W64 Series ISO 5599-1 Valves – Installation & Operating Instructions

Overview

The ROSS Controls® W64 Series represents a premium-quality single-spindle poppet valve built to ISO 5599-1 interface standards. Engineered and manufactured by ROSS Controls, a company founded in 1921 with over 100 years of fluid power expertise, the W64 Series delivers reliable directional control in demanding industrial pneumatic applications. These valves are designed for base mounting and are available with solenoid pilot or remote pressure pilot actuation.

W64 Series valves incorporate a poppet design that offers inherently high resistance to particulate contamination and provides fast, consistent response. The ISO 5599-1 interface ensures interchangeability with other ISO-compliant bases and manifolds, simplifying system integration and future upgrades. Solenoid variants feature IP65-rated electrical enclosures with standard DIN plug-in connectors.

ROSS Controls has served industries ranging from automotive assembly to food and beverage processing since 1921. The W64 Series reflects this heritage through its precision manufacturing and comprehensive service kit availability. Customers requiring technical support can contact ROSS at 1-800-GET-ROSS or visit www.rosscontrols.com.

Key Features

Single-Spindle Poppet Construction

The W64 Series uses a single-spindle poppet valve design machined from bar-stock aluminum. The poppet mechanism provides a direct, positive seating action that minimizes internal leakage and resists the effects of contaminated air supply more effectively than spool-type valves. The construction includes a stainless steel spool with Buna-N seals, delivering consistent performance across a wide range of operating pressures.

ISO 5599-1 Interface Compliance

Designed to the ISO 5599-1 standard, W64 Series valves mount directly on ISO-compliant sub-bases and manifolds. The standardized port layout (Ports 1, 2, 3, 4, 5 plus pilot ports 12 and 14) allows replacement or upgrade without modifying the base or associated piping. This ISO compliance reduces spare parts inventory requirements in facilities operating mixed-supplier pneumatic systems.

IP65-Rated Solenoid Enclosures with DIN Connectors

Solenoid pilot versions of the W64 Series feature IP65-rated enclosures per IEC 60529, providing protection against dust ingress and low-pressure water jets. The plug-in DIN connector interface allows fast solenoid replacement without disturbing system wiring. Solenoids are rated for continuous duty at 24 VDC or 110–120 VAC (50/60 Hz), with LED indicator lights available for visual status confirmation.

Internal or External Pilot Supply Selection

The W64 Series automatically selects between internal and external pilot supply based on system configuration. For applications where inlet pressure falls below the minimum pilot pressure requirement, an external pilot supply can be connected to port 14 in the sub-base, ensuring reliable actuation across a broad range of operating conditions including vacuum and non-air service.

Technical Specifications

The following specifications are drawn directly from the official ROSS Controls W64 Series installation documentation (Doc ID 1283):

Construction Design: Poppet
Mounting Type: Base (ISO 5599-1 interface)
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: Plug-in connector (DIN)
Pilot Supply: Internal or External; selected automatically
Valve Body Material: Bar stock aluminum
Spool Material: Aluminum & stainless steel
Seal Material: Buna-N
Flow Media: Filtered air
Pressure Controlled Valves – Ambient/Media Temperature: Contact ROSS for temperature ranges
Solenoid Pilot Controlled Valves – Ambient Temperature: See product documentation

Compatible lubricants for air line systems include: Amoco American Industrial Oil 32, Amoco Spindle Oil C, Amolite 32; Citgo Pacemaker 32; Exxon Spinesstic 22 and Teresstic 32; Mobil Velocite 10; Non-Fluid Oil Air Lube 10H/NR; Shell Turbo T32; Sun Sunvis 11 and Sunvis 722; Texaco Regal R&O 32; Union Turbine Oil. Avoid oils with phosphate additives such as zinc dithiophosphate, and diester oils. Recommended valve grease: Dow Corning BR-2.

Applications

Industrial Automation and Assembly

W64 Series valves are widely deployed in industrial automation applications including pneumatic cylinder actuation, rotary actuator control, and multi-axis positioning systems. The ISO 5599-1 interface makes them compatible with manifold systems commonly used in automotive assembly, general manufacturing, and packaging machinery. Their poppet construction provides the reliable, repeatable cycling required in high-duty-cycle automation environments.

Process Control and Material Handling

In process industries, W64 Series valves provide directional control for pneumatic actuators in material handling, conveying, and sorting equipment. The availability of both solenoid-pilot and pressure-pilot control options makes these valves adaptable to a wide range of control architectures, from simple on/off control to sophisticated PLC-driven sequences with feedback monitoring.

Safety and Compliance Standards

The W64 Series is designed and manufactured in accordance with ISO 5599-1 dimensional and interface standards. Solenoid electrical enclosures meet IEC 60529 IP65 protection rating. All pneumatic equipment including ROSS W64 Series valves must be installed and maintained exclusively by persons trained and experienced in pneumatic systems.

Prior to installation, all air lines must be blown clean of contaminants. The electrical supply voltage and frequency must correspond exactly to the ratings printed on the solenoid housing to prevent premature solenoid failure. Before any disassembly or service, the electrical power supply must be de-energized, the air supply shut off, and the system fully exhausted. ROSS recommends a 5-micron rated air filter installed close to the valve in the inlet line.

Installation and Setup Guide

Pre-Installation Checks

Before installing a W64 Series valve, confirm that all air lines have been blown clean of scale, weld slag, moisture, and other contaminants. Verify that the supply line is of adequate size and free of crimps, sharp bends, or clogged filter elements that could restrict airflow to Port 1 (inlet). Confirm that the electrical supply voltage and frequency match the solenoid ratings printed on the housing.

Valve and Base Mounting

W64 Series valves mount on ISO 5599-1 compliant sub-bases. Install pipe in valve or base ports by engaging pipe one turn, applying pipe thread sealant to male threads (tape not recommended), and tightening. This sequence prevents sealant from entering and contaminating valve internals. For solenoid pilot models, ensure port 14 in the base is plugged if using internal pilot supply; failure to plug port 14 will allow pilot air to escape.

Pilot Supply Connection

For pressure-controlled valves with single remote control, connect the control line to port 14 in the sub-base or manifold. For double remote pressure control, connect control lines to both ports 12 and 14. For solenoid-controlled models requiring external pilot supply (e.g., when inlet pressure is below minimum pilot pressure), connect the external pilot supply to port 14. For non-air service applications, an external pilot supply is always required.

Electrical Connection

Connect the plug-in electrical connector to the solenoid prongs as illustrated in the installation documentation. If power is supplied by a transformer, it must handle inrush current without significant voltage drop – the W64 Series solenoid draws 11 VA inrush at AC. Solenoid LED indicators, where fitted, provide at-a-glance confirmation of solenoid energization.

Why Choose ROSS Controls

ROSS Controls, founded in 1921, has over 100 years of experience engineering fluid power solutions for the world's most demanding industrial applications. From automotive press lines to semiconductor clean rooms, ROSS products are trusted for their precision, reliability, and comprehensive application support. The W64 Series continues this tradition with ISO-compliant design, full service kit availability, and global distributor support.

Every ROSS pneumatic valve is backed by a one-year warranty and a global network of authorized distributors. ROSS Technical Services provides application engineering support for complex installations, non-standard media, and safety-critical control systems. Contact ROSS at 1-800-GET-ROSS or visit www.rosscontrols.com for distributor locations, downloadable documentation, and service kit ordering.

Download This Document

The official ROSS Controls W64 Series ISO 5599-1 Valves Installation Instructions (Doc ID 1283) can be downloaded directly from the ROSS Controls document library.

PDF Download URL: https://ross-admin-global-us-east.s3.amazonaws.com/production/uploads/document_language_file/file/1283/ROSS_W64_Series_ISO_5599-1_Valves_Installation_Instructions.pdf

Frequently Asked Questions

Q: What standard interface does the W64 Series valve use?

A: The W64 Series uses the ISO 5599-1 interface standard, which defines the mounting hole pattern, port locations, and port sizes for compatibility with ISO-compliant sub-bases and manifolds.

Q: What voltages are available for W64 Series solenoid models?

A: W64 Series solenoid pilot valves are available in 24 volts DC and 110–120 volts AC (50/60 Hz). The voltage rating is printed on the solenoid housing. The electrical supply must correspond exactly to these ratings.

Q: What is the IP rating of the W64 Series solenoid enclosure?

A: The solenoid pilot enclosures are rated IP65 per IEC 60529, providing protection against dust ingress and low-pressure water jets. This rating makes them suitable for typical industrial environments.

Q: Does the W64 Series valve require air line lubrication?

A: No. W64 Series valves do not require air line lubrication. However, they can be used in systems with lubricated air supplied to other mechanisms. Avoid oils with phosphate additives or diester-based oils, which can damage valve seals and components.

Q: How do I connect the pilot supply for external pilot operation?

A: For external pilot supply on solenoid-controlled models, connect the external pilot supply line to port 14 in the sub-base or manifold. Ensure port 14 is not plugged when using external pilot supply. For internal pilot operation, port 14 must be plugged to prevent pilot air from escaping.

Q: Can the W64 Series be used for non-air (vacuum or fluid) applications?

A: Non-air service applications, including vacuum, require an external pilot supply for solenoid-controlled valves. Connect the external pilot supply to port 14 in the base. For fluid media other than air, consult ROSS Technical Services to confirm compatibility.

Q: What pipe thread sealant should I use during installation?

A: Apply pipe thread sealant to male threads only. Pipe thread tape is not recommended as it can shred and contaminate the valve interior. Engage the pipe one turn before applying sealant, then tighten.

Q: Where can I order service kits and replacement parts for the W64 Series?

A: Service kits for W64 Series valves are available from ROSS Controls and authorized ROSS distributors. Contact ROSS at 1-800-GET-ROSS, visit www.rosscontrols.com to locate your nearest distributor, or reference the service kit information in the official installation document (Doc ID 1283).

Q: How should I clean the W64 Series valve?

A: Use a good commercial solvent to clean the valve interior. Do not scrape varnished surfaces. Avoid chlorinated solvents as they damage seals, and avoid abrasive materials which can permanently damage metal parts. Lubricate all sliding surfaces with Dow Corning BR-2 grease before reassembly.

Q: What is the solenoid power consumption of the W64 Series?

A: Each solenoid consumes 6 watts on DC and 11 VA inrush / 8.5 VA holding on 50 or 60 Hz AC. If power is supplied by a transformer, it must handle the 11 VA inrush current without significant voltage drop.