the next actuation attempt The source of the abnormality must be investigated and corrected before further operation Pressure Switch Valves with model numbers ending in the number 1 have apressure switch to provide user feedback when movement of the main valve elements was asynchronous Typical 2 Hand Anti Tie Down Application Customer Customer Supplied Supplied 3 2 Valve 3 2 Valve gt CRossMIRROR Control Reliable Pneumatic 5 2 AND Gate Customer Supplied 5 4 Cylinder 1 3 2 Status Indicator pressure switch sAm T Indicator pressure switch Terminals 1 and 4 are connected when air pressure is present and the valve is Ready to Run If an abnormal operation has occured or pressure is removed from the valve inlet terminals 1 and 2 are connected Note DC voltage pressure switches do not have a ground terminal Pin 1 Common Pin
341. sult in personal injury or equipment damage Valve Body Service Kits These kits contain all parts needed for complete reconditioning of a valve body Included are poppets spindles gaskets seals and instructions for use DIZON 2 eee nss 2104K77 Size J 2105K77 Status Indicator Assembly Service Kit This kit includes all parts needed for complete reconditioning of the status indicator assembly Pressure switch and connector sold separately see below Size 12 amp 30 2151H77 Replacement Pressure Switch This kit includes a replacement pressure switch and electrical connector for the status indicator assembly Size 12 amp 30 1104A30 If you have any questions about installing or servicing your valve call ROSS Technical Services at your nearest ROSS location see page 1 or in the U S A at 1 888 TEK ROSS or 1 706 356 3708 Solenoid Coils Order replacement solenoid coils by the following part numbers Specify voltage and hertz when ordering Pilot solenoids Reset solenoid Size 12 amp 30 306K33 306K33 Complete Solenoid Pilot Assemblies Available for sizes 4 and 8 these assemblies consist of new pilot valve mechanisms and a new solenoid coil ready to bolt in position on the valve Specify voltage and hertz when ordering Pilot solenoids Reset solenoid Sizes 12 amp 30 1391K79 851C79 Pilot Booster Service Kits Available for sizes 12 and 30 th
342. supplied To clean the valve use any good commercial solvent Do not scrape varnished surfaces Also do notuse chlorinated solvents or abrasive materials The former damages seals and abrasives can do permanent damage to metal parts Before reassembling the valve lubricate all sliding surfaces with a grease such as MobilGrease 28 Electrical Contacts In the electrical circuits associated with the valve solenoids keep all switches or relay contacts in good condition to avoid solenoid malfunctions Replace Worn Components In most cases it is not necessary to remove the valve from its installation for servicing However turn off the electrical power to the valve shut off the air supply and exhaust the air in the system before beginning any disassembly operation Service kits are listed on page 3 You may also request a free service manual from ROSS in the U S A at 1 800 GET ROSS IMPORTANT NOTE Please read carefully and thoroughly all the WARNINGS on page 1 and the CAUTIONS on page 4 COMPATIBLE LUBRICANTS Brand Name American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Pacemaker 32 Spinesstic 22 Teresstic 32 Velocite 10 Air Lube 10H NR Turbo T32 Sunvis 11 Sunvis 722 Regal R amp O 32 Union Turbine Oil 2 ROSS CONTROLS VALVE SPECIFICATIONS E P MONITOR Reset solenoid is rated only for intermittent duty Energizing it continuously will lead to solenoid burnout and nullify the reset function
343. sure see Standard Specifications page 3 but must also provide an adequate flow of air on demand Valve Outlet Port 2 For faster pressurizing and exhausting of the mechanism being operated by the valve locate the valve as close as possible to the mechanism The lines must be of adequate size and be free of crimps and sharp bends Valve Exhaust Port 3 Do not restrict the air flow from the exhaust port as this can adversely affect the operation of the valve The valves are factory equipped with a properly sized silencer ROSS MUFFL AIR silencers reduce impact noise by as much as 25 dB with minimum back pressure Electrical Supply DM Series E valves get electrical power through plug in connectors The electrical supply must correspond to the voltage and frequency ratings of the solenoids otherwise the solenoids are subject to early failure If power is supplied by a transformer it must be capable of handling the inrush current without significant voltage drop See Standard Specifications on page 3 for current data Operating Pressures and Temperatures Allowable ranges for pressure and temperatures are given in the Standard Specifications on page 3 Exceeding these values can adversely affect performance and shorten valve life Pipe Installation To install pipe in ports engage pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating
344. sure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakage and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components potentially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused
345. sure from inlet port 1 to outlet port 2 There should be no flow to the exhaust port 3 G De energize the other pilot solenoid As in step B above the valve should again go into a lockout condition H Re energize the pilot solenoid that was de energized in step G above The valve must remain in the lockout condition I De energize both pilot solenoids The valve must remain in the lockout condition J Momentarily energize the reset solenoid again at least 200 milliseconds to reset the valve The valve should return to the ready to run condition as in step E above DM Series E Reset Function Both pilots must be de energized during the reset function A momentary delay is required to complete the reset function after the reset solenoid is energized Lockout Indication The built in status indicator can be used to signal the machine controls that a lockout has occurred The status indicator utilizes a pressure switch The pressure switch has 4 electrical contacts NOTE Contact 4 is a ground During normal operation the pressure switch is pressurized A lockout condition depressurizes the switch until the valve is ready to run after a reset function has been performed Contacts 1 and 2 are closed when the switch is depressurized normally closed and contacts 1 and 3 are closed when an adequate pressure signal is applied to the switch normally open ROSS CONTROLS www rosscontrols com VALVE OPERATION NOTE
346. t must check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous
347. t of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakage and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components potentially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type
348. t Solenoid Power Consumption each solenoid 6 0 watts on DC 15 8 VA inrush and 10 4 VA holding on AC Reset Solenoid Power Consumption 6 0 watts on DC 15 8 VA inrush and 10 4 VA holding on AC Ambient Temperature 15 to 122 F 10 to 50 C Media Temperature 40 to 175 F 4 to 80 C Flow Media Filtered 5 micron recommended lubricated or unlubricated air mineral oils according to DIN 51519 viscosity classes 32 46 Inlet Pressure 30 to 116 psig 2 to 8 bar Pressure Switch Status Indicator Rating Contacts 5 amps at 250 volts AC or 5 amps at 30 volts DC Application Category 4 applications and not press clutch brake applications Solenoid Reset DM Series E includes a 3 2 solenoid reset valve Energize this solenoid momentarily to reset valve after lockout condition occurs NOTE The valve is designed such that both pilot solenoids must be de energized prior to reset and must remain de energized until after the reset signal is removed Otherwise the valve will not reset Electrical Connectors Wired connectors have a 2 meter 6 1 2 ft cord with three 18 gauge conductors Cord is available in either 6 mm or 10 mm diameter and with or without indicator light Without Light With Light 24 volts DC With Light110 volts AC Wired with 6 mm cord 721K77 720K77 W 720K77 Z Wired with 10 mm cord 371K77 383K77 W 383K77 Z For threaded conduit 723K77 724K77 W 724K77 Z For use with drop cord 937K87 936K87 W 936K87
349. t check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakag
350. t the performance of the product or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakage and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm
351. t the right These oils although believed to be compatible could change without notice because manufacturers sometimes reformulate their oils Therefore use oils specifically compounded for air line service If it is a synthetic oil contact the oil manufacturer for compatibility information Cleaning the Valve If the air supplied to the valve has not been well filtered the interior of the valve may accumulate dirt and varnish which can affect the valve s performance VALVE SPECIFICATIONS Pressure Controlled Temperature Range 40 to 175 F 4 to 80 C Flow Media Filtered air 5 micron recommended Inlet Pressure 1 4 to 1 1 2 Port Sizes 15 to 150 psig 1 to 10 bar 1 1 2 to 2 1 2 Port Sizes 30 to 150 psig 2 to 10 bar 2 2 EEZ ON 30 to 150 psig 2 to 10 bar for all sizes Pilot Pressure Must be equal to or greater than inlet pressure IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 6 COMPATIBLE LUBRICANTS Brand Name American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Pacemaker 32 Spinesstic 22 Teresstic 32 Velocite 10 Turbo T32 Sunvis 11 Sunvis 722 Regal R amp O 32 Union Turbine Oil A schedule should be established for cleaning all valves the frequency depending on the cleanliness of the air being supplied To clean the valve use any good commercial solvent Do not scrape varnished surfaces Also do not use chlorinated solvents or abrasive mat
352. t the same time one or both of the valve s monitors will detect this condition and lock the valve out so that it cannot be cycled The L G and E P monitors detect discordance in somewhat different ways but the end result is the same discordance in the shifting of the two main valve elements shuts down the valve The valve cannot be operated again until the locked out monitor s are reset Resetting a Monitor CAUTION Before resetting any monitor power to the pilot solenoids must be turned off Otherwise the press or other mechanism controlled by the valve will cycle immediately and produce a potentially hazardous condition Resetting the L G Monitor The L G monitor is reset pneumatically and must have a line supplying air pressure attached to the pneumatic reset port on the side of the L G monitor housing Also a small 3 2 normally closed reset valve either solenoid or manual to control the reset signal should be installed in this line The L G monitor requires a reset pressure of at least 60 psig 4 bar Applying pressure momentarily to the reset port resets the monitor so that normal operation can be resumed Resetting the E P Monitor The E P monitor is reset electrically An electrical signal applied to terminals 1 and 9 energizes the reset solenoid which in turn resets the monitor Energize the reset solenoid only briefly prolonged energization can burn the solenoid out Coordination of Reset Signals The L G and
353. t voltage drop See Valve Specifications on page 2 for information on in rush current Operating Pressures and Temperatures Allowable ranges for pressure and temperatures are given in the Valve Specifi cations on page 2 Exceeding the values shown can shorten valve life Pilot Supply Pressure Control For valves with single remote pressure control connect the control line to port 14 in the sub base or manifold For valves with double remote pressure control connect the control lines to both ports 12 and 14 in the base See Valve Specifications on page 2 for required pressures Solenoid Control Pressure for the pilot valves is supplied from the inlet port Be sure that the external pilot supply port in the base is plugged or pilot air will escape If the valve must operate with an inlet pressure less than the required pilot pressure see Valve Specifications on page 2 an external pilot supply must be provided Connect to the appropriate port in the base Vacuum or Non Air Service Such applications require an external pilot supply for solenoid valves Connect to the appropriate port in the base Pipe Installation To install pipe in valve or base ports engage pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating the valve ROSS CONTROLS United States TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS web site www rosscont
354. tained only by persons trained and experienced in the maintenance of such equipment Supply Clean Air Foreign material lodging in valves is a major cause of breakdowns The use of a 5 micron rated air filter located close to the valve is strongly recommended The filter bowl should be drained regularly and if its location makes draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should put a fine oil mist into the air line in direct proportion to the rate of air flow Excessive lubrication can cause puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute is adequate Compatible Lubricants Although this valve does not require air line lubrication it may be used with lubricated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components and so cause the valve to malfunction Avoid oils with phosphate additives e g zinc dithiophosphate and diester oils both types can harm valve components The best oils to use are generally petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Some compatible oils are listed at the right These oils although believed to be compatible could change without notice because manufacturers sometimes reformulate their oils Therefore
355. td India TEL 91 44 2624 9040 email rossindia airtelbroadband in ROSS CONTROLS CHINA Ltd China TEL 86 21 6915 7951 email alvinzhurong vip 163 com DIMAFLUID s a s France TEL 33 01 49 45 65 65 web site www dimafluid com VALVE OPERATION On first operation or after repair the pilot valve supply circuit and inherent monitoring elements may need to be reset This reset is accomplished by applying a momentary air signal to the RESET port or by energizing the optional reset solenoid momentarily on the valve After reset the valve will then be ready for operation The air supply to each pilot valve is controlled by the position of the inlet poppets In the ready for operation position these poppets are held on their seats and maintain pilot air flow During shifting of the valve elements the poppets move off seat and momentarily allow pilot air to escape to exhaust If either valve element fails to operate correctly the pilot supply to the other valve element will remain connected to exhaust causing the valve to lockout The internal monitoring system will lock out the valve if the time difference between both elements shifting fully is longer than approximately 125 milliseconds This timing is preset by restricting orifices and chambers in the pilot air circuit The main airflow from port 1 to port 2 is via crossflow passages between both main valves so that both valve elements must be fully shifted in order for
356. te and diester oils both types can harm valve components The best oils to use are generally petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Some compatible oils are listed above at the right These oils although believed to be compatible could change without notice because manufacturers sometimes reformulate their oils Therefore use oils specifically compounded for air line service If it is a synthetic oil contact the oil manufacturer for compatibility information COMPATIBLE LUBRICANTS Brand Name American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Pacemaker 32 Spinesstic 22 Teresstic 32 Velocite 10 Turbo T32 Sunvis 11 Sunvis 722 Regal R amp O 32 Union Turbine Oil Cleaning the Valve If the air supplied to the valve has not been well filtered the interior of the valve may accumulate dirt and varnish which can affect the valve s performance A schedule should be established for cleaning all valves the frequency depending on the cleanliness of the air being supplied To clean the valve use any good commercial solvent Do not scrape varnished surfaces Also do not use chlorinated solvents or abrasive materials The former damages seals and abrasives can do permanent damage to metal parts Before reassembling the valve lubricate all sliding surfaces with a grease such as Mobilgrease 28 Replace Worn Compo
357. ted to control cylinder speed To reduce exhaust noise use an efficient silencer ROSS MUFFL AIR silencers reduce impact noise by as much as 25 dB and produce little back pressure Pilot Supply Solenoid Control Pressure for the pilot valves is supplied from the inlet port Be sure that the external pilot supply port X in the base is plugged or pilot air will escape If the valve must operate with an inlet pressure less than the required pilot pressure see Valve Specifications on page 2 an external pilot supply must be provided Connect to port X in the base Pressure Control Connect the control line s to the ports provided inthe base or manifold See Valve Specifications on page 2 for required pressures Vacuum or Non Air Service Such applications require an external pilot supply for solenoid valves Connect to port X in the base Electrical Supply The voltage and hertz ratings of the valve solenoids are shown on the plate on the top of the valve The electrical supply must correspond to these ratings or solenoid life will be shortened Power is supplied via the 5 pin connector or conduit in the top of the valve See connector diagrams below If power is supplied by a transformer it must be capable of handling the inrush current without significant voltage drop ROSS CONTROLS United States SAE 125 SAE 250 Operating Pressures and Temperatures Allowable ranges for pressure and temperatures are given in the Valve Specific
358. tem the air lines must be blown clean of all contaminants Valve Inlet Port 1 Be sure that the inlet line is of adequate size and does not restrict the air supply Valve Outlet Port 2 For meter out applications the flow control valve port 2 must be connected to the inlet port of the actuator For maximum control of the mechanism being operated by the valve locate the valve as close as possible to the mechanism Pipe Installation To install pipe in valve ports engage pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating the valve Flow adjustment knob Cross Section of Model 1968E2007 Flow Control Valve locking set screw IDENTIFICATION and OPERATION FLOW CONTROL VALVES Free flow from port 1 to port 2 controlled flow from port 2 to port 1 Loosen locking nut turn screw clockwise to reduce air flow counterclockwise to increase flow Tighten locking nut Turn knob counterclockwise to reduce air flow clockwise to increase flow Loosen locking collar where provided Turn knob or screw clockwise to reduce air flow counterclockwise to increase flow Tighten locking collar Turn knob clockwise to reduce air flow counterclockwise to increase flow CHECK VALVES Allow air flow from port 1 to port 2 block reverse flow ROSS CONTROLS United States TEL Tech Svs 888 TEK ROSS Cust
359. ter bowl should be drained regularly and if its location makes draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should put a fine oil mist into the air line in direct proportion to the rate of air flow Excessive lubrication can cause puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute is adequate Note that the double valve itself does not require air line lubrication Compatible Lubricants Although this valve does not require air line lubrication it may be used with lubricated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components and so cause the valve to malfunction Avoid oils with phosphate additives e g zinc dithiophosphate and diester oils both types can harm valve components The best oils to use are generally petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Some compatible oils are listed at the right These oils although believed to be compatible could change without notice because manufacturers sometimes reformulate their oils Therefore use oils specifically compounded for air line service If it is a synthetic oil contact the oil manufacturer for compatibility information Cleaning the Valve It is recommended that the inlet a
360. the valve solenoids keep all switches or relay contacts in good condition to avoid solenoid malfunctions Replace Worn Components After long usage the poppets may show signs of wear The valve can be reconditioned with the use of ROSS service kits See page 3 for information about such kits COMPATIBLE LUBRICANTS Although this valve does not require air line lubrication it may be used with lubricated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components and thereby cause the valve to malfunction The best oils to use are those specifically compounded for air line lubricator service These are generally petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity A few of the compatible lubricants on the market are listed below COMPATIBLE LUBRICANTS Brand Name American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Pacemaker 32 Spinesstic 22 Teresstic 32 Velocite 10 Air Lube 10H NR Turbo T32 Sunvis 11 Sunvis 722 Regal R amp O 32 Union Turbine Oil IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 VALVE SPECIFICATIONS Valve Sizes Series 84 valves are made in three SAE sizes The SAE size of your valve is indicated by the fourth digit from the end of the valve s model number Digit 3 SAE Series 125 Digit 4 SAE Series 250 Digit 6
361. tion To install pipe in valve ports engage pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating the valve web site www rosscontrols com ROSS EUROPA GmbH Germany TEL 49 6103 7597 0 web site www rosseuropa com ROSS ASIA K K Japan TEL 81 427 78 7251 web site www rossasia co jp ROSS UK Ltd United Kingdom TEL 44 121 559 4900 email sales rossuk co uk ROSS SOUTH AMERICA Ltda Brazil TEL 55 11 4335 2200 email vendas ross sulamerica com br ROSS CONTROLS INDIA Pvt Ltd India TEL 91 44 2624 9040 email rossindia airtelbroadband in ROSS CONTROLS CHINA Ltd China TEL 86 21 6915 7951 email alvinzhurong vip 163 com DIMAFLUID s a s France TEL 33 01 49 45 65 65 web site www dimafluid com VALVE MAINTENANCE Pneumatic equipment should be maintained only by persons trained and experienced in the maintenance of such equipment Supply Clean Air Foreign material lodging in valves is a major cause of breakdowns The use of a 5 micron rated air filter located close to the valve is strongly recommended The filter bowl should be drained regularly and if its location makes draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should put a fine oil mist into the air line in direct proportion to the rate of air flow Excessive lubrication can cau
362. tion limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakage and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180
363. tion or servicing your valve call ROSS Technical Services at 1 888 TEK ROSS 835 7677 or 706 356 3708 Valve Body Service Kit Numbers Solenoid Valve Type Size 1 Size 2 Size 3 Coil Single Control 1422K77 1467K77 1471K77 334B33 Momentary Control 1423K77 1468K77 1472K77 334B33 Closed Center 1424K77 1469K77 1473K77 334B33 Open Center 1425K77 1470K77 1474K77 334B33 i D LJ HISSI Typical Spool and Sleeve Cross Section CONVERSION TO EXTERNAL PILOT SUPPLY To convert a W65 Series ISO valve to external pilot supply 1 Remove pipe plug from port 14 on base or manifold 2 Pipe a 1 8 supply line to port 14 3 Pressure in external supply line should be greater than inlet If for any reason the external supply is lost or drops below inlet pressure port 1 the valve will switch back to internal pilot supply Port 14 www rosscontrols com 3 STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Becaus
364. tions and regulations ROSS L O X and L O X with EEZ ON operation products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the U S A Rev 0
365. tives e g zinc dithiophosphate and diester oils both types can harm valve components The best oils to use are generally petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Some compatible oils are listed at the right These oils although believed to be compatible could change without notice because manufacturers sometimes reformulate their oils Therefore use oils specifically compounded for air line service If it is a synthetic oil contact the oil manufacturer for compatibility information Cleaning the Valve If the air supplied to the valve has not been well filtered the interior of the valve may accumulate dirt and varnish which can affect the valve s performance A schedule should be established for cleaning all valves the frequency depending on the cleanliness of the air being supplied Brand Name American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Pacemaker 32 Spinesstic 22 Teresstic 32 Velocite 10 Air Lube 10H NR Turbo T32 Sunvis 11 Sunvis 722 Regal R amp O 32 Union Turbine Oil To clean the valve use any good commercial solvent Do not scrape varnished surfaces Also do not use chlorinated solvents or abrasive materials The former damages seals and abrasives can do permanent damage to metal parts Before reassembling the valve lubricate all sliding surfaces with a grease such as Dow Corning BR 2
366. tlet and flow to the exhaust port is blocked A detent keeps the handle in the open position The handle is not designed to be locked in the open position so that the valve is always ready for shutoff Port Sizes 1 4 and 3 8 Port Sizes 12 and 2 Port Sizes 3 8 1 2 3 4 1 1 OUT OUT EXH OUT OUT EXH VALVE CLOSED With a short inward push of the blue handle the flow of supply air is blocked from the outlet port Downstream air flows from the outlet port to the exhaust port atthe bottom of the valve The valve must be padlocked while in this position during maintenance to prevent it from being inadvertently pulled outward and creating the potential for injury to people or machinery OUT IN Flyback Piston EXH gt EEZ ON FUNCTION When the blue handle is pulled outward inlet air passes through the metered orifice size set by adjusting screw in the handle and begins to pressurize the outlet High pressure air on the top of the flyback piston prevents the spring behind it from sliding the piston along the spool The position of the piston keeps the outlet blocked from the full flow of inlet air www rosscontrols com OUT OUT Port Sizes 3 8 1 2 3 4 1 1 OUT Flyback P
367. tlet 2 outlet 4 connected to exhaust 5 exhaust 3 closed Signal 14 Applied Inlet 1 connected to outlet 4 outlet 2 connected to exhaust 3 exhaust 5 closed 5 2 MOMENTARY CONTROL VALVES i 4 2 5 4 2 14 12 14___ 12 543 543 Pressure Controlled Solenoid Pilot Signal 12 Applied Momentarily Inlet 1 connected to outlet 2 outlet 4 connected to exhaust 5 exhaust 3 closed Signal 14 Applied Momentarily Inlet 1 connected to outlet 4 Outlet 2 connected to exhaust 3 exhaust 5 closed 5 3 DOUBLE SOLENOID VALVES CLOSED CENTER 14 12 iN Plas 513 Closed Center No Signal Applied Ports 1 2 3 4 amp 5 closed Open Center No Signal Applied Inlet 1 closed Outlet 2 connected to exhaust 3 and outlet 4 connected to exhaust 5 5 3 DOUBLE SOLENOID VALVES OPEN CENTER ANa 1 wof____ n Signal 12 Applied Open or Closed Inlet 1 connected to outlet 2 outlet 4 connected to exhaust 5 exhaust 3 closed Signal 14 Applied Open or Closed Inlet 1 connected to outlet 4 Outlet 2 connected to exhaust 3 exhaust 5 closed VALVE SERVICE Valve Body Service Kits These kits listed at the right contain all parts needed for a complete reconditioning of a valve body Included are a spool spacers detent assemblies for valves using them and all required gaskets and seals along with instructions for use
368. to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakage and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components potentially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silence
369. to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIEDWITH RESPECT TO MERCHANTABILITY OR FITNESS FORA PARTICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the U S A Rev 05 09 2009 ROSS CONTROLS All Rights Reserved Form SS050 ROS Series SV27 Sensing Valves Thank You You have purchased a premium quality ROSS pneumatic valve Itis a poppet valve designed for inline mounting and has been built to the highest standards With care in its installation and maintenance you can expect it to have a long and economical service life So before you go any further please take a few minutes to look over the information in this folder Then save it for future reference and for the useful service information it contains A general service manual with more detailed information is available from ROSS up
370. trict the air supply because of a crimp in the line a sharp bend or a clogged filter element Valve Outlet Port 2 For faster pressurizing and exhausting of the mechanism being operated by the valve locate the valve as close as possible to the mechanism The lines must be of adequate size and be free of crimps and sharp bends Valve Exhausts Port 3 Do not restrict the air flow from the exhaust port of the valve body or pilot body as this can adversely affect the operation of the valve However to reduce exhaust noise an efficient silencer may be used ROSS CONTROLS United States TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS Electrical Supply The voltage and hertz ratings of the valve solenoids if any are shown on the pilot housing The electrical supply must correspond to these ratings Other wise the solenoids are subject to early failure If power is supplied by a transformer it must be capable of handling the inrush current without significant voltage drop See Valve Specifications on page 2 for information on inrush current Operating Pressures and Temperatures Allowable ranges for pressure and temperatures are given in the Valve Specifications on page 2 Exceeding the values shown can shorten valve life Pilot Supply Your valve is designated for external pilot supply A supply line must be connected to the G1 8 pilot supply port in the side of the base See Valve specifications on page 2 for pressure req
371. ts needed for a complete reconditioning of a valve body Included are a spool and sleeve assembly all required gaskets and seals and instructions for use Valve Model Valve Body Valve to Base Numbers Service Kit Gasket Solenoid Coils Replacement coils can be ordered by part W6076A2957 1954K77 617B11 number 306K33 Specify the correct voltage and hertz when W6076A4957 1956K77 619B11 W6076A4961 1976K77 619B11 Complete Solenoid Pilot Assemblies These consist of new pilot valve mechanisms and a new coil ready to bolt in position on the valve Order by part number 851C79 and specify the correct voltage and hertz If you need additional information or have questions Valve to Base Gasket If your valve is removed from its base about installation or servicing your valve for any reason a new valve to base gasket must be used to call ROSS Technical Services at ensure a leak free seal This gasket is included as a part of 1 888 TEK ROSS 835 7677 or 706 356 3708 all valve body service kits www rosscontrols com 3 STANDARD CAUTIONS PRE INSTALLATION or SERVICE 1 Before servicing a valve or other pneumatic component be sure that all sources of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training
372. ty Some compatible oils are listed above at the right These oils although believed to be compatible could change without notice because manufacturers sometimes reformulate their oils Therefore use oils specifically compounded for air line service If it is a synthetic oil contact the oil manufacturer for compatibility information Cleaning the Valve If the air supplied to the valve has not been well filtered the interior of the valve may accumulate dirt and varnish which can affect the valve s performance To clean the valve use a solvent which will dry without leaving a residue This is especially important for the spool and sleeve assembly Do not use a chlorinated solvent orabrasive materials The former damages seals and abrasives can do permanent harm to metal parts To reassemble the spool and sleeve put one drop of Anderol 735 or equivalent lubricant on each spool land Insert the spool into COMPATIBLE LUBRICANTS Brand Name American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Pacemaker 32 Spinesstic 22 Teresstic 32 Velocite 10 Air Lube 10H NR Turbo T32 Sunvis 11 Sunvis 722 Regal R amp O 32 Union Turbine Oil the sleeve and rotate it several times to ensure even distribution of the lubricant If the valve is used in a non lubricated application do not use a lubricant for reassembly which can dry out and leave a residue Dry assembly of the spool and sleeve is preferable Each spool and sle
373. ubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components potentially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flow and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conj
374. uirements Pipe Installation The pipe ports in the manifolds of the Select4400 valves are designed to use face sealing fittings Since the pipe threads are not tapered pipe sealant and tape is not recommended web site www rosscontrols com ROSS EUROPA GmbH Germany TEL 49 6103 7597 0 web site www rosseuropa com ROSS ASIA K K Japan TEL 81 427 78 7251 web site www rossasia co jp ROSS UK Ltd United Kingdom TEL 44 121 559 4900 email sales rossuk co uk ROSS SOUTH AMERICA Ltda Brazil TEL 55 11 4335 2200 email vendas ross sulamerica com br ROSS CONTROLS INDIA Pvt Ltd India TEL 91 44 2624 9040 email rossindia airtelbroadband in ROSS CONTROLS CHINA Ltd China TEL 86 21 6915 7951 email alvinzhurong vip 163 com DIMAFLUID s a s France TEL 33 01 49 45 65 65 web site www dimafluid com VALVE MAINTENANCE Pneumatic equipment should be maintained only by persons trained and experienced in the maintenance of such equipment Supply Clean Air Foreign material lodging in valves is a major cause of breakdowns The use of a 5 micron rated air filter located close to the valve is strongly recommended The filter bowl should be drained regularly and if its location makes draining difficult the filter should be equipped with an automatic drain Polycarbonate Bowl Warning Filters and lubricators equipped with polycarbonate bowls are not recommended for use in applications
375. unction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and L O X with EEZ ON operation products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LI
376. und to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the U S A Rev 05 09 2009 ROSS CONTROLS All Rights Reserved Form SS284 Series Uf Sizes 2 and 4 ROSS 5 2 CrossMirror Solenoid Pilot Double Valve Thank You You have purchased a premium quality ROSS pneumatic valve Itis a 4 way double valve with precision stainless steel spools as the main valve elements and is designed to offer added safety to the operation of many pneumatically controlled machines IMPORTANT NOTE This Valve is Not Designed for Controlling Clutch Brake Mechanisms on Mechanical Power Presses With care in its installatio
377. upply Clean Air Foreign material lodging in valves is a major cause of breakdowns The use of a 5 micron rated air filter located as close as possible to the valves actuating the HSR valve is strongly recommended The filter bowl should be drained regularly and if the filters location makes draining difficult the filter should be equipped with an automatic drain Use Only Compatible Lubricants Although the HSR valve does not require air line lubrication it may be used with lubricated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components and thereby cause the valve to malfunction The best oils to use are those specifically compounded for air line lubricator service A few of the compatible lubricants on the market are listed in the table at the left Check Lubricator Supply Rate A lubricator should put atomized oil into the air line in direct proportion to the rate of air flow Excessive air line lubrication can cause puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute of air flow is adequate Note that your HSR valve does not itself require air line lubrication COMPATIBLE LUBRICANTS Brand Name American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Pacemaker 32 Spinesstic 22 Teresstic 32 Velocite 10 Air Lube 10H NR Turbo T32 Sunvis 11 Sunvis 722 Regal R amp O 32 Union Turbine
378. urces of energy are turned off the entire pneumatic system is shut off and exhausted and all power sources are locked out ref OSHA 1910 147 EN 1037 2 All ROSS products including service kits and parts should be installed and or serviced only by persons having training and experience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rati
379. use of breakdowns The use of a 5 micron rated air filter located as close to the valve as possible is strongly recommended The filter bowl should be drained regularly and if the filters location makes draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should put atomized oil into the air line in direct proportion to the rate of air flow Excessive air line lubrication can cause puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute of air flow is adequate Note that your ROSS valve does not itself require air line lubrication See next column for a partial list of lubricants that are compatible with ROSS valves and are suitable for use in compressed air systems Cleaning Valve If the air supplied to the valve has not been well filtered the interior of the valve may accumulate dirt and varnish which can affect the valve s performance Although ROSS poppet valves are very tolerant of dirty air cleaning may sometimes be needed To clean the valve use any good commercial solvent or kerosene Do not use a chlorinated solvent or abrasive materials The former damages seals and abrasives can do permanent damage to metal parts Before reassembling the valve lubricate all sliding surfaces with a grease equivalent to Dow Corning BR 2 Electrical Contacts In the external electrical circuits associated with
380. ust be connected to an external monitor Pressure Switches Some models have two pressure switches that sense that the two valve elements did not move together The pressure switches are only indicators that the valve elements did not move in step with one another and the switches will not lock out the valve They should not be confused with a monitor Each pressure switch has four electrical contacts Contacts 1 and 2 are closed when no air pressure signal is applied to the switch Contacts 1 and 4 are closed when an air pressure signal is applied to the switch Contact 3 is for a ground connection For further information in the use or connection of the pressure switches call your local ROSS distributor or location below or inthe U S A call ROSS Technical Service at 1 888 TEK ROSS web site www rosscontrols com web site www rosseuropa com ROSS ASIA K K Japan TEL 81 427 78 7251 web site www rossasia co jp ROSS UK Ltd ROSS SOUTH AMERICA Ltda ROSS CONTROLS INDIA Pvt Ltd ROSS CONTROLS CHINA Ltd DIMAFLUID s a s TEL 44 121 559 4900 TEL 55 11 4335 2200 TEL 91 44 2624 9040 TEL 86 21 6915 7951 TEL 33 01 49 45 65 65 email sales rossuk co uk email vendas ross sulamerica com br email rossindia airtelbroadband in email alvinzhurong vip 163 com web site www dimafluid com United Kingdom Brazil India China France VALVE OPERATION SOLENOID A SOLENOID B H EX
381. valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and L O X with EEZ ON operation products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY RE
382. valves is a major cause of breakdowns The use of a 5 micron rated air filter located close to the valve is strongly recommended The filter bowl should be drained regularly and if its location makes draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should put a fine oil mist into the air line in direct proportion to the rate of air flow Excessive lubrication can cause puddling in the system and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute is adequate Note that the double valve itself does not require air line lubrication Compatible Lubricants Although this valve does not require air line lubrication it may be used with lubricated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components and so cause the valve to malfunction Avoid oils with phosphate additives e g zinc dithiophosphate and diester oils both types can harm valve components The best oils to use are generally petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Some compatible oils are listed above at the right These oils although believed to be compatible could change without notice because manufacturers sometimes reformulate their oils Therefore use oils specifically compounded for air line serv
383. ve This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT SHALL ROSS BE LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS SHALL EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the U S A Rev 05 09 2009 ROSS CONTROLS All Rights Reserved Form SS149 3 2 Cross Series r Sizes 2 4 amp 8 MirrRor Valves ROSS Thank You You have purchased a premium quality ROSS pneumatic valve It is a high quality CrossMirRorR double valve with dynamic monitoring and inherent lock out capability The valve is designed for base mounting for ease of installation and maintenance With care in its installation and maintenance you can expect it to have a long and economical service life Before you install this valve read the information in this folder
384. w and increased back pressure ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS product POWER PRESSES 10 Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and L O X with EEZ ON operation products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defecti
385. w rossasia co jp ROSS UK Ltd United Kingdom TEL 44 121 559 4900 email sales rossuk co uk ROSS SOUTH AMERICA Ltda Brazil TEL 55 11 4335 2200 email vendas ross sulamerica com br ROSS CONTROLS INDIA Pvt Ltd India TEL 91 44 2624 9040 email rossindia airtelbroadband in ROSS CONTROLS CHINA Ltd China TEL 86 21 6915 7951 email alvinzhurong vip 163 com DIMAFLUID s a s France TEL 33 01 49 45 65 65 web site www dimafluid com VALVE MAINTENANCE Supply Clean Air Foreign material lodging in valves is a major cause of breakdowns The use of a 5 micron rated air filter located as close to the valve as possible is strongly recommended The filter bowl should be drained regularly If the filter s location makes manual draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should put atomized oil into the air line in direct proportion to the rate of air flow Excessive air line lubrication can cause puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute of air flow is adequate Note that your ROSS valve does not itself require air line lubrication Compatible Lubricants Although this valve does not require air line lubrication it may be used with lubricated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components and thereby caus
386. wer is supplied by a transformer it must be capable of handling the inrush current without significant voltage drop See Valve Specifications on page 2 for information on in rush current Pilot Supply Pressure Control For valves with single remote pressure control connect the control line to port 14 in the sub base or manifold For valves with double remote pressure control connect the control lines to ports 12 and 14 in the base See Valve Specifications on page 2 for required pressures Solenoid Pilot Pressure for the pilot valves is supplied from the inlet port Be sure that the external pilot supply port in the base is plugged or pilot air will escape If the valve must operate with an inlet pressure less than the required pilot pressure see Valve Specifications on page 2 an external pilot supply must be provided Connect to the appropriate port in the base Non Air Service Such applications require an external pilot supply for solenoid valves Connect to the appropriate port in the base Pipe Installation To install pipe in valve or base ports engage pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating the valve ROSS CONTROLS United States TEL Tech Svs 888 TEK ROSS Cust Svs 800 GET ROSS web site www rosscontrols com ROSS EUROPA GmbH Germany TEL 49 6103 7597 0 web site www rosseuropa com ROSS ASIA K K
387. with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakage and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components potentially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow c
388. with line pressures greater than 150 psig 10 bar Use filters and lubricators with metal bowls for applications above 150 psig 10 bar Air Line Lubrication In applications involving the manufacture of food type containers air line lubrication should NOT be used However in other non food type applications it may acceptable to use air line lubrication depending on the other equipment in your system Check Lubricator Supply Rate A lubricator should put a fine oil mist into the air line in direct proportion to the rate of air flow Excessive lubrication can cause puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop per minute is adequate Note that this valve itself does not require air line lubrication Compatible Lubricants Although this valve does not require air line lubrication it may be used with lubricated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components and so cause the valve to malfunction Avoid oils with phosphate additives e g zinc dithiophosphate and diester oils both types can harm valve components The best oils to use are generally petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Some compatible oils are listed above at the right These oils although believed to be compatible could change
389. without notice because manufacturers sometimes reformulate their oils Therefore use oils specifically compounded for air line service If it is a synthetic oil contact the oil manufacturer for compatibility information Cleaning the Valve If the air supplied to the valve has not been well filtered the interior of the valve may accumulate dirt rust and varnish which can affect the valve s performance COMPATIBLE LUBRICANTS Brand Name American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Pacemaker 32 Spinesstic 22 Teresstic 32 Velocite 10 Air Lube 10H NR Turbo T32 Sunvis 11 Sunvis 722 Regal R amp O 32 Union Turbine Oil A schedule should be established for cleaning all valves the frequency depending on the cleanliness of the air being supplied To clean the valve use any good commercial solvent Do not scrape varnished surfaces Also do not use chlorinated solvents or abrasive materials The former damages seals and abrasives can do permanent damage to metal parts Before reassembling the valve lubricate all sliding surfaces with NYE 8512S grease Electrical Contacts In the electrical circuits associated with the valve solenoids keep all switches or relay contacts in good condition to avoid solenoid malfunctions Replace Worn Components Turn off the electrical power to the valve shut off the air supply and exhaust the air in the system before beginning any disassembly operation or removing the valve f
390. wls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of bowl failure Do not expose these products to certain fluids such as alcohol or liquefied petroleum gas as they can cause bowls to rupture creating a combustible condition hazardous leakage and the potential for human injury Immediately replace a crazed cracked or deteriorated bowl When bowl gets dirty replace it or wipe it with a clean dry cloth 7 Only use lubricants which are compatible with materials used in the valves and other components in the system Normally compatible lubricants are petroleum based oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity Avoid oils with phosphate type additives which can harm polyurethane components potentially leading to valve failure and or human injury AVOID INTAKE EXHAUST RESTRICTION 8 Do not restrict the air flow in the supply line To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action 9 Do not restrict a valve s exhaust port as this can adversely affect its operation Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves Contamination of the silencer can result in reduced flo
391. xperience with pneumatic equipment Because any installation can be tampered with or need servicing after installation persons responsible for the safety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance 3 All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment In addition overhauled or serviced valves must be functionally tested prior to installation and use 4 Each ROSS product should be used within its specification limits In addition use only ROSS parts to repair ROSS products Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury FILTRATION and LUBRICATION 5 Dirt scale moisture etc are present in virtually every air system Although some valves are more tolerant of these contaminants than others best performance will be realized if a filter is installed to clean the air supply thus preventing contaminants from interfering with the proper performance of the equipment ROSS recommends a filter with a 5 micron rating for normal applications 6 All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only Do not fail to use the metal bowl guard where provided to minimize danger from high pressure fragmentation in the event of b
392. y cause the valve to malfunction The best oils to use are those specifically compounded for air line lubricator service These are generally petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity A few of the compatible lubricants on the market are listed below Brand Name American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Pacemaker 32 Spinesstic 22 Teresstic 32 Harmony 32 Velocite 10 Air Lube 10H NR Turbo T32 Sunvis 11 Sunvis 722 Regal R amp O 32 Union Turbine Oil VALVE SPECIFICATIONS SERIES 31 Temperature Range 40 to 175 F 4 to 80 C Flow Media Filtered air 5 micron recommended Inlet Pressure 5 to 150 psig 0 3 to 10 bar SERIES 36 Temperature Range 40 to 175 F 4 to 80 C Flow Media Filtered air 5 micron recommended Inlet Pressure 5 to 125 psig 0 3 to 8 5 bar IMPORTANT NOTE Please read carefully and thoroughly all the CAUTIONS on page 4 2 ROSS CONTROLS VALVE SERVICE Valve Body Service Kits These kits contain all of the internal parts needed to recondition a valve body Included are poppet and stem assemblies springs and retainers gaskets and seals plus instructions for use Locking Rocker Kits Contain rocker and associated hardware for models with detented action model numbers ending in 07 09 10 or 13 Spring amp Retainer Kits Contain four poppet sprin
393. y controlled clutch and brake mechanism must use a press control double valve with a monitoring device A double valve without a self contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism ENERGY ISOLATION EMERGENCY STOP 11 Per specifications and regulations ROSS L O X and L O X with EEZ ON products are defined as energy isolation devices NOT AS EMERGENCY STOP DEVICES WARRANTY Products manufactured by ROSS are warranted to be free of defects in material and workmanship for a period of one year from the date of purchase ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective This warranty shall be void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOS

Download Pdf Manuals

Related Search

Related Contents

K205取扱説明書を見る  pdf, 144kb - Public Schools of North Carolina  Page 1 Page 2 添付文書 記載例 (WGー = 輸液ポンプ  OdaLog Technical Bulletin  I(enmore Elite    Planet Technology GSD-503 User's Manual  Titan Iron Man  XB-356B  Kärcher 2.645-139.0  

Copyright © All rights reserved. Failed to retrieve file