Ross Controls CATEGORY 4 User Manual

Bulletin E383Bulletin E383

5/2-W ay Double Valves with

5/2-W ay Double Valves with

®

ROSSMIRROR

C

C

ROSSMIRROR

®

Sensing

Sensing

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ROSS safety-related technology
has a long tradition...

ROSS 5/2-way Double Valves with
CROSSMIRROR®-Sensing

For almost 40 years ROSS has been developing double
valves which have made a significant contribution to the
operating safety of pneumatically controlled presses. Du­ring this period our range of double valves has been de­veloped continuously in response to the needs of press
manufacturers and users. Monitoring devices have also
been offered in a variety of designs to satisfy different re­quirements.

The range of double valves in 5/2-way configuration featu­ring the all-new CROSSMIRROR® -sensing system presented
in this leaflet incorporates all our experience and repre­sents the state-of-the-art in ROSS double valves.

Selecting the double valve best suited to each application
requires considerable technical knowledge. If you need
further information or technical advice, please contact
ROSS or your nearest ROSS distributor or sales office.

CAUTION: On mechanical presses and other hazardous
machines with pneumatically operated clutches and bra­kes double valves at least should be used. Double valves
without self-monitoring should be used only if current regu­lations permit.

If the valves are used on presses in Germany, the
„Safety Regulations For Control Systems On Power-dri­ven Presses for Metalworking zH 1/457“ must be obser­ved.

For applications not covered by standard valves, please
consult ROSS. We reserve the right to make technical mo­difications in the course of further product development.

This all-new ROSS-Crossflow double valve with CROSSMIR-

®

-sensing is a 5/2-way valve with two individual soleno-

ROR

id pilot valves each actuating its own individual metal­spool-sleeve valve element.

The spool-and-sleeve valve elements are arranged in par­allel design and - as a safety-related feature - they are con­nected by „crossflow“ channels. In case of normal valve
operation both spools move synchronously; when de-ac­tuated, the spools are in the upper position; and when ac­tuated, they are in the lower position. Because of their red­undant design and their self-monitoring capabilities, ROSS
5/2-way-Crossflow double valves with C
sing provide a very high safety standard for the control of
single- or double acting cylinders or rotary drives.

Additional safety features are incorporated in the base. In
the event of loss of air pressure at the inlet port a check
valve is installed to trap the downstream air, a small bleed
orifice slowly relieves the trapped air. Additionally a small
two-way valve provides safety in the case where inlet pres­sure is restored whilst the solenoids are still energized. To
guard against any sudden cylinder movement, this valve
provides a path to exhaust for one of the pilot valves which
puts the valve into an inoperable state until both solenoids
have been de-energized.

The new ROSS C
gned to exhaust the pilot supply to one solenoid pilot when
only one half of the valve is in an actuated position. This is
accomplished by connecting the pilot air supply system to
the main valve spool and sleeve. The connection is made
such that as the spool moves toward the actuated position
the pilot supply is vented to exhaust via the second valve
element. When the second valve element moves to the ac­tuated position, it blocks the exhausting pilot air thereby
maintaining a constant supply. Pilot supply to the opposite
pilot is connected in a mirror image of the first pilot supply,
hence the name „cross mirror“.

ROSSMIRROR

®

-sensing system is desi-

ROSSMIRROR

®

-sen-

CONTENTS:

Product description........................................ Page 2

Specifications, model numbers ..................... Page 3

Dimensions ................................................... Page 4

Replacement parts ........................................Pages 5, 6

Flow characteristics, valve response times ...Page 7

General information....................................... Page 8

Cautions........................................................ Pages 9, 11

Operating instructions ................................... Page 10

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5/2-Way Double V alves

with CROSSMIRROR®-Sensing

SPECIFICATIONS

Design: Metal-to-metal spool-and-

sleeve valves, pressure-operated.
Air and spring returned.

Operation: Solenoid-operated air­piloted valves, 3/2-way-spring-return.

2)

Media

: compressed air,

dehydrated, filtered (5 µm),
lubricated or unlubricated.

Operating pressure: 2,5 to 10 bar.
Temperature range: 4° C to 50° C.
Mounting orientation: preferably

Pilot solenoid: according to VDE 0580.

Enclosure rating acc. to DIN 400 50 IP

65. Connector socket according to DIN
43650 Form A.

Solenoids rated for continuous duty.
Standard voltages:

24 V DC 110 V DC
24 V 50 Hz, 110 V 50 Hz, 230 V 50 Hz;
24 V 60 Hz, 110 V 60 Hz, 240 V 60 Hz.

Power consumption:

DC solenoids - 5,3 W
AC solenoids - 8,5 VA

vertically.

1)

Monitoring

: dynamically, cyclically,

internally.

The double valves listed have been approved by the following testing
and certificating authority:

BG-Fachausschüsse Eisen und Metall III und Hebezeuge II,
Deutschland: Certificate No. 99035

Double Valve

Nominal Size Operating pressure (bar) Weight Type Model Number3)Replacement valve

Diameter min. max. (kg) (with sub-base) (without sub-base)

10 G 3/8 2,5 10 3,8 CM 5/2 D7776A3410 7776A3400
10 G 3/8 2,5 10 3,9 CM 5/2 D7776A3411 7776A3401

with pressure switch

15 G 1/2 2,5 10 4,8 CM 5/2 D7776A4420 7776A4400
15 G 1/2 2,5 10 5,1 CM 5/2 D7776A4421 7776A4401

with pressure switch

15 G 3/4 2,5 10 4,8 CM 5/2 D7776A5410 7776A4400
15 G 3/4 2,5 10 5,1 CM 5/2 D7776A5411 7776A4401

with pressure switch

3)

Sub-base

Nominal Pipe size Weight Design Model Number

Diameter 1 2 3 4 5 (kg) Feature

10 G 1/2 G 3/8 G 3/8 G 3/8 G 3/8 1,1 D996C91
10 1/2 NPT 3/8 NPT 3/8 NPT 3/8 NPT 3/8 NPT 1, 1 996C91
15 G 3/4 G 1/2 G 1/2 G 1/2 G 1/2 1,6 D1049C91
15 3/4 NPT 1/2 NPT 1/2 NPT 1/2 NPT 1/2 NPT 1,6 1049C91
15 G 3/4 G 3/4 G 3/4 G 3/4 G 3/4 1,6 D1153C91
15 3/4 NPT 3/4 NPT 3/4 NPT 3/4 NPT 3/4 NPT 1,6 1153C91

Notes

1) In addition, a pressure-switch-monitored model of this valve is available. In case of a malfunction or pressure failure, the pressure
switch can be used for signaling abnormal operation. Important Note: The pressure switch is not designed to be integrated in a safety
circuitry as its response may be delayed, depending on the type of malfunction.

2) It is recommended to use compressed air, filtered and unlubricated. If lubricated air must be used, we recommend oils conforming to
ISO viscosity classes 32-46 (DIN 51519).

3) When ordering the valve, specify AC or DC voltage and frequency for operating the pilot solenoids (see Specifications above).

Sub-base is equipped

with check valve in
pipe connection 1 and
2/2-way valve as reset

after pressure energy

failure

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5/2-Way Double V alves

with CROSSMIRROR®-Sensing

Dimensions –

Valve with ported sub-base

Dimensions –

Valve with ported sub-base and

pressure switch

Dimensional drawings:

Mounting interface sub-base to machine
dimensions: D; E; F; G and H

Dimensions in mm

ND 10 282 104 81 115,6 75 119,5 7 7 or M 6
ND 15 310 108 106 136 81 122 7 7 or M 6

ND 10 282 172 81 115,6 75 119,5 7 7 or M 6
ND 15 310 175 106 136 81 122 7 7 or M 6

ABCDEFGH ø

Double valve with ported sub-base

Double valve with ported sub-base

and pressure switch

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5/2-Way Double V alves

with CROSSMIRROR®-Sensing

Replacement parts –
Valve with pressure switch

Valve Numbers

7776A3401
7776A4401

Pos. Qty. 7776A3401 7776A4401 Description

1 1 854C89 883C89 Sensing as semb ly
2 1 420H90 418A90 Inlet spool/sleeve
3 1 421H90 419A90 Outlet spool/sleeve
4 2 1044H79 1044H79 Pilot assembly

4a 2 – – Coil

5 2 577A09 603A09 Actuation piston
6 2 583A32 503A32 Seal
7 2 139J22 143J22 Retaining ring
8 4 288A32 289A32 Bumper

9 2 1460A25 1585A25 Spacer
10 2 478A13 497A13 Compression spring
11 1 860A11 886A11 Gasket (pilot-to-body)
12 1 861A11 885A11 Gasket (body-to-sub-base)

B 1 1575K77 1577K77 Seal kit

Pressure switch assembly Sub-base assembly

Pos. Qty. 854C89 883C89 Description

1 1 518E30 518E30 Pressure switch
2 1 522E30 522E30 Connector socket
3 1 207A13 207A13 Spring
4 1 200A97 200A97 Insert assy.
5 1 144J22 144J22 Retaining ring
6 1 580A09 580A09 Piston
7 1 768J32 768J32 U-cup seal
8 1 678B25 678B25 Stem guide
9 1 207J15 207J15 O-Ring

10 1 131J22 131J22 Retaining ring

Pos. D996C91Qty. Description

1 1 D1048B91 D1130B91 Valve body assembly
2 1 488A13 222A13 Spring
3 1 185A88 351A88 Valve poppet assembly
4 1 D332B85 D334B85 Check valve assembly
5 1 147A90 147A90 Spool assembly
6 1 157A85 157A85 Plug assembly
7 1 133J22 133J22 Retaining ring

D 1 1576K77 1578K77 Seal kit

D1049C91

D1153C91

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