Rockford Systems DM2 D Series User manual

5795 Logistics Parkway • Rockford, Illinois 61109 • Toll-Free 1-800-922-7533 • Phone [phone] Fax
815-874-6144 • Web Site www.rockfordsystems.com • E-Mail [email protected]
Manual No. KSL-288
INSTALLATION MANUAL FOR
DM2SERIES D
DUAL-SOLENOID VALVES
IMPORTANT: PLEASE REVIEW THIS ENTIRE
PUBLICATION BEFORE INSTALLING, OPERATING
OR MAINTAINING THE AIR VALVE.

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SECTION 1—IN GENERAL ...................... 2-4
SECTION 2—OVERVIEW.........................5-6
SECTION 3—SPECIFICATIONS ...................7-8
SECTION 4—VALVE FUNCTION ..................9-10
SECTION 5—INSTALLATION ...................11-12
SECTION 6—PRELIMINARY INFORMATION..........13
SECTION 7—MAINTENANCE ......................14
SECTION 8—ORDERING INFORMATION ............15
SECTION 9—REPAIR KITS ........................16
SECTION 10—ORDER FORM FOR LITERATURE ......17
SECTION 11—RMA REQUEST FORM ...............17
DANGER
SECTION 1—IN GENERAL
Safety Precautions
DANGER indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
This safety alert symbol identies important safety messages in this
manual. When you see this symbol, be alert to the possibility of personal
injury, and carefully read the message that follows.
CAUTION used without the safety alert symbol indicates a potentially haz-
ardous situation which, if not avoided, may result in property damage.
CAUTION
Ecient and safe machine operation depends on the development, implementation and enforcement of a safety pro-
gram. This program requires, among other things, the proper selection of point-of-operation guards and safety devices
for each particular job or operation and a thorough safety training program for all machine personnel. This program
should include instruction on the proper operation of the machine, instruction on the point-of-operation guards and
safety devices on the machine, and a regularly scheduled inspection and maintenance program.
Rules and procedures covering each aspect of your safety program should be developed and published both in an
operator’s safety manual, as well as in prominent places throughout the plant and on each machine. Some rules or
instructions which must be conveyed to your personnel and incorporated in to your program include:
DANGER
Never place your hands or any part of your body in this machine.
Never operate this machine without proper eye, face and body protection.
Never operate this machine unless you are fully trained and instructed and unless you have
read the instruction manual.
Never operate this machine if it is not working properly—stop operating it and advise your supervisor
immediately.
Never use a foot switch to operate this machine unless a point-of-operation guard or device is provided
and properly maintained.
Never operate this machine unless two-hand trip, two-hand control or presence-sensing device is installed
at the proper safety distance. Consult your supervisor if you have any questions regarding the proper safety
distance.
Never tamper with, rewire or bypass any control or component on this machine.
A company’s safety program must involve everyone in the company, from top management to operators, since only as
a group can any operational problems be identied and resolved. It is everyone’s responsibility to implement and com-
municate the information and material contained in catalogs and instruction manuals to all persons involved in machine
operation. If a language barrier or insucient education would prevent a person from reading and understanding various
literature available, it should be translated, read or interpreted to the person, with assurance that it is understood.
FOR MAINTENANCE AND INSPECTION ALWAYS REFER TO THE OEM’S (ORIGINAL EQUIPMENT
MANUFACTURER’S) MAINTENANCE MANUAL OR OWNER’S MANUAL. If you do not have an owner’s
manual, please contact the original equipment manufacturer.
© 2019 Rockford Systems, LLC. All rights reserved. Not to be reproduced in whole or in part without written permission. Litho in U.S.A.
DM2Series D Dual-Solenoid Valves
TABLE OF CONTENTS

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(Continued on next page.)
Safety References
OSHA ACT AND FEDERAL REGULATIONS
Since the enclosed equipment can never overcome a me-
chanical deciency, defect or malfunction in the machine
itself, OSHA (Occupational Safety and Health Administra-
tion) has established certain safety regulations that the
employers (users) must comply with so that the machines
used in their plants, factories or facilities are thoroughly
inspected and are in rst-class operating condition before
any of the enclosed equipment is installed.
1. U.S. Government—An Act—Public Law 91-596,
91st Congress, S. 2193, December 29, 1970:
Duties
SEC. 5. (a) Each employer—
(1) shall furnish to each of his employees employ-
ment and a place of employment which are free
from recognized hazards that are causing or are
likely to cause death or serious physical harm to
his employees;
(2) shall comply with occupational safety and health
standards promulgated under this Act.
(b) Each employee shall comply with occupational
safety and health standards and all rules, regu-
lations, and orders issued pursuant to this Act
which are applicable to his own actions and con-
duct.
2. OSHA 29 CFR Sections that an employer (user)
must comply with include:
1910.211 Denitions.
1910.212 General requirements for all machines.
1910.217 Mechanical power presses.
1910.219 Mechanical power-transmission apparatus.
3. OSHA 29 CFR 1910.147 The control of hazardous
energy (lockout/tagout).
4. OSHA Publication
“General Industry Safety and Health Regulations Part
1910,” Code of Federal Regulations, Subpart O
This publication can be obtained by contacting:
U.S. Government Printing Oce
P.O. Box 371954
Pittsburgh, PA 15250-7954
Phone: [phone]
http://bookstore.gpo.gov
ANSI SAFETY STANDARDS FOR MACHINES
The most complete safety standards for machine tools
are published in the ANSI (American National Standards
Institute) B11 series. The following is a list of each ANSI
B11 Standard available at the printing of this publication.
B11–2008 General Safety Requirements
B11.1 Mechanical Power Presses
B11.2 Hydraulic Power Presses
B11.3 Power Press Brakes
B11.4 Shears
B11.5 Iron Workers
B11.6 Lathes
B11.7 Cold Headers and Cold Formers
B11.8 Drilling, Milling, and Boring Machines
B11.9 Grinding Machines
B11.10 Metal Sawing Machines
B11.11 Gear and Spline Cutting Machines
B11.12 Roll Forming and Roll Bending Machines
B11.13 Automatic Screw/Bar and Chucking Machines
B11.14 Withdrawn (Now see ANSI B11.18)
B11.15 Pipe, Tube and Shape Bending Machines
B11.16 Metal Powder Compacting Presses
B11.17 Horizontal Hydraulic Extrusion Presses
B11.18 Coil Processing Systems
B11.19 Performance Criteria for Safeguarding
B11.20 Integrated Manufacturing Systems
B11.21 Lasers
B11.22 CNC Turning Machines
B11.23 Machining Centers
B11.24 Transfer Machines
B11.TR1 Ergonomic Guidelines
B11.TR2 Mist Control Considerations
B11.TR3 Risk Assessment
B11.TR4 Programmable Electronic Systems (PES/PLC)
B11.TR5 Sound Level Measurement Guidelines
B11.TR7 Risk Assessment
R15.06 Robotic Safeguarding
B15.1 Mechanical Power Transmission Apparatus
B56.5 Guided Industrial Vehicles and Automated
Function of Manned Industrial Vehicles
B65.1 Printing Press Systems
B65.2 Binding and Finishing Systems
B65.5 Stand-Alone Patten Presses
B151.1 Horizontal (Plastic) Injection Molding Machines
B152.1 Hydraulic Die Casting Presses
B154.1 Rivet Setting Machines
B155.1 Packaging Machinery
01.1 Woodworking Machinery
These standards can be purchased by contacting:
ANSI—American National Standards Institute
25 West 43rd Street, 4th Floor
New York, New York 10036
Phone: [phone]
www.ansi.org
SECTION 1—IN GENERAL
DM2Series D Dual-Solenoid Valves

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WARRANTY
Rockford Systems, LLC warrants that this product will be free from defects in material and workmanship for a period
of 12 months from the date of shipment thereof. ROCKFORD SYSTEMS LLC’s OBLIGATION UNDER THIS WARRANTY
IS EXPRESSLY AND EXCLUSIVELY LIMITED to repairing or replacing such products which are returned to it within the
warranty period with shipping charges prepaid and which will be disclosed as defective upon examination by Rockford
Systems, LLC. This warranty will not apply to any product which will have been subject to misuse, negligence, accident,
restriction and use not in accordance with Rockford Systems, LLC’s instructions or which will have been altered or
repaired by persons other than the authorized agent or employees of Rockford Systems, LLC. Rockford Systems, LLC’s
warranties as to any component part is expressly limited to that of the manufacturer of the component part.
Warranty, Disclaimer and Limitation of Liability
LIMITATION OF LIABILITY
Under no circumstances, including any claim of negligence,
strict liability, or otherwise, shall Rockford Systems, LLC be li-
able for any incidental or consequential damages, or any loss
or damage resulting from a defect in the product of Rockford
Systems, LLC.
DISCLAIMER
The foregoing Warranty is made in lieu of all other warranties,
expressed or implied, and of all other liabilities and obligations
on the part of Rockford Systems, LLC, including any liability for
negligence, strict liability, or otherwise, and any implied warranty
of merchantability or tness for a particular purpose is expressly
disclaimed.
NATIONAL SAFETY COUNCIL SAFETY MANUALS
Other good references for safety on machine tools are the
National Safety Council’s Safety Manuals. These manu-
als are written by various committees including the Power
Press, Forging and Fabricating Executive Committee.
Copies of the following publications are available from
their library:
• Power Press Safety Manual - 5th Edition
• Safeguarding Concepts Illustrated - 7th Edition
• Forging Safety Manual
These manuals can be obtained by contacting:
National Safety Council
1121 Spring Lake Drive
Itasca, IL 60143-3201
1-800-621-7615
www.nsc.org
OTHER SAFETY SOURCES
National Institute of Occupational Safety and Health
(NIOSH)
4676 Columbia Parkway
Cincinnati, OH 45226
Toll-Free: 1-800-35-NIOSH (1-800-356-4674)
Phone: [phone]
www.cdc.gov/niosh
OTHER SAFETY SOURCES (CONTINUED)
Robotic Industries Association (RIA)
900 Victors Way, Suite 140
P.O. Box 3724
Ann Arbor, MI 48106
Phone: [phone]
www.roboticsonline.com
NEMA (National Electrical Manufacturers
Association)
1300 North 17th Street, Suite 1847
Rosslyn, VA 22209
Phone: [phone]
www.nema.org
NFPA (National Fire Protection Association)
1 Batterymarch Park
Quincy, MA 02269-9101
Phone: [phone]
www.nfpa.org
For additional safety information and assistance in devis-
ing, implementing or revising your safety program, please
contact the machine manufacturer, your state and local
safety councils, insurance carriers, national trade asso-
ciations and your state’s occupational safety and health
administration.
SECTION 1—IN GENERAL
DM2Series D Dual-Solenoid Valves

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DM2Series D Dual-Solenoid Valves
SECTION 2—OVERVIEW
INTRODUCTION
Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and
brake mechanism must use a press control dual-solenoid valve with a monitoring device. The consensus requirements
of the regulations and good safety practices require that, in case of a failure within the valve, the clutch and brake
mechanisms be quickly exhausted, a monitor takes action to prevent further operation, and a method to alert person-
nel is incorporated.
The DM2 Series D dual-solenoid valve has two valve elements independently controlled by two solenoid pilots. The two
valve elements share common inlet, outlet, and exhaust ports. When the pilot valves are simultaneously energized, the
valve elements operate so that the valve functions as a 3/2 normally closed valve. If the valve elements fail to move
simultaneously, the dynamic monitoring of the valve detects this failure and thereby exhausts downstream air, locks
out the valve, and prohibits further operation. When a valve lockout occurs, the valve will retain the fault information
regardless of air or electrical changes. The system can only be reset by a dened operation/procedure, and will not self
reset (turn o and on), or reset when inlet air supply is removed and re-applied.
Valve element redundancy provides an additional safety factor, as the likelihood of a malfunction in both valve elements
in the same cycle is considered extremely remote. Therefore, a lockout condition is not necessarily an indication that
the valve has become faulty; rather, it is an indication that the monitor has detected nonsimultaneous movement of the
main valve elements, and that there is a condition in the system that needs correction.
For safety reasons, do not install any pneumatic devices between the valve and the clutch/brake or air cylinder,
including quick-dump valves.
If both valves fail simultaneously on the same stroke (cycle), this valve will not prevent a repeat stroke.
Never place the hands or any body part in the point of operation of this press at any time, for any reason.

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SECTION 2—OVERVIEW
DM2Series D Dual-Solenoid Valves
Valve Sizes
DM2Series D dual-solenoid valves are available in five sizes, providing a broad range
of flow capabilities. For convenience, valves are designated by the nominal sizes 2, 4,
8, 12, and 30 with outlet ports ranging from 1/4 " to 2".
Simplified Schematic
Sizes 2, 4, 8, 12 and 30
•DynamicMonitoringWithCompleteMemory—Memory, monitoring, and air flow
control functions are simply integrated into two identical valve elements. Valves
lock out due to asynchronous movement of valve elements during actuation or de-
actuation, resulting in a residual outlet pressure of less than 1% of supply. Overt
action is required for reset–cannot be reset by removing and re-applying supply
pressure. Reset can only be accomplished by remote air signal, optional
electricalsolenoidresetsignal,oroptionalmanualreset.
•Basic3/2NormallyClosedValveFunction—Dirt tolerant, wear compensating poppet
design for quick response and high flow capacity. Teflon back-up rings on pistons to
enhance valve endurance–operates with or without inline lubrication.
•StatusIndicator(Optional)—Includes a pressure switch with both normally open
and normally closed contacts to provide status feedback to the press control system
indicating whether the valve is in the lockout or ready-to-run condition. The status
indicator can be ordered installed or purchased separately and added to any DM2
Series D base.
•Silencers—All models include high-flow, clog-resistant silencers.
•Mounting—Base mounted with NPT pipe threads. Inlet and outlet ports on both
sides provide for flexible piping. Plugs for unused ports are included.
Sizes 12 and 30
•Intermediate Pilots—Increases pilot air flow for fast valve response, making it
possible to use the same size solenoids as valve sizes 2, 4, and 8, thereby reducing
electrical power requirements for these larger valves.
Size8
Size30
SelfMonitored-Clutch/BrakeControl
Size2
Size12
Size4
Features
•Base mounted
•Highly contaminant tolerant poppet construction
•High flow, clog-resistant silencers
•Provides redundancy, dynamic monitoring and memory for the mechanical
press industry regarding the control of pneumatically controlled clutch and brake
applications

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DM2Series D Dual-Solenoid Valves
SECTION 3—SPECIFICATIONS
DIMENSIONS DIMENSIONS– inches (mm)
SIZE 4
1/2 " inlet–1/2 " outlet
1/2 " inlet–3/4 " outlet
View X
(Base mounting hole pattern)
Valveenvelope
(Based in overall hole dimnsions at left.)
With
SIZE 2
1/4 "inlet–1/4 " outlet
3/8 " inlet–3/8 " outlet
2.99
(75.9)
View X
(Base mounting hole pattern)
Valve envelope
(Based in overall hole dimnsions at left.)
0.22 (5.6)
(4 places)
4.00 (101.6)
4.00 (101.6)
0.25
(6.4)
2.04
(51.9)
4.79 (121.6)
1.19
(30.2)
0.82
(20.9)
1.37
(34.9)
9.99
(253.8)
With Status
Indicator
4.50 (114.3)
4.00 (101.6)
0.25
(6.4)
7.73
(196.4)
2.99
(75.9)
2.04
(51.9)
0.64 (16.3)
With Solenoid Reset
10.63
(270.0)
With Status
Indicator &
Solenoid Reset
0.64
(16.2)
CV:
1 to 2: 2.17
2 to 3: 3.66
CV:
1 to 2: 2.80
2 to 3: 6.70
SIZE 8
3/4 " inlet–3/4 " outlet
1" inlet–1" outlet
View X
(Base mounting hole pattern)
Valve envelope
(Based in overall hole dimnsions at left.)
With
View X
(Base mounting hole pattern)
Valve envelope
(Based in overall hole dimnsions at left.)
With
CV:
1 to 2: 4.63
2 to 3: 12.55

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DM2Series D Dual-Solenoid Valves
SECTION 3—SPECIFICATIONS
SIZE 30
11/2 " outlet–2" outlet
SIZE 12
1" inlet–1" outlet
1" inlet–11/2 "outlet
View X
(Base mounting hole pattern)
Valve envelope
(Based in overall hole dimnsions at left.)
12.61
(320.23)
With Pressure
Switch
11.27
(286.26)
View X
(Base mounting hole pattern)
Valve envelope
(Based in overall hole dimnsions at left.)
12.61
(320.23)
With Pressure
Switch
11.27
(286.26)
View X
(Base mounting hole pattern)
Valve envelope
(Based in overall hole dimnsions at left.)
12.61
(320.23)
With Pressure
Switch
11.27
(286.26)
View X
(Base mounting hole pattern)
Valve envelope
(Based in overall hole dimnsions at left.)
14.25
(361.98)
15.48
(393.14)
With Pressure
Switch
View X
(Base mounting hole pattern)
Valve envelope
(Based in overall hole dimnsions at left.)
14.25
(361.98)
15.48
(393.14)
With Pressure
Switch
View X
(Base mounting hole pattern)
Valve envelope
(Based in overall hole dimnsions at left.)
14.25
(361.98)
15.48
(393.14)
With Pressure
Switch
DIMENSIONS–inches (mm)
CV:
1 to 2: 8.86
2 to 3: 20.78
CV:
1 to 2: 20.22
2 to 3: 53.68
STANDARD SPECIFICATIONS
Pilot Solenoids—According to VDE 0580. Enclosure rating ac-
cording to DIN 40050, IEC 60529 IP65. Two solenoids, rated for
continuous duty (additional solenoid on optional reset).
Standard Voltages—24 volts DC; 110 volts AC, 50/60 Hz.
Power Consumption (each solenoid)
Sizes 2, 4, 12, 30—For primary and reset solenoids
6.0 watts on DC; 15.8 VA inrush and 10.4 VA holding on AC.
Size 8—Primary solenoids:
15 watts on DC; 36 VA inrush and 24.6 VA holding on AC.
Reset solenoid:
6.0 watts on DC; 15.8 VA inrush and 10.4 VA holding on AC.
Electrical connection—DIN 43650, Form A.
Ambient Temperature—15° to 120°F (-10° to 50°C).
Media Temperature—40° to 175°F (4° to 80°C).
Flow Media—Filtered, lubricated or unlubricated (mineral oils
according to DIN 51519, viscosity classes 32-46); 5-micron
recommended.
Inlet Pressure— Size 2: 45 to 150 psig (3.1 to 10.3 bar).
Sizes 4, 8, 12, 30: 30 to 120 psig (2.1 to 8.3 bar).
Reset Pressure—For remote air reset option–must be equal to
inlet pressure.
Manual Pressure—Encapsulated, push button actuation.
Pressure Switch (Status Indicator) Rating—Contacts–5 amps
@ 250 volts AC, or 5 amps @ 30 volts DC.
Monitoring—Dynamically, cyclically, internally during each ac-
tuating and de-actuating movement. Monitoring function has
memory and requires an overt act to reset unit after lockout.
Mounting orientation—Preferably horizontally (valve on top of
base) or vertically (with pilot solenoids on top).
Port Threads—NPT
Functional Safety Data—Category 4 PL e; B10d: 20,000,000;
PFH: 7.71x10-9; MTTFd: 301.9 (nop: 662400).
Certications—CE Marked for applicable directives, BG, CSA/
UL, TSSA for appropriately tested valves.
Vibration/Impact Resistance—Tested to BS EN 60068-2-27.
Valve Weight—Valve and base assembly with status indicator
and solenoid reset:
Size 2: 5.0 lb (2.3 kg)
Size 4: 6.0 lb (2.8 kg)
Size 8: 9.1 lb (4.2 kg)
Size 12: 15.5 lb (7.1 kg)
Size 30: 32.6 lb (14.8 kg)

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DM2Series D Dual-Solenoid Valves
SECTION 4—VALVE FUNCTION
Optional reset solenoid valve
Optional Status Indicator
VALVE SCHEMATIC
EXHAUST
OUTLET
INLET
AB
Pilot Valve B Pilot Valve A
Pilot supply/timing chamber A
Piston
Outlet chamber
Inlet poppet
Timing orifice
Flow restrictor
Reset piston
Exhaust chamber
Exhaust poppet
Crossover passages
Inlet chamber
Spring stop
Return spring
Reset poppet
MAIN VALVE INTERNALS

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DM2Series D Dual-Solenoid Valves
SECTION 4—VALVE FUNCTION
E
X
H
A
U
S
S
T
T
T
T
T
T
T
T
INLET
O
U
T
L
E
T
EXHAUST
OUTLET
INLET
AB
EXHAU
S
S
T
T
T
T
T
T
T
T
I
N
L
E
T
O
U
T
L
E
T
EXHAUST
OUTLET
INLET
AB
AB
E
X
H
A
U
S
S
T
T
T
T
T
T
T
T
INL
E
T
O
U
T
L
E
T
EXHAUST
OUTLET
INLET
AB
Status indicator (optional)
in normal ready-to-run position
Size 12 & 30 pilots
VALVE DE-ACTUATED (READY-TO-RUN)
The ow of inlet air pressure into the
crossover passages is restricted by
the size of the passage between the
stem and the valve body opening.
Flow is sucient to quickly pres-
surize pilot supply/timing chambers
A and B. The inlet poppets prevent
air ow from crossover passages
into the outlet chamber. Air pressure
acting on the inlet poppets and re-
turn pistons securely hold the valve
elements in the closed position. (Air
passages shown out of position and
reset adapter omitted for clarity.)
VALVE ACTUATED
Energizing the pilot valves simul-
taneously applies pressure to both
pistons, forcing the internal parts to
move to their actuated (open) posi-
tion, where inlet air ow to crossover
passages is fully open, inlet poppets
are fully open and exhaust poppets
are fully closed. The outlet is then
quickly pressurized, and pressure in
the inlet, crossovers, outlet, and tim-
ing chambers is quickly equalized.
De-energizing the pilots quickly
causes the valve elements to return
to the ready-to-run position.
VALVE LOCKED OUT
Whenever the valve elements operate in a suciently asynchronous manner, either on actuation or
de-actuation, the valve will move to a locked out position. In the locked out position, one crossover
and its related timing chamber will be exhausted, and the other crossover and its related timing cham-
ber will be fully pressurized. The valve element (side B) that is partially actuated has pilot air available
to fully actuate it, but no air pressure on the return piston to fully de-actuate the valve element. Air
pressure in the crossover acts on the dierential of side B stem diameters creating a latching force.
Side A is in a fully closed position, and has no pilot air available to actuate, but has full pressure on
the inlet poppet and return piston to hold the element in the fully closed position.
Inlet air ow on side A into its crossover is restricted, and ows through the open inlet poppet on side
B, through the outlet into the exhaust port, and from the exhaust port to atmosphere. Residual pres-
sure in the outlet is less than 1% of inlet pressure.
The return springs are limited in travel, and can only return the valve elements to the intermediate
(locked out) position. Sucient air pressure acting on the return pistons is needed to return the valve
elements to a fully closed position.
RESETTING THE VALVE
The valve will remain in the locked out position, even if the inlet air supply is removed and re-applied. A
remote reset signal (air or electric), or a manual push button actuation must be applied to reset the valve.
Reset is accomplished by momentarily pressurizing the reset port. Actuation of the reset piston physi-
cally pushes the main valve elements to their closed position. Inlet air fully pressurizes the crossovers
and holds the inlet poppets on seat. Actuation of the reset piston opens the reset poppet, thereby,
immediately exhausting pilot supply air, thus, preventing valve operation during reset. (Reset adapter
added to illustration.)
De-actuation of reset pistons causes the reset poppets to close and pilot supply to fully pressurize.
Reset air pressure can be applied by a remote 3/2 normally closed valve, or from an optional 3/2 nor-
mally closed solenoid, or a manual push button mounted on the reset adapter.
STATUS INDICATOR
The status indicator pressure switch will actuate when the main valve is op-
erating normally, and will de-actuate when the main valve is in the locked
out position or inlet pressure is removed. This device is not part of the valve
lockout function, but, rather, only reports the status of the main valve.
Size 12 and 30 valves require relatively large pilots to actuate and de-actuate
the main valve elements. In order to achieve extremely quick valve response
for such large pilots, a two-stage solenoid pilot system is incorporated into
the design. This keeps the electrical current required to operate the pilots to
a minimum.
Valve ready-to-run Valve actuated
Valve locked out
EXHAUST
OUTLET
INLET
AB
Resetting the valve

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DM2Series D Dual-Solenoid Valves
SECTION 5—INSTALLATION
Pressure Regulator
Clutch and
Brake
Combination
Filter and
Water Separator
Pressure Gauge
Volume
DM2Series D Duel-Solenoid Valve
(Status Indicator – Optional)
Lubricator
Lockout Valve
Air Lines—Before installing this valve in a new or existing sys-
tem, the air lines must be blown clean of all contaminants. It is
recommended that a 5-micron-rated air lter 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 have any restrictions (e.g., a crimp in the line,
a sharp bend, or a clogged lter element). The air supply must
not only provide sucient pressure (see standard specica-
tions, page 8), but must also provide an adequate ow 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 restrictions (e.g., a crimp in the line,
a sharp bend, or a clogged lter element).
Valve Exhaust (Port 3)—Do not restrict the air ow from the ex-
haust port as this can adversely aect the operation of the valve.
The valves are factory equipped with a properly sized muer.
Only the muer furnished should be used.
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 restrictions (e.g., a crimp in the
line, a sharp bend, or a clogged lter element). Reset signals
must be momentary.
Electrical Supply—DM2 Series D dual-solenoid valves get elec-
trical power through plug-in connectors. The electrical supply
must correspond to the voltage and Hertz ratings of the sole-
noids. Otherwise, the solenoids are subject to early failure. If
power is supplied by a transformer, it must be capable of han-
dling the inrush current without signicant voltage drop. See
standard specications on page 8 for inrush current data.
Operating Pressures and Temperatures—Allowable ranges
for pressure and temperatures are given in the standard speci-
cations on page 8. Exceeding these values can adversely aect
performance and shorten valve life.
Pipe Installation—To install pipe in base ports, engage the pipe by
one turn, then 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—Always perform a test procedure after installation
and/or repair prior to normal use. Observe normal press op-
eration 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.
Test Procedure—
1. 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.
2. Energize both solenoids and the valve should remain in the
lockout condition.
3. De-energize both pilot solenoids and reset the valve.
4. Electrically energize both pilot solenoids simultaneously
again. De-energize the other pilot solenoid this time. Again,
this should result in a lockout.
5. Energize both pilot solenoids. The valve should remain in a
lockout condition.
6. De-energize both pilot solenoids and then reset the valve.
After satisfying these tests, energizing both pilot solenoids si-
multaneously should result in normal operation.
Fault Indication—If fault indication is desired, Rockford Systems,
LLC oers a status indicator option that can be used to signal to
the press controls that a fault has occurred. The status indicator uti-
lizes a pressure switch. The pressure switch has four electrical con-
tacts. During normal operation, the pressure switch is pressurized.
A lockout condition depressurizes the switch until the valve is re-
set. Contacts 1 and 2 are closed when the switch is depressur-
ized (normally closed) and contacts 1 and 3 are closed when an
adequate pressure signal is applied to the switch (normally open).
Please read and make sure you understand all installation instructions before proceeding with the installation.
INSTALLATION CONSIDERATIONS
Pneumatic equipment should be installed only by persons trained and experienced in such installation.
The exhaust air muer must be kept clean at all times. Never operate the machine unless the muer is clean. The
muer must be cleaned on a regular basis.

12
Rockford Systems, LLC—www.rockfordsystems.com
Call: 1-800-922-7533
DM2Series D Dual-Solenoid Valves
SECTION 5 —INSTALLATION
ELECTRICAL CONSIDERATIONS
DIN Connectors
Each DM2 Series D dual-solenoid valve is furnished with two 3-pin DIN connectors for electrical connection to the pilot solenoids.
See page 15 for replacement connectors and/or for electrical connectors with a light and translucent housing to serve as indicator
lights.
WIRING
Pilot Solenoids—Should be red simultaneously from separate channels to operate the valve normally.
Status Indicator (Pressure Switch) Terminal Designations
Terminal 1 - common
Terminal 2 - N.C. (normally closed) contact (N.O. contact held closed with normal operation and inlet pressure within specications)
Terminal 3 - N.O. (normally open) contact (N.C. contact held open with normal operation and inlet pressure within specications)
Ground symbol terminal - not used
Terminals 1 and 3 are connected when air pressure is present and the valve is ready-to-run. If a fault has occurred or pressure is
removed from the valve inlet, terminals 1 and 2 are connected.
Pilot Solenoid
A
Signal A Common
Status Indicator
(pressure switch)
4
3
2 1
Pilot Solenoid
B
Signal B Common
Reset
Solenoid
Reset Signal Common
Pin 1: Common
Pin 2: Normally Closed
Pin 3: Normally Open
Pin 4: Not Used
Note—In the event of a fault, remove power from pilot solenoids A & B, then momentarily energize the reset solenoid to return the
valve to the ready-to-run state. Wait at least 250 ms after removing power from the reset solenoid before trying to re-energize the
pilot solenoids.
Pilot Solenoid
A
Signal A Common
Status Indicator
(pressure switch)
4
3
2 1
Pilot Solenoid
B
Signal B Common
Reset
Solenoid
Reset Signal Common

13
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DM2Series D Dual-Solenoid Valves
SECTION 6—PRELIMINARY INFORMATION
STARTUP
Before startup, the installation must be checked thoroughly by persons trained and experienced in the operation of pneumatic
equipment. Make sure that specifications given on the valve label (e.g. max. operating pressure and electrical characteristics)
will be in accordance with the operating specifications of the press. When operating pressure is initially applied, it may be
necessary to actuate the reset valve momentarily to move the main valve into the ready-to-run condition. Make sure that the
inlet supply and the exhaust path are not restricted. Operating pressure must comply with the minimum and maximum limits.
FUNCTIONAL TEST
Test Result
1. Solenoid A actuated Valve moves into lockout mode, slight leakage at exhaust port 3
2. Solenoid B actuated Valve moves into lockout mode, slight leakage at exhaust port 3
3. Solenoids A and B actuated with Valve operates properly
Dt < 0.1 s
4. Solenoids A and B actuated with Valve moves into lockout mode, slight leakage at exhaust port 3
Dt > 0.1 s
5. After lockout, permanent signal on Valve cannot be moved into ready-to-run mode
reset valve–solenoids A and B
or only A/only B actuated
PRESSURE TEST
After a valve lockout, the dual-solenoid valve must be moved
into the ready-to-run position by using the reset valve. In gen-
eral, if the valve is in the lockout mode and one or both of the
solenoids are energized, the valve should not reset with applica-
tion or application and removal of the reset signal. If the valve
is in the ready-to-run mode after the reset solenoid valve has
been actuated momentarily, the valve will function normally with
application and removal of pilot solenoid signal. However, if the
valve elements cycle asynchronously, the valve will go to the
lockout mode. Provided that both solenoids are de-energized,
removal of reset signal will return the valve to the ready-to-run
mode.
An additional test to perform:
• With the valve in the ready-to-run mode, exhaust and re-
pressurize the inlet port. The valve should remain in the
ready-to-run mode.
• With the valve in the lockout mode, exhaust and re-pres-
surize the inlet port. The valve should remain in the lockout
mode.
LOCKOUTS
Any asynchronous movement between both piston elements for
a time period > 0.1 s will result in a lockout of the valve. This can
be due to one or more of the various causes below:
• worn piston seals
• delayed response of the main valve elements due to dirt or
varnished lubricant
• electrical signals to solenoid incomplete or unable to main-
tain proper voltage
• independent electrical signals to solenoids are not received
concurrently
• delayed response of solenoid pilots or booster pilots due to
damaged components, dirt, or varnished lubricant
• collection of excessive water or lubrication
MAINTENANCE, TESTING
Maintenance and testing procedures must follow the rules and
regulations set by the respective national work-safety institu-
tions. These procedures should only be performed by persons
trained and experienced in the use of pneumatic equipment.
Regulations generally require that maintenance and test proce-
dures be performed at least once a year.
REPAIR
Rockford Systems, LLC would be happy to service this special-
ized dual-solenoid valve for you at its factory repair center. Call
1-800-922-7533 for information. If you service the valve your-
self, be sure to turn o electrical power to the valve, shut o the
air supply, exhaust the air in the system, and lockout all power
sources before beginning any disassembly operation. Custom-
ers maintaining their own valves should make sure that only
original spare parts are used.
Pneumatic equipment should be repaired only by
persons trained and experienced in the repairing
of such equipment, guided by these operating in-
structions. Information about valve repair and/or
the exchange of a valve must be written down in
the machine operation documentation.

14
Rockford Systems, LLC—www.rockfordsystems.com
Call: 1-800-922-7533
DM2Series D Dual-Solenoid Valves
SECTION 7—MAINTENANCE
Supply Clean Air—Foreign material lodging in valves is a ma-
jor cause of breakdowns. The use of a 5-micron-rated air lter
located close to the valve is strongly recommended. The l-
ter bowl should be drained regularly, and if its location makes
draining dicult, the lter should be equipped with an automatic
drain.
Check Lubricator Supply Rate—A lubricator should put a ne
oil mist into the air line in direct proportion to the rate of air ow.
Excessive lubrication can cause puddling in the valve and lead
to malfunctions. For most applications an oil ow rate in the lu-
bricator of one drop per minute is adequate. Note that the dual-
solenoid 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 below. These oils, although be-
lieved to be compatible, could change without notice because
manufacturers sometimes reformulate their oils. Therefore, use
oils specically compounded for air line service. If it is a synthet-
ic oil, contact the oil manufacturer for compatibility information.
Cleaning the Valve—If the air supplied to the valve has not
been well ltered, the interior of the valve may accumulate dirt
and varnish which can aect the valve’s performance.
A schedule should be established for cleaning all valves, the fre-
quency depending on the cleanliness of the air being supplied.
To clean the valve, use any good commercial solvent. Do not
scrape varnished surfaces. 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 o the electrical power to the valve, shut o the air supply,
exhaust the air in the system, and lock out before beginning any
disassembly operation. See page 16 for repair kits.
Maker Brand Name
Amoco .................... American Industrial Oil 32
Amoco Spindle Oil C
Amolite 32
Citgo ....................... Pacemaker 32
Exxon ...................... Spinesstic 22
Teresstic 32
Mobil ....................... Velocite 10
Non-Fluid Oil .......... Air Lube 10H/NR
Shell ........................ Turbo T32
Sun ......................... Sunvis 11
Sunvis 722
Texaco .................... Regal R&O 32
Union ...................... Union Turbine Oil
COMPATIBLE LUBRICANTS
Pneumatic equipment should be maintained only by persons trained and experienced in the maintenance of such
equipment.
After any maintenance, always operate the machine numerous times in all modes of operation before allowing
the operator to start production. Always make sure all point-of-operation safeguarding is in place, adjusted and
operating properly for the job and the operator.

15
Rockford Systems, LLC—www.rockfordsystems.com
Call: 1-800-922-7533
DM2Series D Dual-Solenoid Valves
SECTION 8—ORDERING INFORMATION
COMPLETE DM2SERIES D DUAL-SOLENOID VALVES*
REPLACEMENT PARTS/ACCESSORIES
STATUS INDICATOR—RCY-319
The status indicator pressure switch actu-
ates when the valve is in a ready-to-run
condition and de-actuates when the valve is
in a lockout condition or when the inlet air
pressure has been removed. Although the
valves can be purchased with this option al-
ready installed, the status indicator can be
purchased separately. This includes a 4-pin
DIN connector (without cable) that can be
eld wired.
RESET VALVES FOR MODELS WITH REMOTE RESET
Dual valves with an electrical reset require a direct solenoid con-
trol, base, and electric reset pushbutton.
Part No. RCY-317-110—Direct Solenoid Control (110 VAC)
Part No. RCY-317-24—Direct Solenoid Control (24 VDC)
Part No. RCY-318—Base
Part No. LLD-1172—Electric Reset Pushbutton
RCY-317
RCY-318
LLD-1172
ELECTRICAL CONNECTORS
Electrical connectors are required to connect
the valve solenoids to the drop cords supply-
ing electrical power.
Each 3-pin DIN connector can be positioned
so that the cord exits upward or to the side.
Cords of 6mm to 10mm diameter can be used
(not included). Connectors with a light in a translucent housing
are also available to serve as indicator lights.
Part No. RCY-315—Electrical Connector
Part No. RCY-316-110—Electrical Connector W/Light (110 VAC)
Part No. RCY-316-24—Electrical Connector W/Light (24 VDC)
AIR PUSHBUTTON RESET—RCD-055
Dual valves with remote reset
require a small reset valve and
the installation of a 1/8 line from
the reset valve to the reset port.
This air pushbutton is suitable
for this purpose
CAUTION
Do not use electrical connectors with surge suppressors, as this may increase valve response time when
de-actuating the solenoids.
*Two RCY-315 electrical connectors supplied with each dual-solenoid valve.
Cross Ref.
Item Number Size Description Part Numbers
110VAC 24VDC
RCL-528 12 1” dual sol valve w/ sol reset w/ electric reset pushbutton & status indicator RCL-628 RCL-728
RCL-532 41/2 " dual sol valve w/ sol reset w/ electric reset pushbutton & status indicator RCL-632 RCL-732
RCL-535 30 11/2 " dual sol valve w/ sol reset w/ electric reset pushbutton & status indicator RCL-635 RCL-735
RCL-551 41/2 " dual sol valve RCL-651 RCL-751
RCL-552 41/2 " dual sol valve & status indicator RCL-652 RCL-752
RCL-553 41/2 " in 3/4 " out dual sol valve RCL-653 RCL-753
RCL-554 41/2 " in 3/4 " out dual sol valve w/ status indicator RCL-654 RCL-754
RCL-555 81" dual sol valve remote w/ air pushbutton reset RCL-655 RCL-755
RCL-556 81" dual sol valve remote w/ air pushbutton reset & status indicator RCL-656 RCL-756
RCL-557 30 11/2 " in 2" out dual sol valve remote w/ air pushbutton reset RCL-657 RCL-757
RCL-558 30 11/2 " in 2" out dual sol valve remote w/ air pushbutton reset & status indicator RCL-658 RCL-758
RCL-559 81" dual sol valve w/ remote reset RCL-659 RCL-759
RCL-560 81" dual sol valve w/ remote reset & status indicator RCL-660 RCL-760
RCL-561 30 11/2 " in 2" out sol valve w/ remote reset RCL-661 RCL-761
RCL-562 30 11/2 " in 2" out sol valve w/ remote reset & status indicator RCL-662 RCL-762
RCL-570 21/4 " dual sol valve RCL-670 RCL-770
N/A 12 1" dual sol valve RCL-676 RCL-776

16
Rockford Systems, LLC—www.rockfordsystems.com
Call: 1-800-922-7533
DM2Series D Dual-Solenoid Valves
SECTION 9—REPAIR KITS
REPAIR KITS
SIZES 2, 4 & 8
1/4 " inlet–1/4 " outlet
3/8 " inlet–3/8 " outlet
1/2 " inlet–1/2 " outlet
1/2 " inlet–3/4 " outlet
3/4 " inlet–3/4 " outlet
1" inlet–1" outlet
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
C E
A
A
A
A
A
DB
Reset port - ₈
(remote reset models)
SIZES 12 & 30
1" inlet–1" outlet
1" inlet–11/2 " outlet
11/2 " inlet–2" outlet
Reset port - ₈
(remote reset models)
A
D
A
A
A
A
A
F
B
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A A
A
A
A
E
C
Example: RCY-310-24 for solenoid coil reset with 24VDC
Item Description Size 2 Size 4 Size 8 Size 12 Size 30 110VAC 24VDC
AValve body service kit RCY-300 RCY-301 RCY-302 RCY-303 RCY-304 n/a n/a
BComplete primary solenoid pilot RCY-305 RCY-306 RCY-307 RCY-308 RCY-308 -110 -24
CComplete reset solenoid pilot RCY-309 RCY-309 RCY-309 RCY-309 RCY-309 -110 -24
DSolenoid coil – pilots RCY-310 RCY-310 RCY-314 RCY-310 RCY-310 -110 -24
ESolenoid coil reset RCY-310 RCY-310 RCY-310 RCY-310 RCY-310 -110 -24
FPilot booster service kit – – – RCY-311 RCY-311 -110 -24
Not shown Status indicator assembly kit RCL-312 RCL-312 RCL-312 RCL-312 RCL-312 n/a n/a
Not Shown Replacement pressure switch RCL-313 RCL-313 RCL-313 RCL-313 RCL-313 n/a n/a
Add voltage
modier to part no.
Specify -110 for 110VAC or -24 for 24VDC when ordering part numbers in gray.

17
Rockford Systems, LLC—www.rockfordsystems.com
Call: 1-800-922-7533
DM2Series D Dual-Solenoid Valves
SECTION 10—ORDER FORM FOR LITERATURE
SECTION 11—RETURN MATERIALS AUTHORIZATION REQUEST FORM
SECTION 10—ORDER FORM FOR LITERATURE
To return material for any reason contact our sales department at 1-800-922-7533 for an RMA Number. All returned mate-
rials shipments must be prepaid. Complete this form and send with material to Rockford Systems, LLC, 4620 Hydraulic
Road, Rockford, IL 61109-2695. Make sure the RMA Number is plainly identified on the outside of the shipping container.
Company
Address
City State Zip
Phone Fax
Contact Name Representative
Items Authorized To Return on RMA No. Original Invoice No. Date
Part No. Serial No. Description
Service Requested Full Credit 25% Restocking Repair & Return Warranty Replacement
Reason for return (describe in detail):
Return Materials Authorized By Date
This instruction manual references signs and literature available for your machines. This order form is for your conve-
nience to order additional signs and/or literature as needed. (This order form is part of your installation manual so
please make a copy of it when ordering.)
Company
Address
City State Zip
Phone Fax
Name Purchase Order No. Date
Part No. Description Quantity Required
KSL-288 Installation Manual for DM² Series D Dual-Solenoid Valves
KSL-051 Booklet - Mechanical Power Press Safety (MPPS)
CNTRLS Catalog - Press and Press Brake Control Systems
SFM Catalog - Shields For Machinery
For prices and delivery, please use address, phone or fax number listed on the front cover of this manual.
Your Signature Date
SECTION 11—RETURN MATERIALS AUTHORIZATION REQUEST FORM
SECTION 10—ORDER FORM FOR LITERATURE
Toreturn material for any reason contact our sales department at 1-800-922-7533 for an RMA Number. All returned
mate-rials shipments must be prepaid. Complete this form and send with material to Rockford Systems, LLC, 5795
Logistics Parkway, Rockford, IL 61109. Make sure the RMA Number is plainly identified on the outside of the shipping
container.
Company
Address
City State Zip
Phone Fax
Contact Name Representative
Items Authorized To Return on RMA No. Original Invoice No. Date
Part No. Serial No. Description
Service Requested Full Credit 25% Restocking Repair & Return Warranty Replacement
Reason for return (describe in detail):
Return Materials Authorized By Date
This instruction manual references signs and literature available for your machines. This order form is for your conve-
nience to order additional signs and/or literature as needed. (This order form is part of your installation manual so
please make a copy of it when ordering.)
Company
Address
City State Zip
Phone Fax
Name Purchase Order No. Date
Part No. Description Quantity Required
KSL-288 Installation Manual for DM² Series D Dual-Solenoid Valves
KSL-051 Booklet - Mechanical Power Press Safety (MPPS)
CNTRLS Catalog - Press and Press Brake Control Systems
SFM Catalog - Shields For Machinery
For prices and delivery, please use address, phone or fax number listed on the front cover of this manual.
Your Signature Date
SECTION 11—RETURN MATERIALS AUTHORIZATION REQUEST FORM

5795 Logistics Parkway
Rockford, Illinois 61109
Toll-Free 1-800-922-7533
Phone [phone] | Fax [phone]
[e-mail]
www.rockfordsystems.com
KSL-288/RS/0619