ROSS Pneumatic Control System Full Series

ROSS Pneumatic Control System Full Series

In the field of industrial pneumatics, ROSS Controls has become a leading global manufacturer of directional control valves, safety pneumatic products, and air source processing units with over 75 years of experience. Its product line covers ISO standard valves, series bus communication modules, reliable control dual valves, explosion-proof valves, locking valves, and FRL units, providing comprehensive solutions for applications such as mechanical presses, hydraulic equipment, automated assembly lines, hazardous environments, and energy isolation. This article provides a systematic and in-depth analysis of ROSS's core product series, technical features, and selection criteria based on its latest product catalog.

ISO standard valve series: integration of modularity and high performance

ROSS provides valve assemblies that comply with ISO 15407-1, ISO 15407-2, ISO 5599/I, and ISO 5599/II standards, covering various specifications such as size 00 (18 mm), 0 (26 mm), 1, 2, 3, etc., to meet global installation size requirements.

1. W66 series (ISO 15407-1/2)

Sizes 00 and 0, 5/2 single/dual electronic control and 5/3 dual electronic control.

Structural form: Spool&Sleeve, providing high switching speed and lubrication free operation.

Interface form: ISO 15407-1 is lead out type, ISO 15407-2 is plug in type for easy maintenance.

Standard voltage: 24 V DC (1.0 W power consumption) and 120 V AC (2.0 VA).

Working pressure: Vacuum to 145 PSI (10 bar); The minimum pressure for two position valves is 20 gauge, and for three position valves it is 30 gauge.

Flow rate: Size 00 Cv=0.55, Size 0 Cv=1.1.

Material: Die cast aluminum valve body, PBT end cap, thermosetting plastic coil.

Can integrate serial bus communication (see later).

2. W60/W64/W65 series (ISO 5599/I and ISO 5599/II)

Sizes 1, 2, 3, 5/2 single/dual electric control, 5/3 dual electric control and pneumatic valve.

W60 series: Precision stainless steel valve core/sleeve, high reversing speed, long life, suitable for lubrication free operation.

W64 series: Poppet structure with high tolerance to dirty air.

W65 series: ISO 5599/II plug-in type, valve body can be replaced without rewiring, facilitating serial bus integration.

Flow rate: Size 1 Cv ≈ 0.8~1.0, Size 2 Cv ≈ 1.9~2.3, Size 3 Cv ≈ 3.8~4.0.

Working pressure: Vacuum to 150 PSI (10 bar); The pilot pressure for size 1 is ≥ 30 PSI, and size 2/3 is ≥ 15 PSI.

Power consumption: AC 11 VA shock/8.5 VA hold, DC 6 W。

Optional high temperature (fluororubber) seal.

The attachments include intermediate pressure regulator, intermediate flow control, blank station board, isolation board, etc.

All ISO valves can be paired with the ROSS Serial Bus system to achieve centralized or distributed I/O control.

Serial Bus Communication System: Integrated Pneumatic and I/O

The ROSS serial bus system is based on Turck's BL67 modular I/O or its own PointBus architecture, supporting DeviceNet ™、 ControlNet ™、 EtherNet/IP ™、 PROFIBUS DP ™  Waiting for mainstream industrial Ethernet and fieldbus protocols.

1. Centralized and remote configuration

Centralized: The valve island is tightly installed with I/O modules, with 8 points per I/O module, connected to sensors and actuators through M12, M8, or M23 connectors.

Remote configuration: Extend valve island and remote I/O through M23 12 pin cable to adapt to distributed layout.

Partition remote: Separate pneumatic valves, I/O modules, and power supplies in enclosures with different levels of protection.

2. Key modules

Communication adapter: RPSSCDM12A（DeviceNet M12）、RPSSCDM18PA（DeviceNet M18）、RPSSCCNA（ControlNet）、RPSSCENA（EtherNet/IP）、RPSSCPBA（Profibus）。

I/O module: 8-point digital input/output (optional PNP/NPN), 2-point analog input/output (0-10 V or 4-20 mA), and 4-point relay output (2 A).

Valve drive module: RPSSV32A, supports 32 point output, drives ISO size 00/0/1/2/3 valves.

Power expansion module: RPSSSE24A, one additional module needs to be added every 12 modules to provide an additional 5V bus current (maximum 1.3 A).

Terminal module: RPSSTERM is used at the end of the bus.

The system supports up to 63 I/O modules, 264 inputs and 264 outputs, with a protection level of IP65/66/67 and a working temperature range of -20 ° C to 60 ° C.

Safety related products: from energy isolation to reliable control

ROSS has L-O-X in the field of safety aerodynamics ®  Lock valve EEZ‑ON ®  Soft start valve, DM1/DM2 series dual valve, pilot operated one-way valve CrossMirror ®  Rich product lines including dual valves and explosion-proof valves.

1. L‑O‑X ®  Manual locking valve (15 series)

Function: 3/2 normally closed, used for energy isolation in pipelines, in compliance with OSHA standards (1910.147).

Features: Red handle, padlockable only in the closed position, full flow exhaust port (≥ intake size).

Installation form: Modular (Slim Line, Modular, Classic) and stainless steel versions.

Interface size: 1/4 "to 2", Cv from 2.67 to 40.38.

Working pressure: 0-145 PSI (Slim Line) or 0-300 PSI (Classic).

Optional pressure switch (5 PSI drop closed) and pop-up indicator.

2. EEZ‑ON ®  Soft start valve (19/27 series)

Function: Gradually establish downstream pressure to prevent sudden equipment action during startup.

Structure: 2/2 or 3/2 normally closed, with adjustable needle valve, fully open when downstream pressure reaches about 50% of intake pressure.

Interface: 1/4 "to 1 1/2", Cv 1.2~30。

Integration options: Can be combined with L-O-X (blue handle, partially open first and then fully open).

3. Control Reliable Double Valves

The highest safety level valve used for energy isolation and press clutch/brake control.

DM1 series E (dynamic monitoring, no memory)

3/2 normally closed, two valve cores are monitored synchronously. If asynchronous action occurs, the outlet is cut off (residual pressure<1%).

Automatically reset after fault clearance (no latch memory).

Interface: 1/4 "and 3/8", Cv 1.3~2.2。

Certification: Compliant with ISO 13849-1 Class 4 PL e.

DM2 ®  Series E (Dynamic Monitoring+Memory)

Add a latch function on the basis of DM1, and after a fault, it must be manually reset through a reset solenoid valve or remote gas signal.

The same applies to 3/2 normally closed, 1/4 "and 3/8", Cv 1.3~2.2。

Reset method: Built in solenoid valve (24 V DC or 110/120 V AC).

DM2 ®  Series C (suitable for high traffic)

Sizes 4, 8, 12, and 30 correspond to 1/2 "to 2" interfaces.

Cv：4.4~22， Weight 5.9~34.7 lb.

Integrated status indicator pressure switch (NO/NC contact).

Reset can be achieved through remote gas signals, solenoid valves, or manual buttons.

DM2 ®  Series D (dedicated to press clutch/brake)

Compliant with OSHA 1910.217 and ANSI B11.2 standards.

Built in total dynamic monitoring and complete memory, it must be automatically reset after a fault occurs.

Basic dimensions 2, 4, 8, 12, 30, Cv 2.17~20.22。

Optional remote gas reset, electromagnetic reset, or manual reset.

The export response time can be calculated using the formula t=M+F × V (where M is the mechanical constant and F is the milliseconds per cubic inch).

4. Pilot operated one-way valve (19, 27, SV27 series)

Function: Load retention to prevent the cylinder from accidentally falling.

Type: 2/2 normally closed, pilot pressure open, one-way cutoff without pilot.

Integrated pressure relief function: optional remote pneumatic pressure relief, manual pressure relief, or electromagnetic pressure relief.

The SV27 series integrates a double pole single throw switch (DPST) that provides position feedback and can be used for safety circuits (Cat.2 PL d).

5. CrossMirror ®  Double valve (77 series and CM series)

Used to reliably return the cylinder to its original position (such as press protection).

77 series: 5/2 dual valves, built-in dynamic monitoring, output port 2 (return) maintains pressure in case of failure.

CM series: Modular design, can be combined into multiple valve groups, with status indication and reset function.

6. Explosion proof valves (27 series and 21 series)

Certification: CSA/FM Class I Div 1&2, Groups A-D; Class II Div 1 & 2，Groups E‑G； ATEX Ex m II T4。

Structure: Poppet valve, valve body material: Acetal for the 27 series and aluminum for the 21 series.

Temperature range: Standard -40 ° F to 140 ° F, 21 series low temperature can reach -4 ° F (-20 ° C).

Voltage: 24 V DC (4.6 W) or 120 V AC (6.8 VA).

Provide 2/2, 3/2, and 4/2 functions, with interfaces ranging from 1/4 "to 2".

The conversion kit can upgrade ordinary valves to explosion-proof on-site.

Air source processing unit (FRL)

ROSS offers a full range of filters, regulators, lubricators, and their combination units, with modular design for easy assembly.

1. Filter

Particle filter: 5, 20, 40 µ m filtration accuracy, polycarbonate or metal cup body, manual or automatic drainage.

Condensed filter: 0.3 µ m or 0.01 µ m, used to remove oil mist and water mist.

Activated carbon adsorption filter: removes oil vapor and hydrocarbons.

Series: Bantam (1/8-1/4 ", flow rate 30 scfm), Miniature (23 scfm), Mid Size (75 scfm), MD3 ™ （92 scfm）、Full‑Size（155 scfm）、MD4 ™ （205 scfm）、High‑Capacity（1000 scfm）。

Optional differential pressure indicator, external automatic drainage, etc.

2. Voltage regulator

Structure: piston type (high flow rate) or diaphragm type (high sensitivity).

Specification: Same series as the filter, with an adjustable outlet pressure range of 0-125 PSI or 0-250 PSI.

Special types: high-precision regulator, remote pilot regulator, high-pressure regulator (400 PSI inlet).

Comes with overflow/non overflow options.

3. Lubricator

Type: Sight Feed or Wick Feed.

Match the flow rate with the corresponding series, equipped with a quick oil filling cup or standard oil filling port.

4. Combination unit

Filtering+pressure regulation: saves space and reduces pressure difference.

Filtering+lubrication: suitable for systems that require lubrication.

Filtering, pressure regulation, and lubrication (FRL): a complete triple component.

Integrated filtration/pressure regulation+lubrication: more compact, such as the MD3/MD4 series.

All FRL units adopt modular clamp connections (MD series), which can be quickly disassembled and assembled, and provide various installation brackets and port blocks.

Other important product lines

Dale series: Direct acting lift valves (2/2, 3/2), suitable for high flow, harsh environments, with manual reset option.

21 series: Metal lift valve, suitable for high/low temperature (-40 ° C to 150 ° C) and vacuum applications.

95 series: Compact spool valve, 1/8 "-1/2", Cv 0.9-4.5, extremely low power consumption (2.5 W DC).

SAE 80/84 series: Complies with SAE standards in the automotive industry and comes with various in car connectors.

AIR‑FUSE ®： Flow diffuser, automatically reduces flow when hose ruptures to prevent whipping, in compliance with OSHA requirements.

Foot operated valve, manual valve, mechanical valve: multiple operating modes.

Attachments and selection precautions

Electrical connector: DIN 43650 Form A/C or M12, with optional indicator lights.

Muffler: Standard brass or stainless steel, high flow noise reduction type.

Pressure switch: used for downstream pressure monitoring or status indication.

Pre installed cable kit: includes J-Box or multi pin cables to simplify wiring.

Material compatibility: Avoid using lubricating oil containing phosphate ester additives to prevent damage to polyurethane components.

Environmental restrictions: The polycarbonate cup body must not come into contact with organic solvents, ammonia, strong acids, etc.

Safe application: Dual valves used for press clutch/brake must be equipped with monitoring devices (such as DM2 built-in monitoring or external monitoring).