ISO Base Mounted Valve Series Coverage

ISO 15407-1 and ISO 15407-2 Valves - W66 Series

The catalog extensively covers ROSS Controls W66 Series valves conforming to ISO 15407-1 and ISO 15407-2 standards. These compact, high-performance base mounted valves are available in Size 00 (18mm) and Size 0 (26mm) configurations, offering exceptional versatility for space-constrained applications requiring robust pneumatic control.

W66 Series Key Features and Specifications:

The W66 Series employs proven spool and sleeve construction technology, delivering superior dirt tolerance and extended service life compared to sealed designs. Available in both solenoid pilot controlled and pressure controlled actuation options, these valves provide reliable switching for demanding industrial environments.

Actuation Options:

• Single solenoid pilot with spring return (5/2-way, 2-position)
• Double solenoid pilot operation (5/2-way, 2-position and 5/3-way, 3-position)
• Pressure controlled variants for pneumatic signal operation
• Internal or external pilot supply configurations

Technical Specifications:

• Operating pressure range: Vacuum to 145 psig (9.9 bar)
• Minimum operating pressure: 20 psig for 2-position, 30 psig for 3-position
• Standard voltages: 24V DC and 120V AC options
• Flow media: Filtered air (5-micron filtration recommended)
• Materials: Die-cast aluminum body, PBT end caps, zinc-plated steel fasteners

Mounting Configurations:

• Individual sub-base mounting for single valve installations
• Multi-station manifold bases supporting up to 32 valve positions
• Drop-cord electrical connections (ISO 15407-1)
• Plug-in electrical connections (ISO 15407-2)
• Serial Bus communication-compatible base mounting

ISO 5599-1 and ISO 5599-2 Valves - W65 Series

The W65 Series represents ROSS Controls' solution for standard ISO 5599-1 and ISO 5599-2 pneumatic valve applications. Available in Size 1, Size 2, and Size 3 configurations, these valves deliver scalable flow performance from 1.0 Cv (980 Nl/min) to 3.4 Cv (3,300 Nl/min), accommodating a wide range of pneumatic actuator and cylinder control requirements.

W65 Series Comprehensive Specifications:

Built on spool and sleeve design principles, the W65 Series eliminates wear-prone seals while maintaining tight shutoff and responsive switching characteristics. The base-mounted electrical connector design simplifies maintenance by eliminating wire disconnection during valve removal.

Size and Flow Performance:

• Size 1: 1.0 Cv (980 Nl/min) - Compact applications with 1/8" to 1/4" port sizes
• Size 2: 2.3 Cv (2,300 Nl/min) - Medium flow with 1/4" to 3/8" port sizes
• Size 3: 3.4 Cv (3,300 Nl/min) - High flow applications with 1/4" to 1/2" port sizes

Valve Functions Available:

• 5/2-way, 2-position (single and double solenoid)
• 5/3-way, 3-position with power center, closed center, or open center configurations
• Solenoid pilot controlled and pressure controlled actuation
• Spring return and detent operation modes

Electrical Connection Options:

• Base-mounted plug-in connectors (ISO 5599-2) - tool-free valve removal
• Drop-cord connections (ISO 5599-1) with various cable lengths
• Manifold collective wiring: 25-pin D-Sub, 19-pin round, M23 12-pin
• 16-point terminal strip connections for traditional wiring
• Serial Bus TURCK BL67 valve driver module integration

TURCK BL67 Serial Bus I/O System Integration

Complete Centralized Serial Bus Communication Solution

The catalog provides exhaustive coverage of the ROSS-TURCK integrated Serial Bus communication system, built on TURCK's proven BL67 Modular I/O platform. This IP67-rated, industrial-grade I/O system eliminates the need for control cabinet mounting, enabling direct machine-mounted installation for reduced wiring costs and simplified troubleshooting.

BL67 System Architecture and Capabilities:

The TURCK BL67 system represents a complete pneumatic and I/O integration solution, combining the ruggedness required for industrial environments with the flexibility of modular Ethernet-based communication. Supporting multiple industrial protocols through a single hardware platform, the BL67 system future-proofs automation investments.

Communication Module Options:

• EtherNet/IP Gateway (BL67-GW-EN-IP) - Direct integration with Rockwell Automation, Allen-Bradley ControlLogix and CompactLogix systems
• Modbus TCP/IP Gateway (BL67-GW-EN) - Universal connectivity for Modbus TCP applications
• PROFINET Gateway - Seamless Siemens PLC integration with PROFINET IO support
• DeviceNet, ControlNet, CANopen - Legacy protocol support for existing installations

Programmable Gateway Options:

• Non-programmable gateways (BL67-GW-EN, BL67-GW-EN-IP) for straightforward I/O mapping
• Programmable gateways (BL67-PG-EN-IP) for complex logic, data processing, and edge computing applications

H3: Input/Output Module Specifications and Configurations

The catalog details the complete range of BL67 I/O modules, supporting both digital and analog signals with high-density packaging. Each communication module supports up to 32 station modules, with each station module accommodating up to 8 individual I/O modules, enabling systems exceeding 256 total I/O points.

Digital Input Modules:

• 8-point and 16-point digital input configurations
• PNP and NPN sensor compatibility
• Short-circuit and overload protection
• Diagnostic LED indication for each input channel

Digital Output Modules:

• 8-point and 16-point output configurations
• 0.5A and 2A current ratings per channel
• Short-circuit and overload protected outputs
• Individual channel diagnostic feedback

Analog I/O Modules:

• 4-20mA, 0-10V analog input and output modules
• 12-bit and 16-bit resolution options
• Isolated and non-isolated variants
• Sensor supply outputs for 2-wire transmitter connection

ROSS Valve Driver Modules:

• RPSSV16A (T1 designation) - 16 output valve driver for compact manifold systems
• RPSSV32A (T2 designation) - 32 output valve driver for large multi-station manifolds
• Integrated circuit boards mount directly to valve manifold bases
• Single address and double address configuration options
• Pre-wired cable assemblies for quick BL67 connectivity

Environmental Protection and Certification

IP67 Protection Class:
The BL67 system achieves IP67 (NEMA 1, 3, 4, 12, 13) ingress protection, enabling installation directly on machinery without protective enclosures. This eliminates cabinet space requirements and reduces installation costs while providing robust protection against dust, dirt, and temporary liquid exposure.

Operating Conditions:

• Operating temperature: 32°F to 131°F (0°C to 55°C)
• Storage temperature: -13°F to 185°F (-25°C to 85°C)
• Relative humidity: 5% to 95% non-condensing
• Vibration resistance: 1.0g at 5-10 Hz
• Shock resistance: 15g

Certifications:

• UL Listed (United States)
• C-UL Listed (Canada - CSA)
• CE Marked (European Union)
• Electromagnetic compatibility per EN 61131-2

Environmental Suitability:
The catalog specifies appropriate and inappropriate application environments. BL67 modules excel in typical industrial machine and conveyor applications with exposure to dirt, dust, coolants, and hydraulic fluids. However, continuous submersion, 100% humidity environments, and high-pressure washdown applications require fully potted alternatives such as ROSS AIM stations.

Manifold Systems and Sub-Base Configurations

Single Sub-Base and Manifold Base Options

The catalog provides detailed specifications for all valve mounting configurations, from individual sub-bases for single valve applications to multi-station manifold bases supporting up to 32 valves in a single integrated assembly.

Individual Sub-Base Features:

• Direct mounting to machine frames or pneumatic panels
• Available with standard NPT or BSPP threaded ports
• Port sizes from 1/8" to 3/4" depending on valve size
• Compatible with all W65 and W66 Series valves
• Integrated pilot supply routing

Multi-Station Manifold Systems:

• 2, 4, 8, 16, 24, and 32 station configurations
• Common supply and exhaust distribution
• Modular plug-together electrical connections
• Collective wiring end plates (25-pin D-Sub, 19-pin round)
• Serial Bus communication-ready with integrated circuit boards

Manifold Accessories and Enhanced Functionality

Pressure Regulation Options:

The catalog extensively covers interposed pressure regulator configurations that mount between the valve and manifold base, providing precise downstream pressure control without additional piping.

• Common Pressure Regulator - Single regulator controls pressure for entire manifold
• Independent Pressure Regulator - Individual regulation for each valve station
• Selector Regulator - Switchable between multiple preset pressures
• Pressure ranges: 2-60 psig with gauge, 5-125 psig with gauge
• Unregulated pilot pressure maintains consistent valve shifting

Flow Control Solutions:

Interposed flow control units provide independent meter-in and meter-out speed control for pneumatic cylinders without external plumbing.

• Separate exhaust flow adjustment for extension and retraction
• Adjustment screws located on 12 o'clock position for easy access
• Mounts with dedicated studs (valve uses standard mounting bolts)
• Not designed as shutoff device (not bubble-tight when fully closed)

Individual Valve Shutoff:

Interposed shutoff units enable manual isolation of individual manifold stations for maintenance without depressurizing the entire system, supporting lockout/tagout procedures and reducing downtime.

• Quarter-turn manual actuation
• Isolates all ports including pilot supply
• Locking mechanism prevents unintended operation
• Maintains manifold station spacing and alignment

Transition Plates:

Enable mixed valve sizing within a single manifold assembly, optimizing flow capacity and cost by using appropriate valve sizes for each application.

• Connect different ISO sizes (Size 1 to Size 2, Size 2 to Size 3)
• Maintain proper port alignment and sealing
• Integral supply and exhaust crossover passages

Serial Bus Circuit Board and Addressing Systems

Integrated Circuit Board Technology

The catalog details ROSS proprietary circuit board technology that mounts directly to manifold bases, providing integrated valve driving circuitry and communication interfaces. This eliminates external wiring between I/O modules and individual valves, dramatically reducing installation complexity.

Circuit Board Types and Addressing:

• Single Address Boards (J designation) - One network address per manifold station, suitable for simple on/off control
• Double Address Boards (M designation) - Two network addresses per station, enabling independent control of dual solenoid valves and pilot pressure monitoring
• 32 Output Expansion Boards (N, P designations) - Ribbon cable connection to RPSSV32A valve driver module for systems exceeding 16 outputs

Expansion Configuration Examples:

For manifold systems requiring more than 16 valve outputs, the catalog provides clear wiring diagrams showing:

• Outputs 1-24: Direct connection via RPSSV16A or RPSSV32A base units
• Outputs 25-32: Expansion via ribbon-connected circuit boards
• Mixed single and double address configurations
• Proper termination requirements

Cable Assemblies and End Stations

Pre-Assembled Cable Options:

ROSS offers factory-assembled cables in standard lengths, ensuring reliable connections and reducing field installation errors.

• 16-point terminal strip end stations
• 25-pin D-Sub end stations (standard and low-profile)
• 19-pin round Brad Harrison connector end stations
• M23 12-pin end stations
• Cable lengths: 3, 6, 9, and 12 feet standard (custom lengths available)

Serial Bus End Stations (L6 designation):

Dedicated end station assemblies with integrated TURCK BL67 valve driver modules provide plug-and-play Serial Bus connectivity.

• Pre-installed RPSSV16A or RPSSV32A valve driver modules
• Factory-tested cable assemblies ensure first-time connection success
• Eliminates field wiring errors and commissioning delays

Product Selection and Ordering Process

Model Number Configuration System

The catalog includes detailed model number builders with step-by-step selection processes. Each option selection is color-coded (typically red) to guide users through:

1. Basic valve size and ISO standard selection
2. Function selection (5/2, 5/3, center condition)
3. Actuation type (solenoid pilot, pressure control)
4. Voltage specification
5. Operator override options (locking, non-locking, single, double)
6. Mounting configuration (sub-base, manifold)
7. Electrical connection type
8. Circuit board and Serial Bus options

Example Model Number Breakdown:

The catalog provides annotated examples showing how each character and number in a ROSS model number specifies particular features, enabling precise product matching to application requirements.

Sub-Base and Manifold Ordering

Sub-bases and manifold components are ordered separately from valves, allowing flexibility in system configuration. The catalog provides:

• Port size and thread type selection (NPT vs BSPP)
• Manifold station quantity selection
• End station kit model numbers
• Pressure regulator and flow control options
• Blocking disk and transition plate part numbers

Technical Data and Performance Specifications

Flow Characteristics and Cv Values

Comprehensive flow performance data enables proper valve sizing for specific actuator requirements:

• W66 Series Size 00: Cv 0.5 (490 Nl/min)
• W66 Series Size 0: Cv 0.8 (780 Nl/min)
• W65 Series Size 1: Cv 1.0 (980 Nl/min)
• W65 Series Size 2: Cv 2.3 (2,300 Nl/min)
• W65 Series Size 3: Cv 3.4 (3,300 Nl/min)

Flow curves and pressure drop data support cylinder speed calculations and system pressure loss analysis.

Response Times and Electrical Specifications

Valve Response Performance:

• Solenoid pilot valves: 20-50 millisecond typical response
• Pressure controlled valves: Response dependent on pilot pressure and flow
• Spring return time: 15-30 milliseconds typical

Solenoid Specifications:

• Bi-polar solenoid design with surge suppression standard
• Continuous duty rated for 24/7 operation
• Visual indicator lights integrated into solenoid cap
• Power consumption: 1.0-2.0 VA for DC, 2.0-4.0 VA for AC
• Coil temperature rise: Maximum 60°C above ambient
• Insulation class: Class F (155°C)

Materials of Construction and Chemical Compatibility

Standard Materials:

• Valve bodies: Die-cast aluminum alloy (corrosion resistant)
• End caps and covers: Polybutylene Terephthalate (PBT) thermoplastic
• Internal spools: Hard-anodized aluminum
• Seals and O-rings: Nitrile (Buna-N) rubber standard
• Fasteners: Zinc-plated steel (stainless steel available)
• Solenoid housing: Thermoset plastic encapsulation

Media Compatibility:

The catalog specifies filtered compressed air as the standard media, with 5-micron filtration recommended to maximize service life. Compatible lubricants listing includes:

• Petroleum-based hydraulic oils (ISO VG 32-68)
• Synthetic lubricants (polyol ester, PAG)
• CTFE greases for seal lubrication

Non-compatible media requiring special materials are identified, including aggressive chemicals, corrosive gases, and high-temperature applications requiring alternative seal materials.

Installation and Maintenance Information

Mounting and Assembly Guidelines

The catalog provides dimensional drawings showing:

• Valve overall dimensions for clearance verification
• Mounting hole patterns and fastener specifications
• Recommended torque values for assembly bolts
• Manifold station spacing for different valve sizes
• Clearance requirements for solenoid removal and override operation

Installation Best Practices:

• Surface flatness requirements for manifold bases (0.002" per inch recommended)
• Port alignment tolerances
• Gasket installation procedures
• Electrical connection assembly sequences
• Pilot pressure connection routing

Service and Troubleshooting

Maintenance Intervals:

Recommended service intervals based on operating conditions:

• Clean room environments: 10 million cycles
• Standard industrial: 5 million cycles
• Harsh environments (high contamination): 2 million cycles

Service Kit Availability:

The catalog references complete service kits containing:

• Replacement seals and O-rings
• Gasket sets for valve and base interfaces
• Solenoid coil assemblies
• Pilot piston components
• Installation instructions and parts diagrams

Common Troubleshooting Scenarios:

• Valve fails to shift: Check pilot pressure, verify solenoid energization, inspect for contamination
• Slow response: Verify minimum operating pressure, check for downstream restrictions, inspect exhaust ports
• Air leakage: Inspect seals, verify proper mounting torque, check for foreign material

Applications and Industry Solutions

Manufacturing and Assembly Automation

The Serial Bus valve systems excel in automated manufacturing environments requiring distributed pneumatic control with centralized monitoring and diagnostics. Typical applications include:

• Pick-and-place automation systems
• Robotic work cell actuator control
• Automated guided vehicle (AGV) pneumatic circuits
• Packaging equipment valve manifolds
• Material handling conveyor diversions

Benefits in Manufacturing:

• Reduced cabinet space through IP67-rated field mounting
• Simplified troubleshooting with individual valve monitoring
• Faster changeovers with fieldbus configuration storage
• Predictive maintenance through cycle counting and diagnostic data

Process Control and Continuous Manufacturing

Serial Bus integration enables sophisticated process control strategies:

• Batch process valve sequencing
• Pneumatic actuator position control
• Process pressure regulation
• Automated cleaning-in-place (CIP) systems
• Product changeover automation

Process Industry Advantages:

• Recipe-driven valve sequence programming
• Data logging for process validation
• Remote monitoring and diagnostics
• Reduced operator intervention

Safety and Machine Guarding Integration

ROSS Controls' safety system expertise extends to Serial Bus valve integration:

• Integration with safety PLCs and safety-rated I/O
• Lockout/tagout (LOTO) support through interposed shutoffs
• Emergency stop circuit interfaces
• Safety gate interlock valve control
• Dual-channel safety system connections

Support Resources and Additional Documentation

Complementary Technical Documentation

The catalog references additional ROSS Controls resources available for download:

• Individual valve series installation instructions
• BL67 system configuration guides
• 3D CAD models in multiple file formats (STEP, IGES, Parasolid, STL)
• Control system integration application notes
• Safety system design white papers

Engineering and Technical Support Services

Pre-Sales Engineering Support:

ROSS Controls technical team provides:

• Application consultation and valve selection assistance
• System configuration and part number building
• Flow calculations and cylinder sizing verification
• Custom manifold design for unique requirements
• 3D modeling support for machine design integration

Post-Sales Technical Services:

• Installation troubleshooting assistance via 1-888-TEK-ROSS
• Warranty support and RMA processing
• Retrofit and upgrade consultation
• Training programs for distributor and end-user personnel
• On-site commissioning support (fee-based)

Warranty and Quality Assurance

ROSS Controls Product Warranty

Standard warranty coverage includes:

• 18-month warranty from date of shipment
• Coverage for defects in materials and workmanship
• Repair or replacement at ROSS discretion
• Expedited warranty claim processing

Warranty Exclusions:

• Damage from improper installation or application
• Normal wear from extended service
• Contamination or improper media
• Modifications or repairs by unauthorized personnel

TURCK BL67 System Warranty

TURCK provides separate warranty coverage for BL67 communication and I/O modules:

• 36-month warranty on electronic modules
• Coverage for manufacturing defects
• Advanced replacement options for critical applications

Why Choose ROSS Controls Serial Bus Solutions

Industry-Leading Pneumatic Control Expertise

Since 1921, ROSS Controls has specialized in pneumatic control systems for safety and general automation. This catalog represents the integration of nearly a century of valve engineering expertise with cutting-edge digital communication technology.

Core Competencies:

• Deep understanding of pneumatic system dynamics
• Proven valve designs with millions of installations worldwide
• Application-specific engineering for challenging environments
• Commitment to safety and machine productivity

Strategic Partnership with TURCK

The ROSS-TURCK collaboration delivers:

• Best-in-class valve technology paired with proven I/O systems
• Single-source responsibility for integrated solutions
• Joint technical support for seamless system integration
• Continuous product development responding to market needs

Total Cost of Ownership Advantages

Serial Bus valve systems reduce total installed costs through:

• Reduced Wiring Costs: 50-70% reduction in cable requirements compared to traditional home-run wiring
• Faster Installation: Plug-together connectivity cuts commissioning time
• Simplified Troubleshooting: Diagnostic LEDs and network monitoring pinpoint issues quickly
• Lower Maintenance Costs: Individual valve monitoring enables predictive maintenance
• Improved Uptime: Faster fault identification reduces mean time to repair (MTTR)

Future-Ready Automation Infrastructure

Industry 4.0 and Smart Manufacturing Enablement

The BL67 Serial Bus platform positions pneumatic systems as intelligent components in smart manufacturing ecosystems:

• Data Acquisition: Valve state monitoring, cycle counting, and pressure sensing
• Predictive Analytics: Maintenance scheduling based on actual usage patterns
• Recipe Management: Pneumatic sequences stored and recalled digitally
• Production Tracking: Integration with MES and ERP systems

Scalability and Expansion Flexibility

Serial Bus architecture supports growth:

• Add valve stations without rewiring
• Upgrade communication protocols via gateway replacement
• Integrate new sensor types through I/O module expansion
• Scale from simple machines to plant-wide networks

Download Your Complete Catalog Today

Comprehensive Resource for Pneumatic Automation

This catalog serves as your complete reference for specifying, ordering, and implementing ROSS Controls base mounted valves with TURCK Serial Bus communication integration. With detailed technical specifications, dimensional drawings, model number builders, and application guidance, you'll have everything needed to design efficient, reliable pneumatic control systems.

What You'll Gain:

• Complete product specifications for valve selection
• Technical data for proper system sizing and performance prediction
• Clear ordering information for accurate part number configuration
• Installation guidance for successful first-time implementation
• Integration details for major industrial control systems

Contact ROSS Controls for Expert Support

Customer Service:

• Phone: 1-800-GET-ROSS (1-800-438-7677)
• Email: sales@rosscontrols.com
• Online: www.rosscontrols.com/contact

Technical Support:

• Phone: 1-888-TEK-ROSS (1-888-835-7677)
• Email: techsupport@rosscontrols.com
• Online chat available during business hours