Ross 21 Series User manual

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.
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
whose model numbers end with a 001, 011, 051, or 061
are valves designed for high-temperature service.Valves
whose model numbers end with a 002, 003, 012, 013, 052,
053, 062, or 063 are valves 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 airlinesmustbe blowncleanof allcontaminants.
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 clo
gged 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 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. 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 formostvalvesandrequires nospecial 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.
21Series Poppet Valves
For High Temperature and Low Temperature Applications
Single Solenoid
Pilot Controlled Valve
Direct Double Solenoid
Pilot Controlled Valve
Pressure
Controlled
Valve
ROSS CONTROLS®
Important Note: ROSS 21 Series 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.

Construction: Poppet.
Mounting Type: Inline.
Flow Media: Filtered air.
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 (2.1 bar) is required.
Safety Integrity Level (SIL) – Certified by TÜV Rheinland in
accordance to IEC 61508 and IEC 61511 safety integrity level
2 (SIL 2) and EN ISO 13849-1, PL c or PL d (with application
specific diagnosis) in singular application with HFT = 0 and SIL
3 and PL e in redundant application with HFT ≥1.
Pressure Controlled
Ambient/Media Temperatures:
High Temperature: 0° to 300°F (-17° to 150°C).
Low Temperature: -40° to 175°F (-40° to 80°C).
For temperatures below 40°F (4°C) air must be free of
water vapor to prevent formation of ice.
Inlet Pressure: 30 to 150 psig (2 to 10 bar).
Solenoid Pilot Controlled
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.
Ambient Temperature:
High Temperature: 0° to 250°F (-17° to 122°C).
Low Temperature: -40° to 120°F (-40° to 50°C).
Media Temperature:
High Temperature: 0° to 300°F (-17° to 150°C).
Low Temperature: -40° to 175°F (-40° to 80°C).
Inlet Pressure:
Port Sizes 1/4 to
1½ : 15 to 150 psig (1.0 to 10 bar).
Port Sizes
1½ to 2½ : 30 to 150 psig (2 to 10 bar).
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 an 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 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.
IMPORTANT NOTE: Please read carefully and thoroughly
all the CAUTIONS and WARNINGS on page 4.
COMPATIBLE LUBRICANTS
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
2ROSS CONTROLS®
VALVE SPECIFICATIONS
VALVE MAINTENANCE
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, 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.

3
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 pilot section.
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 the main supply pressure.
CONVERSION TO EXTERNAL PILOT SUPPLY Pilot
Exhaust
Port
External
Pilot
Supply
Port
Internal
Pilot
Supply
Passage
Adaptor
Plate
Figure 1
Valve Body Service Kits. These kitscontain allpartsneeded for
complete reconditioning of a valve body. Included are poppets,
spindle,all required gasketsand seals, andinstructions foruse.
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:
High Temperature: 947K87
Low Temperature: 946K87
For double solenoid pilots:
Low Temperature: 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:
High Temperature: 257B04
Low Temperature: 411B04
For double solenoid pilots:
Low Temperature: 171C95
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,
please consult ROSS.
*Consult ROSS Technical Services for high-pressure
and vacuum service kits.
VALVE SERVICE Valve
Type
Port
Sizes
Body
Size
Temperature
Service
Type
Valve Body
Kit Number*
Gasket &
Seal
Kit Number*
2/2
Normally
Closed
1/4, 3/8,
1/2 3/8 High 207K77 198K77
Low 237K77 228K77
1/2,
3/4, 1 3/4 High 208K77 199K77
Low 238K77 229K77
1, 1¼,
1½1¼High 209K77 200K77
Low 239K77 230K77
2/2
Normally
Open
1/4, 3/8,
1/2 3/8 High 213K77 198K77
Low 243K77 228K77
1/2,
3/4, 1 3/4 High 214K77 199K77
Low 244K77 229K77
1, 1¼,
1½1¼High 215K77 200K77
Low 245K77 230K77
3/2
Normally
Closed
1/4, 3/8,
1/2 3/8 High 219K77 201K77
Low 249K77 231K77
1/2,
3/4, 1 3/4 High 220K77 202K77
Low 250K77 232K77
1, 1¼,
1½1¼High 221K77 203K77
Low 251K77 233K77
3/2
Normally
Open
1/4, 3/8,
1/2 3/8 High 225K77 201K77
Low 255K77 231K77
1/2,
3/4, 1 3/4 High 226K77 202K77
Low 256K77 232K77
1, 1¼,
1½1¼High 227K77 203K77
Low 257K77 233K77
4/2
1/4, 3/8,
1/2 3/8 High 260K77 258K77
Low 264K77 262K77
1/2,
3/4, 1 3/4 High 261K77 259K77
Low 265K77 263K77
1, 1¼,
1½1¼High 278K77 277K77
Low 289K77 288K77

Form SS099
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. If you have any
questions, call your nearest ROSS location listed in the table below.
4. Each ROSS product should be used within its specification limits.
In addition, use only ROSS parts to repair ROSS products.
WARNINGS: Failure to follow these directions can adversely affect
the performance of the product or result in the potential
for human injury or damage to property.
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 or damage to property. 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 which risks human injury, and/or damage to property.
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
must 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.
WARNINGS:
ROSS expressly disclaims all warranties and responsibility for any
unsatisfactory performance or injuries caused by the use of the
wrong type, wrong size, or an 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® valves
and L-O-X® valves with EEZ-ON® operation are defined as energy
isolation devices, NOT AS EMERGENCY STOP DEVICES.
STANDARD WARRANTY
All products sold by ROSS CONTROLS are warranted for a one-year period [with the exception of
all Filters, Regulators and Lubricators (“FRLs”) which are warranted for a period of seven years]
from the date of purchase to be free of defects in material and workmanship. 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
becomes 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 IS ROSS LIABLE TO PURCHASER, USER, THEIR
EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGESWHICH MAY RESULT FROM A BREACH OFTHE WARRANTY
DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS. NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF
ROSS MAY EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN.
CAUTIONS And WARNINGS