Ross DM2 C Series User manual

Control Reliable Double Valves Basic Size 4, 12 & 30
Thank You! You have purchased a premium-quality ROSS®pneumatic valve. It is a high
quality DM2® Series C explosion proof double valve with dynamic monitoring and inherent lockout capability for
Category 3 and 4 applications (except press clutch/brake applications). The valve is designed for base mounting
for ease of installation and maintenance. With care in its installation and maintenance you can expect it to have a
long and economical service life. Before you install this valve, read the information in this folder completely, and
save it for future reference.
NOTE: This valve is expressly not intended for use in press clutch/brake applications.
ROSS produces the DM2® Series Dand a number of other double valve configurations specifically for use with
press clutch/brake applications.
ROSS CONTROLS®www.rosscontrols.com
VALVE INSTALLATION
DM
2® Series C Explosion Proof
Size 12
illustrated
Pneumaticequipmentshouldbeinstalledonlybypersonstrainedandexperienced
in such installation.
Application: DM2® Series C double valves are intended for use in Category 3
& 4 applications except press clutch/brake applications.
Air Lines: Before installing this valve in a new or existing system, the air lines
must be blown clean of all contaminants. It is recommended that a 5-micron
rated 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
clogged filter element. The air supply must not only provide sufficient pressure
(see Standard Specifications, page 3), but must also provide an adequate flow
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 crimps and
sharp bends.
Valve Exhaust (Port 3): Do not restrict the air flow from
the exhaust port as this can adversely affect the operation of the valve. The
valves are factory equipped with a properly sized silencer. ROSS silencers
reduce impact noise by as much as 25 dB, and produce little back pressure.
Reset Solenoid: DM2® Series C double valves are supplied with a 3/2 normally
closed solenoid valve for reset purposes. Electrical reset signal must be
momentary and of correct voltage.
Electrical Supply: DM2® Series C double valves get electrical power through
plug-in connectors. The electrical supply must correspond to the voltage
and hertz ratings of the solenoids. Otherwise, the solenoids are subject to
early failure. If power is supplied by a transformer, the power supply must
be capable of handling the maximum power. See Valve Specifications on
page 3 for information on maximum power.
Operating Pressures and Temperatures: Allowable ranges for pressure and
temperatures are given in the Standard Specifications on page 3. Exceeding
these values can adversely affect performance and shorten valve life.
Pipe Installation: To install pipe in base 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. 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: After installation or repair and prior to normal use, the internal lockout
feature of the DM2® Series C double valve must be tested for proper functioning.
Observe normal equipment operation 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, the valve is designed such that both pilot solenoids must be de-energized
prior to reset, and must remain de-energized until after the reset signal is
removed. Otherwise, the valve will not reset.
A) 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.
B) Energize both solenoids and the valve should remain in the lockout condition.
C) De-energize both pilot solenoids and reset the valve.
D) Electrically energize both pilot solenoids simultaneously again. De-energize
the other pilot solenoid this time. Again, this should result in a lockout.
E) Energize both pilot solenoids. The valve should remain in a lockout condition.
F) De-energize both pilot solenoids and then reset the valve.
After satisfying these tests, energizing both pilot solenoids simultaneously
should result in normal operation.
Fault Indication: The built-in status indicator can be used to signal the machine
controls that a fault has occurred. The status indicator utilizes a pressure switch.
The pressure switch has 4 electrical contacts. During normal operation the
pressure switchispressurized. A lockout conditiondepressurizestheswitch until
the valve is reset. Contacts 1 and 2 are closed when the switch is depressurized
(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.
Additional technical documentation is available for download at www.rosscontrols.com.
If you have any questions about installation or servicing your valve, please contact ROSS or your authorized ROSS distributor, see contact
information listed at the back of this document, or visit www.rosscontrols.com to find your distributor.
VALVE OPERATION
On first operation, or after repair, the pilot valve supply circuit and inherent
monitoring elements may need to be reset. This reset is accomplished by
applying a momentary air signal to the RESET port or by energizing the
optional reset solenoid momentarily on the valve. After reset, the valve will
then be ready for operation.
The air supply to each pilot valve is controlled by the position of the inlet
poppets. In the ready-for-operation position these poppets are held on their
seats and maintain pilot air flow. During shifting of the valve elements the
poppets move off seat and momentarily allow pilot air to escape to exhaust.
If either valve element fails to operate correctly, the pilot supply to the other
valve element will remain connected to exhaust causing the valve to lockout.
The internal monitoring system will lock out the valve if the time difference
between both elements shifting fully is longer than approximately 125
milliseconds. This timing is preset by restricting-orifices and chambers in
the pilot air circuit.
The main airflow from port 1 to port 2 is via crossflow passages between
both main valves, so that both valve elements must be fully shifted in order
for port 2 to be pressurized.
If the valve locks out, further operation is prevented until the valve has been
reset. Electrical signals to the solenoids must be "off" to allow the valve to
be reset.
The DM2® Series C valve is completely self-contained and does not need
an external monitoring system.

2ROSS CONTROLS®
STANDARD SPECIFICATIONS
IMPORTANT NOTE: Please read carefully and thoroughly all the CAUTIONS and WARNINGS on page 4.
Construction: Dual poppet.
Mounting Type: Base mounted.
Pilot Solenoids: According to VDE 0580. Enclosure rating according to DIN
400 50 IP 65. Three solenoids, rated for continuous duty.
Standard Voltages/Pilot Solenoids Power Consumption
(each solenoid): Primary and reset solenoids:
24 volts DC, 4.6 watts; 120 volts AC, 60 Hz, 6.8 volt amps.
Enclosure Rating: IP65, IEC 60529.
Electrical Connection: Three-wired end sleeve for strands, thread 1/2-NPT
for cable conduit.
Ambient Temperature: 15° to 122°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).
Inlet Pressure: 30 to 120 psig (2 to 8 bar).
Pressure Switch (Status Indicator) Rating: Contacts - 1 amps at 250
volts AC, SPDT.
Pressure Switch Enclosure Rating: IP66.
Monitoring: Dynamically, cyclically, internally during each actuating 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.
Functional Safety Data: Category 4 PL e; B10D: 20,000,000; PFHD:
7.71x 10 -9 ; MTTFD: 301.9 (nop: 662400).
Certifications: CE Marked for applicable directives, DGUV Test, CSA/UL,
TSSA for appropriately tested valves.
Vibration/Impact Resistance: Tested to BS EN 60068-2-27.
Applicable Requirements: C22.2 No. 0-10 - General Requirements - Canadian Electrical Code, Part II; CSA C22.2 No. 25-1966 - Enclosures for use
in Class II Groups E, F and G Hazardous Locations; CSA C22.2 No. 142-M1987 - Process Control Equipment; C22.2 No. 213-M1987 - Nonincendive
Electrical Equipment for Use in Class I, Division 2 Hazardous Locations; CAN/CSA E79-0-95 - Electrical apparatus for explosive atmospheres, Part 0:
General requirements; CAN/CSA E79-18-95 - Electrical apparatus for explosive atmospheres, Part 18: Encapsulation "m".
APPROVED for use in the following Hazardous Locations –
Ex m II T4 and Division 1
Specifications in accordance to CSA certificate: Class I, Division 1, Groups A, B, C and D; Class II, Groups E, F and G; Class III; Class I, Division 2,
Groups A, B, C, D.
Specifications in accordance to FM certificate: Explosion-proof Class I, Division 1, Groups A, B, C, D, T4, Ta = 60 °C (encapsulation/explosion-proof
Class I, Zone 1, AEx m II T4, Ta = 60 °C; dust-ignition-proof for Class II/III, Division 1, Groups E, F and G, T4, Ta = 60 °C); Nonincendive Class I, Division
2, Groups A, B, C, D, T4, Ta = 60 °C; Suitable for Class II, III, Division 2, Groups E, F, G, T4, Ta = 60 °C
When and why does the valve require a reset signal?
The valve will only require a reset when the valve has detected asynchronous
movement of the two independent internal elements. This condition will be
indicated by a fault signal from the pressure switch feedback device and
an audible leak from the silencer. Reset is accomplished by applying a
momentary signal to the reset solenoid. The DM2®Series C valves have
an anti-tie-down feature that requires both main valve solenoids to be de-
energized while resetting.
Why will my valve not reset?
1. There are a few common conditions that can prevent reset from occurring.
2. If the main valve solenoids are energized the valve will not reset. This is
a safety feature of the DM2®Series C valves that prevents unintended
pressure output from occurring upon valve reset.There should be at least
a 200 ms delay between removing power from the reset solenoid and
applying power to the main valve solenoids.
3. If the pneumatic supply to port 1 is not sufficient the valve will not reset.
This is not unusual for initial testing and startup if full plant pressure and
volume is not applied and quick connects or small hoses are used.
4. If the supply pressure was removed before de-energizing the valve it
is possible that both valve elements are in the faulted condition. This
condition results in a greater leakage rate to the exhaust port when the
supply is reapplied, and increases the insufficient supply issue mentioned
in item #2.
5. The reset solenoid may be mounted backwards. In this case energizing the
reset solenoid will result in the release of air through the reset solenoid’s
exhaust port (through the nut mounted on the stem of the solenoid) and
no reset action can occur.
DM2®Operation Timing Chart
Outlet
Pressur
ized
Reset
Signal
Main
Solenoids
Supply
Pressure
Applied
1. Operating signal to main solenoids should be dual
channel, concurrent operation. Discordance of signals
should be less than 25 msec.
2. Tu rning off supply pressure while valve is energized
will result in a fault and then valve must be reset.
3. Fault detection is constant.
VALVE RESET INFORMATION
DM2®Reset Timing Chart
Outlet
Pressur
ized
Reset
Signal
Main
Solenoids
Supply
Pressure
Applied
1. Reset anti-tie-down feature requires main solenoids to be off
during reset.
2. Reset duration is momentary - 200 msec. min. recommended.
3. At end of reset signal, time is required for pilot chambers to
refill before operation - 200 msec. recommended.
4. Fault detection is constant.
5. Tu rning off supply pressure while valve is energiz
ed will result
in a fault and then valve must be reset.

www.rosscontrols.com 3
Complete Solenoid Pilot Assemblies
Basic
Size
Solenoid
Coil
Type
Model Number
Voltage
24 volts DC 110 or 120 volts AC
4Pilot 1556C7916 1556C79105
12 & 30 Pilot 1492K7916 1492K79105
All
Sizes Reset 1488G7916 1488G79105
Valve Body Service Kits. These kits contain all parts needed for complete
reconditioning of a valve body. Included are poppets, spindles, gaskets, seals, and
instructions for use.
Status Indicator Assembly Service Kit. This kit includes all parts needed for complete
reconditioning of the status indicator assembly. Pressure switch and connector sold
separately.
Pilot Booster Service Kits. Available for sizes 12 and 30, these kits contain all parts
needed for complete reconditioning of a pilot booster. Included are poppets, gaskets,
seals, and instructions for use.
Replacement Pressure Switch. This kit includes a replacement pressure switch and
electrical connector for the status indicator assembly.
Solenoid Coils. Order replacement by part number provided at the right. For other
voltages, consult ROSS.
Complete Solenoid Pilot Assemblies. These assemblies consist of new pilot valve
mechanisms and a new solenoid coil, ready to bolt in position on the valve. For other
voltages, consult ROSS.
Replacement Solenoid Coils
Basic
Size
Solenoid
Coil
Type
Model Number
Voltage
24 volts DC 110 or 120 volts AC
4, 12,
30
Pilot 409B3316 409B33105
Reset 409B3316 409B33105
Basic
Size
Valve Body
Service
Kit Number
Status Indicator
Assembly Service
Kit Number
Pilot Booster
Service
Kit Number
Replacement
Pressure Switch
Kit Number
4 2102K77 2151H77 – 1260H30
12 2104K77 2151H77 2106K77 1260H30
30 2105K77 2151H77 2106K77 1260H30
If you have any questions about installing or servicing your
valve, call ROSS Technical Services at your nearest
ROSS location (see page 4) or in the U.S.A. at:
1-888-TEK-ROSS.
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
VALVE MAINTENANCE
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 the double 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
on page 2. 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.To clean the valve, use any good commercial
solvent. Do not scrape varnished surfaces.
ROSS would be happy to service this valve for you at its factory repair center. If you purchased your valve from ROSS please contact ROSS
customer service, if you purchased your valve thru an authorized ROSS distributor please contact the distributor for return instructions.
However, if you choose to service this valve yourself, it is strongly recommended that you visit our website at
www.rosscontrols.com for available downloadable technical documentation.
When servicing the valve yourself, be sure to turn off electrical power to the valve, shut off the air supply, exhaust the air in the system, and lock-
out all power sources before beginning any disassembly operation. Listed below are kits for servicing DM2® Series C double valves, as well as
replacement solenoid information.
CAUTION: Before operating the DM2® Series C double valve, be sure to complete the test procedure (TEST), on page 1, upon installation
and after any maintenance is performed on the valve. Failure to do so could result in personal injury or equipment damage.
VALVE SERVICE
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 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 off the electrical power to the
valve, shut off the air supply, exhaust the air in the system,
and lockout before beginning any disassembly operation.
Service kits are listed on page 3.

Printed in the U.S.A – Rev. 05/17 © 2017, ROSS CONTROLS®. All Rights Reserved. Form SS307
Content subject to change.
CAUTIONS And WARNINGS
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.
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 contaKitminants
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.
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 DAMAGES WHICH MAY RESULT FROM A BREACH OF THE 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.
STANDARD WARRANTY
ROSSCONTROLS USA TEL: [phone] web site: www.rosscontrols.com
ROSS EUROPA GmbH Germany TEL: [phone] web site: www.rosseuropa.com
ROSS ASIA K.K. Japan TEL: [phone] web site: www.rossasia.co.jp
ROSS UK Ltd. UK TEL: [phone] web site: www.rossuk.co.uk
ROSS SOUTH AMERICA Ltda. Brazil TEL: [phone] email: [email protected]
ROSS CONTROLS INDIA Pvt. Ltd. India TEL: [phone] email: [email protected]
ROSS CONTROLS (CHINA) Ltd. China TEL: [phone] web site: www: rosscontrolschina.com
ROSS FRANCE S.A.S. France TEL: [phone] web site: www.rossfrance.com
ROSS CANADA (6077170 CANADA INC. AnIndependent RepResentatIve)Canada TEL: [phone] (416-251-ROSS) web site: www.rosscanada.com