HBB Series Redundant Hydraulic Block and Bleed Safety Valve Systems Operating Instructions (RC-HBB-OI)

Overview

The ROSS Controls HBB Series provides redundant hydraulic block and bleed safety valve systems for applications requiring the highest levels of hydraulic safety performance. The HBB Series is designed to allow the flow of hydraulic fluid into a hydraulic system and to block that flow while simultaneously bleeding downstream energy when the safety function is activated.

The HBB Series achieves Category 4, Performance Level e per ISO 13849-1:2015 and SIL 3 per IEC 62061:2001, with DGUV certification (HSM 220187) confirming independent third-party safety verification. The Declaration of Conformity is available at www.rosscontrols.com.

Available in three sizes — D03, D05, and D07 — with flow capacities of 10, 20, and 50 gallons per minute respectively, the HBB Series covers a broad range of hydraulic press and machine safety applications. ROSS Controls, founded in 1921, has extended its 100+ years of fluid power expertise from pneumatics to hydraulic safety solutions.

Key Features

Block and Bleed Safety Function

When the HBB safety function is activated (valve off or faulted), the system simultaneously blocks the hydraulic supply and bleeds downstream energy to the tank (T port). This dual action — blocking upstream and relieving downstream — provides the most complete hydraulic energy isolation, preventing actuator movement from stored pressure. Note: the ability to bleed may be affected by downstream components such as PO checks or counterbalance valves, which must be considered in the system safety design.

Cat. 4 PL e / SIL 3 Performance — DGUV Certified

DGUV certification (HSM 220187) per ISO 13849-1:2015 confirms Category 4, PL e performance. This certification requires independent testing and verification of the redundant valve design, making the HBB Series one of the most stringently certified hydraulic safety valve products available.

Flexible Mounting with Redundant Port Options

The HBB Series features redundant inlet (P1, P2) and outlet/tank ports, providing piping flexibility to fit diverse hydraulic system layouts. D03 and D05 sizes use in-line SAE threaded ports; D07 uses flanged ports (flanges sold separately). Preferred orientation is horizontal, but any orientation is acceptable.

Integrated Pressure Relief Valve Option

An integrated pressure relief valve option is available for system overpressure protection. Factory preset relief valve settings are available at 1100, 1700, 2200, 2800, 3300, 3900, 4400, 5000, and 5500 psi, corresponding to maximum system operating pressures of 1000 through 5000 psi.

Technical Specifications

Specifications from HBB Series operating instructions (RC-HBB-OI):

Safety Category: Cat. 4, PL e per ISO 13849-1:2015
Safety Integrity Level: SIL 3 per IEC 62061:2001
DGUV Certification: HSM 220187
Standard Voltage: 24 volts DC
Power Consumption: Size D03 & D07 — 30 watts each solenoid; Size D05 — 36 watts
Flow Capacity — Size D03: 0 to 10 gpm; SAE-08 ports (P1, P2, T)
Flow Capacity — Size D05: 0 to 20 gpm; SAE-12 ports
Flow Capacity — Size D07: 0 to 50 gpm; 1-1/4 inch P1/P2 ports; 1-1/2 inch T port (Code 62/61 flanges)
Weight: D03 — 22.7 lb (10.3 kg); D05 — 53.4 lb (24.2 kg)
Ambient Temperature: -22° to 158°F (-30° to 70°C)
Media Temperature: -4° to 176°F (-20° to 80°C)
Flow Media: Mineral Oil HLP, HL per DIN 51524; Vegetable Oil HETG per VDMA 24568
Seal Type: Buna-N
Material Type: Ductile Iron
Valve Type: Double (redundant)
Monitoring: External
Communication: None (standard)

Applications

Hydraulic Press Energy Isolation and Safety Shutoff

Hydraulic presses — including stamping presses, forming presses, and die casting machines — use the HBB Series to block hydraulic flow and bleed downstream pressure during die change, maintenance, and emergency stop events. The Cat. 4, PL e / SIL 3 performance rating satisfies the most demanding hydraulic machine safety requirements.

Industrial Hydraulic Machinery Safety Circuits

Any industrial hydraulic system requiring a redundant safety block-and-bleed function — including injection molding machines, industrial robots, heavy-duty actuator systems, and materials handling equipment — can deploy the HBB Series. The three available sizes accommodate a wide range of hydraulic system flow rates from 10 to 50 gpm.

Safety and Compliance Standards

ISO 13849-1:2015 — Category 4, PL e
IEC 62061:2001 — SIL 3
DGUV Certification — HSM 220187
DIN 51524 — Hydraulic fluid specification (Mineral Oil HLP, HL)
VDMA 24568 — Vegetable oil hydraulic fluid specification
Machinery Directive 2006/42/EC — Declaration of Conformity available at www.rosscontrols.com

Installation and Setup Guide

Mounting and Port Connections

Mount the HBB Series valve preferably in a horizontal orientation (any orientation is acceptable). D03 and D05 sizes connect via SAE threaded ports. D07 uses Code 62 flanges for P1/P2 ports and Code 61 flanges for the T port — flanges are sold separately and must be ordered for D07 applications. Plugs for unused redundant ports are included.

Pressure Relief Valve Selection

Select the integrated pressure relief valve setting to match your system's maximum operating pressure. The factory preset relief valve is set approximately 10% above maximum system operating pressure (e.g., 1100 psi preset for 1000 psi system). If no pressure relief valve is required, specify the "No Pressure Relief Valve" option in the model number.

External Monitoring System Integration

The HBB Series uses external monitoring (model number code "X" for monitoring type). Connect the inductive position switches to the external safety monitoring system per the wiring diagram. Inductive position switch connector pinout: Pin 1 — Supply +24 VDC; Pin 2 — Output Signal NC; Pin 3 — Ground; Pin 4 — Output Signal NO. Note: PNP position switches can be wired as NO or NC by the user.

Why Choose ROSS Controls

ROSS Controls has extended its 100+ year fluid power heritage — founded in 1921 — to hydraulic safety with the HBB, HBH, and HDBH series. The HBB Series combines ROSS's deep expertise in redundant valve design with rigorous hydraulic safety standards, delivering DGUV-certified Cat. 4, PL e / SIL 3 performance in hydraulic block-and-bleed applications. Contact ROSS at 1-800-GET-ROSS or visit www.rosscontrols.com.

Download This Document

The official HBB Series Hydraulic Block and Bleed Safety Valve Systems Operating Instructions (RC-HBB-OI) are available as a free PDF download.

PDF Download URL: https://ross-admin-global-us-east.s3.amazonaws.com/production/uploads/document_language_file/file/203/ROSS_Hydraulic_Block_and_Bleed_HBB_Series_Operating_Instructions_RC-HBB-OI.pdf

Frequently Asked Questions

Q: What is the block and bleed safety function?

A: The block and bleed function simultaneously blocks the hydraulic supply flow (blocks Port P1/P2) and bleeds downstream energy to the tank port (T) when the safety function is activated. This provides complete upstream blocking and downstream pressure relief in a single valve operation.

Q: What safety certifications does the HBB Series carry?

A: The HBB Series carries Category 4, PL e per ISO 13849-1:2015; SIL 3 per IEC 62061:2001; and DGUV certification HSM 220187. Declaration of Conformity is available at www.rosscontrols.com.

Q: What are the available sizes and flow rates?

A: D03: 0–10 gpm with SAE-08 ports. D05: 0–20 gpm with SAE-12 ports. D07: 0–50 gpm with Code 62 flanged P1/P2 ports and Code 61 T port (flanges sold separately).

Q: What hydraulic fluids are compatible?

A: Compatible fluids include Mineral Oil HLP and HL per DIN 51524, and Vegetable Oil HETG per VDMA 24568.

Q: What is the operating temperature range?

A: Ambient temperature: -22° to 158°F (-30° to 70°C). Media (hydraulic fluid) temperature: -4° to 176°F (-20° to 80°C).

Q: Does the HBB Series include an integrated monitor?

A: No — the HBB Series uses external monitoring (monitoring type "X"). The inductive position switches must be wired to an external safety monitoring or safety relay system.

Q: Are flanges included with the D07 size?

A: No. Flanges for the P1, P2, and T ports on D07 size are not included — they must be purchased separately.

Q: Can the downstream bleed function be affected by other circuit components?

A: Yes. PO check valves, counterbalance valves, and closed-center directional valves downstream of the HBB can block or restrict the bleed function. Careful safety design analysis of the full hydraulic circuit is required to confirm that the downstream bleed function operates as intended.

Q: What voltage is required for the HBB Series?

A: Standard voltage is 24 volts DC. Power consumption is 30 watts per solenoid for D03 and D07 sizes, and 36 watts per solenoid for D05.

Q: Is the HBB Series suitable for long-term hydraulic holding applications?

A: Block and Bleed functions are intended to block supply and bleed downstream energy when switched off — not for long-term holding. If extended holding is required, additional components such as PO checks or mechanical locking devices should be incorporated into the circuit.