Ross M35 Series Quick setup guide

IntegratIon guIde
M35 SerieS
Safety exhauSt Double ValVeS

2 © 2021, ROSS CONTROLS®. All Rights Reserved.
M35 Series Integration Guide
Table of Contents
Integration Guide – M35 Safety Exhaust Valve
Page
General Information
Introduction 3
Pulse Testing 3
Exhaust Times and Faulted Flow Rates 3
Soft Start Adjustment 4
Pneumatic Schematic 4
M35 Wiring (Pinouts) 5
M35 LED Status Lights (Operation) 5
Operation & Monitoring Requirements for M35 Valves 6
Valve Operation 6 - 7
Feedback Monitoring (General)
Synchronicity 7
While Actuated
8
No Supply Pressure During Actuation / Loss of Supply Pressure While Actuated
No Supply Pressure Applied Before Actuation
Valve Fault & Safety System Reset
M35 Validation Test Procedure for Valve Operation and External Monitoring Logic 9 - 11
Cautions, Warnings and Standard Warranty Cover
Global Locations
Disclaimer:
Sample Logic and any and all related diagrams contained in ROSS Controls’ Integration guide were developed and
validated using dual channel electro-mechanical input signals in a laboratory environment and are provided to you
for illustrative purposes only. Because of the many variables and unique requirements associated with any particular
application, all persons responsible for installing and integrating ROSS products must satisfy themselves that the ROSS
product is the correct product for the application and operates as intended. Because of the variability described above,
ROSS Controls cannot assume responsibility or liability for actual use of its products based upon samples, examples
and diagrams contained in its websites and documents.

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M35 Series Integration Guide
Introduction
ROSS Controls offers a variety of safety valves for use in various safety functions such as safe exhaust, safe cylinder return, and
safe load holding/stop. This document focuses specifically on ROSS Controls’ M35 Series valves that are used for safe exhaust
functions and utilize solid state pressure sensors to provide feedback to a safety control system for external monitoring.
Pulse Testing
In dual channel safety circuits, pulse testing is a method utilized to detect fault conditions that, otherwise, may be undetected. Pulse
testing of the solenoids is required in dual channel circuits in order to reach performance level e (PL e). However, pulse testing of
the feedback sensors is not required. Pulse testing of the solenoids will not affect the performance of the ROSS M35 valve.
There are two methods of pulse testing outputs. The most common method is to use the native pulse testing instruction embedded
by the manufacturer in Safety PLCs and Safety Relays. The other method is to use custom programming code generated by the
user. We recommend the use of native pulse testing instructions of the respective manufacturers’ Safety PLCs or Safety Relays
because these instructions are fixed and cannot be tampered with. These instructions typically have a frequency of 400ms to
600ms and a duration of 0.4ms to 0.8ms. Pulse testing the outputs to the solenoids on the M35 valve at this frequency and duration
does not affect the performance of the valve, but does provide a method to monitor for the occurrence of wiring faults in the output
portion of the safety circuit controlling the valve solenoids.
Exhaust Times and Faulted Flow Rates
When designing a safety circuit, the machine stopping time is a critical factor that determines the placement of guarding solutions. One
factor in safe distance calculations is the exhaust time of the valve that is responsible for isolating and dumping the pneumatic energy
from the machine.The faster your valve exhausts the quicker the machine can stop and the closer your safety devices may be placed
to the hazardous area. This can improve overall operating efficiency, and possibly allow the footprint of the machine to be smaller.
Even more important than exhaust time is the “Faulted exhaust flow rate”. Faulted exhaust flow rate is the exhaust rate of the valve
in its worst state. Double valves (redundant valve systems used for safety applications) will not exhaust quite as quickly when there
is an internal fault condition in the valve, such as when one of the redundant valve components is actuated and the other one is
not actuated. For this reason, double valves used in safety circuits should always be sized using faulted flow rates as the worst
case condition.
The chart below shows the M35 valve’s very high-flow faulted exhaust flow times at various downstream volumes and operating
pressures.
Exhaust Time – Normal and Faulted Conditions (s)
Volume
ft3(L)
Normal
or
Faulted
Operating Pressure
30 psig (2 bar) 90 psig (6 bar) 145 psig (10 bar)
to 15 psig
(1 bar)
to 7 psig
(0.5 bar)
to 15 psig
(1 bar)
to 7 psig
(0.5 bar)
to 15 psig
(1 bar)
to 7 psig
(0.5 bar)
0.071 (2) N0.055 0.071 0.094 0.112 0.120 0.135
F0.072 0.098 0.147 0.183 0.200 0.247
0.35 (10) N0.131 0.208 0.317 0.393 0.424 0.507
F0.185 0.301 0.533 0.710 0.789 1.024
0.71 (20) N0.226 0.379 0.597 0.746 0.804 0.971
F0.326 0.555 1.016 1.368 1.526 1.997
1.41 (40) N0.416 0.721 1.155 1.451 1.564 1.899
F0.608 1.063 1.983 2.685 3.000 3.941
5.30 (150) N1.462 2.604 4.227 5.326 5.743 7.006
F2.160 3.855 7.298 9.929 11.107 14.635

4 © 2021, ROSS CONTROLS®. All Rights Reserved.
M35 Series Integration Guide
Soft Start Adjustment
The function of the optional EEZ-ON
®
(soft start) module is to, on energization, allow outlet pressure to increase at a slower than
normal rate until it reaches approximately 50% of inlet pressure, at which point the valve will then open fully to finish filling the
system at full flow rate. This feature can be used to lessen the shock of sudden, rapid pressurization of cylinders, and to gradually
refill the system.
The EEZ-ON
®
module has an adjusting screw that is used to control the rate of pressurization according to number of turns and
inlet pressure. The chart below can be used to approximate the number of turns (clockwise from full open) it will take in order to
adjust the soft start for your system. The necessary setting is dependent upon the number of turns, inlet pressure, and downstream
volume to be filled by the valve.
0
1000
2000
3000
4000
5000
6000
0186420
N Liters/min
Turns (counterclockwise)
M35 Series Soft Start Adjustment - Flow vs Number of Turns and Inlet Pressure
30 psig (2 bar) 60 psig (4 bar) 90 psig (6 bar) 115 psig (8 bar) 145 psig (10 bar)
SCFM
180
140
100
80
40
220
0
Pneumatic Schematic
The ROSS M35 valve schematic shows patented cross flow technology and solid state pressure sensors for status feedback.
The red box highlights the optional soft-start in the unit.
2
3
1Pressure
Sensors
Solenoid
B
Solenoid
A
-
+
-
+
Sensor A
Sensor B
Valve Schematic
Valve Simplied Schematic
21 3
Optional Soft Start

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M35 Series Integration Guide
M35 LED Status Lights (Operation)
Sensor Power (SEN PWR): This
LED indicates whether or not power is
applied to the feedback sensors.
Green: Power applied.
OFF: No power applied.
Solenoid Power LED‘s: These
LED‘s operate independently to indicate
power is applied to the solenoids.
Green: Power applied.
OFF: No power applied.
FAULT (FLT): Flashing Red: Sensors are in different States.
OFF: Sensors in same state – no issue.
M35 Wiring (Pinouts)
The M35 valve is available with various wiring options for both the solenoid cable and the sensor cable. For example, the following
model number is wired internally with the DB wiring option:
Model Number: M35S40GAEXDBGA
This means the valve in this example is wired with the D solenoid configuration and the B Sensor configuration. Use these diagrams
to determine the proper pinouts for your valve.
NOTE: The sensors must be wired with 24 volt (+) and 0 volt (-) connections in parallel as shown below. See Pressure Sensor
M12 pinouts below.
Pin Conguration
Combinations
Solenoid Sensor
A A AA
A B AB
A C AC
C C CC
D B DB
D C DC
Solenoid
M12 Pinouts
A
5
1
3
4
2
Sol 2 Sol 1
+
-
+
Sol 2 Sol 1
C
+
-
Sol 2 Sol 1
D
+
-
5
1
3
4
2
5
1
3
4
2
Pressure Sensor
M12 Pinouts
Sensor A Sensor B
AB
Sensor A Sensor B
+
-
-
+
-
+
C
Sensor A Sensor B
+
-
-
+
-
+
5
1
3
4
2
5
1
3
4
2
5
1
3
4
2
Illustrations shown above indicate the pin-outs for the valve connectors.

6 © 2021, ROSS CONTROLS®. All Rights Reserved.
M35 Series Integration Guide
Operation & Monitoring Requirements for M35 Valves
The intent of this document is to provide guidance on how to operate and monitor the M35 valve for safe operation. A test procedure
is also provided for verification and validation of the user’s external safety control monitoring system.
Valve Operation
The M35 valve is a redundant safety exhaust (dump) valve. Its function is that of a 3/2, normally closed, single-solenoid valve.
However, because the valve is redundant it has two operating solenoids that must be operated simultaneously in order to actuate
the valve. In addition, each valve element has a single, pressure sensor that is wired as a PNP type sensor (each to be wired in
parallel with the other sensor - not in series) to indicate position of each element.
Actuating the valve will supply pressure from port 1 (supply) to port 2 (outlet) and close port 3 (exhaust).
De-actuating the valve will close port 1 (supply) and open port 2 (outlet) to port 3 (exhaust). De-actuation of the valve is accomplished
by turning off both solenoids simultaneously.
Normal operation occurs when both sets of valve internals shift within 50 msec of each other. For example, when both solenoids
are signaled to energize, we would expect both proximity sensors to turn off within 50 msec of each other. Each sensor only reacts
to its associated solenoid.
In the event of a valve fault where one of the redundant valve components does not operate synchronously as commanded, the
valve will perform its safety function which is to shut off supply and exhaust downstream pressure to atmosphere.
The fault should be latched in by the safety monitoring system until a reset is performed.
Failure of the valve to shift synchronously leads to a fault in the M35 valve. This could happen for a variety of reasons, such as:
• Compromised piston seals
• Main valve elements experiencing a switching delay due to dirt, debris or resinous oil
• Insufficient 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, debris or resinous oil
• Excessive water build-up in the valve
Feedback Monitoring (General)
The M35 valve is equipped with pressure sensors that must be monitored by the user’s external safety control & monitoring system
to detect any fault condition within the valve.
NOTE: The pressure sensors are transducers with a discrete pressure switch point that is factory set and non-adjustable.
A pressure sensor (wired as a PNP) is associated with each one of the redundant valve elements for valve position sensing. Sensor
feedback should always be opposite the solenoid actuating signals. In other words, when the solenoids are energized, the sensor
outputs should be off and when the solenoids are de-energized, the sensor outputs should be on.
This valve uses pressure-based feedback sensing technology. Downstream pressure build-up time is subject to several application
parameters including, but not limited to supply pressure, outlet volume, pipe size, and soft-start setting. Additionally, downstream
exhaust time is also subject to various factors such as downstream pressure, outlet volume, and pipe size. Therefore, reaction
times of the feedback pressure sensors to actuation/de-actuation signals are application specific.
WARNING: It is possible to operate at a cycle rate that could result in non-monitored operation. To prevent exceeding this rate,
ensure that the valve is de-actuated (both sensor outputs should be on) before attempting to energize the solenoids. Likewise,
ensure that the valve is actuated (both sensor outputs should be off) before attempting to de-energize the solenoids.
NOTE: In the event of a stop signal from any safety system input, the safety system should immediately shut off the safety controller
outputs to the valve solenoids (as required by the application) regardless of the condition of the feedback sensors.
Refer to EN ISO13849-1 for Cat 3 vs Cat 4 monitoring.
Automatic RESET is not recommended by ROSS.

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M35 Series Integration Guide
Valve Operation and General Feedback Monitoring Ladder Logic Example
E-Stop Button Safety Stop Signal
Door**
Interlock Switch
Reset
Safety Stop
Signal
< >
**Could be an Input from any Safety Device,
such as a light curtain.
Actuate
Signal
Sensor
A
Sensor
B
Safety
Stop
Signal
Sync.
Fault*
While
Actuated
Fault*Solenoids Energized
Solenoid A
Solenoids
Energized
Solenoids
De-energized
Actuate
Signal
Sensor
B
Sensor
A
Actuate
Signal
Loss Of
Pressure
Fault*< >
< >
< >
Solenoid B
< >
Solenoids De-energized
*Explained in the next sections.
Solenoids
De-energized
General
Feedback
Fault
Sensor
A
Solenoids
Energized
Solenoids
De-energized General Feedback Fault
Reset
< >
General Feedback
Fault
Sensor
B
Synchronicity
In a valve that is functioning normally, a small amount of non-synchronous behavior is inherent even when the solenoid actuation
signals are applied simultaneously. This is due to minor variations between the two redundant channels as a result of manufacturing
tolerances and other variations. However, non-synchronous behavior that exceeds the time values listed below is abnormal and
should be registered as a fault.
1. “A” side actuation fault detection – if sensor A does not switch off within 50 msec after sensor B switches off, this should be
registered as a fault.
2. “B” side actuation fault detection – if sensor B does not switch off within 50 msec after sensor A switches off, this should be
registered as a fault.
3. “A” side de-actuation fault detection - sensor A does not switch on within 50 msec after sensor B switches on, this should be
registered as a fault.
4. “B” side de-actuation fault detection – if sensor B does not switch on within 50 msec after sensor A switches on, this should
be registered as a fault.
Synchronicity Ladder Logic Example
Sensor A Sensor B
EN
< >
< >
< >
DN
TON
Timer On Delay
Sync. Timer
Timer Value = 50ms
Sync. Fault Reset
Sensor A Sensor B
Sync. Timer Sync. Fault

8 © 2021, ROSS CONTROLS®. All Rights Reserved.
M35 Series Integration Guide
While Actuated
During normal actuation it is possible to see a momentary pressure spike in the sensing area (typically 10 msec duration or less)
which causes the sensors to momentarily switch off, then back on before switching off again for the duration of the actuation signal.
In order to consider the valve successfully actuated, both sensors should switch off and remain off for at least 25 msec. However,
once the valve is successfully actuated, if either sensor switches from off to on, this should immediately be registered as a fault.
While Actuated Ladder Logic Example
Solenoids
Energized
While Actuated
Fault Reset
Sensor A < >
Sensor B
While Actuated Fault
EN
< >
< > DN
TON
Timer On Delay
While Actuated Timer
Timer Value = 25ms
While Actuated Timer
Sensor A Sensor B
No Supply Pressure During Actuation / Loss of Supply Pressure While Actuated
The condition of no supply pressure during actuation should be detected by the safety control monitoring system and registered as
a fault. No supply pressure present during actuation will cause the sensors to remain off (not sensing pressure) even though the
solenoids are energized. However, during normal actuation, there is a reaction time that must be allowed for between energizing
the solenoids and the sensors switching on (sensing pressure). This time will vary depending on supply pressure, outlet volume,
pipe size, and soft-start setting. A 2-second delay to account for this reaction time can be used for most applications, but may
need to be longer if necessary for your application parameters.
The condition of loss of supply pressure while the valve is actuated must be detected by the safety control monitoring system. Loss
of supply pressure while actuated should cause both sensors to switch on due to lack of pressure in both valves’ outlet port even
though the valve is still energized. This fault can be detected when the solenoids are energized and one or both sensors go from
off (sensing pressure) to on (not sensing pressure).
No Supply Pressure During Actuation / Loss of Supply Pressure While Actuated Ladder Logic Example
Solenoids
Energized
Reset
< >
Loss Of
Pressure Fault
EN
< >
< > DN
TON
Timer On Delay
Loss Of Pressure Timer
Timer Value = 2 seconds
Sensor
A
Sensor
B
Loss Of
Pressure Timer
Loss Of
Pressure Fault
No Supply Pressure Applied Before Actuation
Monitoring of supply pressure may also be utilized if deemed beneficial for the application, but is not required. If you choose to
detect this condition it would require the addition of an upstream pressure switch or transducer. The condition of the pressure switch
or transducer should be monitored to prevent actuation of the valve when supply pressure is insufficient.
NOTE: No ladder logic example provided for additional equipment.
Valve Fault & Safety System Reset
Any detected fault in the valve system should cause the safety control system to de-actuate the valve by removing power from both
solenoids. Any fault should be latched in by the safety monitoring system until a reset is performed. A reset of the safety control
system should only be possible after the valve sensors indicate that the valve is in the de-actuated state (both sensor outputs are on).
The valve solenoids must be de-energized during Reset.
Safety System Reset Ladder Logic Example
< >
Reset Button Actuate Signal Sensor A Sensor B Reset

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M35 Series Integration Guide
NOTE 1: This validation test procedure should only be performed with an M35 valve that is known to be functioning properly. If basic valve function is in
question please refer to Section 8 of the Product Operating Instructions for the Valve Test Procedure.
NOTE 2:
These procedures require fault simulation. It will be necessary to induce faults electrically by disabling a different solenoid or sensor at different times.
This will be most easily done by disconnecting solenoid or sensor wires at the safety controller. Also, be aware that this would only be possible with
solenoid wiring option A. See product data sheet.
NOTE 3: Power for the sensor/LED board needs to be maintained throughout the entire procedure. Pins 1 and 3 must remain connected at all times during this
validation test.
NOTE 4: If FLT light is ashing and either or both solenoid lights are ON – it indicates the monitoring logic is not properly detecting this fault. The M35 unit
should be powered down and monitoring logic reviewed and re-tested before putting into operation again.
NOTE 5: If FLT light is ashing and both solenoid lights are OFF – it indicates the unit has an internal malfunction and should be replaced before continuing
operation.
NOTE 6: Port 2 should be connected to a small volume of approximately 20 cubic inches (~ 300 cubic centimeters) with a gauge or pressure sensor teed into
the line.
NOTE 7:
Supply pressure will need to be supplied to inlet port 1. Insufcient supply ow and/or maximum soft-start settings (adjustment screw almost all the
way in) could prevent detection of some induced faults during the validation test. Be sure not to restrict inlet ow with undersized piping/tubing. Also,
begin testing with the soft start screw backed all the way out - counter-clockwise).
NOTE 8: “-” Indicates no change from previous step.
NOTE 9: Actuate Signal is the signal to switch on the solenoids either from a physical input switch or a software signal.
* Fault should be detected within 50 msec.
** Fault should occur immediately.
M35 Validation Test Procedure for Valve Operation and External Monitoring Logic
Step Action
Sensor
Power
LED
Actuate
Signal
Solenoid
LEDs Port
Conditions
Outlet
Pressure
Sensor Conditions Safety
System
Fault
Valve
Fault
LED
Pass/Fail
Sensor
A
Sensor
B
Sol A & Sol B Sol A Sol B Port 2 (P/F)
1Energize solenoids A & B Green ON Green Green 1 to 2 | 3 Pressure OFF OFF No OFF
2De-energize solenoids A & B Green OFF OFF OFF 1 | 2 to 3 None ON ON - -
3 Disconnect solenoid signal wire from solenoid B Green OFF OFF OFF 1 | 2 to 3 None ON ON No OFF
4Attempt to energize solenoids A & B Green ON - - - - - - Yes*-
5 Reconnect solenoid B Green - - - - - - - - -
6De-energize solenoids A & B Green OFF - - - - - - - -
7 Reset the safety control system Green - - - - - - - No -
8 Disconnect solenoid signal wire from solenoid A Green OFF OFF OFF 1 | 2 to 3 None ON ON No OFF
9Attempt to energize solenoids A & B Green ON - - - - - - Yes*-
10 Reconnect solenoid A Green - - - - - - - - -
11 De-energize solenoids A & B Green OFF - - - - - - - -
12 Reset the safety control system Green - - - - - - - No -
13 Energize solenoids A & B Green ON Green Green 1 to 2 | 3 Pressure OFF OFF No OFF
14 Disconnect solenoid signal wire from solenoid A Green - OFF OFF 1 | 2 to 3 None ON ON Yes*-
15 Reconnect solenoid A Green - - - - - - - - -
16 De-energize solenoids A & B Green OFF - - - - - - - -
17 Reset the safety control system Green - - - - - - - No -
18 Energize solenoids A & B Green ON Green Green 1 to 2 | 3 Pressure OFF OFF No OFF
19 Disconnect solenoid signal wire from solenoid B Green - OFF OFF 1 | 2 to 3 None ON ON Yes*-
20 Reconnect solenoid B Green - - - - - - - - -
21 De-energize solenoids A & B Green OFF - - - - - - - -
22 Reset the safety control system Green - - - - - - - No -

10 © 2021, ROSS CONTROLS®. All Rights Reserved.
M35 Series Integration Guide
23 Disconnect sensor output wire from sensor A Green OFF OFF OFF 1 | 2 to 3 None OFF ON Yes** OFF
24 Attempt to energize solenoids A & B Green ON - - - - - - - -
25 De-energize solenoids A & B Green OFF - - - - - - - -
26 Reconnect sensor A Green - - - - - ON - - -
27 Reset the safety control system Green - - - - - - - No -
28 Disconnect sensor output wire from sensor B Green OFF OFF OFF 1 | 2 to 3 None ON OFF Yes** OFF
29 Attempt to energize solenoids A & B Green ON - - - - - - - -
30 De-energize solenoids A & B Green OFF - - - - - - - -
31 Reconnect sensor B Green - - - - - - ON - -
32 Reset the safety control system Green - - - - - - - No -
33 Energize solenoids A & B Green ON Green Green 1 to 2 | 3 Pressure OFF OFF No OFF
34 Disconnect sensor output wire from sensor A Green - - - - - - - - -
35 De-energize solenoids A & B Green OFF OFF OFF 1 | 2 to 3 None -ON Yes*-
36 Reconnect sensor A Green - - - - - ON - - -
37 Attempt to energize solenoids A & B Green ON - - - - - - - -
38 De-energize solenoids A & B Green OFF - - - - - - - -
39 Reset the safety control system Green - - - - - - - No -
40 Energize solenoids A & B Green ON Green Green 1 to 2 | 3 Pressure OFF OFF No OFF
41 Disconnect sensor output wire from sensor B Green - - - - - - - - -
42 De-energize solenoids A & B Green OFF OFF OFF 1 | 2 to 3 None ON -Yes*-
43 Reconnect sensor B Green - - - - - - ON - -
44 Attempt to energize solenoids A & B Green ON - - - - - - - -
45 De-energize solenoids A & B Green OFF - - - - - - - -
46 Reset the safety control system Green - - - - - - - No -
47 Remove supply air from port 1 Green OFF OFF OFF 1 | 2 to 3 None ON ON No OFF
48 Energize solenoids A & B Green ON - - - - - - Yes*** -
49 Resupply air to port 1 Green ON - - - - - - - -
50 De-energize solenoids A & B Green OFF - - - - - - - -
51 Reset the safety control system Green - - - - - - - No -
52 Energize solenoids A & B Green ON Green Green 1 to 2 | 3 Pressure OFF OFF No -
53 Remove supply air from port 1 Green - OFF OFF 1 | 2 to 3 None ON ON Yes** -
54 Resupply air to port 1 Green - - - - - - - - -
55 De-energize solenoids A & B Green OFF - - - - - - - -
56 Reset the safety control system Green - - - - - - - No -
* Fault should be detected within 50 msec.
** Fault should occur immediately.
*** Fault should occur after 2 seconds.
Step Action
Sensor
Power
LED
Actuate
Signal
Solenoid
LEDs Port
Conditions
Outlet
Pressure
Sensor Conditions Safety
System
Fault
Valve
Fault
LED
Pass/Fail
Sensor
A
Sensor
B
Sol A & Sol B Sol A Sol B Port 2 (P/F)