Ross HDBH Series User manual

HDBH Series
Redundant Safety Valve System
Hydraulic Dual Block & Stop
Operating Instructions
www.rosscontrols.com
RC-HDBH-OI EN
Cat. 4
PL e SIL 3
Functional Safety
Pending
Pending

HDBH Series Operating Instructions
2www.rosscontrols.com
SCHEMATIC
WIRING DIAGRAM
Inductive Position Switch
Connector
A
A B
B
A
A B
B
G
G
a
a
1A
1B
P
P
A
A
B
B
T
T
Valve Side
Manifold Side
1 = Supply +24 volts DC
2 = Output Signal NC
3 = Ground
4 = Output Signal NO
NO NC
1
4
3
2
PRODUCT LABEL IDENTIFICATION
OVERALL DIMENSIONS
MODEL NUMBER ISO Size Monitoring Weight lb (kg)
HDBHDC3BAEXA 06 (D03) External 15.0 (6.80)
~ 4.5 (115)~ 5.5 (140)
~ 10.0 (255)
5.03 (127.8)
~ 3.9 (100)
~ 3.4 (87)
2.23 (56.7)
2.06 (52.4)
Inductive Position
Switch Connector
Solenoid
Connector
Bracket
Connection Bar
Tamper-resistant
Bracket
Dimensions – inches (mm)
2.25 (57.2)
1.75 (44.5)
0.13 (3.2)
0.13 (3.2)
0.75
(19.1)
2.25 (57.2)
1.13
(28.6)
2.25 (57.2)
1.75 (44.5)
0.47 (11.9)
(4X) Ø0.219 (5.6) Thru
Spacer Kit
0.75 inches (19.1 mm)
Spacer Kit
1.75 inches (44.5 mm)
Spacer Kits
Kit Type Height inches (mm) Model Number
Ductile 0.75 (19.1) 2548B25
1.75 (44.5) 2549B25
Spacer kits can be used to raise the HDBH system higher above the manifold surface
in order to avoid interference with other devices on the manifold. Kits are either 0.75”
or 1.75” tall. Combine kits as necessary to achieve the desired spacing.
1A
1B
P
P
A
A
B
B
T
T
G
G
B
B
A
T
A
T
A
TB
A
B
T
XX
X
X
X
X
X
X
X4.0 (101.6)
~ 7.9 (201.67)
2.0 (50.8) 2.0 (50.8)
In-line Mounting Kit Kit Number
2790B77
In applications where installation on a manifold is not practical, the in-line mounting kit can be used
to facilitate installation in-line between a directional valve and actuator (typically a cylinder). The
2790B77 kit provides 2 mounting plates with multiple SAE 06 ports for the A, B, and T ports in order
to provide for exibility in piping. At least one of the T ports must be piped back to the tank. Through
holes (0.422” dia.) for mounting the assembly are included in the plates. All assembly hardware
and plugs are included, but mounting hardware for the assembly must be provided by the customer.
Dimensions – inches (mm)
Dimensions – inches (mm)

HDBH Series Operating Instructions
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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 6 “Notes on Safety,”
before working with the product.
For more information see last page for contact information, or 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. Product Identication
The valve assembly is marked with Model Number, Revision level, and a serial number which
can be used to identify date of manufacture and location. Please contact ROSS CONTROLS®
for further information.
Product label identification & product key identification example, see page 2.
3. Prerequisites for Use of 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.
3.1. 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 hydraulic control technology.
All work may be performed only by properly trained and qualied individuals who have
been specically instructed for the tasks assigned to them. The levels of responsibility
of personnel are to be clearly delineated by the owner/operator. Protective clothing
and gear is to be worn when performing all work. The relevant safety and accident
prevention regulations are to be adhered to. Any special safety requirements specied
in the documentation for the unit/system are to be complied with.
4. Package Contents
Items included:
• Dual Block & Stop Safety Valve System
• Operating instructions
5. Service, Repair, and Maintenance
fIn case of technical problems or a required repair, please contact your local ROSS®
representative.
fChecks should be conducted once a month to ensure valves are in functioning order.
5.1. Maintenance
WARNING
- All activities of maintenance must be conducted by competent and qualied staff
- Always depressurize the relevant part of the system before any maintenance operation on
the hydraulic system.
When/if a valve is replaced; a basic functional test should be performed (see 8.1 Test
Procedure).
It is important that all the check-up operations, even if simple, are programmed and
reported on specic maintenance program schedules.
Before the inspection, cleaning should be undertaken if necessary.
WARNING
- Always ensure cleanliness when working on the HDBH Valve.
- Do not perform maintenance with the equipment functioning!
- Penetrating dirt and liquids will cause faults!
- Safe function of the HDBH valve is not ensured when operated with contaminated uid.
- Certain solvents and aggressive cleaning agents or detergents may damage the seals
on the HDBH valve and make them age faster.
- Never use solvents or aggressive detergents as these can cause damage to the
hydraulic system and seals!
- The water pressure of a high-pressure cleaner can damage the seals of the HDBH valve.
- Do not use a high-pressure cleaner.
- Pay attention to prevent detergent penetration into the HDBH valve.
- Check that all seals and electrical plug connections are rmly tted to prevent the
penetration of detergents.
6. 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.
6.1. Intended Use
The HDBH Series Dual Block & Stop Safety Valve System is a safety component
designed and manufactured in accordance with Machinery Directive 2006/42/EC.
The HDBH system is comprised of two single valves which make it a redundant design
for meeting the needs and requirements of safe hydraulic Block & Stop applications.
Typically, these systems are designed to meet Category 4, PL e / SIL 3 applications if
properly implemented into the safety control & monitoring system.
NOTE: Block and Stop functions are meant to momentarily stop an actuator (linear
or rotary), but not to hold in place for an extended period of time. The HDBH valve is
a spool type valve and normal spool leakage will occur. Applications where long term
holding is necessary should also incorporate other components such as PO check,
counterbalance, or mechanical locking devices.
The HDBH system is a sandwich-mount device that is designed to be installed directly
between a manifold and a directional valve. In applications where installation on a
manifold is not practical, a mounting kit (ROSS part number - 2790B77) can be used
to facilitate installation of the HDBH valve in-line between a directional valve and
actuator (cylinder). The HDBH system allows or blocks ow between the directional
valve and its associated cylinder (actuator) by opening both ports to allow movement
or by closing both ports to stop movement as needed.
During normal operation the HDBH system is held actuated, allowing the ow of oil
through the HDBH system unit. In a situation where immediate pressure and ow shut-
off is needed, the HDBH system can be turned off to immediately block the ow both
into and out of the cylinder.
The HDBH system is designed to be externally monitored by a safety control &
monitoring system for safe, redundant operation of the valves. Each single valve in
the HDBH system is equipped with a PNP inductive position switch. Monitoring both
of these switches on each actuation and de-actuation of the HDBH system provides
a diagnostic coverage of up to 99%. Monitoring of the two inductive position switches
must be done by an external monitoring system.
The unit cannot be used by itself. It is designed for installation in a machine. ROSS
and its suppliers will assume no liability in the event that the system or parts thereof
are not used in accordance with their designated use or if modications are made in
a non-authorized manner.
Any drawings, hydraulic or electric circuit diagrams, parts lists and acceptance
certicates (inspection reports) supplied do not form a part of these operating
instructions. They are supplied for the purpose of illustrating the unit or procuring parts.
6.1.1. Safety Function According to ISO 13849 and EN 692
The Machinery Directive has a dual objective: to permit the free movement of
machinery within the internal market while ensuring a high level of protection of health
and safety. A hydraulic valve system designed and specied as being capable of
performing a safety function as well as normal production use is a “safety component”
where other parts of the denition are met. However, a similar valve where the
manufacturer markets it only for normal production use would not be considered a
safety component.
The HDBH Dual Block & Stop system is 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 power loss, wear, contamination, or similar
situations).

HDBH Series Operating Instructions
4www.rosscontrols.com
The safety function of the HDBH Series Dual Block & Stop system is to only supply
ow into and out of a cylinder or designated portion of the hydraulic machine/system
when the two valve elements are actuated simultaneously, but to block the ow in
both directions in both cylinder lines when both valves are shut-off or if only one of
the two valves is de-actuated. A fault in the system where only one valve actuates
when switching on or only one de-actuates when switching off prevents ow of oil from
moving downstream or upstream in both ports. Monitoring of the two inductive position
switches by the user’s external safety control & monitoring system makes it possible to
detect these fault situations and to shut off and prevent further electrical energization
of the solenoids.
Port identication on the manifold according to ISO 16874
The HDBH Series Dual Block & Stop system is designed and manufactured in
accordance with the identication requirements laid out in the ISO 16874:2004
standard.
6.1.2. Common Cause Failure – CCF
The product has been engineered and manufactured according to the fundamental
and proven safety principles of ISO 13849-1:2015 and -2:2012.
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.
6.1.3. Critical failure modes and causes:
• Failure of the safety function - caused by simultaneous incomplete return of both
solenoid valves (1A and 1B).
• Maintain hydraulic oil quality, i.e., proper ltration.
• Operate within prescribed temperature limits.
• Install the valve such that the normal stroke travel of the valve elements is
perpendicular to the main direction of machine vibration and/or mechanical shock.
• Do not use a test pulse longer than recommended by the HDBH Integration Guide.
• Avoid external magnetic elds.
6.1.4. Diagnostic Coverage
A diagnostic coverage of 99% is achievable through appropriate integration of the
HDBH Series Dual Block & Stop system into the safety control system. The monitoring
system must check for the proper change of state of each valve’s inductive position
switch (Switch 1A and 1B) with each change of state of the safety control system
outputs to the valve solenoids (Sol 1A and 1B). Detection of a fault by the safety control
& monitoring system must trigger a shut-off of the safety controller’s outputs to the
valve solenoids (Sol 1A and 1B).
6.1.5. Fault Modes
Note that normal operation requires that Sol 1A and 1B be energized simultaneously for
switching the HDBH system on, and de-energizing both Sol 1A and 1B simultaneously
for switching the HDBH system off.
NOTE: The switches are supplied with both NC and NO contacts. The statements
below only refer to whether or not the switches are actuated.
Faults that could occur during normal operation are:
Sol 1A and 1B energized simultaneously
Switch 1A ON, Switch 1B OFF
Switch 1A OFF, Switch 1B ON
Switch 1A OFF, Switch 1B OFF
Sol 1A and 1B de-energized simultaneously
Switch 1A ON, Switch 1B OFF
Switch 1A OFF, Switch 1B ON
Switch 1A ON, Switch 1B ON
6.1.6. Foreseeable Misuse
WARNING
Risk of Injury!
Misuse may result in injury or damage.
fThe product must be used exclusively as intended.
Foreseeable misuse includes:
• Bypassing the safety function or diagnostics.
• Replacing the safety valves with unauthorized valves.
• Tampering with the position switches.
• Failing to utilize the position switches to verify valve operation on every cycle -
when energizing and de-energizing.
• Allowing continued operation of the valve when one or both valve shifted signals
(from position switches) are not conrmed.
• Operating at pressures above maximum operating pressure.
6.2. Responsibilities of the System Owner
Observation of general requirements pertaining to hazards:
• Unusual noises, vibration, defects or damage is to be remedied immediately as it
may point to potential hazards.
• Generally speaking, no maintenance work may be done on the hydraulic system
and power units as long as they are under hydraulic pressure or the power supply
has not been switched off.
• Prior to performing any maintenance work, pressure accumulators are to be
depressurized.
• The hydraulic system has to be depressurized at any time work is done on the gas
side of an accumulator.
• Note the load pressures present. Also note any loads applied. If necessary, make
sure that the loads are secured or properly supported.
• Hydraulic systems may only be operated by properly trained and instructed
personnel.
• All safety devices and equipment are to be checked to see that they function properly.
• Safety devices and equipment may not be removed, deactivated or circumvented
owing to the accident hazard posed by this action.
• General safety and accident prevention regulations pertaining to operating the unit/
system are to be adhered to.
• Comply with the further requirements of ISO 13849 (e. g., MTTFD, CCF, DC, PLr,)
if you intend to use the product in higher categories (2 to 4).
• Check 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.
• Selection and installation of replacement valves must take place in accordance
with the manufacturer’s specications.
6.3. Safety Instructions
The HDBH Series Dual Block & Stop System features a state-of-the-art design.
Reliable and safe operation cannot be ensured unless all the instructions, settings and
output limits applicable to the unit supplied are adhered to.
The systems involved are pressure-generating systems whose components feature
pressurized liquid; consequently, the systems may pose a hazard if not dealt with
properly.
6.3.1. Additional Safety Considerations
• When implementing surge suppression measures, be sure to check whether or
not this extends the valve system 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 system.
• Supply the proper voltage as overvoltage situations can result in solenoid
burnout.
7. Assembly and Installation
CAUTIONS
Risk of injury due to installation while pressurized or with live parts!
fInstallation 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 from being switched back on again.
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 storage temperature represents the permissible ambient temperature and depends on the
type of valve in question.
fObserve the temperature information in chapter 10 “Technical Data.”
7.1. Installation Instructions
Secure the system using the through holes in the manifold. Refer to pattern for the
required dimensions, - see dimensional drawings on page 2.
7.1.1. Component Inspection: Prior to use, a careful examination of
the HDBH valve system must be performed. The HDBH valve system must be
checked for correct style, size, catalog number and external condition, and must
be examined for cleanliness, absence of external defects or gouges or otherwise
deformed parts or other imperfections. DO NOT use any item that displays any signs
of nonconformance. Any accessory including, but not limited to, ttings, bolt kits,
hoses, sub-bases, manifolds and electrical connectors must be subjected to the
same examination.

HDBH Series Operating Instructions
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7.1.2. Filtration: Fluid cleanliness is a necessity in any hydraulic system. Fluid
lters need to be installed and maintained in the system to provide the required level of
cleanliness. Filters can be placed in the inlets.
7.1.3. Accessory Ratings: All accessories used in combination with the
selected or intended HDBH valve system must be used in accordance with the HDBH
specications.
7.2. Electrical Connections
Install the electrical connectors (EN 175301-803 Form A type, pre-wired or non-
prewired) for both the valve solenoids.
Install the inductive position switch connector (M12, 5-pin, A-coded) on each valve and
follow the electrical wiring schematics of the switch on page 2.
8. 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 must be carefully inspected by a qualied,
trained professional.
Make sure that the technical specications match the operating criteria of the machine
and/or the hydraulic system.
8.1. HDBH Test Procedure for Valve Operation
NOTE 1: This valve test procedure only checks for proper function of the HDBH
system. Please refer to the HDBH Integration Guide for the External Monitoring
Validation Procedure.
NOTE 2: The valve test procedure requires fault simulation. It will be necessary
to induce faults electrically by disabling a different solenoid or switch at different
times. This will be most easily done by disconnecting solenoid or switch cables
at the valve.
NOTE 3: The HDBH is designed to work in association with a directional control
valve and a cylinder (or other actuator). The following test procedure only
checks the function of the HDBH system, and it may be necessary to modify this
procedure to accommodate the various operating modes of the directional valve
being used with the HDBH.
NOTE 4: The PNP position switches are supplied with both NC and NO contacts.
NOTE 5: - indicates no change from previous step.
Step Action Sol 1A Sol 1B Flow
YES/NO?
Switch Conditions Pass/Fail
Switch 1A Switch 1B
(NC) (NO) (NC) (NO) (P/F)
1Energize
solenoid 1A ON OFF NO OPEN CLOSED CLOSED OPEN
2
De-energize
both
solenoids
OFF OFF NO CLOSED OPEN - -
3Energize
solenoid 1B OFF ON NO - - OPEN CLOSED
4
De-energize
both
solenoids
OFF OFF NO - - CLOSED OPEN
5
Energize
both
solenoids
1A & 1B
ON ON YES OPEN CLOSED OPEN CLOSED
6
De-energize
both
solenoids
OFF OFF NO CLOSED OPEN CLOSED OPEN
8.1. Limitations Due to System Leakage
Even though the HDBH is designed to redundantly block ow, it is important to
periodically test for leakage within the HDBH and the system it controls, as any leak
within the HDBH itself, interconnecting hoses, connectors, cylinders or other actuators,
or even other valves in the circuit may cause unexpected movement. In order to test
for leakage within the HDBH itself, it is necessary to check for actuator (cylinder)
movement when the HDBH is in each of the following conditions:
WARNING
Performing this test could cause injury or damage to equipment due to unexpected or
uncontrolled movement. Take all necessary precautions to ensure worker safety prior to
initiating this test.
A) fully de-energized (both solenoids 1A & 1B de-energized)
B) solenoid 1A energized with solenoid 1B de-energized
C) solenoid 1A de-energized with solenoid 1B energized. 
Depending on the application, it may be necessary to preposition actuators and/or
other valves such that energizing the HDBH would allow motion to occur. This sets up
the circuit so that the HDBH valve is the sole motion-controlling device during testing.
For example, if a cylinder is fully retracted, a leak that normally allows retract motion to
occur could be masked because the cylinder is already fully retracted.
This test helps to troubleshoot leaks within the HDBH system. Other leaks within the
associated system can affect the outcome of this test.
WARNING
If any leakage is discovered within the system, measures should be taken to eliminate the
leak(s) as failing to do so could limit the ability of the safety system to safely stop motion
when required.
WARNING
Continued operation of the system without periodic leakage inspections can lead to unexpected
movement.
9. Disconnecting and Removal
CAUTIONS
Risk of injury due to installation while pressurized or with live parts!
fDisconnecting a hydraulic component while the system is pressurized or while electrical power
is supplied can result in injury or death due to sudden pressure release, unexpected movement,
or electric shock.
fIsolate and lock out the electrical and hydraulic systems before disconnecting the unit.
10. Technical Specications
Construction Design Spool type
Actuation
One solenoid per valve element
Solenoids must be operated synchronously
Direct solenoid operated, spring return
Mounting
Type: Sandwich-style mounted (interposed) between
base/manifold and directional valve
Footprint: ISO 4401-03-02-0-05 (NG 6 or D03)
Solenoids
Version as per VDE 0580. Rated for continuous duty.
Electrical connection according to EN 175301-803 Form A
Enclosure rating according to DIN 400 50 IP 65
Standard Voltages 24 volts DC
Power Consumption (each solenoid) 30 watts
Inductive Position Switch (2 per system) PNP (M12, 5-pin, A-coded)
Maximum Current (each switch) 400mA maximum
Temperature Range (recommended) Ambient: -22° to 160°F (-30° to 70°C)
Media: -4° to 140°F (-20° to 60°C)
Flow Media
Hydraulic Fluids:
Mineral Oil HLP, HL-DIN 51524
Vegetable Oil HETG - VDMA 24568
Pressure Ports P, A, B :
5000 psi (344 bar)
Port T : 3000 psi (210 bar)
Construction Material
Valve Body: Cast Steel
Spool: Steel
Seals: Buna-N
End-brackets: Unfilled Nylon 12
Side-brackets (label): 304 Stainless Steel
Functional Safety Data MTTFd: 150 years

HDBH Series Operating Instructions
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Technical Characteristics Of PNP Inductive Position Switch
Type Of Switch Contactless inductive position switch with integrated amplifier
Supply Voltage [V] 20-32 V DC
Ripple Max [%] ≤ 10
Max Current [mA] 400
Reaction Time [ms] 15
Max Peak Pressure [bar] 400
Mechanical Life Virtually Infinite
Switch Logic PNP
1supply + 24 V DC
4NO output signal
2NC output signal
3GND
OUTPUT SIGNAL STATUS FOR EACH VALVE IN THE HDBH SYSTEM
Hydraulic configuration
ON
OFF
ON
OFF
Spool position
Pin 2
Pin 4
S
Note: PNP Position Switch can be electrically wired by the consumer as NO or NC and then the status
of the output signal will be in accordance to the selected configuration.
= Intermediate spool position corresponding to the hydraulic configuration change.
11. Disposal
Dispose of the valve in accordance with the applicable statutory regulations in your
country.

HDBH Series Operating Instructions
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Printed in the U.S.A. – Rev. 10/29/20, © 2020 ROSS CONTROLS®. All Rights Reserved. Content subject to change. Form RC-HDBH-OI
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