Ross CrossMirror 77 Series User manual

Certificates and Declarations are available for download at www.rosscontrols.com.
CrossMirror®Double Valve
77 Series – Safe Return Valves
Operating Instructions
RC-77-OI
EN
www.rosscontrols.com
PRODUCT CREDENTIALS
Performance Level
Per ISO 13849-1:2015
Safety Integrity Level
Per IEC 2061:2001 DGUV Certication Declaration of Conformity Certicate of Compliance
Cat. 4
PL e SIL 3
Functional Safety
HSM 13022
Sicherheit geprüft
tested safety
√
HSM 02064
Sicherheit geprüft
tested safety
√

2© 2023, ROSS®, All Rights Reserved.
77 Series Operating Instructions
www.rosscontrols.com
SIMPLIFIED SCHEMATICS
Solenoid Pilot Controlled Pressure Controlled
2
4
1
3
5
2
4
1
3
5
PRODUCT LABEL IDENTIFICATION
Solenoid Pilot Controlled Valve Pressure Controlled Valve
VALVE ONLY
VALVE & BASE YD7776A4421W
Y7776A4401W
2
4
1
3
5
CROSSMIRROR®
PRESSURE 2.5 - 10 BAR
www.rosscontrols.com
U.S. PATENT NO 5,850,852 & WORLWIDE PATENTS
YD7786A4421W
Y7786A4401W
2
4
1
3
5
VALVE ONLY
VALVE & BASE
CROSSMIRROR®
PRESSURE 2.5 - 10 BAR
www.rosscontrols.com
U.S. PATENT NO 5,850,852 & WORLWIDE PATENTS
Series
Valve Function
5/2
Basic Size Port Size
Base
Mount
Inlet Outlet
2 1/2 3/8 341
4
3/4 1/2 442
1/2 3/4 541
SAE12 SAE12 Blank 4H 1
Revision
Level
Y 77 7 6 A 3410 W
Current Voltage
*
DC 24 V W
AC
110 V, 50 Hz
120 V, 50/60 Hz Z
230 V, 50/60 Hz ** Y
* For other voltages consult ROSS.
** 230 V AC (OSHA regulations limit press control voltage
to no more than 120 V AC in the US).
Actuation
Solenoid Pilot
Status Indicator
None 0
Mechanical Pressure Switch
DIN EN 175301-803 Form A
(connector included)
1
Port Thread
NPT
Blank
GD
SAE – Straight Thread S
PRODUCT KEY IDENTIFICATION
Solenoid Pilot Controlled Valves – Valve and Base Assembly
Pressure Controlled Valves – Valve and Base Assembly
Series
Valve Function
5/2
Basic Size Port Size
Base
Mount
Inlet Outlet
2 1/2 3/8 341
4
3/4 1/2 442
1/2 3/4 541
SAE12 SAE12 Blank 4H 1
Y 77 8 6 A 3410 W
Current Voltage
*
When None selected for Status Indicator
Blank
DC 24 V W
AC
110 V, 50 Hz
120 V, 50/60 Hz Z
230 V, 50/60 Hz ** Y
* For other voltages consult ROSS.
** 230 V AC (OSHA regulations limit press control voltage to
no more than 120 V AC in the US).
Actuation
Pressure Controlled
Status Indicator
None 0
Mechanical Pressure Switch
DIN EN 175301-803 Form A
(connector included)
1
Revision
Level
ENGLISH
Port Thread
NPT
Blank
GD
SAE – Straight Thread S

© 2023, ROSS®, All Rights Reserved. 3
77 Series Operating Instructions
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Valve Only
Actuation Port Sizes Basic
Size
Valve Model Number #
With Status Indicator Switch Without Status Indicator Switch
1 2, 4 24 V DC 110-120 V AC 230 V AC 24 V DC 110-120 V AC 230 V AC
Solenoid Pilot
Controlled
1/2 3/8 2 Y7776A3401W Y7776A3401Z Y7776A3401Y Y7776A3400W Y7776A3400Z Y7776A3400Y
All All 4 Y7776A4401W Y7776A4401Z Y7776A4401Y Y7776A4400W Y7776A4400Z Y7776A4400Y
Pressure
Controlled
1/2 3/8 2 Y7786A3401W Y7786A3401Z Y7786A3401Y Y7786A3400
3/4 1/2 4 Y7786A4401W Y7786A4401Z Y7786A4401Y Y7786A4400SAE 12 SAE 12
3/4 3/4 4 Y7786A54401W Y7786A54401Z Y7786A54401Y
# Valve include status indicator switch with DIN EN type connection, for status indicator switch with M12 type connection consult ROSS.
MANUFACTURING INFORMATION Manufacturing Site Site Abbreviation Valve Printing
(example May 2022)
Date and site of manufacture
ROSS CONTROLS USA
(L) (5 22 L)
(FE) (5 22 FE)
ROSS EUROPA (G) (
5 22 G)
ROSS UK (RB) (
5 22 RB)
ROSS ASIA (J) (
5 22 J)
See back page for ROSS addresses.
ROSS SOUTH AMERICA (B) ( 5 22 B)
ROSS CONTROLS CHINA (C) (
5 22 C)
ROSS CONTROLS INDIA (RCI) (
5 22 RCI)
ENGLISH
Base Only
Port Sizes Basic Size Base Model Number
1 2, 4 NPT Thread G Thread
1/2 3/8 2 Y996C91 YD996C91
3/4 1/2 4 Y1049C91 YD1049C91
3/4 4 Y1153C91 YD1153C91
SAE 12 SAE 12 4 Straight Thread
Y1159G91
Valves, Bases
Technical Data Weight
lb (kg)
Valve Basic Size
Flow
CV(Nl/min) Valve and Base Assembly
1-2 1-4 2-3 4-5 Solenoid Pilot Controlled Pressure Controlled
With Status Indicator Switch 22.0 (1968) 1.6 (1574) 1.6 (1574) 2.8 (2755) 8.4 (3.8) 8.4 (3.8)
4 3.2 (3149) 3.4 (3346) 2.7 (2657) 7.2 (7085) 11.2 (5.1) 11.6 (5.3)
Without Status Indicator Switch 22.0 (1968) 1.6 (1574) 1.6 (1574) 2.8 (2755) 7.6 (3.4) 7.6 (3.4)
4 3.2 (3149) 3.4 (3346) 2.7 (2657) 7.2 (7085) 10.2 (4.6) 10.6 (4.8)

4© 2023, ROSS®, All Rights Reserved.
77 Series Operating Instructions
www.rosscontrols.com
Solenoid Pilot Controlled
Base Assembly
Pilot Valve Assembly
Valve Body
Pressure Switch Assembly
Connector Socket
Port 2 & 4 (Outlet)
Port 1 (Inlet)
Solenoids
VALVE SCHEMATICS
Solenoid Pilot Controlled Pressure Controlled
3
154
2
12
12
3
154
2
Pressure Switch
(optional)
Pilot Valve
Pilot Valve
Base
Base
Air Supply
Chambers
Pressure Switch
(optional)
Air Pilot ValveAir Pilot Valve
Chambers
Base
Base
Air Supply
ENGLISH
Signal Ports
1/8 - 27 NPT Valve Body Pressure Switch Assembly
Connector Socket
Port 1 (Inlet)
Pressure Controlled
Base Assembly Port 2 & 4 (Outlet)
Typical 2-Hand-Anti-Tie-Down Application
1
5
3
4
2
S1 S2
CrossMirror®Control Reliable
Pneumatic 5/2 “AND” Gate
Customer Supplied
3/2 Valve
CrossMirror®Control Reliable
Pneumatic 5/2 “AND” Gate
Customer Supplied
Cylinder

© 2023, ROSS®, All Rights Reserved. 5
77 Series Operating Instructions
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Solenoid Pilot Controlled Valves – Valve and Base Assembly with Remote Reset
DIMENSIONS
Inches (mm)
Basic Size 2
with Status Indicator Switch
4.55
(115.6)
6.68 (169.7)
2.09
(53.2) 0.97
(24.6)
3.16
(80.3)
6.68
(169.7)
0.85
(21.5)
2.95
(74.9)
11.09 (281.8)
3.50
(88.9)
11.09 (281.8)
6.68 (169.7)
4.07
(103.4)
without Status Indicator Switch
4.55
(115.6)
2.09
(53.2) 0.97
(24.6)
3.16
(80.3)
0.85
(21.5)
2.95
(74.9)
11.09 (281.8)
3.50
(88.9)
11.09 (281.8)
4.07
(103.4)
2.95
(74.9)
4.07
(103.4)
Basic Size 4
with Status Indicator Switch
5.35
(135.9)
0.78
(19.7)
3.20
(81.3)
7.38
(187.4)
2.59
(65.8)
1.00
(25.5)
6.36
(161.5)
3.75
(95.3)
12.17 (309.0)
2.59
(65.8)
5.35
(135.9)
0.78
(19.7)
3.20
(81.3)
4.88
(124.0)
5.35
(135.9)
without Status Indicator Switch
5.35
(135.9)
0.78
(19.7)
3.20
(81.3)
7.38 (187.4)
2.59
(65.8)
1.00
(25.5)
3.75
(95.3)
12.17 (309.0)
2.59
(65.8)
0.78
(19.7)
3.20
(81.3)
4.88
(124.0)
5.35
(135.9)
4.25
(108.0)
4.25
(108.0)
For additional information, and to assist you with piping and connectivity designs, our products are available in downloadable 2D drawings and 3D CAD models in a wide range of
options including native formats, visit www.rosscontrols.com.
ENGLISH

6© 2023, ROSS®, All Rights Reserved.
77 Series Operating Instructions
www.rosscontrols.com
Pressure Controlled Valves – Valve and Base Assembly with Remote Reset
DIMENSIONS
Inches (mm)
Basic Size 2
with Status Indicator Switch
4.55
(115.6)
6.68 (169.7)
2.95
(74.9)
4.07
(103.4)
2.10 (53.2) 0.97
(24.6) 6.00 (152.4)
3.16
(80.3)
6.68
(169.7)
10.85 (275.7)
0.85
(21.5) 2.95
(74.9)
3.50
(88.9)
without Status Indicator Switch
4.55
(115.6)
6.58 (167.2)
2.95
(74.9)
4.07
(103.4)
2.10
(53.2)
3.50
(88.9)
0.85
(21.5) 2.95
(74.9)
10.85 (275.7)
4.07
(103.4)
3.16
(80.3)
Basic Size 4
with Status Indicator Switch
5.35
(135.9)
6.86 (174.2)
0.78
(19.7)
3.20
(81.3)
4.11
(104.4)
2.59
(65.8) 1.00
(25.5) 7.14 (181.3)
6.36
(161.5)
3.75
(95.3)
11.92 (302.9)
2.59 (65.8) 3.20
(81.3)
6.86 (74.2)
5.35
(135.9)
without Status Indicator Switch
5.35
(135.9)
0.78
(19.7)
3.20
(81.3)
4.11
(104.4)
2.59
(65.8) 1.00
(25.5) 7.14 (181.3)
3.75
(95.3)
11.92 (302.9)
2.59 (65.8) 3.20
(81.3)
5.35 (135.9)
0.78
(19.7)
4.25
(108.0)
For additional information, and to assist you with piping and connectivity designs, our products are available in downloadable 2D drawings and 3D CAD models in a wide range of
options including native formats, visit www.rosscontrols.com.
Base Assembly Port 2 & 4 (Outlet)
ENGLISH

© 2023, ROSS®, All Rights Reserved. 7
77 Series Operating Instructions
www.rosscontrols.com
ENGLISH

8© 2023, ROSS®, All Rights Reserved.
77 Series Operating Instructions
www.rosscontrols.com
Package Contents
Items included: • 77 Series valve
• Operating instructions
1. About this Documentation
These instructions contain important information for the safe and appropriate
assembly and commissioning of the product.
fRead these instructions all the way through, particularly section 2. “Notes on
Safety”, before working with the product.
fMake these operating instructions available to the engineer and assembly
technician of the machine/system in which the product will be used.
fKeep these operating instructions for the entire product life cycle.
Additional documentation:
• SISTEMA libraries
• DGUVcerticate:GermanSocialAccidentInsurance
• Product catalog and other technical documents
For more information visit www.rosscontrols.com.
fIn addition, observe all applicable local and national regulations on accident
prevention and on environmental protection.
1.1. Warning Notices in these Operating Instructions
In these operating instructions, warning notices precede sections with handling
requirements which incur risks of personal injury or material damage.
Warnings are structured as follows:
SIGNAL WORD
Type or source of hazard!
Consequences
fMeasures to avert danger
• Warning triangle: Indicates a risk of fatal or severe injuries.
• Signal word: Indicates the severity of the danger.
• Type or source of hazard: States the type of danger or the source of the hazard.
• Consequences: Describes possible consequences of ignoring the warning.
• Measures to avert danger: Indicates how to avoid the danger. It is essential that the
measures to avert danger are complied with.
DANGER
Indicates an imminent and serious danger that will result in
severe or even fatal injury if you fail to avoid it.
WARNING
Indicates a possible danger that could result in severe or even
fatal injury if you fail to avoid it.
CAUTION
Indicates a danger that may result in minor to moderate injuries if
you fail to avoid it.
ATTENTION
Indicates potential property damage that may be incurred by the
product or its surroundings if you fail to avoid it.
2. Notes on Safety
The product has been manufactured according to the accepted rules of current
technology.
There is risk of injury or damage if the following safety instructions and warnings given
in this instruction manual are not observed.
2.1. Intended Use
The 77 Series of double valves are safety components designed and manufactured in
accordance with Machinery Directive 2006/42/EC and bear the CE and UKCA mark.
The 77 Series line of double valves are redundant 5/2 valves that are designed to
meet the needs and requirements of Safe Return.
Cylinder/Actuator (5/2 valves) applications for machinery with pneumatic controls.
Typically, these valves are implemented to meet the Category 4 and/or Performance
Level e requirements of a machine’s (or system’s) safety circuit as determined by a
risk assessment of the hazards and tasks required of employees that interact with the
machine/system.
fSee section 3“Technical Data” for the standards and test values complied with and
adhered to by the product. See the declaration of conformity for product-relevant
directives. The 5/2 77 Series valves are designed to control the direction of air
ow into and out  of a double-acting cylinder or other pneumatic actuator in
order to drive the cylinder forward or backward to suit the requirements of the
machine operation. However, the 77 Series valve does this with the same level of
control expected of the machine’s system’s safety circuit. The safety function of
the 77 Series valve is to return the cylinder/actuator to its home “safe” position
whenever a fault occurs within the valve.
NOTE: Maintenance tasks require following full lock-out/tag-out procedures to
relieve hazardous energy and prevent unexpected startup.
2.1.1. Safety Function According to ISO 13849
77 Series valves are designed in accordance with the requirements listed in ISO
13849-1 and -2. Their “fail-to-safe” safety function is ensured even in case of a fault
within the valve (e.g., caused by wear, contamination, or similar situations).
The safety function of the 5/2 77 Series valve is to drive a double-acting cylinder
or other pneumatic actuator forward when the two valve elements are actuated
simultaneously, but to drive the cylinder or other actuator back to its home “safe”
position when both valve elements are shut off or if only one of the two valves is
actuated. A fault in the system where only one valve actuates when switching on or
only one de-actuates when shutting off causes the 77 Series valve to supply air to
port 2 of the valve and to simultaneously open port 4 to exhaust (port 5). This, in turn,
causes the cylinder or other actuator to return to its home “safe” position.
In the event of loss of air pressure at the inlet port a check valve (may be removed on
customerrequest)isinstalledtotrapthedownstreamair,asmallbleedoriceslowly
relieves the trapped air
Attention: There may be some movement because of gravity or pressure balance,
whiletheairwillbeventedviathebleedorice
All 77 valves are equipped with a dynamic “CrossMirror” monitoring function (self-
contained).
The 77 Series valves are self-testing, redundant systems in accordance with the
requirements listed in ISO 13849-1 and -2.
The control outputs of the safety system must be designed and constructed to meet the
Category and/or Performance Level requirements of the safety system, as determined
by the risk assessment of the machine. Normally, the outputs to the solenoids are
dual-channel outputs from a safety relay or safety PLC.
2.1.2. Common Cause Failure – CCF
The product has been engineered and manufactured according to the fundamental
and proven safety principles of ISO 13849-1 and -2.
Critical failure modes and causes:
• Failure of the safety function - caused by simultaneous incomplete return of both
solenoid valves (A and B).
• Common Cause Failures (CCF) are failures of different components, resulting
from a single event. CCF are not to be confused with cascading faults or common
mode faults. Common cause failures can cause loss of the safety function,
especially in dual channel circuits where both channels could fail simultaneously
due to a single event.
• Maintaincompressedairquality,i.e.,ltration,pressureregulation,.
• Avoid oils that can cause valve seals to swell, soften, or otherwise deteriorate.
• Operating outside of prescribed temperature limits.
• Install the valve such that the normal stroke travel of the valve elements are
perpendicular to the main direction of machine vibration and/or mechanical shock.
• DonotuseatestpulselongerthanallowedbytheTechnicalSpecications.
• Avoidexternalmagneticelds.
• Do not plug the valve exhaust port.
• Useonlyhigh-ow,non-cloggingsilencers,withsimilar orhigherspecications
as ROSS®silencers.
2.1.3. Diagnostic Coverage
A diagnostic coverage of 99% is achievable through appropriate integration of the 77
Series valve into the safety control system.
WARNING: In the event of loss of pressure during a fault could cause unexpected
movement of a cylinder that is being controlled by the valve.
2.1.4. Foreseeable Misuse
WARNING
Risk of Injury!
Misuse may result in injury or damage.
fThe product must be used exclusively as intended.
The product must be used exclusively as intended.
ENGLISH

© 2023, ROSS®, All Rights Reserved. 9
77 Series Operating Instructions
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Foreseeable misuse includes:
• Use outdoors
• Bypassing the safety function or diagnostics
• Operation in low-demand mode per IEC 61508
• Operating at pressures below minimum operating pressure or above maximum
operating pressure.
ROSS CONTROLS is not liable for any damages resulting from improper use.
The user alone bears the risks of improper use of the product.
2.2. Responsibilities of the System Owner
• Observe the information on assembly and operating conditions listed in the
operating instructions, or the data sheet.
• Comply with the further requirements of ISO 13849 (e. g., CCF, DC, PLr, software)
if you intend to use the product in higher categories (2 to 4).
• Make sure that the maximum number of switching cycles (B10D) within the service
life TM is not exceeded. If the expected number of switching cycles for a component
exceeds the B10D value during its period of use, suitable replacement intervals have
tobespecied.
• Switch the valve at least once a month to ensure its proper operation.
• Make sure that the fundamental and proven safety principles in accordance with
ISO 13849 for implementation and operation of the component are complied with.
• Make sure that the permissible switch-on and switch-off pulses for feedback-free
operation of the pneumatic devices are observed.
• If you operate the 77 Series valve together with an electric two-hand control, it must
comply with the ISO 13851 standard. Selection and installation of this two-hand
controlmusttakeplaceinaccordancewiththemanufacturer’sspecications.
2.3. Safety Instructions
• When implementing surge suppression measures, be sure to check whether or
not this extends the valve shut off response time which could extend the machine
stopping time.
• In case of high levels of machine vibration, use appropriate vibration-reducing
elements when installing the valve.
• Supply the proper voltage - under-/ overvoltage situations can result in solenoid
burnout or failure.
• Make sure that the silencer’s ow capacity is not restricted as this could affect
system performance.
• Ifrequired,replacethesilencerwithamodelequivalentorhigherinspecications
as ROSS®silencers.
3. Technical Specications
Function 5/2 Normally Closed Valve
Construction Design Dual Spool
Actuation
Electrical
Solenoid pilot operated with spring and air return.
One solenoid per valve element – both to be operated
synchronously.
Pneumatic
Air actuated pilots operated with spring and air return.
One air-pilot per valve element – both to be operated
synchronously.
Mounting Type Base; Manifold
Orientation Any, preferably vertical
Connection Threaded; NPT, G
Monitoring Dynamic, cyclic, internal – with any change in switching
state and in any switching state.
Temperature
Ambient 40° to 122°F (4° to 50°C)
Media 40° to 175°F (4° to 80°C)
Flow Media Compressed (neutral gases) air according to ISO 8573-1
Class 7:4:4.
Operating Pressure
Solenoid Pilot
40 to 150 psig (2.7 to 10 bar)
NOTE: Main solenoids must be off
when performing reset procedure
Pressure
Controlled 40 to 100 psig (2.7 to 7 bar)
Solenoids
Electrical Data
Operating Voltage Power Consumption
(each solenoid)
24 volts DC 14 watts
110-120 volts AC, 50/60 Hz 5.8 watts nominal, 6.5
watts maximum
230-240 volts AC, 50/60 Hz
Rated for continuous duty
Supply Voltage For CSA/UL compliance, in DC applications the valve
must be connected to a NEC Class 2 power supply.
Enclosure Rating IP65, IEC 60529
Electrical Connection DIN EN 175301-803 Form A
Uses cord-grip connectors at solenoids
Pressure Switch Maximum
Current/Voltage
4A, 250 volts AC
50 mA, 24 volts DC
Pressure Switch Rating Rated in excess of 15 million cycles; electrical life of
switch varies with conditions and voltage
Safety
Classication
Directives 2006/42/EC (Machinery Directive) 2004/108/EC (EMC
directive)
Standards ISO 13849-1, IEC61508/IEC62061, DIN EN 61326-3-1
Category Max. 4, PL e, SIL 3.
Vibration resistance
(DIN EN 60068-2-6) 0.35 mm ± 0.05 mm displacement at 10 Hz–55 Hz
Shock Test
(based on DIN EN 60068-2-27)
Acceleration 30 G
Shock Duration 18 ms
Shock Waveform 1/2-sine
B10D Valve According to ISO 13849-1 and -2: 20 million cycles
Maximum Cycle Rate 2 Hz
Common Cause Failure (CCF) > 65
Diagnostic Coverage (DC) 99%
Sound Pressure Level [dB(A)]
The sound pressure level is inuenced by the individual
systems used for reduction of noise emissions. Use
only silencers with exhaust ow capability greater than
the exhaust capability of the 77 Series valve, e.g., do
not restrict the valve exhaust. The 77 Series valve does
not have integrated silencer option. Use of the product
without the silencer is not recommended.
Flow Rates: See page 3.
Minimum Operation Frequency Once per month, to ensure proper function.
4. Prerequisites for Use of the Product
Make these operating instructions available to the engineer and assembly technician of the
machine/system in which the product will be used.
Keep these operating instructions for the entire product life cycle.
ATTENTION
Qualied Personnel – Assembly, installation, commissioning, maintenance, and
decommissioning should only be carried out by qualied personnel that have the required
knowledge of and experience in dealing with electrical and pneumatic control technology.
5. Assembly and Installation
CAUTIONS
Risk of injury due to installation while pressurized or with live parts!
Installation while pressurized or with electrical power switched on can result in injuries due
to sudden pressure build-up or electric shock.
fDe-energize and de-pressurize the relevant system parts before installing the valves.
fSecure the system to prevent it being switched back on again.
ENGLISH

10 © 2023, ROSS®, All Rights Reserved.
77 Series Operating Instructions
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ATTENTION
Destruction of components!
Chemical substances can damage the surface, the markings and the seals of the device.
fInstall the valve such that it is protected against the effects of chemicals.
Damage to the device through storage at incorrect temperatures!
The ambient temperature represents the permissible storage temperature and depends on
the type of valve in question.
fObserve the temperature information in chapter 3 “Technical Specications.”
5.1. Mechanical Installation
Secure the valve using the through holes in the valve base. Refer to pattern for the
required dimensions, see dimensional drawings on page 4 through 5.
5.2. Pneumatic Installation
5.2.1. Electrically-actuated
77 Series Valve for Safe Return Cylinder/Actuator – Connect the compressed air
supply to port 1, connect ports 2 & 4 to the pneumatic actuator, port 3 and 5 are the
exhaust ports.
5.2.2. Pneumatically-actuated
77 Series Valve for Safe Return Cylinder/Actuator – Connect the pneumatic pilot
signals to the signal ports, the compressed air supply to port 1, connect ports 2 & 4 to
the pneumatic actuator, port 3 and 5 are the exhaust ports. Signal ports 1 & 2 needs to
be connected to the outputs of the two-hand control or the outputs of other valves used
to control the 77 Series valve. The control valves shall be 3/2 NC valves.
5.3. Electrical Connections
Electrical connections to the solenoids are made with EN 175301-803 Form A
receptacles on the valve.
The cables and cable connections as well as the electrical control for the double valves
must comply with the applicable safety regulations.
Solenoid Pinout
DIN EN 175301-803 Form A
2
1
G
1 2
41 - Positive
2 - Negative
4 - Ground
Pressure Switch for Status Indicator Pinout
1
2
4
1
4
2
G
1 - Common
2 - Normally Closed
4 - Normally Open
G - Ground
Solenoid Connector Pinout
DIN EN 175301-803 Form A
12
3
4
1 - Black
2 - Black
4 - Green/Yellow (Ground)
Status Indicator Connector Pinout – ROSS Connector
1
2
4
G
1 - Common
2 - Normally Closed
4 - Normally Open
G - Ground
6. Commissioning and Operation
CAUTIONS
Damage to health due to loud noise!
Levels above 70 dB(A) may lead to damage to health!
fAlways wear ear protectors when working on the product.
Before commissioning, the installation has to be carefully inspected by a qualied,
trained professional.
Make sure that the technical specications matches the operating criteria of the
machine and/or the pneumatic system.
Always set the compressed air supply to a level that ensures that the minimum
operatingpressureisadheredto(seechapter3"TechnicalSpecications").
6.1. Test Procedure
For pneumatically actuated version: Solenoid = Signal Port
Valve for Safe Return Cylinder/Actuator Application
1. Solenoid A energized – Valve is faulted, port 2 is pressurized, port 4 is
exhaustedthrough port 5. Status-indicator feedback has to change
2. Reset valve by de-energizing both solenoids – Valve is off, port 2 is pressurized,
port 4 is exhausted through port 5. Status-indicator feedback has to change
3. Solenoid B energized – Valve is faulted, port 2 is pressurized, port 4 is exhausted
through port 5. Status-indicator feedback has to change
4. Reset valve by de-energizing both solenoids – Valve is off, port 2 is pressurized,
port 4 is exhausted through port 5. Status-indicator feedback has to change
5. Solenoids A & B energized – Valve is on, port 4 is pressurized, port 2 is exhausted
through port 3. Status-indicator feedback is not changing
6. Solenoids A & B de-energized – Valve is off, port 2 is pressurized, port 4 is
exhausted through port 5. Status-indicator feedback is not changing
Failure of the valve to shift not synchronously leads to a fault in the 77 Series valve.
This could happen for a variety of reasons, such as:
• Defective piston seals,
• Main valve elements experiencing a switching delay due to dirt or resinous oil,
• Insufcientelectricalsignalstovalvesolenoids;suitablevoltagenotavailable,
• Receipt of signals at solenoids not synchronous,
• Pilot valves experiencing a switching delay due to damaged components, dirt, or
resinous oil,
• Excessive water build-up in the valve.
7. Maintenance
fIf used properly, the 77 Series valves will not require maintenance. Unless otherwise
required, ROSS®recommends performing a functional test at least once a month.
8. Service & Repair
fIn case of technical problems or a required repair, please contact your local ROSS
representative.
9. Disconnecting and Removal
CAUTIONS
Risk of injury due to disconnecting while pressurized or with live parts!
Disconnecting while pressurized or with electrical power switched on can result in injuries or
death due to sudden pressure release, unexpected movement, or electric shock.
fDe-energize and de-pressurize the relevant system parts before disconnecting the valve.
fIsolate and lock out the system to prevent it from being switched back on again before
disconnecting the valve.
10. Disposal
Dispose of the valve in accordance with the applicable statutory regulations in your
country.
ENGLISH

© 2023, ROSS®, All Rights Reserved. 11
77 Series Operating Instructions
www.rosscontrols.com
ENGLISH

Printed in the U.S.A. – Rev. 04/03/23 Content subject to change. © 2023 ROSS®, All Rights Reserved. Form RC-CM-77-OI
AmericAs
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europe
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AUTOMATIC VALVE INDUSTRIAL LLC USA Tel: [phone] www.automaticvalve.com
ROSS DECCO COMPANY USA Tel: [phone] www.rossdecco.com
ROSS PNEUMATROL Ltd. United Kingdom Tel: [phone] www.pneumatrol.com
manufactIS GmbH Germany Tel: [phone] www.manufactis.net