Ross W60 Series User manual

Pneumatic equipment should be installed only by
persons trained and experienced in such installation.
Air Lines: Before installing a valve in a new or an
existing system, the air lines must be blown clean of
all contaminants. It is recommended that an air filter be
installed in the inlet line close to the valve.
Valve Inlet (Port 1): Be sure that the supply line is of
adequate size and does not restrict the air supply because of
a crimp in the line, sharp bends, or a clogged filter element.
Valve Outlets (Ports 2 & 4): For faster pressurizing and
exhausting of the mechanism being operated by the valve,
locate the valve as close as possible to the mechanism.
The lines must be of adequate size and be free of crimps
and sharp bends.
Valve Exhausts (Ports 3 & 5): To reduce exhaust noise
use an efficient silencer. ROSS silencers reduce impact
noise by as much as 25 dB, and produce little back pressure.
Electrical Supply: The voltage and hertz ratings for
solenoid pilot-operated valves are printed on the side of
each solenoid. It is important that
the electrical supply used to power
the valve is equal to these ratings
to avoid possible solenoid burnout.
The electrical connection for such
valves is achieved by means of
a connector whose connections
correspond to the prongs pictured in
the sketch of a typical solenoid pilot.
If power is supplied by a transformer it must be capable
of handling the inrush current without significant voltage
drop. See Valve Specifications on page 2 for information
on inrush current.
Operating Pressures and Temperatures: Allowable
ranges for pressure and temperatures are given in the
Valve Specifications on page 2. Exceeding the values
shown can shorten valve life.
Pilot Supply:
Pressure Control: For valves with single remote pressure
control, connect the control line to port 14 in the sub-base
or manifold. For valves with double remote pressure
control, connect the control lines to both ports 12 and
14 in the base. See Valve Specifications on page 2 for
required pressures.
Solenoid Control: Pressure for the pilot valves is supplied
from the inlet port. Be sure that port 14 in the base is
plugged or pilot air will escape. If the valve must operate
with an inlet pressure less than the required pilot pressure
(see Valve Specifications on page 2), an external pilot
supply of sufficient pressure must be provided. Connect
the external pilot supply to port 14 in the base.
Vacuum or Non-Air Service: Such applications require
an external pilot supply for solenoid valves. Connect to
port 14 in the base.
Pipe Installation: To install pipe in valve or 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.
Thank You!
You have purchased a premium-quality ROSS® pneumatic valve.
It is a stainless-steel spool and sleeve valve built to the highest standards.
With care in its installation and maintenance you can expect it to have a
long and economical service life. So before you go any further, please
take a few minutes to look over the information in this document. Then,
save it for future reference and for the useful service information it contains.
W60 Series ISO 5599-1 Valves
Please read and make sure you understand all installation instructions before proceeding with the installation.
Additional technical documentation is available for download at 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 rosscontrols.com to find your distributor.
VALVE INSTALLATION
ROSS CONTROLS®rosscontrols.com

IMPORTANT NOTE: Please read carefully and thoroughly all
the WARNINGS and CAUTIONS on page 4.
Supply Clean Air: Foreign material lodging in valves is a major
cause of breakdowns. The use of an air filter located as close
to the valve as possible is strongly recommended. The filter
bowl should be drained regularly. If the filter's location makes
manual draining difficult, the filter should be equipped with an
automatic drain.
Check Lubricator Supply Rate: A lubricator should put
atomized oil into the air line in direct proportion to the rate of
air flow. Excessive air line 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 of air flow
is adequate. (Note that your ROSS valve does not itself 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 thereby
cause the valve to malfunction. The best oils to use are those
specifically compounded for air line lubricator service.
Cleaning 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. To clean
the valve use a solvent which will dry without leaving a residue.
This is especially important for the spool-and-sleeve assembly.
Do not use a chlorinated solvent or abrasive materials which
can damage seals or do permanent damage to metal parts.
To reassemble the spool and sleeve put one drop of Anderol
735 (or equivalent lubricant) on each spool land. Insert the
spool into the sleeve and rotate it several times to ensure
even distribution of the lubricant. If the valve is used in a non-
lubricated application, do not use a lubricant for reassembly
which can dry out and leave a residue. Dry assembly of the
spool and sleeve is preferable. Each spool and sleeve is a
matched set, so care must be taken not to reverse the position
of the spool in the sleeve.
Before inserting the spool-and-sleeve into the valve body,
very lightly lubricate the O-rings with a lubricant compounded
for use on Buna-N seals. Do not use Anderol; it causes the
O-rings to deteriorate.
Electrical Contacts: In the external electrical circuits
associated with the valve solenoids, keep all switches
orrelay contactsingood condition to avoid solenoid malfunctions.
Replace Worn Components: After long usage the spool and
sleeve may show signs of wear, as indicated by excessive
air leakage between ports. The valve can be completely
reconditioned with the use of a ROSS valve body service kit.
See page 3 for information about such kits.
VALVE SPECIFICATIONS
Typical cross section of a ROSS W60 Series
spool and sleeve valve body, spring return model shown.
2 ROSS CONTROLS®
VALVE MAINTENANCE
Construction Design Spool and Sleeve
Mounting Type Base
Flow Media Filtered air
Construction Material
Valve Body: Bar Stock Aluminum
Spool: Stainless Steel
Seals: Buna-N
Pressure Controlled Valves
Temperature Ambient/Media: 40° to 175°F (4° to 80°C)
For other temperature ranges, consult ROSS.
Operating Pressure
Vacuum to 150 psig (10 bar)
Pilot Supply - External:
ISO Size 1: Minimum 30 psig (2 bar)
ISO Size 2 & 3: Minimum 15 psig (1 bar)
Pilot supply pressure must be equal to or greater
than inlet pressure.
Solenoid Pilot Controlled Valves
Solenoids Rated for continuous duty
Voltage 24 volts DC; 110-120 volts AC, 50/60 Hz
Power Consumption
(each solenoid)
6 watts on DC; 11 VA inrush, 8.5 VA holding on 50
or 60 Hz
Enclosure Rating IP65, IEC 60529
Electrical Connections EN 175301-803 Form A connector
Temperature
Ambient: 40° to 120°F (4 to 50°C)
Media: 40° to 175°F (4° to 80°C)
For other temperature ranges, consult ROSS.
Pilot Supply Internal or External; Selected automatically
Operating Pressure
Vacuum to 150 psig (10 bar)
Pilot Supply - Internal or External:
ISO Size 1: Minimum 30 psig (2 bar)
ISO Size 2 & 3: Minimum 15 psig (1 bar)
When external pilot supply, pressure must be equal
to or greater than inlet pressure.
Manual Override Flush; Metal, non-locking

VALVE SERVICE
Valve Body Service Kits: These kits contain all parts
needed for a complete reconditioning of a valve body.
Included are a spool and sleeve assembly, all required
gaskets and seals, detent assemblies for valves requiring
them, and instructions for use.
Valve-to-Base Gasket: If your valve is removed from its
base for any reason, a new valve-to-base gasket must be
used to ensure a leak-free seal. (This gasket is included
as a part of all valve body service kits.)
Solenoid Coils: Replacement coils for solenoid
controlled valves can be ordered by part number listed
in the table below.
Complete Solenoid Pilot Assemblies: These assem-
blies consist of new pilot valve mechanisms and a new
solenoid coil, ready to bolt in position on the valve.
rosscontrols.com 3
Listed below are the parts and service kits most
likely to be needed if your valve requires service.
Valve Model
Number
Valve Body
Service Kit
Valve-to-Base
Gasket
W6056B2411 1020K77 617B11
W6056B2417 831K77 617B11
W6056B3411 832K77 618B11
W6056B3417 916K77 618B11
W6056B4411 833K77 619B11
W6056B4417 917K77 619B11
W6057B2411 837K77 617B11
W6057B2417 838K77 617B11
W6057B3411 839K77 618B11
W6057B3417 840K77 618B11
W6057B4411 841K77 619B11
W6057B4417 842K77 619B11
W6076B2401 1020K77 617B11
W6076B2407 831K77 617B11
W6076B3401 832K77 618B11
W6076B3407 916K77 618B11
W6076B4401 833K77 619B11
W6076B4407 917K77 619B11
W6077B2401 837K77 617B11
W6077B2407 838K77 617B11
W6077B3401 839K77 618B11
W6077B3407 840K77 618B11
W6077B4401 841K77 619B11
W6077B4407 842K77 619B11
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
rosscontrols.com for available downloadable technical documentation.
Voltage
Complete Solenoid
Pilot Assemblies
Replacement
Solenoid Coils
Part Number Part Number
24 volts DC
48 volts AC 851C79165 306K33165
110-120 volts AC
48 volts DC 851C79166 306K33166
210-220 volts AC
110 volts DC 851C79167 306K33167
Electrical
Connector Electrical Connector Type Cord Length
meters (feet)
Cord
Diameter
Electrical Connector Model Number
Without
Light
Lighted Connector*
24 Volts DC 120 Volts AC
EN 175301-803
Form A
Prewired Connector (18 gauge) 2 (6½) 6-mm 721K77 720K77-W 720K77-Z
Prewired Connector (18 gauge) 2 (6½) 10-mm 371K77 383K77-W 383K77-Z
Connector for threaded conduit
(1/2 inch electrical conduit fittings) – – 723K77 724K77-W 724K77-Z
Connector Only – – 937K87 936K87-W 936K87-Z
*Lights in connectors with a translucent housing can be used as indicator lights to show when solenoids are energized.

Printed in the U.S.A. – Rev. 06/19 © 2019, ROSS CONTROLS®. All Rights Reserved. Form SS097
Content subject to change.
PRE-INSTALLATION or SERVICE
1. Before servicing a valve or other pneumatic component, be sure
that all sources of energy are turned off, the entire pneumatic system
is shut off and exhausted, and all power sources are locked out (ref:
OSHA 1910.147, EN 1037).
2. All ROSS®products, including service kits and parts, should
be installed and/or serviced only by persons having training and
experience with pneumatic equipment. Because any installation can be
tampered with or need servicing after installation, persons responsible
for the safety of others or the care of equipment must check every
installation on a regular basis and perform all necessary maintenance.
3. All applicable instructions should be read and complied with before
using any fluid power system in order to prevent harm to persons
or equipment. In addition, overhauled or serviced valves must be
functionally tested prior to installation and use. If you have any
questions, call your nearest ROSS location listed in the table below.
4. Each ROSS product should be used within its specification limits.
In addition, use only ROSS parts to repair ROSS products.
WARNINGS: Failure to follow these directions can adversely affect
the performance of the product or result in the potential
for human injury or damage to property.
FILTRATION and LUBRICATION
5. Dirt, scale, moisture, etc. are present in virtually every air system.
Although some valves are more tolerant of these contaminants than
others, best performance will be realized if a filter is installed to clean
the air supply, thus preventing contaminants from interfering with the
proper performance of the equipment. ROSS recommends a filter
with a 5-micron rating for normal applications.
6. All standard ROSS filters and lubricators with polycarbonate
plastic bowls are designed for compressed air applications only. Do
not fail to use the metal bowl guard, where provided, to minimize
danger from high pressure fragmentation in the event of bowl failure.
Do not expose these products to certain fluids, such as alcohol or
liquefied petroleum gas, as they can cause bowls to rupture, creating
a combustible condition, hazardous leakage, and the potential for
human injury or damage to property. Immediately replace a crazed,
cracked, or deteriorated bowl. When bowl gets dirty, replace it or
wipe it with a clean dry cloth.
7. Only use lubricants which are compatible with materials used in
the valves and other components in the system. Normally, compatible
lubricants are petroleum based oils with oxidation inhibitors, an
aniline point between 180°F (82°C) and 220°F (104°C), and an ISO
32, or lighter, viscosity. Avoid oils with phosphate type additives
which can harm polyurethane components, potentially leading to
valve failure which risks human injury, and/or damage to property.
AVOID INTAKE/EXHAUST RESTRICTION
8. Do not restrict the air flow in the supply line. To do so could reduce
the pressure of the supply air below the minimum requirements for
the valve and thereby cause erratic action.
9. Do not restrict a valve’s exhaust port as this can adversely affect
its operation. Exhaust silencers must be resistant to clogging and
must have flow capacities at least as great as the exhaust capacities
of the valves. Contamination of the silencer can result in reduced
flow and increased back pressure.
WARNINGS:
ROSS expressly disclaims all warranties and responsibility for any
unsatisfactory performance or injuries caused by the use of the
wrong type, wrong size, or an inadequately maintained silencer
installed with a ROSS product.
POWER PRESSES
10. Mechanical power presses and other potentially hazardous
machinery using a pneumatically controlled clutch and brake
mechanism must use a press control double valve with a monitoring
device. A double valve without a self-contained monitoring device
should be used only in conjunction with a control system which
assures monitoring of the valve. All double valve installations involving
hazardous applications should incorporate a monitoring system which
inhibits further operation of the valve and machine in the event of a
failure within the valve mechanism.
ENERGY ISOLATION/EMERGENCY STOP
11. Per specifications and regulations, ROSS L-O-X® valves
and L-O-X® valves with EEZ-ON® operation are defined as energy
isolation devices, NOT AS EMERGENCY STOP DEVICES.
CAUTIONS And WARNINGS
ROSSCONTROLS USA Tel: [phone] www.rosscontrols.com
ROSS EUROPA GmbH Germany Tel: [phone] www.rosseuropa.com
ROSS ASIA K.K. Japan Tel: [phone] www.rossasia.co.jp
ROSS UK Ltd. UK Tel: [phone] www.rossuk.co.uk
ROSS SOUTH AMERICA Ltda. Brazil Tel: [phone] www.rosscontrols.com.br
ROSS CONTROLS INDIA Pvt. Ltd. India Tel: [phone] www.rosscontrols.com
ROSS CONTROLS (CHINA) Ltd. China Tel: [phone] www.rosscontrolschina.com
ROSS FRANCE S.A.S. France Tel: [phone] www.rossfrance.com
ROSS CANADA Canada Tel: [phone]-ROSS (7677) www.rosscanada.com
(6077170 CANADA INC. A
N
INDEPENDENT REPRESENTATIVE)
STANDARD WARRANTY
All products sold by ROSS CONTROLS are warranted for a one-year period [with the exception of
all Filters, Regulators and Lubricators (“FRLs”) which are warranted for a period of seven years]
from the date of purchase to be free of defects in material and workmanship. ROSS’ obligation
under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS
and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective. This warranty
becomes void in the event that product has been subject to misuse, misapplication, improper maintenance, modification or tampering.
THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS
ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE. ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL
OCCUPATIONAL SAFETY AND/OR HEALTH LAWS OR REGULATIONS. IN NO EVENT IS ROSS LIABLE TO PURCHASER, USER, THEIR
EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL 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.