35 Series CrossFlow™ Double Valves with Dual Pressure Switches Operating Instructions (RC-35CF-OI)
Overview
The ROSS Controls 35 Series CrossFlow™ Double Valves with Dual Pressure Switches represent the most advanced configuration in the 35 Series press safety family. These valves achieve up to Category 4, Performance Level e per ISO 13849-1:2015 and SIL 3 per IEC 62061 when properly integrated into a compliant safety monitoring system. DGUV certification (HM 210002) and Declaration of CE Conformity confirm the highest safety credentials.
The 35 Series CrossFlow™ design incorporates dual pressure switches to provide simultaneous monitoring of both valve elements. When properly implemented with a compatible external safety monitor or safety PLC, these valves satisfy the requirements for the most demanding press safety circuits in both North American (OSHA, ANSI) and European (EN 692, Machinery Directive) regulatory environments.
Product key identification covers Basic Size 4 (port sizes 1/4 and 3/8) and larger sizes (Basic Sizes 8, 12) with flanged ports and various actuation options including DC solenoid, AC solenoid, M12 solid state pressure sensors, and EN mechanical pressure switches. ROSS Controls has been the trusted name in press safety valves since 1921. Contact ROSS at 1-800-GET-ROSS or visit www.rosscontrols.com.
Key Features
Up to Cat. 4, PL e / SIL 3 with External Safety Monitor
The 35 Series CrossFlow™ achieves its highest safety ratings — Category 4, Performance Level e, SIL 3 — when integrated with a compatible safety monitoring system. DGUV certification (HM 210002) per ISO 13849-1:2015 is documented and available for download at www.rosscontrols.com.
Dual Pressure Switches for Complete Element Monitoring
Two pressure switches, one per valve element, continuously monitor whether both elements shift synchronously. Basic Size 4 models support both EN mechanical pressure switches and M12 solid state pressure sensors. These dual switch outputs provide the feedback needed for Cat. 4 safety monitoring implementations.
Product Key for Custom Configuration
The 35 Series CrossFlow™ product key covers port thread (NPT blank, G-D), actuation (DC current, AC current), pressure switch options (none, two EN mechanical, two M12 solid state), port sizes (1/4, 3/8 for Basic Size 4; 1/2 and 3/4 for larger sizes), and inlet orientation (left-hand, right-hand). Flanged port options are available for larger sizes. This configurability allows the valve to match diverse press room plumbing layouts.
CrossFlow™ Architecture
Both main valve elements must shift fully before Port 2 can be pressurized. CrossFlow™ passages between the elements provide this physical redundancy. The dual pressure switches verify synchronous shifting of both elements, and the external safety monitor acts on any detected discordance to prevent further press cycling.
Technical Specifications
Specifications from the 35 Series CrossFlow™ operating instructions (RC-35CF-OI):
- Safety Category (with external monitor): Up to Cat. 4, PL e per ISO 13849-1:2015
- Safety Integrity Level: Up to SIL 3 per IEC 62061
- DGUV Certification: HM 210002
- Valve Type: CrossFlow™ double valve with dual pressure switches
- Basic Size 4 Port Sizes: 1/4 and 3/8 inch (NPT or G thread)
- Larger Basic Sizes: Flanged ports, 1/2 and 3/4 inch
- Actuation Options: DC solenoid, AC solenoid
- Pressure Switch Options: None; two EN mechanical; two M12 solid state pressure sensors
- Inlet Orientation: Left-hand (Z) or right-hand (Y)
- Mounting: Inline
- External Monitor Required: Yes
- Declaration of CE Conformity: Available at www.rosscontrols.com
Applications
Mechanical Power Press Safety — Highest Safety Category
The 35 Series CrossFlow™ with dual pressure switches and a compatible safety monitor is deployed in the most demanding mechanical press safety applications requiring documented Category 4, PL e performance. Stamping, forming, blanking, and progressive die press applications with the highest operator risk levels are appropriate targets for this valve configuration.
Press Brake and Shear Machine Safety
Press brake and power shear applications with air clutch/brake mechanisms can use the 35 Series CrossFlow™ to achieve Cat. 4 safety performance when combined with a certified external safety monitor. The flanged port options for larger sizes accommodate the high flow rates needed by large-tonnage press brake installations.
Safety and Compliance Standards
- ISO 13849-1:2015 — Up to Cat. 4, PL e (with external safety monitor)
- IEC 62061 — Up to SIL 3
- DGUV Certification — HM 210002
- OSHA 29 CFR 1910.217 — Mechanical power press safety
- ANSI B11.1 — Mechanical power press safety
- EN 692 — Mechanical power press safety (EU)
- Machinery Directive 2006/42/EC — Declaration of CE Conformity
Installation and Setup Guide
Air Supply Preparation
Blow all air lines clean before installation. Install a 5-micron-rated air filter close to the valve inlet. Adequate supply pressure and volume on demand are critical — insufficient supply can cause nuisance lockouts.
Electrical and Pressure Switch Connections
Connect pilot solenoids per the valve's circuit diagram. For pressure switch models, wire both pressure switches to the external safety monitor per the wiring diagram supplied with the valve. M12 solid state pressure sensors use standard M12 connector wiring. Contact ROSS Technical Service at 1-888-TEK-ROSS for connection guidance.
External Safety Monitor Integration
The external safety monitor must be selected and configured to respond to the dual pressure switch outputs. The monitor must inhibit valve cycling when element discordance is detected. Proper monitor selection and integration is essential for achieving Cat. 4, PL e / SIL 3 performance.
Why Choose ROSS Controls
ROSS Controls was founded in 1921 and has over 100 years of expertise in fluid power and press safety. The 35 Series CrossFlow™ represents the latest evolution of ROSS's proven press safety valve technology, achieving the highest available safety ratings when properly integrated. Contact ROSS at 1-800-GET-ROSS or visit www.rosscontrols.com.
Download This Document
35 Series CrossFlow™ Double Valves Operating Instructions (RC-35CF-OI) are available as a free PDF download from ROSS Controls.
PDF Download URL: https://ross-admin-global-us-east.s3.amazonaws.com/production/uploads/document_language_file/file/1711/35_Series_CrossFlow_Series_Double_Valves_Operating_Instructions_RC-35CF-OI.pdf
Related Products and Resources
- 35 Series SERPAR® CrossFlow® Double Valves (Basic Size 1 & 2, SS146)
- 35 Series SERPAR® CrossFlow® with Pressure Switches (Basic Sizes 4–30, SS147)
- 35 Series SERPAR® Double Valves with Dual Monitoring
- DM2® Series D/F Double Valves Operating Instructions (RC-DM-DF-OI)
- ROSS External Safety Monitors — for use with CrossFlow™ valves
- ROSS L-O-X® Lockout Valves — energy isolation
Frequently Asked Questions
Q: What safety category does the 35 Series CrossFlow™ achieve?
A: Up to Category 4, PL e per ISO 13849-1:2015 and SIL 3 per IEC 62061, when properly integrated with a compatible external safety monitoring system. DGUV certification HM 210002 is available for download at www.rosscontrols.com.
Q: Do these valves include an integrated safety monitor?
A: No. These valves use dual pressure switches to detect valve element discordance and must be connected to an external safety monitor or safety PLC. The external monitor provides the lockout function.
Q: What are the pressure switch options?
A: Options include no pressure switches, two EN mechanical pressure switches, and two M12 solid state pressure sensors. The M12 option provides modern sensor interface for integration with safety PLCs.
Q: What port sizes are available?
A: Basic Size 4 uses 1/4 and 3/8 inch port sizes (NPT or G). Larger Basic Sizes use flanged ports in 1/2 and 3/4 inch sizes. Consult the product key identification section of the operating instructions for full configuration details.
Q: What inlet orientation options are available?
A: Left-hand (Z) and right-hand (Y) inlet orientations are available, allowing the valve to be configured for different press control panel plumbing layouts.
Q: Where can I download the DGUV certification?
A: DGUV certification HM 210002 and the Declaration of CE Conformity are available for download at www.rosscontrols.com.
Q: What external monitors are compatible with this valve?
A: Contact ROSS Technical Service at 1-888-TEK-ROSS for guidance on compatible external safety monitors for the 35 Series CrossFlow™.
Q: How does the CrossFlow™ architecture differ from a standard double valve?
A: In a standard parallel double valve, the elements are arranged so either element alone could pass air. In the CrossFlow™ design, airflow passes through passages that cross between both elements, requiring both to shift fully before Port 2 can be pressurized. This adds physical redundancy on top of the electronic monitoring provided by the dual pressure switches.