Ross Controls W80 User Manual
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ROSS Valves for SAE Bases
The SAE Standard Interface, though originally developed by
U.S. auto companies in the early 1970s, has quickly gained wide
acceptance throughout the industry. Due to the design's ruggedness
and high-flow characteristics, the Society of Automotive Engineers
(SAE) established it as a new standard. This ensures that valves
designed to fit the SAE interface will be interchangeable, regardless
of manufacturer. In practical terms, the user can change from
one brand of valve to another without changing installed bases or
manifolds.
ROSS valves are available in SAE sizes 125, 250 and 500. Both
poppet and metal spool-and-sleeve construction are offered. The
valves described in this bulletin are all solenoid-pilot controlled.
SOLENOID PILOTS
Internal or External Pilot Supply. Valves in this bulletin are made
for internal pilot supply. However, they are easily converted for use
with an external pilot supply by moving a single pipe plug in the
bottom of the valve.
With solenoid pilot control, the main valve is shifted by applying air
pressure to an actuating piston or spool end. There is no mechanical
connection between the solenoid plunger in the pilot and the main
valve mechanism as there is in a valve actuated by a direct-acting
solenoid. If the valve mechanism were to stick, the plunger in a
solenoid-pilot-controlled valve could complete its travel and avoid
the high current flow which results when the travel is incomplete.
Thus overheating and solenoid burnout are avoided. Furthermore,
under average shop conditions, air pressure produces a valve-shifting
force much greater than that from a direct-acting solenoid, so that
the problem of valve sticking is minimized.
Indicator Lights. An indicator light is wired to each solenoid
circuit so that the light is illuminated whenever the solenoid is
energized.
Hard Wiring. An electrical opening, threaded 1/2 NPSC, is available
for use with conventional fittings.
ELECTRICAL CONNECTORS
Electrical connections to the valves can be made with sealed 4 or 5-pin
connectors (ANSI Standard B93.55) or by conventional hard wiring.
Sealed Connector. A 4 or 5-pin straight connector wired as required
by either the Ford Motor Company or the Chrysler Corporation
is available. Valves may be ordered with mini- or micro-change
connectors. See the wiring diagrams below for the various options
available.
Ford Wired 5-pin
mini-connector (all voltages)
Ford Wired 4-pin
micro-connector (24 vdc)
Chrysler Wired 5-pin
mini-connector (all voltages)
Chrysler Wired 5-pin
micro-connector (24 Volts DC)
Chrysler Wired 5-pin
micro-connector
(120 volts / 60 Hz)
Poppet Valve Construction
Single Control. 5-port, 2-position (5/2) valves that require a main-
tained signal to keep the valve in its shifted position. Internal air
pressure provides the force to return the valve when the signal is
removed.
Series 84
Poppets are face sealing valve elements which can open or close
passageways without sliding friction or the close tolerances required
of spool valves. Poppets don't build up breakaway resistance due
to varnish, and are highly tolerant of dirty air.
ROSS poppet valves have rugged internals and self-adjusting
exhaust poppet seats which equalize wear and promote long life.
Designed for use with or without air line lubrication.
Double Control. 5-port, 2-position (5/2) valves that require only a
momentary signal to shift the valve in either direction. A mechanical
detent and differential air pressure keep the valve in its shifted
postion.
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MANUAL OVERRIDES
Each solenoid pilot has a non-locking override button for manual actuation of
the valve. For Size 500 valves, locking buttons and extended buttons are also
available. See page 9.
VALVE RESPONSE TIME
Average response constants for each valve are listed in the charts on pages
4 thru 6. These constants, designated M and F, can be used to determine the
amount of time required to fill or exhaust a volume of any size by using the
following formula:
ValveResponseTime(msec)=M+(F•V)
In this formula, M represents the average time in milliseconds (msec) for
the valve parts to move after the valve is energized. F is the average number
of milliseconds required for a flow of one standard cubic inch through the valve.
V is the number of cubic inches in the volume to be filled or exhausted.
The valve response time given by this formula is the average number of
milliseconds required to fill the volume V to 90 per cent of supply pressure, or
to exhaust the volume to 10 per cent of supply pressure. Response times will
be valid for any pressure in the range specified for the valve under "Standard
Specifications."
Note that F values are listed under two headings: "In-Out" and "Out-Exh."
The In-Out values are used to calculate fill times, and the Out-Exh. values are
used to calculate exhaust times.
SAMPLE PROBLEM. Using a ROSS double solenoid size 250 poppet valve,
how long will it take to fill a 250-cubic-inch chamber to 90% of supply pressure?
SOLUTION. The poppet valves are described on page 4 of this bulletin. From
the chart at the bottom of the page, we find that the response constants for a
size 250 valve are M = 20 and F = 0.54. Using these values in the response
time formula we have:
Valve Response Time (msec) = 20 + (0.54)(250)
= 20 + 135
= 155 msec
SERIES 80
Spool Valve Construction
The matched spool and sleeve used in each of these
valves is made of precision finished, hardened, stainless steel. The spool moves on a micro-inch film of air
between spool and sleeve so that wear is minimized.
For use in systems with or without air line lubrication.
Single Control. 5-port, 2-position (5/2) valves require
a maintained signal to keep the valve shifted. A spring
provides the return force after the signal is removed.
Double Momentary Control. 5-port, 2-position (5/2)
valves require only a momentary signal to shift the
valve in either direction. A mechanical detent keeps
the valve in its shifted position.
FLOW RATINGS
IMPORTANT NOTE. Widely different test standards are used by different
manufacturers in the determination of Cv ratings of valves. For this reason,
the Cv values given in the charts on pages 4, 5, and 6 should not be used in
comparing ROSS valves with those of other makers. These Cv values are
intended only for use with performance charts published by ROSS.
The Cv ratings in the charts on pages 4, 5, and 6 are averages for the various
flow paths through the valve and are for steady flow conditions.
PORT IDENTIFICATION
Ports on bases and in diagrams are designated by the following letters:
A: Outlet port
B: Outlet port
EA: Exhaust port (from port A)
EB: Exhaust port (from port B)
X: External pilot supply port
STANDARD SPECIFICATIONS (for valves on page 5):
Solenoids: AC or DC power. Rated for continuous duty.
Standard Voltages:
SAE Size 125, 250 models: 100-110 volts, 50 Hz; 100-120 volts, 60
Hz; 24 volts DC; 110 volts DC. For other voltages, consult ROSS.
SAE Size 500 models: 100-110 volts, 50 Hz; 100-120 volts, 60
Hz; 24 volts DC; 110 volts DC. For other voltages, consult ROSS.
Power Consumption: Each solenoid:
SAE Size 125, 250 models: 8 VA inrush; 6 VA holding on 50/60
Hz; 8 watts on DC.
P: Inlet port
SAE Size 500 models: 87 VA inrush; 30 VA holding on 50/60 Hz;
14 watts on DC.
Indicator Light: One for each solenoid.
Ambient Temperature: 40° to 120°F (4° to 50°C).
Media Temperature: 40° to 175°F (4° to 80°C).
Flow Media: Filtered air; 5 micron recommended.
Inlet Pressure: Vacuum to 150 psig (10 bar).
Pilot Pressure: At least 15 psig (1 bar).
Options: Pressure Controlled Valves–Interposed Pressure
Regulators.
Closed Center, Double Control. 5-port, 3-position
(5/3) valves require a maintained signal to shift the
valve in either direction from center. In the center
position all ports are closed.
Open Center, Double Control. 5-port, 3-position
(5/3) valves require a maintained signal to shift the
valve in either direction from center. In the center
position the outlet ports are connected to the exhaust
ports and the inlet port is closed.
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© 2012, ROSS CONTROLS®. All Rights Reserved.
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Series 80 Spool & Sleeve Valves for SAE Bases
5/2 Spool Valves
SAE Size 125
Single or Double Solenoid
SAE Size 250
B
Single or Double Solenoid
A
SAE Size 500
Single Solenoid
C
SAE Size 500
Double Solenoid
Valve Model Numbers (Base not included)
SAE Chrysler Wired 5-pin Chrysler Wired 5-pin Ford Wired 5-pin Chrysler Wired 5-pin Ford Wired 4-pin Avg.
Size micro-connector micro-connector mini-connector mini-connector Hardwire micro-connector C
(120 volts / 60 Hz) (24 Volts DC) (all voltages) (all voltages) (24 Volts DC)
Single Solenoid Pilot Valves
V
Note: For wiring
diagrams, see page 3.
125 8076C3311 8076C3321 8076C3331 8076C3341 8076C3351 8076C3361 1.4
250 8076C4311 8076C4321 8076C4331 8076C4341 8076C4351 8076C4361 4.0
500 8076B6311 8076B6321 8076B6331 8076B6341 8076B6351 8076B4361 8.2
Double Solenoid Pilot Valves
Single Solenoid
125 8076C3312 8076C3322 8076C3332 8076C3342 8076C3352 8076C3362 1.4
250 8076C4312 8076C4322 8076C4332 8076C4342 8076C4352 8076C4362 4.0
500 8076B6312 8076B6322 8076B6332 8076B6342 8076B6352 8076B6362 8.0
*Bases and manifolds on pages 7-9.
Double Solenoid
5/3 Spool Valves
SAE Size 125
Double Solenoid
SAE Size 250
Double Solenoid
SAE Size 500
Double Solenoid
Valve Model Numbers (Base not included)
SAE Chrysler Wired 5-pin Chrysler Wired 5-pin Ford Wired 5-pin Chrysler Wired 5-pin Ford Wired 4-pin Avg.
Size micro-connector micro-connector mini-connector mini-connector Hardwire micro-connector C
(120 volts / 60 Hz) (24 Volts DC) (all voltages) (all voltages) (24 Volts DC)
V
Power Center Solenoid Pilot Valves
125 – – 8077B3910 8077B3904 – – 1.4
250 – – 8077A4907 8077A4904 – – 4.0
Single Solenoid Pilot Valves
125 8077C3312 8077C3322 8077C3332 8077C3342 8077B3352 8077C3362 1.4
250 8077C4312 8077C4322 8077C4332 8077C4342 8077C4352 8077C4362 4.0
500 8077B6312 8077B6322 8077B6332 8077B6342 8077B6352 8077B6362 8.0
Closed Center Solenoid Pilot Valves
125 8077C3312 8077C3322 8077C3331 8077C3341 8077C3351 8077C3362 1.4
250 8077C4312 8077C4322 8077C4331 8077C4341 8077C4351 8077C4362 4.0
500 8077B6312 8077B6322 8077B6331 8077B6341 8077B6351 8077B6362 8.0
*Bases and manifolds on pages 7-9.
Measurements: Dimensions & Weights
5/3 Spool Valves
SAE Dimensions inches (mm) Weight
Size A B C lb (kg)
5/2 Spool Valves
SAE Dimensions inches (mm) Weight
Size
A B C lb (kg)
Single Solenoid Pilot Valves
125 5.5 (140) 1.8 (45) 5.1 (129) 3.5 (1.6)
250 7.3 (185) 2.6 (65) 5.6 (142) 6.5 (2.9)
500 10.1 (257) 3.0 (76) 4.8 (121) 8.3 (3.7)
Double Solenoid Pilot Valves
125 5.5 (140) 1.8 (45) 5.1 (129) 3.5 (1.6)
250 7.3 (185) 2.6 (65) 5.6 (142) 7.0 (3.2)
500 11.2 (285) 3.0 (76) 4.8 (121) 9.5 (4.3)
STANDARD SPECIFICATIONS: See page 4.
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Power Center Solenoid Pilot Valves
125 5.5 (140) 1.8 (45) 5.1 (129) 3.5 (1.6)
250 7.3 (185) 2.6 (65) 5.6 (142) 6.5 (2.9)
Open Center Solenoid Pilot Valves
125 5.5 (140) 1.8 (45) 5.1 (129) 3.5 (1.6)
250 7.3 (185) 2.6 (65) 5.6 (142) 7.0 (3.2)
500 12.0 (306) 3.0 (76) 4.8 (121) 9.5 (4.3)
Closed Center Solenoid Pilot Valves
125 5.5 (140) 1.8 (45) 5.1 (129) 3.5 (1.6)
250 7.3 (185) 2.6 (65) 5.6 (142) 7.0 (3.2)
500 12.0 (306) 3.0 (76) 4.8 (121) 9.5 (4.3)
Note: For wiring diagrams, see page 3.
Note: For wiring
diagrams, see page 3.
Power Center
Open Center
Closed Center
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