21 & 27 Series Headline Poppet Valves – Operation Manual (RE-07)

Overview

The ROSS Controls® 21 and 27 Series Headline poppet valves are electrically and pneumatically actuated inline poppet valves available in 2/2-way, 3/2-way, and 4/2-way configurations. The comprehensive operation manual RE-07 (Rev. 08.2016) covers the full Headline 27/21 series product range and is published in nine languages: German (DE), English (EN), French (FR), Italian (IT), Spanish (ES), Russian (RU), Portuguese (PT), Japanese (JA), and Chinese (ZH).

The Headline 27/21 series builds on the proven ROSS Controls poppet valve heritage dating back to the company's founding in 1921. The operation manual provides complete dimensional drawings for 2/2, 3/2, and 4/2-way configurations, actuation type illustrations, and detailed dimensional data for multiple connection thread sizes. Connection threads are available in 1/4–3/8–1/2 inch, 1/2–3/4–1 inch, and 1–1-1/4–1-1/2 inch sizes, with the 4/2-way configuration also available in 1-1/2–2–2-1/2 inch.

Both pneumatic and electrical actuation are available for each valve configuration; the illustration in the operation manual shows pneumatic actuation, with electrical actuation details covered in Chapter 12. Contact ROSS at 1-800-GET-ROSS or visit www.rosscontrols.com.

Key Features

Multilingual Operation Manual – Nine Languages

The RE-07 operation manual supports global deployment of 21/27 Series Headline valves with documentation in German, English, French, Italian, Spanish, Russian, Portuguese, Japanese, and Chinese. This multilingual coverage simplifies compliance in international manufacturing and equipment supply chains, enabling maintenance personnel worldwide to reference safety and operating procedures in their native language.

2/2, 3/2, and 4/2-Way Poppet Valve Configurations

2/2-way Headline valves are available in normally closed configuration (valve shown in the operation manual with illustration of the poppet valve body cross-section). 3/2-way valves accommodate applications requiring both supply and exhaust control. 4/2-way valves (available in 1-1/2 to 2-1/2 inch port sizes) serve applications requiring reversal of actuator direction.

Comprehensive Dimensional Data for Multiple Thread Sizes

The RE-07 manual provides complete dimensional drawings with labeled dimensions AA through LL for each valve configuration. For 2/2-way valves: thread sizes 1/4–1/2 (dimensions AA 88mm, BB 72mm, CC 77mm, DD 48mm), 1/2–1 inch (AA 113mm, BB 90mm), and 1–1-1/2 inch (AA 166mm, BB 167mm). These dimensions enable accurate mechanical design and mounting specification without requiring physical prototypes.

Both Electrical and Pneumatic Actuation Available

All Headline 27/21 configurations support both pneumatic actuation (remote air pilot) and electrical actuation (solenoid pilot). The RE-07 manual's dimensional illustrations show the pneumatic actuation configuration; electrical actuation dimensions and wiring are covered in Chapter 12 of the manual. This dual-actuation availability maximizes flexibility for hazardous area and standard industrial applications.

Technical Specifications

The following information is from the official ROSS Controls 21/27 Series Poppet Valves Operation Manual RE-07 Rev. 08.2016 (Doc ID 1280). For complete dimensional data and actuation specifications, refer to the official document:

Document: RE-07/08.2016 – Multilingual Operation Manual
Languages: DE, EN, FR, IT, ES, RU, PT, JA, ZH
Valve configurations: 2/2-way, 3/2-way, 4/2-way poppet valves
Actuation types: Pneumatic and electrical (both available for all configurations)
Connection thread sizes (2/2, 3/2): 1/4–3/8–1/2 inch; 1/2–3/4–1 inch; 1–1-1/4–1-1/2 inch
Connection thread sizes (4/2): 1-1/2–2–2-1/2 inch
2/2-way 1/4–1/2 key dimensions: AA=88mm, BB=72mm, CC=77mm, DD=48mm, EE=17.5mm, FF=8.7mm, GG=39mm, HH=52mm, JJ=37mm, KK=71.4mm, LL=39.7mm
2/2-way 1/2–1 key dimensions: AA=113mm, BB=90mm, CC=77mm, DD=59mm
2/2-way 1–1-1/2 key dimensions: AA=166mm, BB=167mm, CC=104mm, DD=86mm
For actuation chapter details: see Chapter 12 of Doc ID 1280

Applications

Global Equipment Supply and International Manufacturing

The multilingual RE-07 manual supports ROSS 21/27 Series Headline valves deployed in international manufacturing equipment. Machinery builders supplying equipment globally can ship with this single comprehensive manual and satisfy documentation requirements across Europe, North America, South America, Russia, and Asia-Pacific markets without additional translation costs.

High-Flow 4/2-Way Actuator Reversal Applications

4/2-way Headline valves in the 1-1/2 to 2-1/2 inch size range provide high-flow directional control for large-bore double-acting cylinder reversals in presses, clamping systems, and other heavy actuator applications. The poppet construction handles the high flow rates required for rapid large-actuator cycle times.

Safety and Compliance Standards

The RE-07 operation manual covers safety requirements for all Headline 27/21 series configurations. The 21 and 27 Series poppet valves must not be used for air clutch/brake control on mechanical power presses (this restriction applies to all 21 and 27 Series variants). All installation and maintenance must be performed by trained pneumatic equipment personnel.

Please read all applicable CAUTIONS and WARNINGS in the official RE-07 manual before installation. Disconnect electrical supply and depressurize all air lines before servicing. For safety-critical applications, refer to the SIL certification data for 21 Series valves documented in the separate 21 Series installation instructions (Doc ID 56).

Installation and Setup Guide

Actuator Selection

Select either pneumatic or electrical actuation based on control system requirements. For hazardous areas or where electrical connection is undesirable, pneumatic actuation using a remote air pilot signal is recommended. For PLC or relay-controlled systems, electrical (solenoid) actuation is standard. Chapter 12 of the RE-07 manual provides detailed instructions and wiring diagrams for electrical actuation.

Dimensional Reference for System Design

Use the dimensional drawings in the RE-07 operation manual during system design to verify clearances, pipe routing, and manifold mounting arrangements. The labeled dimension reference (AA through LL) in the manual provides all critical envelope and port dimensions for each valve configuration and thread size.

Pilot Supply Connection

For pneumatic actuation models, the pilot supply pressure must equal or exceed inlet pressure. Connect the pilot supply to the designated pilot port. For electrical actuation models, refer to the solenoid specifications in Chapter 12 and the 21 Series (Doc ID 56) or 27 Series (Doc ID 63) installation instructions for pilot pressure requirements.

Why Choose ROSS Controls

ROSS Controls, with over 100 years of fluid power engineering, provides comprehensive multilingual documentation for global deployment. The 21/27 Series RE-07 operation manual reflects ROSS's commitment to supporting customers worldwide with clear, complete, and translated technical documentation. Combined with full service kit availability, the Headline 27/21 series offers a complete lifecycle solution.

Contact ROSS at 1-800-GET-ROSS or www.rosscontrols.com.

Download This Document

The official ROSS Controls 21 & 27 Series Poppet Valves Operation Manual RE-07 (Doc ID 1280) can be downloaded from the ROSS Controls document library.

PDF Download URL: https://ross-admin-global-us-east.s3.amazonaws.com/production/uploads/document_language_file/file/1280/21_27_Series_Poppet_Valves_Operation_Manual_RE-07-Rev.08.2016.pdf

Frequently Asked Questions

Q: What valve series are covered in the RE-07 operation manual?

A: The RE-07 manual covers both the 21 Series and 27 Series Headline poppet valves in all available sizes: 2/2-way, 3/2-way, and 4/2-way configurations, with pneumatic and electrical actuation options.

Q: What languages is the RE-07 manual available in?

A: The RE-07 manual is published in German, English, French, Italian, Spanish, Russian, Portuguese, Japanese, and Chinese, supporting global deployment of Headline 27/21 series valves.

Q: Can 21 Series valves be used for press clutch/brake applications?

A: No. ROSS 21 Series and 27 Series valves are expressly not intended for use as control valves for air clutch/brake mechanisms on mechanical power presses. Only double valves conforming to OSHA standards should be used in press applications.

Q: What does "Headline series" mean for ROSS poppet valves?

A: The Headline designation refers to the inline mounting configuration of the 21 and 27 Series poppet valves, where the valve installs directly in the pneumatic line. This compact arrangement simplifies piping and allows the valve to be positioned close to the actuated mechanism.

Q: How do I select between pneumatic and electrical actuation?

A: Both pneumatic pilot and electrical solenoid actuation are available for 21 and 27 Series valves. Chapter 12 of the RE-07 manual covers actuator specifications and wiring. Pneumatic actuation is preferred in hazardous areas or where electrical connections are not practical.

Q: What dimensional data is available in the RE-07 manual?

A: The RE-07 manual includes dimensional drawings for 2/2-way, 3/2-way, and 4/2-way configurations across all thread sizes (1/4 through 2-1/2 inch). Labeled dimensions AA through LL cover all key envelope and port dimensions in millimeters.

Q: Where can I download the RE-07 operation manual?

A: The RE-07 operation manual (Doc ID 1280) is available for download from the ROSS Controls document library at www.rosscontrols.com.

Q: What is the revision status of the RE-07 manual?

A: The current revision is RE-07/08.2016, indicating an August 2016 revision. Always verify that you have the current revision by checking www.rosscontrols.com for the latest documentation.